‘foster’ cold- room technicians’

hand-book

( REVISED )

1

‘Foster’ cold- room

Technicians’ Hand-book

Contents

General Information

Interconnection wiring between different units

Layout diagrams

5

6

Page

3

Description of main components

Generator panel

Cold-room panel (old type)

‘Solo’ Units

7 & 18

19 & 25

Circuit/Layout Diagrams

Walk-In-cold rooms

Walk-In-Freezer rooms

Normal Operation

1. Initial starting & normal operations

2. Alarm condition (high temp in cold-room)

3. Mains Power Supply failure conditions

27

28

28

4. Alarm Condition – Generator engine failure

Trouble-shooting

28

A. No general power failure, but generator is running

B. No power failure, Mains power available upto generator panel, but generator is running

31

32

C. In case of power failure, Generator is running but unit not working 33

9 - 17

20 - 25

D. Generator does not start in case of power failure

E. Alarm condition – Generator Engine Failure

F. Cold-room panel/Unit

G. Battery does not get charge

34

34

36

36

H. Cold-room temperature observed to be different than the set range 37

37 J. Maintenance of battery.

Appendix :

2

FOSTER

WALK-IN-COLD-ROOM

GENERAL INFORMATION

The Cold Room: One of the most important links in the cold-chain is Walk-In-Cold Room. This is used for bulk storage of vaccines at + 4

0

to +8

0

C at state level or regional storages.

This insulted room is kept cold by two numbers of identical cooling units, mounted on its walls. The working of the cooling units are controlled by their thermostats, which switch ON and switch OFF the compressors depending upon the inside temperatures. The thermostats of units are so adjusted that one unit works when the inside temperature is about + 5

0

C and goes off at about + 4

0

C and the other works when the temperature is about + 7’0C and goes off at about + 6

0

C.

The evaporator-fans of the cooling units (inside the

cold-room) blow the cold air from the units and

circulate the air inside the cold-room. They run

continuously so long the unit is on.

The condenser-fans of the units (outside the cold-room) cool the condenser coils and they run only when the compressors work.

Power-supply: The cooling-units run from 220 volts single- phase, 50 Hz. AC power supply, normally from the mains (network).

Stand-by Generator & Generator Panel: To keep the cooling units running on the event of Network (Mains) power failure, a stand- by generator is provided. In case of power failure, the generator can be start automatically.

In case of ‘Automatic’ selection, the generator panel senses the power failure and sends signals automatically to start the generator. If the generator could not start on the first starting signal the control sends another two more starting signals to the generator at intervals. Even then. If the generator does not start an alarm is given (The alarm can be put off by bringing the MAN/AUT selector switch to ‘0’ position once).

If the generator starts and runs, the power from the

3

generator is connected after little delay, to one of the cooling units only, to continue the cooling. The unit to work from generator is to be pre-selected by selector switch on the cold room panel. When Mains power returns the generator power is cut off and the generator is stopped and also the Mains power is reconnected to the units automatically by the generator panel. Also, during the running of the generator, if its lube oil pressure becomes low or the engine temperature becomes high the generator is stopped automatically and an alarm is given (The alarm can be put off by bringing the MAN/AUT selector switch to ‘0’ position

IMPORTANT: The 12 volts car battery on the generator is not only for starting the engine, but also for supply of 12 V. DC to the generator panel. So if the battery voltage is low or the battery is discharged the generator will not start in case of power failure both automatically and manually.

Alarm system: The alarm system provided in the cold-room panel, monitors the cold-room temperature and actuates Audio & Visual alarm when the temperature rises to about + 10

0

C.

After the temperature becomes normal, the alarm can be put off by pressing the Reset button, But if the temperature still remains higher, this can be put off only by switching off the mains supply.

Temperature Recorder: The temperature recorder records the cold-room temperature continuously on a circular chart. The chart runs one complete round in 7 days. So the chart is to be changed each week. Also when exhausted, its writing ink capsule is to be changed.

4

Automatic Defrostion: The moisture in the air inside the cold-room gets frozen and form frost on the evaporator coils of the units. For better cooling efficiency they are to be melted from time to time.

Defrosting is done automatically by the defrost timers in the cooling units. The timers put off the units for a present time twice in 24 hours at an interval of 12 hours.

This allows the frost to melt and drain out.

INTERCONNECTION WIRING BETWEEN DIFFERENT UNITS

5

FOSTER

6

COLD ROOM

DESCRIPTION OF MAIN COMPONENTS IN CONTROL PANELS

GENERATOR PANEL:

MAN/AUT selector switch – to select Manual or ‘Automatic’ operation of Generator At ‘0’

Position the generator Start/Stop and alarm functions are OFF.

Voltmeter – to indicate Generator Voltage when the generator is running.

Ammeter- to indicate current drawn from the generator.

MAINS IN (Green) Indicator lamp – to indicate when Mains power is made available to cold-room.

ALARM (Red) Indicator lamp – to indicate failure of generator

Fuses – S1 (5A) – Control D.C

S2 (5A) – Battery charging D.C

S3 (5A)

S4 (5A) – AC to Battery charger

S5 (5A)

S6 (5A) Control A.C from Mains.

S7 (5A)

S8 (5A) Control A.C from Generator.

Generator Breaker. MI – Circuit Breaker for Generator

# Power supply from generator comes to Terminals A & O of MI.

NK – Contactor Mains Power Supply

# Power supply from mains comes to Terminals 2T1 & 4T2 of NK.

GK – Contact, Generator power supply

# Power from Generator panel goes from Terminals R & O of terminal strip to Cold-Room panel.

7

COLD-ROOM PANEL: (new type)

B1, Circuit breaker – to trip-off power to Cold-room panel in case of fault or overload.

B2, Alarm Rest Button- ‘Cold-room high temperature Alarm can be put OFF by pressing this button after alarm Condition is over.

B3, selector switch – to select working of Unit-I or Unit-2 from generator power at ‘0’ position power to both The units is

OFF, (either from Mains or from

Generator).

Indicator lamp (Red) - to indicate alarm condition.

T1 Alarm thermostat – works and actuate the alarm in case of high temperature in the cold-room.

C1, Alarm relay –

C2 Low voltage protector. to operate the alarm system.

COOLING UNITS

Thermometer – to indicate inside the temperature.

S1, ON or OFF switch - to put the unit ON or OFF.

CB1, circuit breaker – to trip –OFF power to the compressor in Case of fault or overload.

CB2, circuit breaker – to trip – OFF the unit control & fans in case of Fault or overload.

C1, contactor for compressor – to put the compressor ON & OFF.

Thermostat – to sense the temperature inside the cold-room & to put the compressor & considerfan ON or OFF as per requirement.

8

DESCRIPTION OF MAIN COMONENTS

* T1 Startingprogramme s=8 sec.(staring time) only if

5 sec. pause fitted

Date 850227 Corr

851125

Hjalte Nattestad a-s

Nattestad Dk 2800 Glostaup . Denmark

Eel 02-456265

Orawn jb ls

Consir 01

861110

Scase

SWITCHBOARD

1*220V / 50Hz 3-68-137

Order no

6940

No COMPONENT DESCRIPTION RECOMMENDED

S1 5A 5*20 mm fuse Pilot fuse 12v ADJUSTMENT

S2 5A 5*20 mm fuse Charging rectifier 12v

S3 5A 5*20 mm fuse Charging rectifier 220v

S4 5A 5*20 mm fuse Charging rectifier 220v

S5 5A 5*20 mm Pilot fuses main 220v

S6 5A 5*20 mm Pilot fuses main 220v

S7 5A 5*20 mm Pilot fuses main 220v

M1 Mini circuit breaker Alternator

GK Contactor Alternator

Nk Contactor Mains

N1 Ralay Main senaing11-pin-nocketrelay220v

T1 Time delay FI 12v atarting time 20 sec(30.)

T2 Time delar FU 12v atop time 20sec(30.)

T3 Time 220v delayed alternator 10sec.(5)

E1 Charging rectifier 220v/12v/5A

RH1 Relay Start

RH2 Relay Stop

R1 Relay 11-pin-socket-relay 12v DC

R2 Relay 11-pin-socket-relay 12v Dc

Mains

1*220v

9

12 V .DC from Battery

A1

MAN / AUT(1-2) closed on

Either selection

R1= Dc sensing relay

*R1 (1-3)remains closed so long correct DC voltage is available from any of

Battery/charging rectifier bill opens when DC is available from dynamo when generator is running.

# N1 (8-11) closes on mains power failure.

M = Starting motor of generator engine.

T1 = Starting time (delay to operate)

R2 = Alarm relay

@ T1 (9-11) closes after preset time on Starting

Failure.

10

220 V. GENERATOR PANEL (Part)

‘ FOSTER ‘ WALK-IN-COLD-ROOM

N1 = Mains sensing relay.

61 & 62 are aux contact of generator contactor which are normally closed.

NK – mains contactor.

220 V.AC To generator 220 V. AC

FROM MAINS battery for TO COLD-ROOM

Charging PANEL

COLD – ROOM OPERATTING FROM MAINS SUPPLY

DIAGRAM :1

11

220 V. GENERATOR PANEL (PART)

‘ FOSTER ‘ WALK-IN-COLD-ROOM

220 V

1 Ø

TERNATOR *M1=

Generator

Breaker, normally kept CLOSED

T3 delay to operate,

Allows generator to build up voltage

T2 = Stop timer

61 & 62 are contact of

NK contactor which are normally closed.

220 V.AC

TO COLD-ROOM

PANEL

DIAGRAM :3

COLD ROOM OPERATING FROM GENERATOR SUPPLY

12

12 V.DC from Battery

* A1 (1-2) closed on either

MAN / AUT selection

Ø A1(11-12) closed at AUTO

Selection

# N1(6-7) closes and return of mains-power

@R2 (9-11) closes and stops engine in alarm condition

T2 = stopping time,delay to release, holds itself & RH2 for preset time (through

T2(1-3) to allow the engine to stop completely.

GENERATOR STOPPING CIRCUIT

DIAGRAM :4

13

GENERATOR PANEL (PART)

‘ FOSTER ‘ WALK –IN – COLD / FREEZER-ROOM

12 V . DC from Battery

* A1(1-2) closed on either MAN / AUT selection

P2 (6-7) holding contacts for R2

Closws when engine lube oil pressure is low

Closes when engine temperature is high

T1(9-11) closes after preset time on engine starting faiure

GENERATOR FAILURE ALARM CIRCUIT

DIAGRAM :5

14

COLD ROOM PANEL(220V 1-Ø)

(New type)

DIAGRAM :6

15

DIAGRAM :7

16

12 V .DC SUPPLY & BATTERY CHARGING CIRCUIT

Generator – Panel

(Part)

# S4 fuse is not used in this circuit

in generator-panels for 3-phase

400 V.used with the Freezer

Rooms.

(-ve) when DC is abailable

from Batt/Charging

rectlfier & generator is not

running

(+ve) when Generator is

running & DC is available

from Dynamo.

DIAGRAM :8

17

DESCRIPTION OF MAIN COMPONENTS

GENERATOR PANEL

A1 = Selector switch MAN/AUT

C1 = Capacitor 220 Mfd,for starting – timer T1

D1 = Diode for RH1. 1 A

D2 = Diode for RH2. 1 A

D3 = Diode Auto start circuit 1 A

E1 = Automatic charging rectifier 12 V/5 A for battery charging and D.C supply,

GK = Contactor, generator power

J1 = Voltmeter, generator power, 0-250 V.AC,

J2 = Ammeter, generator power, 0 – 40 A. AC,

M = Starter motor, 12 V.DC for engine starting

M1 = Circuit breaker, generator power output ckt

NK = Contactor, mains power

N1 = Relay, mains sensing, 220 V, AC (remains operated so long mains power is available),

R1 = Relay, D.C sensing 12 V, DC (remains operated so long

12 V.DC is available),

R2 = Alarm Relay Generator Failure 12 V.DC

RH1 = Start relay, 12/20 A (for starter motor supply),

RH2 = Stop relay 12/20 A (for stop solenoid supply),

S1 = Fuse, 5 A, (DC supply for control circuit),

S2 = Fuse, 8 A, (DC output from charging rectifier),

S3 = Fuse, 5 A

S4 = Fuse, 5 A AC input charging rectifier

S5 = Fuse, 5 A

S6 = Fuse, 5 A AC input to relays N1, NK & lamp X2 from mains

S7 = Fuse 5 A

S8 = Fuse 5 A AC input relays T3, GK & voltmeter from generator

T1 = Starting timer, 12 V.DC (0-60 sec) Fi (Delay operate operates only when generator fails to start within its present time),

T2 = Stop timer, 12 V.DC (0-60 sec) Fu (operates instantane-

ously and releses after its present time),

T3 = Delayed alternator timer, 230 V.AC, (Delay to operate allows generator to build up voltage),

X1 = ALARM/AUTO STOP indicator lamp 12, V (Generator failure

X2 = MAINS IN indicator lamp 220 V.

Z1 = START press button (N.O) for manual starting of Genr.

Z2 = STOP press button (N.O) for manual stopping of Genr.

18

COLD-ROOM PANEL (and cold-room)

Indicator lamp (Red) – to indicate Alarm condition, 220V

B1 = Circuit breaker, (power input to panel)

B2 = Alarm Rest button (N.C)

B3 = Selector switch Unit ½ operation on generator supply

B4 = Switch for room lamps (on cold-room wall)

C1 = Alarm relay, 220 V, to operate the alarm system

C2 = Low voltage protector

H = Door heater, (in cold-room door)

L1 = Room light, 220V (inside cold-room)

Lo = Room light, 220 V, (outside cold-room)

N = Switch bl location indicator neon 220 V

T1 = Alarm thermostat (set operate at + 10’0C

TR = Temperature Recorder Unit (on cold-room wall)

(Set for 1 revolution in 7 days)

SOLO COOLING UNITS

C1 = Contactor 220 V for compressor motor supply

CB1 = Circuit breaker (compressor motor circuit)

CB2 = Circuit breaker (control circuit &fan motors)

S1 = Power ON/OFF switch of the unit

T1 = Defrost Timer

t o

= TEMP STAT Thermostat for compressor motor control

M = Compressor motor (Condensing Unit)

HP/LP = Pressostat (Differential), Compressor & Condenser- fan control circuit)

POWER NEON = Power ON indicator lamp, 220 V

REFGN NEON = Compressor & condenser – fan supply ON

indicator LAMP 220V

EVAP.FAN = Evaporator fans (inside cold-room)

COND. FAN = Condenser fans (outside cold-room).

19

DESCRIPTION OF MAIN COMONENTS

No COMPONENT DESCRIPTION RECOMMENDED

S1 5A 5*20 mm fuse Pilot fuse 12v

ADJUSTMENTS

S2 5A 5*20 mm fuse Charging rectifier 12v

S3 5A 5*20 mm fuse Charging rectifier 220v

S4 5A 5*20 mm fuse Pilot fuse mains R

S5 5A 5*20 mm fuse Pilot fuse mains S

S6 5A 5*20 mm fuse Pilot fuse mains T

S7 5A 5*20 mm fuse Pilot fuses alternator 220v

S8 5A 5*20 mm fuse Pilot fuses alternator 220v

M1 Mini circuit breaker Alternator

GK Contactor Alternator

Nk Contactor Mains

N1 Ralay Main senaing11-pin-nocketrelay220v

T1 Time delay FI 12v atarting time 20 sec(30.)

T2 Time delar FU 12v atop time 20sec(30.)

T3 Time 220v delayed alternator 10sec.(5)

E1 Charging rectifier 220v/12v/5A

RH1 Relay Start

RH2 Relay Stop

R1 Relay 11-pin-socket-relay 12v DC

R2 Relay 11-pin-socket-relay 12v Dc

Mains

3*400/231V

5 sec. pause fitted

Hjalte Nattestad a-s

Nattestad Dk 2800 Glostaup . Denmark

Eel 02-456265

* T1 Startingprogramme s=8 sec.(staring time) only if

Date 850227 Corr

851125

Orawn jb ls

Consir 01

861110

Scase

SWITCHBOARD

1*220V / 50Hz 3-68-137

Order no

6940

20

21

FREEZER ROOM OPERATING FROM MAINS SUPPLY

DIAGRAM : 1(a)

22

400 V(3-Ø)GENERATOR PANEL(part)

FOSTER WALK-IN-FREEZER-ROOM

.

400 V.

3 -0 AC

TO

Cold – room

Panel

* M1 = Generator

Breaker

FREEZER – ROOM OPERATING FROM GENERATOR SUPPLY

Normally kept

CLOSED.

T3 delay to operate, allows generator to build up voltage.

DIAGRAM : 3(a)

23

‘FOSTER’ WALK- IN-(FREEZER ROOM)

DIAGRAM : 6(a)

24

‘FOSTER’ WALK- IN-(FREEZER ROOM)

‘SOLO’ COOLING UNITS(400 V.3-Ø)

DIAGRAM : 7(a)

25

TROUBLE

SHOOTING

FOSTER

COLD-ROOM

# The COLD-ROOM panel referred

here is of Old-type.

26

FOSTER WALK COLD-ROOM

OPERATION & TROUBLE –SHOOTING

1) INITIAL STARTING & NORMAL OPERATIONS:

# Before connecting the Battery on the generating set be sure that the MAN/AUT selector switch on the generator-panel is at ‘0 ‘ position.

# Before switching the mains power supply ON, keep the MAN/AUT selector on the generator-panel at ‘0’ position and On-OFF ‘switch (S1) of cooling units at OFF positions.

Put the Main-switch ON (Refer-Digram 1), if mains power is

Present, main power will be available at terminals R (2T1) & 0

(4T2) on relay NK of generator panel. Relay N1 (in generator panel) will operate which in turn will operate relay NK and ‘Mains-In’ indicator leap (X2) will glow. Relay NK operating the mains supply will be available at the outgoing terminals R & O from where it goes to the cold-room panel.

The power supply for the cold room panel is extended (from the above

R &O terminal points either from mains (as explained above) or from the Alternator of the Generating Set (which we will discuss later under network failure condition.

Depending upon the position of selector switch (b2) on cold-room panel (for operation of unit 1 or unit 2), the power supply coming from Terminals R & O of Generator Panel will be extended to the selected unit (unit 1 and unit 2) and the corresponding indicator lamp (either h1 or h2) will glow. Power supply for unit 1 is extended from outgoing terminals 1 and 2 and that for unit 2 is extended from terminals 3 and 4 of the cold room panel to the terminals L &N of the selected unit.

Both the cooling units are similar ,but only one unit works at a time as per selection by selector ‘b2’ of cold room panel.

On putting ‘ON’ the switch of the unit, the ‘power’ neon will glow and Evaporator-Fan will run. The Evaporator fan runs continuously so long the unit is ‘ON’, When the temperature inside the cold room is higher than required and the unit is not in defrost cycle the thermostat will operate the contactor C1. In turn the compressor and condenser fan will start functioning and

‘Refrigeration’ neon will glows accordingly. When the required low temperature is attained inside the cold room thermostat cuts off the contactor C1 which, in turn stops the compressor. The

‘condenser-fan’ also stops and ‘Ref neon goes off’. When the temperature inside cabinet again rises and attains the preselected / present higher limits, the thermostat will again operate and the above action will be repeated. This way the temperature inside the cold room will be maintained within the required ranges.

27

2.Alarm Condition

There are alarm circuits (a) in the cold panel for high temperature inside the cold-room and (b) in the generator panel for low engine tube oil pressure and/or high temperature and failure of the engine to start (Detail at item: 4 at page 3).

When temperature inside the cold room rises to or above the present temperature thermostat T1 operates. Its contacts close and operate light and audio alarm (If any) and also alarm relay C1. The alarm continues even If alarm condition is over.

The alarm should go off when reset button b2 is pressed and temperature inside the cold-room panel has come down. It will not go off till the temperature the temperature inside the cold room comes down below +

10

0

C even though b2 is pressed.

3 Mains Power Supply Failure Condition (Generator Panel)

As soon as the main power fails. Relay N1 and NK drop off and

lamp X2 extinguishes. a) When MAN/AUT selector is at 0 OFF position, the generator will not start automatically and cannot be started manually also. b) When MAN/AUT selector is at (MANUAL) position

The generator-set will not start automatically but can be started manually by pressing START button. On pressing the start button relay RH1 operates and the starter of the engine (M) works and starts the engine. Release the start button when the engine gains speed. When the generator has built up required voltage relay T3 will operate after the present time (10 sec) (Ref Diag 2,3) and will turn operate relay GK, which will extend the generator power supply to R&O output terminals for cold room panel (consumption).

28

When mains power supply will return relay N1 will operate again but NK will not operate and also X2 will not glow. Now to stop the engine press STOP button (Ref Daig 3 & 4) On pressing STOP button relays T2 and RH2 will operate and T2 will hold itself and RH2 for present time (20 sec) to permit the engine to stop completely.

At the same time T2 will oake GK to release (Ref Diag. 3 & 1)

GK releasing Generator supply to cold-room panel will the cut-off and NK will be operated which will extend the mains-supply to cold-room panel again. If by any chance, when the generator was running for trail etc, power failure occurs within that period N1 and NK will release and GK will operate and will connect generator power supply to cold room panel.

But on return of mains power supply the engine is to be stopped manually by pressing STOP button as explained above and then only the mains-contactor NK will operate extending mains power supply to the cold room panel. c) When MAN/AUT Selector is at 2 Automatic) position (Ref Diag

1,2)

In case of mains power failure, relays N1 and NK releases. The release of NK disconnects the mains supply circuit from output to cold room panel and also operates relay RH1 that will make the starter of the Engine (M) work. When engine picks up speed, T3 will operate after a present time (10 sec) (Ref Diag

3). T3 will operate GK and generator power supply will be extended to the cold room panel. When engine picks up speed

R1 will release & in turn release RH1 and stop engine starter.

When mains power supply returns, relay N1 will operate again,

Which in turn will operate RH2 and T2(Ref. Diag.4), The

Operation of RH2 will make the ‘stop-solenoid’ work to stop the engine. T2 will operate and will hold itself and RH2 for preset time (20 sec) to permit the engine to stop completely, also T2, while operating, will release OK which will withoraw the generator supply and operate NK to reconnect the mains supply to the cold-room panel..

4) Alarm Condition: Generator Engine Failure

If engine failure alarm lamp X1 glows and give alarm signal and the generator is observed to be not functioning or in standstill, it will indicate any of the following: a). Starting failure – (engine failed to start) b) Too low lube oil pressure Due to which the engine c) Two high engine temperature was stopped automatically

29

a) Starting Failure: Under power failure condition when MAN/AUT selector is at 2 (AUTO) position, NK releasing operates RH1 (as detailed earlier at 3c) and also Relay T1 gets supply to operate. But it actually operate only after the lapse of present time (20 sec) If the engine tried but could not start during above time, T1 will operate and will release RH1 and hence stops starter (M) and also blocks further start command

(If generator starts within the present time of T1 of GK will operate before the above present time. Then T1 will be prevented from operation and no alarm will come). b) Too low lube oil pressure: If lube oil pressure becomes low

(normal) 2.B BAR 40 Psi in the engine while running the oil switch (P) in the engine will operate which will in turn operate Relay R2 and Alarm lamp X1 will glow and also audio-alarm will come. R2 operating operates RH2 and T2 and engine will stop detailed earlier at 3c R2 will hold itself and X1 till it is reset (To reset bring MAN/AUT selector switch to 0 position). c) Too High Engine Temperature

The alarm will stop when the selector is turned to ‘0’ position. But in case of above failures (in a & b) it will not actuate again and engine can be tried to start/started after due checkup and attention. But in case of high engine temperature (for engine running for longer period poor ventilation etc) engine thermostat will operate and remain closed till the temperature reduces to required level. Hence turning selector to MAN or AUT position may actuate R2 and

X1 again and stop any further starting if the temperature of the engine is still high than normal.

30

Trouble-Shooting (Genr Panel/ MAINS-CKT)

NOTE: In case of electrical troubles – always check the FUSES and circuit breakers first

Circuit breakers trip off/ fuses blow off when there is an overload in the circuit in which they are incorporated. In such cases reset (put on again) the circuit breaker/replace the blown – off fuse with one of same capacity and observe if the same trips off/blows- off again. If trip/blow-off occurs again this will mean that there is a persistent fault in the circuit. Assistance from

Maintenance Engineer will be necessary to rectify them.

A. No General Power Failure. But Generator Is Running (Local power

failure condition)

Blowing-off of fuse in main-switch or tripping-off of circuit breaker in the mains-supply circuit or at any other stage of the network may also actuate the generating set. To confirm it, connect an electrical lamp across R (2T1) & 0 (4T2) terminals on NK relay. If mains-supply circuit defective the lamp will not glow. (Also with a multimeter or voltmeter the mains supply at the control may be tested across the above points). In such cases put the mains switch OFF & ascertain and locate the fault in the mains circuit (If required, through local PWD/SEB/PHE electrical technicians) and rectify it

After rectification, put the mains-supply switch ON again.

31

B) NO POWER FAILURE; POWER AVAILABLE UPTO (2T1 6

0 (4T2 ON NK RELAY BUT GENERATOR IS RUNNING.

Check Fuses S5 and S6 – if defective – replace

If OK

Observe Relay N1 – if not operating – replace

If operating

Observe Relay NK – if not operating – replace

If operating

After replacement, the engine should—if not— NOTIFY MAINTENANCE

Stop now and mains power to cold room ENGINEER

Panel will be available

32

C ) IN CASE OF POWER FAILURE GENERATOR IS RUNNING BUT UNIT NOT

WORKING

1. Check if Voltage shown - If not - a) check fuses S7 & S8 & replace

If yes

defective ones.. b) Check generator breaker N1, If

2.

R&O

Tripped-off, reset

Check voltage across terminals c) Check Alternator output voltage

across terminals. A-D

If not If available, the i) If no voltage, alternator may

Available fault is beyond

Generator panel be defective

NOTIFY MAINTENANCE ENGINEER

(see F at page12) ii) If voltage available .

3. Observe relay Ok

If operating

If not operating

Observe T3 & Aux. 61-62 of NK

Check the continuity of If operating Any of above not operating-

The panel AAMETER.

If defective – replace.

Replace.

OK should operate now.

(By shorting the 2 Ok should terminals, of the ammeter, operate –

UNITS can be kept operat -

Ing till replacement)

If Operating If not operating, OK may be

Defective – replace.

If OK If OK not

Operating operating

NOTIFY MAINTENANCE

ENGINEER

4. Observe voltage across If not available

R & O again. NOTIFY MAINTENANCE ENGINEER

If available

Proceed as per

‘F’ in page. 10

33

D) GENERATOR DOES NOT START IN CASE OF POWR FAILURE

Check MAN/AUT selector position. If it is at ‘0’ or MAN (I) Position, the generator will not start automatically. Change position to AUT (2), the generator should start automatically,

If it does not start, then change selector position to MAN (1) and try to start manually.

GENERATOR DOES NOT START IN EITHER ‘MAN’ OR ‘AUTO’ POSITION OF

SELECTION :

(While checking as below, put selector at ‘0’position),

2.

1. Check battery connections – If defective – Take out fuse S3 4

Rectify Battery connection

& refix the fuse.

If OK

Check fuse S1 - If loose or defective - rectify/replace it

If OK

3. Check connections to terminals 1 & 2 - If defective / loose – rectify it.

If ok

4. Check connection battery - If poor – fit a good replacement battery

If ok

5. Return selector to ‘MAN’ & ‘AUTO’ positions one after another and observe again if

Generator can be started, if not = NOTIFY

Maintenance Enginer

E) ALARM CONDITION - GENERATOR ENGINE FAILURE

ALARM /AUT STOP Lamp ‘x1’ will glow (& give give audio alarm) in case of any of the following failure: Reset alarm by turning ‘MAN/AUT’ ‘SELECTOR to ‘0’ position once.

(Alarm will get cancelled in case of 1 & 2 below but will activate again in case of 31.

(I) STARTING FAILURE.

Engine failed to start automatically in Mains power failure condition.

Check fuel lever in generator engine fuel tank, if empty, fill up, a) b) Check for any looseness at the terminals c) Check battery for discharged /undercharged condition. If discharged – replace with a charged battery ( and also follow as 6 below & notify MAINTENANCE ENGINEER)

34

NOTE: *Turn MAN/AUT Selector to 0 before removing the battery & turn into AUT or MAN position after replacement.

**Polarities are to be marked before disconnection & new Battery should be connected accordingly.

(d) Try to start the generator again. If does not start – notify

Maintenance Engineer.

(2) TOO LOW LUBE OIL PRESSURE

(a) Check lube oil level in the engine chamber – If less – add required quantity

(b) Start generator and observe lube oil pressure on the gauge. It should be normally 2.8 BAR (40 psi). If the pressure is observed to be around the same, but alarm comes on again – the pressure – switch may be defective

(which may have to be replaced) or generator might have stopped due to high engine temperature.

Follow as E (3) below & NOTIFY Maintenance Engineer

(3) TOO HIGH ENGINE TEMPERATURE

Alarm stops when selector turned to 0 but actuates again when turned to either MAN or AUT position. a) Turn selector to ‘0’. b) Allow generator engine to cool down. c) Turn selector to AUT or MAN position and observe I alarm comes again. If it comes allow more time to cool down further When

Alarm does not actuate again can be started on AUTO or

‘MAN’ selection.

NOTE: If mains power supply return within the above OFF period of

Generator, it will be extended automatically to the cold-room panel by operation of N1 & NK. In that case, wait till engines cools down

& then turn selector to AUTO position for turn selector to AUT and allow the engine to cool down.

:For any abnormality observed in the above steps notify maintenance engineer.

______________________________________________________________

IMPORTANT If the MAINS POWER SUPPLY VOLTAGE BECOMES TOO LOW

GENERATOR may start and run automatically, in such cases, it is advised to keep the

MAINS power supply switch OFF till correct voltage is restored in the supply.

35

F) COLD ROOM PANEL / UNIT

Power supply( either from MAINS or GENRATOR) is available at R-O, outlet terminals of

generator – panel , but UNIT not working.

1 . Check if switch B1 is OFF – if OFF – put it ON

2. Check supply voltage at terminal outlet 1-2 (for UNIT-1, selector b3

at position1) & 3-4 (for Unit 2, selector b3 at position -2) If not

available- notify . Maintenance enginer.

If ON

3 . Check switch ‘S1’ and Circuit – Breakers CB1, CB2 on selected unit if OFF Put ON

If ON

4 . Observe the following :

•

Power neon should glow

•

Evaporator fan should run

And

•

If cold room temp is higher then pre set – and also if not in defrost cycle, compressor, cond fan should run and refrigeration neon should glow – if not – NOTIFY

Maintenance Enginer.

NOTE : If all the above are working but yet, no cooling is obtained, observe the “sight-

glass” in the unit, if you can see the liquid gas. If no ges is observed or, only bubbles

are observed – Refrigerant must have leaked out from the system.

NOTE : Repeat steps 3 & 4 above, with the other unit also. By selecting the same with

selector b3 on cold – room panel and NOTIFY OBSERVATIONS TO Maintenance

Engineer.

G) . BATTERY DOES NOT SET CHARGE

Check fuses , S1,S3,S4. If no changing is observed even after that, notify

Maintenance Engineer.

36

H) COLD ROOM-TEMPERATURE OBSERVED TO BE DIFFERENT THAN THE

I)

SET RANGE

Normally, the unit thermostat are adjusted in such a way that units starts working when the cold room inside temperature is around 8’

0

C and goes of when temperature comes down to around 4

0

C is observed that actual temperature during normal operation varies than the pre-set range NOTIFY Maintenance Engineer.

NOTE:(When large quantity of fresh vaccines is put inside the room the temperature may go up temporarily but will come down again after some time – this may not be considered as abnormality. However if temperature remains above 8’0C for more than an hour alarm in the cold room panel will come. Reset by turning selector to 0 position.

MAINTENANCE OF BATTERY a) Open the cap on each cell and measure the specific gravity of the acid in each cell with a hydrometer. Record the readings in a table. The gravity can very from 1.28

(when full charged) to 1.12 (when completely charged) if the gravity is blow 1.23 battery is to be charged separately. NEVER DISCONNECT THE BATTERY

BEFORE ‘FUSE S 3 is taken out’. Refix fuse after battery is reconnected. b) The acid level in the cells should be about 5 to 10 mm above the top of the seperators. If not refill with distilled water (never add

ACID)

c) Battery should always be kept clean and dry. d) The charging rectifier operates automatically and keeps the battery fully charged. The battery voltage is normally 12 to 14.4 volts. e) If the battery is mounted on the generator frame ensure that it is held firmly by the arrangement provided. f) Check the connection of terminal-clean and poles of the battery. It should be tight and clean. If sulphation is observed the same should be cleaned and refitted. The above connection point should always be kept covered with some petroleum jelly.

37

appendix

Appendix a) b) c) d) e) f) g) h)

I) j)

Content

Sequence of operation of relays

Loading instructions, Safety Precautions, General Maintenance

WIC Check-chart (for Operators)

Generator set – Maintenance

WIC/WIF Check-list (for Technicians

Testing Board Type 8610 and testing of different relays

Testing procedure for Dynamo and charging relay

Maintenance of Charger E1

Cold-room Panel, 1-phase 220V (Old Type)

Freezer-room Panel, 3-Phase

400 V (New Type)

38

APPENDIX

a

FOSTER

Cold-Room

Sequence of operation of relays

Generator/power-supply panel

1.Mains power ON

2.Mains power OF selector at AUTO starting failure

3.Generator RUNNING Selector at AUTO/MANUAL

4.Mains power Returns selector at AUTO

5.Mains power OFF Selector at MANUAL

6.Mains power RETURNS Selector at MANUAL

Cold-room Panel

Solo Units

Page .

40

40

41

42

43

43

44

45

39

Foster Cold – Room

Generator / power – supply panel

LEGEND :

+ = Operator / Close

- = release / open

(-) = not operate

(+) = held operated

MAINS POWER ‘ON ‘

N1

+

_(8-11)

(6-7)

+

-

prevents auto start

prepares auto stop ckt

(1-3)

+

X2

+

NK

+

_ (61-62)

prevents operation of gk

(51-52)

-

prevents +ve supply from charging relay

(main contacts)

+

Extend ‘MAINS’ supply to

Cold –room panel (at R.O)

MAINS POWER ‘ OFF ‘ Select at ‘ AUTO ‘ – R1

+

- (1-3)

+

prepares start – ckt

NK

+

N1- _ (1-3) – prevents Nkoperation

(8-11)

+

(main

Contact) RH1 T1 (start)

Disconnect ‘MAINS’

Supply ckt. from (87-30)

+

(after pre-set time,20 sec)

Cold-room panel

M

+

(starts) T1 + _ (1-4)- if generator could not

Start during above preset time

(9-11)

+

This contact prevents further start

command releases RH1 hence m

ALARM

+

X1

+

R2

+

_ (1-4)

(6-7)

+

-

prevents RH1 operation

(9-11)

+

prepares RH2 path

Holds R2, X1 and ALARM continues unit

RESET BY BRINGING SELECTOR TO ‘O’ POSITION

* STARTING FAILURE

40

FOSTER COLD – ROOM

Generator / power – supply panel

GENERATOR ‘ RUNNING ‘

R1

-

T3 (starts)

When engine (after pre-set time 10ses

Picks up speed allowing generator to buildup voltage)

& DC is available from

Dynamo T3

+

(1-3)

+

(1-3)

-

GK

+

_(61-62)

-

prevents NK operation

(13-14)

+

prepares auto- stop ckt

(5-6)

+

prepares ‘low lubeoil alarm’ ckt.

(main (51-52)

-

Contacts)

+

T1

(-)

IF GENERATOR RUNS WITHIN

Extend ‘GENERATOR’ THE PRE-SET TIME DELAY OF

Supply to cold-room In case OPERATION OF T1(20 sec).

Panel (at R.O) R1 doesnot release i.9 GK OPERATES BEFORE

THE LAPSE OF ABOVE PRE-SET

TIME (20 SEC),T1 WILL NOT

OPERATE & HENCE ALARM CKT.

WILL REMAIN IN-OPERATIVE

FOR THE ABOVE PERIOD.

RH 1

-

(87-30)

-

M

–

(stops)

*The above sequence of operation is common for both ‘ AUTO ‘ and ‘ MANUAL ‘

position Of selector – switch .

41

FOSTER COLD – ROOM

Generator / power – supply panel

MAINS POWER ‘ RETURNS ‘ (ON again) selector at ‘ AUTO ‘

N 1

+

_ (8-11)

-

prevents auto –start

(1-3)

+

prepares NK ckt .(standby).

(6-7)+

RH2

+

T2

+

(and hols for preset time, 20sec.

Allowing the generator to stop

(87-30)

+

completely)

STOP SOLENOID

+

(1-4)

-

prevent RH1 operation for

preset time,20 sec.

(8-11)

-

(1-3)

+

GK

-

_ (main contacts)- withdraw

(+) generator supply from cold-room

RH2, T2 holds operated panel for pre-set time (51-52)+ prepares RH1ckt

(standby)

(after lapse of (13-14)- prevents auto–stop ckt

Pre-set time of T2) (5-6)- prevents low lube oil

alarm ckt.

T2

-

(61-62)

+

(1-3)

-

NK

+

_ (61-62)

-

prevents operation

Of GK

RH2

-

(51-52)

- prevents ‘+ve’ supply

From charging-relay.

(87-30)

-

(main contacts)+

STOP SOLENOID

–

Extend ‘ MAINS ‘ supply to

Cold – room panel again

42

FOSTER COLD – ROOM

Generator / power – supply panel

MAINS POWER ‘ OFF

‘ ,

selector at ‘ MANUAL ‘ R1+ (1-3)

+

prepares

Start ckt.

NK

-

N1

-

_ (1-3)

-

prevents NK operation

(main contacts)-

‘ START ‘ Button Pressed

Disconnect ‘ MAINS ‘

Supply from (contacts)

+

Cold – room panel

RH1

+

(87-30)

+

M

+

(starts)

After Generator pick up speed,

‘ START ‘ button Released

(contacts)

RH1

–

GENERATOR ‘ RUNNING ‘

(see page) (87-30)

-

M

-

(stop)

MAINS POWER ‘ RETURNS ‘ (ON again) , selector at ‘MANUAL ‘

N 1

+

_ (NK

- and X2

–

as GK

+

)

‘ STOP ‘ Button Pressed

(contacts)

+

RH 2

+

T2

+

(87-30)+

STOP SOLENOID

+

* Next sequence of operation

Similar to that detailed in page C ,

for selector at ‘ AUTO ‘

43

FOSTER

COLD ROOM PANEL

(New type)

1 phase , 220V

Sequence of operation

B1

+

C2

+

when voltage is Door

+

Temp

+

Power

above set limit Heater Recorder supply

(supply at for lights

9,10) (at.7-8)

B3 (at 1) B3 (at2)

Power supply for Power supply for

Unit-1 (at1-2) unit-2 (at 3-4)

When running on when running on

Generator supply generator supply

And also for and also for

UNIT-2 (at,3-4) UNIT-1 (at,1-2)

Through NK(33-34)

+

through NK (33-34)

+

When running on when running on

Network supply network supply

Cold – room TEMP. HIGH , above pre – set limit

T 1

+

C1

+

C1 will hold till reset by pressing

B2 after Alarm condition is over

ALARM

+

(supply at 5-6)

44

FOSTER COLD – ROOM

“ SOLO “ UNITS

Normal running : CB1

+

, CB2

+

(to be kept on)

S1

+

Power

+

Evpr

+

T1 (working , normal)#

Neon Fan

(6-7)

+

(If system refrigerant pressures

Within pre-set limits, HP/ LP

+

)

(If coldroom temp higher than

Pre –set lower limit

THERMOSTAT

+

)

THERMOSTAT

+

C1

+

Condr

+

Refrign

+

Fan Neon

(1-2)

+

COMPRESSOR +

* When pre –set low temp attained

the cold - romm

THERMOSTAT +

C1

+

Condr

+

Refrign

+

Fan Neon

(1-2

)+

COMPRESSOR

+

DEFROSTING : 2 cycles of 20 min. duration each per day at 12 hours intervals (pre – set)

T1 (Working, during defrosting)

(6-7)-

C1

+

CONDr

+

REFRIGN

+

FAN NEON

(1-2)

+

COMPRESSOR - # After defrosting period T1 (6-7)

+

Running continues as above

again & normal

45