You are on page 1of 45

‘foster’

cold- room

technicians’
hand-book
( REVISED )

1
‘Foster’ cold- room
Technicians’ Hand-book

Contents Page
General Information 3

Interconnection wiring between different units 5


Layout diagrams 6

Description of main components


Generator panel
Cold-room panel (old type) 7 & 18

‘Solo’ Units 19 & 25

Circuit/Layout Diagrams
Walk-In-cold rooms 9 - 17

Walk-In-Freezer rooms 20 - 25
Normal Operation

1. Initial starting & normal operations 27


2. Alarm condition (high temp in cold-room) 28
3. Mains Power Supply failure conditions 28
4. Alarm Condition – Generator engine failure 28
Trouble-shooting

A. No general power failure, but generator is running 31


B. No power failure, Mains power available upto generator panel, but 32
generator is running
C. In case of power failure, Generator is running but unit not working 33
D. Generator does not start in case of power failure 34
E. Alarm condition – Generator Engine Failure 34
F. Cold-room panel/Unit 36
G. Battery does not get charge 36
H. Cold-room temperature observed to be different than the set range 37
J. Maintenance of battery. 37

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 + 40 to +80C 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 + 50C and goes
off at about + 40C and the other works when the
temperature is about + 7’0C and goes off at about + 60C.

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 + 100C.

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 – to operate the alarm system.

C2 Low voltage protector.

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 & consider-
fan ON or OFF as per requirement.

8
DESCRIPTION OF MAIN COMONENTS

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

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


5 sec. pause fitted
Date 850227 Corr
851125
Hjalte Nattestad a-s 861110 SWITCHBOARD
1*220V / 50Hz 3-68-137
Nattestad Dk 2800 Glostaup . Denmark
Orawn jb ls
Eel 02-456265
Consir 01 Scase Order no
6940

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

TERNATOR *M1=
Generator
220 V Breaker, normally
1Ø 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
o
t = 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-nocket-
relay220v
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

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


5 sec. pause fitted

Date 850227 Corr


851125
Hjalte Nattestad a-s 861110 SWITCHBOARD
1*220V / 50Hz 3-68-137
Nattestad Dk 2800 Glostaup . Denmark
Orawn jb ls
Eel 02-456265
Consir 01 Scase 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
Normally kept
CLOSED.

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

FREEZER – ROOM OPERATING FROM GENERATOR SUPPLY

.
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 +
100C 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


defective ones..
If yes b) Check generator breaker N1, If
Tripped-off, reset
2. Check voltage across terminals c) Check Alternator output voltage
R&O across terminals. A-D
If not If available, the i) If no voltage, alternator may
Available fault is beyond be defective
Generator panel NOTIFY MAINTENANCE ENGINEER
(see F at page12)
ii) If voltage available .

3. Observe relay Ok If not operating

If operating Observe T3 & Aux. 61-62 of NK

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


The panel AAMETER. Replace.
If defective – 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),

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


Rectify Battery connection
& refix the fuse.
If OK

2. 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.

a) Check fuel lever in generator engine fuel tank, if empty, fill up,

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
SET RANGE

Normally, the unit thermostat are adjusted in such a way that units
starts working when the cold room inside temperature is around 8’0C
and goes of when temperature comes down to around 40C
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.

I) 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 Content

a) Sequence of operation of relays

b) Loading instructions, Safety Precautions, General Maintenance


c) WIC Check-chart (for Operators)
d) Generator set – Maintenance

e) WIC/WIF Check-list (for Technicians

f) Testing Board Type 8610 and testing of different relays


g) Testing procedure for Dynamo and charging relay
h) Maintenance of Charger E1

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

j) Freezer-room Panel, 3-Phase


400 V (New Type)

38
APPENDIX a

FOSTER
Cold-Room
Sequence of operation
of relays

Generator/power-supply panel Page .

1.Mains power ON 40
2.Mains power OF selector at AUTO starting failure 40
3.Generator RUNNING Selector at AUTO/MANUAL 41
4.Mains power Returns selector at AUTO 42
5.Mains power OFF Selector at MANUAL 43
6.Mains power RETURNS Selector at MANUAL 43

Cold-room Panel 44
Solo Units 45

39
Foster Cold – Room
Generator / power – supply panel

LEGEND :
+ = Operator / Close
- = release / open
(-) = not operate
(+) = held operated
MAINS POWER ‘ON ‘
+ -
N1 _(8-11) prevents auto start
(6-7)+ 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) prevents RH1 operation
(9-11)+ prepares RH2 path
+
(6-7)

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

T1+

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) again & normal
Running continues as above

45