Booklet On Roof Mounted Package Unit of LHB Coaches-30 - 03 - 2021

(For Official Use Only)
भारत सरकार GOVERNMENT OF INDIA

रे ल मंत्रालय MINISTRY OF RAILWAYS
Booklet on
Roof Mounted Package Unit
of LHB AC Coaches
End User: Electrical Coaching Maintenance Staff
CAMTECH/E/2020-21/EP-06/RMPU-LHB/1.0
March, 2021
Maharajpur, GWALIOR - 474 005

ii
Booklet
on
Roof Mounted Package Unit (RMPU)
of LHB AC Coaches
iii
QUALITY POLICY
“We at RDSO, Lucknow are committed to maintain and update

transparent standards of services to develop safe, modern and cost
effective railway technology complying with statutory and regulatory
requirements, through excellence in research, designs and standards
by setting quality objectives, commitment to satisfy applicable
requirements and continual improvements of the quality
management system to cater to growing needs, demand and
expectations of passenger and freight traffic on the railways through
periodic review of quality management systems to achieve continual
improvement and customer appreciation. It is communicated and
applied within the organization and making it available to all the
relevant interested parties.”
iv
FOREWORD
Air conditioning of the Railway Coaches is a priority requirement for passenger comfort
and to provide a comfortable environment inside the coach for passengers travelling in a train.
In LHB coaches, air conditioning i.e. supply of clean fresh air at a controlled uniform
temperature is achieved by provision of two Roof Mounted Package Units (RMPU) in each
coach. The proper upkeep and maintenance of these units is essential to ensure proper working
during the journey of the train.
To ensure wide dissemination of knowledge on Roof Mounted Package Units of LHB

Coaches, CAMTECH, Gwalior has prepared this booklet. This booklet comprises brief on
technical and constructional features, functional description, working of RMPU and its
Microprocessor Controller, maintenance activities etc.
I am sure that this booklet will be useful for field maintenance staff of coaching stock in
their day to day working and improving the reliability and safety of coaching stock on Indian
Railways.
CAMTECH Jitendra Singh

Date: Principal Executive Director
v
PREFACE
Air-conditioning of railway coaches is a priority passenger amenity for the maximum

comfort and well-being of passengers in a railway travel. Microprocessor controlled, two air
conditioning package units (RMPUs) are provided on roof of each LHB coach and they are
controlled by single microcomputer based controller. These air conditioning units work in fully
automatic mode. Depending on ambient temperature, available modes of heating, ventilating,
cooling and dehumidifying are selected and controlled.
These units can work satisfactorily on End On Generation (EOG) and Head On
Generation (HOG) type AC coaches. The generator car is provided only with one air
conditioning unit. Each RMPU comprises two distinct refrigeration circuits i.e. two compressors,
two condensers, two cooling coils, one heater etc. The RMPU of LHB coaches has various
features like thermal switch protection for motors, pressure transducers for LP/ HP
measurement, NTC type temperature sensors, humidity control through Hygrostat,
Connections through Harting connectors (Plug & Socket) etc.
Booklet on “Roof Mounted Package Unit (RMPU) of LHB AC Coaches” has been prepared
by CAMTECH, Gwalior with the objective to disseminate the knowledge. This booklet comprises
the details of RMPU and microprocessor Controller Unit along with functional details and
maintenance practices. This booklet also comprises the basic terminology used in heating,
ventilation and air conditioning (HVAC). This will be useful for electrical coaching maintenance
staff over Indian Railways.
It is clarified that this booklet does not supersede any existing provisions laid down by
Railway Board/ RDSO, OEMs. This booklet is for guidance only and it is not a statutory
document.
I am sincerely thankful to Shri B. C. Agrawal, SSE/EL/CAMTECH, Smt. Sangeeta

Shrivastava, JE/IT/CAMTECH, and all field personnel who helped us in preparing this handbook.
Technological up-gradation & learning is a continuous process. Please feel free to write us for
any suggestion/ addition/ modification in this booklet.
CAMTECH, Gwalior Himanshu Maheshwari

Date: 30.03.2021 Dy. Director /Electrical
vi
CONTENTS
Page No.
FOREWORD.................................................................................................................................................iv
PREFACE.......................................................................................................................................................v
CONTENTS...................................................................................................................................................vi
LIST OF FIGURES........................................................................................................................................viii
ISSUE OF CORRECTION SLIP.........................................................................................................................ix
DISCLAIMER.................................................................................................................................................x
OUR OBJECTIVE............................................................................................................................................x
ABBRIVIATIONS...........................................................................................................................................xi
CHAPTER 1 GENERAL DESCRIPTION....................................................................................................1
1. INTRODUCTION.................................................................................................................................1
2. WHY AIR CONDITIONING IN RAILWAY COACHES IS REQUIRED.........................................................2
3. BASIC REQUIREMENTS FOR COACH AIRCONDITIONING SYSTEM......................................................2
4. SALIENT FEATURES OF RMPU FITTED ON LHB AC COACHES..............................................................2
5. TRANSPORT AND STORAGE...............................................................................................................3
6. TECHNICAL DATA (PER UNIT).............................................................................................................3
7. DETAILS OF AIR CONDITIONING SYSTEM IN LHB AC COACH..............................................................5
7.1. Compact Air Conditioning Unit (RMPU).............................................................................5
7.1.1. Compressors.......................................................................................................................6
7.1.2. Condensers and Condenser Fans.......................................................................................7
7.1.3. Evaporators (cooling unit)..................................................................................................8
7.1.4. Supply Air Fan and Blower Motor.......................................................................................9
7.1.5. Heating Assembly...............................................................................................................9
7.1.6. Pressure Transducers.......................................................................................................10
7.1.7. Air Filters..........................................................................................................................10
7.1.8. Humidity Control..............................................................................................................10
7.1.9. NTC type sensors..............................................................................................................11
7.1.10. Protections.......................................................................................................................11
7.1.11. Other Components, Control and Safety Devices of RMPU...............................................12
7.1.12. Fresh Air Screens..............................................................................................................13
8. ELECTRICAL CONTROL PANELS........................................................................................................13
9. Microprocessor Based Controller for RMPU....................................................................................14
9.1. LAYOUT OF LEDS IN MICROPROCESSOR CONTROL UNIT.......................................................17
9.2. Microprocessor Control Panel...............................................................................................19
vii
9.3. Fault Storage/ Self Diagnostic System...................................................................................20

10. FUNCTIONS AND MODES OF OPERATION OF RMPU.......................................................................20
10.1. Pre-Heating Mode.................................................................................................................21
10.2. Pre-Cooling Mode..................................................................................................................21
10.3. Normal Operation Mode.......................................................................................................21
10.4. Cooling Mode........................................................................................................................21
10.4.1. Temperature Regulation in Cooling Mode................................................................22
10.5. Heating Mode........................................................................................................................22
10.5.1. Temperature Regulation in Heating Mode...............................................................22
10.6. De-Humidification..................................................................................................................23
10.7. Shut Down Mode...................................................................................................................23
10.8. Manual mode........................................................................................................................23
10.9. Sleep Mode Operation...........................................................................................................23
10.10.Other Functions of Controller................................................................................................24
11. PROTECTION DEVICES (MCBs AND FUSES)......................................................................................24
12. CONTACTORS & RELAYS...................................................................................................................25
13. THREE PHASE POWER TERMINAL FOR RMPU..................................................................................26
14. ADDITIONAL FEATURES OF RMPU DOUBLE DECKER........................................................................27
CHAPTER 2 MAINTENANCE......................................................................................................................28
2. General............................................................................................................................................28
2.1. Refrigerant Pipe Line/ Capillary...............................................................................................31
2.2. Compressors...........................................................................................................................31
2.3. Condenser Fans Motor/ Blades and Blower Motor/ Impeller32
2.4. Return/ Fresh Air Filters..........................................................................................................33
2.5. HP/ LP/ OHP Cutout Switch.....................................................................................................34
2.6. Heater.....................................................................................................................................34
2.7. NTC sensors.............................................................................................................................34
2.8. Expansion Valve/ Capillary Tubes............................................................................................35
2.9. Evaporator Coil........................................................................................................................35
2.10. Filter Drier & Sight Glass........................................................................................................35
2.11. Access Doors..........................................................................................................................36
2.12. Drip Tray................................................................................................................................36
2 13. Condenser Area36
2.14. Microprocessor Controller.....................................................................................................37
CHAPTER 3 RMPU TROUBLE SHOOTING............................................................................................38
REFERENCES...............................................................................................................................................48
viii
LIST OF FIGURES
Figure 1: LHB Coach fitted with RMPUs at both ends................................................................1

Figure 2: Compact air conditioning unit (RMPU)........................................................................6
Figure 3: Major Sections of RMPU............................................................................................. 6
Figure 4: Compressors in RMPU.................................................................................................7
Figure 5: Axle fans (Condenser Fans) along with motors in RMPU............................................7
Figure 6: Condenser units in RMPU............................................................................................8
Figure 7: Evaporators units in RMPU..........................................................................................8
Figure 8: Twin-sucking radial fans for the supply air in RMPU...................................................9
Figure 9: Heating Unit in RMPU................................................................................................. 9
Figure 10: pressure transducers (pressure switches).................................................................10
Figure 11: Humidity sensor........................................................................................................ 10
Figure 12: NTC type temperature sensor...................................................................................11
Figure 13: HP/ LP Cut Out (Cartridge type).................................................................................11
Figure 14: Overheat protector (Bimetallic type thermal switch)................................................12
Figure 15: Fresh Air Screens.......................................................................................................13
Figure 16: Control Panel for RMPU............................................................................................13
Figure 17: Switch Board Cabinet................................................................................................ 14
Figure 18: Block diagram of Control System of RMPU...............................................................15
Figure 20: Microprocessor Based Controller for RMPU..............................................................16
Figure 21: Operation Panel for Air Condition System.................................................................19
ix
ISSUE OF CORRECTION SLIP
The correction slips to be issued in future for this handbook will be numbered as
follows:
CAMTECH/ E/EP-06/2020-21/RMPU/1.0/C.S. # XX date---
Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).
CORRECTION SLIPS ISSUED
Sr. No. Date of Issue Page no. & Item no. modified Remarks
x
DISCLAIMER
It is clarified that the information given in this booklet does not

supersede any existing provisions laid down by the Railway Board, RDSO
and OEM’s Manual. This document is not statuary and instructions
given are for the purpose of guidance only. If at any point contradiction
is observed, then Railway Board/RDSO guidelines and OEM’s
Maintenance and Operating Manuals may be referred.
OUR OBJECTIVE
To upgrade maintenance technologies and methodologies and achieve

improvement in productivity and performance of all Railway assets
and manpower which inter-alia would cover reliability, availability,
utilization and efficiency.
If you have any suggestion & any specific comment, please write to us:
Contact person: Dy. Director (Electrical)
Postal Address: Centre for Advanced Maintenance Technology,

Opposite Hotel Adityaz, Near DD Nagar,
Maharajpur, Gwalior (M.P.) Pin Code – 474 005
Phone: 0751 - 2470740
Fax: 0751 – 2470841
E-mail: direlcamtech@gmail.com
xi
ABBRIVIATIONS
Abbreviation Details
AC Alternating Current
AC Air Conditioner/ Air Conditioning
CB Circuit Breaker
CP Control Pressure
DBT Dry Bulb Temperature
DC Direct Current
DU Display Unit
EOG End On Generating
ESTI Thermal Fuse to Prevent Excessive Heater Temperature
FA Fresh Air
FAT Fresh Air Temperature
GD Grains Difference
HMI Human Machine Interface (Display Unit)
HOG Head On Generating
HP High Pressure
HVAC Heating, Ventilation And Air Conditioning
ICF Integral Coach Factory
IEC International Electro Technical Commission
IOH Intermediate Overhaul
IR Indian Railways
IS Indian Standards
IV Inter Vehicular
K Coefficient Of Heat ‚ Transfer-K Cal/Hr/M2/°C
kg Kilogram
kW Kilo Watt
LCD Liquid Crystal Display
LED Light Emitting Diode
LHB Linke-Hofmann-Busch
LHS Left Hand Side
LP Low Pressure
xii
MCB Miniature Circuit Breaker

MCS Mode Control Switch (Rotary Switch On The AC Control Panel)
MPCB Motor Protection Circuit Breaker
NTC Negative Temperature Coefficient
OHP Overheat Protector (Thermal Switch In Supply Air Opening To Prevent Overheating)
PC Personal Computer
POH Periodic Overhauling
PPE Personal Protective Equipment
PS Power Supply
RAT Return Air Temperature
RCF Rail Coach Factory
RDSO Research Design And Standards Organization
RH Relative Humidity
RHS Right Hand Side
RMPU Roof Mounted Packaged Unit
RMPU Roof Mounted Package Unit (= Roof Mounted Air Conditioner)
RPM Revolution Per Minute
SA Supply Air
SAT Supply Air Temperature
SG Self-Generating
SMI Standard Maintenance Instruction
SS Stainless Steel
t Tonne
TD Ambient Temperature Difference
TDS Solar Temperature Difference
TL Train Lighting
U Coefficient Of Heat Transfer For Window Due To Solar Heat Gain
UPF Unity Power Factor
USB Universal Serial Bus
V Voltage
-ve Negative
WBT Wet Bulb Temperature
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 1
CHAPTER 1
GENERAL DESCRIPTION
1. INTRODUCTION
Microprocessor controlled, two air conditioning package units (RMPUs) are provided on
roof of each LHB coach (2 tier, 3 tier & chair car) at the both ends. Both air conditioning
package units are controlled by single microcomputer based controller, mounted in switch
board cabinet and fed from battery net. These air conditioning units work in fully automatic
mode. Depending on ambient temperature, available modes of heating, ventilating, cooling
and dehumidifying are selected and controlled. These units can work satisfactorily on Self
Generating (SG), End On Generation (EOG) and Head On Generation (HOG) type AC
coaches.
The total cooling capacity of each LHB coach is 14.0 TR (2x22.5 kW) fitted with two nos.
RMPU units of 7.0 TR. each. The generator car is provided only with one air conditioning
unit. The units used in the different coaches of LHB variant are identical except in double
decker LHB chair cars. In double decker LHB chair car two units of 10 TR each are provided
at both ends.
Figure 1: LHB Coach fitted with RMPUs at both ends
In EOG and HOG coaches, power supply to these units are fed from 60 kVA step down
transformers, stepping down 750 V, 3 Φ AC, 4 wire, 50 Hz supply to 415 V, 3 Φ AC, 4 wire,
50 Hz supply. The 750V supply is fed to entire rake through two feeders running on both
sides of coaches along the full length of rake. This supply is either fed by power cars or
hotel load converters fitted on electric locomotives.
Air conditioned air is supplied via perforated ceiling in the passenger room, air
conditioning of entrance areas, toilets and pantry with return air. The 7.0 TR RMPU for
LHB coaches are being manufactured as RRDSO specification no.
RDSO/PE/SPEC/AC/0061-2005 (Rev.-1), December 2011. The RMPU is as per RDSO
Booklet on Roof Mounted Package Unit (RMPU of LHB AC Coaches March, 2021
drawing no. RDSO/PE/SK/AC/0069-2004 (Rev.-1). The Microprocessor Controller of RMPU

for LHB coaches and double decker coaches are being manufactured as per RDSO
specification no. RDSO/PE/SPEC/AC/0139-2009 (rev.-1), December, 2011.
The general functions of AC system for all type of coaches and generator cars are:
 Ventilation
 Air heater
 Air cooling
 Air dehumidification
 Air filtering
2. WHY AIR CONDITIONING IN RAILWAY COACHES IS REQUIRED

 Passengers during railway travel are adversely affected by infiltration of air
unpleasantly laden with dust due to open windows. This is more in case of high speed
passenger carrying trains.
 Secondly for a tropical country like India, the temperature varies from 48-degree C
during summer to 2-degree C during winter.
 Air-conditioning of railway coaches is, therefore, necessary for the maximum comfort
and well-being of passengers in a railway travel.
 In keeping passenger comfort on priority, air conditioning of coaches for passengers
is being done by the Indian Railways.
3. BASIC REQUIREMENTS FOR COACH AIRCONDITIONING SYSTEM

 Supply of clean fresh air at a controlled uniform temperature in the coach.
 Providing, within the confines of the Railway carriages to the continuously changing
number of on-board passengers.
 Provision for heating as well as cooling on a train that travels through areas of widely
differing climate during its journey round the year.
 Operation of the air conditioning equipment from self-generated power (Self
generating coaches), power from power cars (EOG coaches), power from locomotives
(HOG coaches) and controlled on the train.
 Securing sufficient air movement throughout the various section of the railway
coaches.
4. SALIENT FEATURES OF RMPU FITTED ON LHB AC COACHES

 Micro-Controller based AC Package unit. Control and regulation function of air
conditioning system (two nos. RMPU) are performed by single Microprocessor
controller unit with software installed in it.
 The refrigeration system comprises two distinct refrigeration circuits i.e. two
compressors, two condensers, two cooling coils, one heater etc.
 Servo-Motor Controlled Fresh Air Damper for automatic Pre-cooling / Pre-heating.
 Micro-Processor Control (with RS 232 Port) with fault Diagnostics and Data
acquisition system.
 Motors protected with Thermal switches.
 Pressure transducers for LP/ HP measurement

 NTC type temperature sensor
 Humidity Control through Hygrostat.
 Condenser Fan of Fire Retardant Plastic Blades.
 Compressor- hermetically sealed scroll type.
 Automatic temperature setting based on ambient temperature sensor and switch
over to Pre-cooling /Pre- Heating mode.
 Improved air duct design for better air flow and cooling.
 Connections through Harting connectors (plug & socket)
 Evaporator unit water tight
 Protective mesh of 3 mm SS over condenser fans
 Suck through type arrangement
 Light in weight
 Low cost of installation
 Power supply- 415 +/-5% V , 3 ph, 50 Hz+- 3%
 Control supply 110V ac, Single phase
 Capacity with one condenser- 75%
5. TRANSPORT AND STORAGE

 For ease of transportation, the air conditioner is mounted on a transport frame. It is
recommended not to unpack and remove the air conditioner from the transport
frame until it is to be installed on the coach roof.
 When the transport frame is not used, make sure the air conditioner is supported
under its mounting brackets and a gap remains under air conditioner in order to
avoid damages to the enclosure and the air interfaces.
 Do not place the air conditioner on the floor.
 The air conditioner must be stored in a weather protected space. Do not store the air
conditioner in the open. While in storage, all openings must be kept sealed to
prevent the ingress of rain water, dust, insects and rodents.
6. TECHNICAL DATA (PER UNIT)
S.No. Description Details

1. Application LHB Coaches & Power Cars
2. Cooling Capacity 7.0 TR
3. Heating capacity 6.0 kW
4. Compressor capacity 3.5 TR (two nos.)
5. Maximum power consumption 16.5 kVA
6. Supply Voltage 415 V, 3 Ø, AC, 50 Hz
7. Operating voltage 415 V, 3 Ø, AC, 50 Hz

8. Control Voltage 110 ± 30% V DC
9. Fan motor axial (for condenser) 1HP, 415V, 3 Ø
10. Fan motor radial (for evaporator) 1.5HP, 415V, 3 Ø
3
11. Fresh air supply (m /hr) 820 m3/h
12. Supply air flow 4000 m3/h±10%
13. Condenser Fan 0.75 kW, 415 V, 3 Ø, AC, 50 Hz, 1400
RPM (two nos.)
14. Supply air fan (Blower Motor) 1.1 kW, 415 V, 3 Ø, AC, 50 Hz, 1400
RPM (one no.)
15. Refrigerant R 407C
16. Weight (kg) 630 Approx.
17. Dimensions (mm) LxWxH 2220 x 2200 x 500
18. Material of enclosure Stainless steel (unpainted)
Safety Devices Provided in the RMPU
Equipment Protection Specifications Remark

Compressor motor 1 Temperature switch above 130 degree C
Compressor motor 2 Temperature switch above 130 degree C
Condenser fan motor 1 Temperature switch above 130 degree C
Condenser fan motor 2 Temperature switch above 130 degree C
Supply air fan Temperature switch above 130 degree C
Electric heater Thermostat (Over heat Beyond 65 degree C due
protection or OHP) to any reason
If OHP not acted then at 85 disconnection by
degree C, microprocessor by
opening respective
contactor
Fusible link (ESTI) at 130 degree C by
bursting the bulb &
permanent disconnection
of supply
Pressure switch / -sensor
Range 30-23 bar,
High pressure switch set at 430psig (29.65 bar) Auto Reset
Range 3.2 – 2.2 bar,
Low pressure switch set at 30psig (2.07 bar) Auto Reset
Control pressure switch
(discharge pressure of Range 20-16 bar
compressor) set at 275 psig (18.96 bar) Auto Reset
The AC package unit can work satisfactorily under following conditions:
Summer condition Dry Bulb Wet Bulb % R. H.

Outside (Dry summer) 50 degree C 25 degree C --
Outside (Wet summer) 40 degree C 28 degree C --
Inside (dry and wet) 20 to 25 degree C 60-40%
Winter Conditions
Outside - 4 degree C
Inside 17-21 degree C
7. DETAILS OF AIR CONDITIONING SYSTEM IN LHB AC COACH

The AC system for the LHB coaches consists of the following assemblies:
 Compact air conditioning unit
 Duct system
 Exhaust air system (Exhaust air unit, WC/WC exhaust fan, WC/ Switch cabinet
exhaust fan)
 Circulating air duct system
 Fresh air screen
 Open/closed-loop control devices
 Sensors
7.1. Compact Air Conditioning Unit (RMPU)
Each compact air conditioning unit (RMPU) has two separate cooling circuits consisting of
the following major components:
 Two hermetic sealed scroll compressors.
 Two condensers with Cu pipes and pre coated Aluminium fins.
 Two axel fans (condenser fans) with motors for cooling the condensers.
 Two evaporators (cooling units)
 Two twin-sucking radial fans for the supply air (driven by the Evaporator blower
motor)
 Three maintenance covers
 Two air inlets for circulating air
 One air outlet for supply air
 Control and safety devices
 Pipelines/fittings
 Two mixed air filters
Figure 2: Compact air conditioning unit (RMPU)
Figure 3: Major Sections of RMPU
7.1.1. Compressors
Two hermetic sealed scroll compressors along with Cu pipe lines are provided for two
cooling circuits in each RMPU. They are fixed with anti-vibration mounting pads for
reliable operation.
Each compressor of minimum 3.5 TR capacity at 60 Degree C condensing and 5 Degree

C evaporating temperature, making total rating of AC package unit 7 TR.
Figure 4: Compressors in RMPU
7.1.2. Condensers and Condenser Fans

Two Condensers with Cu tubes and pre coated Aluminium fins are provided for two
cooling circuits in each RMPU. These are air cooled and two axle fan (condenser fans)
along with motors are also provided in each unit for the cooling of the condenser fins.
They are fixed with anti-vibration mounting pads for reliable operation.
Figure 5: Axle fans (Condenser Fans) along with motors in RMPU
Figure 6: Condenser units in RMPU
7.1.3. Evaporators (cooling unit)
Two evaporators units with Cu pipes and pre coated Aluminium fins are provided for two
cooling circuits in each RMPU.
Figure 7: Evaporators units in RMPU
7.1.4. Supply Air Fan and Blower Motor
Two twin-sucking radial fans for the supply air (driven by single Evaporator blower
motor) are also provided in each unit for the supply of cooling air.
Figure 8: Twin-sucking radial fans for the supply air in RMPU
7.1.5. Heating Assembly
Each RMPU also has one three phase stainless steel heater element (one set) without
fins of 6 kW capacity. The heating coil is supplied with 415V-3~50Hz supply. Heater has
following protections:
1. Over heat protection switch for heater One

2. ESTI-1 cartridge + 130 degree C for ultimate disconnection of power One
supply
Figure 9: Heating Unit in RMPU
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 10
7.1.6. Pressure Transducers

Following pressure transducers (pressure switches) are provided in RMPU for the
protection and indication of various pressure (LP, HP) parameters while working of
RMPU. They ensure safe and reliable working of RMPU.
1. Pressure switch 23/20 bar Two

2. Pressure switch 23/20 bar Two
3. Pressure switch 0-40 bar Two
Figure 10: pressure transducers (pressure switches)

7.1.7. Air Filters
Following air filters are provided in RMPU for the filtration of air at various locations
while working of RMPU. They ensure clean air supply. Material is progressively
structured, non – woven break resistant, thermally bonded fire retardant synthetic
material.
1. Fresh air filters Two
2. Mixed (supply) air filters Two
3. Return air filters Two
7.1.8. Humidity Control
Relative humidity is controlled inside coach by RMPU and is

monitored by one Hygrostat (Range: 30-100% RH) located at
return air duct. It restricts the relative humidity level inside
the air conditioning compartment to a maximum of 60 %
under any circumstances. Desired temperature is achieved by
switching on heaters (50%) as per logic, such that the
combined power consumption does not exceed the
permissible power under cooling capacity.
Figure 11: Humidity sensor
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 11
7.1.9. NTC type sensors

Three NTC type temperature sensors for each RMPU
(total 06 nos. per coach) are provided to control the
temperature inside the LHB AC coach. The location of
temperature sensors are 1 Return Air, 1 supply air, 1
Air duct in one RMPU.
Figure 12: NTC type temperature sensor
The following temperature settings can be maintained inside the air conditioned
compartment by means of seven positions of the stepped rotary switch provided on the
Switch Board Cabinet.
Position of the Temperature

Rotary switch Cooling Heating
1 20.0 Deg C 17.0 Deg C
2 20.5 Deg C 17.5 Deg C
3 21.2 Deg C 18.2 Deg C
4 21.9 Deg C 18.9 Deg C
5 22.6 Deg C 19.6 Deg C
6 24.3 Deg C 20.3 Deg C
7 25.0 Deg C 21.0 Deg C
7.1.10. Protections
 LP, HP cut outs have been provided in the refrigerant circuit for protection in
case of low pressure and high pressure respectively.
Figure 13: HP/ LP Cut Out (Cartridge type)
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 12
Overheat protector (Bimetallic type thermal switch) has been provided in the heater
circuit.
Figure 14: Overheat protector (Bimetallic type thermal switch)

 ESTI protection has been provided in the heater circuit to operate at 130°C in
case of failure of overheat protector for ultimate disconnection of power supply
to heater.
 Individual electrical protection has been provided by MCB’s.
 In-built overheat protection has also been provided in the motors windings,
which are interlocked with microprocessor.
7.1.11. Other Components, Control and Safety Devices of RMPU

Following other components are also provided for control and safe working of RMPU.
S. No. Components Quantity per unit

1. Filter dryer Two
2. Pressure sensor 0-10 bar (HP, LP) Two
3. Solenoid valve Two
4. Thermostatic expansion valve suitable for Two
automobile application
5. Maintenance covers Six
6. Air inlets for circulating air Two
7. Air inlets for fresh air Two
8. Air outlet for supply air One
9. Anti-vibration mounting pads for whole unit Six
10. Anti-vibration mounting for compressors as required
11. Anti-vibration mounting for condensers motors as required
12. Stainless steel drip trays complete with Two
arrangement for drainage of condensate water
13. Liquid receiver as required
14. Power & control connectors (M/F) along with one for power and
accessories one for control supply
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 13
7.1.12. Fresh Air Screens

In each coach/ generator car four air screens are installed at the coach ends parallel to
the air conditioning unit. These screens are fitted with exchangeable air filters.
Figure 15: Fresh Air Screens
8. ELECTRICAL CONTROL PANELS
Figure 16: Control Panel for RMPU
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 14
Figure 17: Switch Board Cabinet
9. Microprocessor Based Controller for RMPU
The control and regulation of both RMPUs is performed by one microprocessor controller,
which is located in switch board cabinet and fed from battery net. This is designed as per
RDSO specification no. RDSO/PE/SPEC/AC/0139- 2009 (Rev.1) effective from December,
2011.
The salient features of microprocessor based controller are given below:
 It is a fully automated control and monitoring system for all capacity RMPU units.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 15
 The controller has fault diagnostic facility for continuous storage of various electrical
faults in the system, in time sequence manner.
 The fault data can be downloaded from the controller for analysis purpose.
 This unit works on 110 ± 30% V DC/AC.
 A Real Time Clock (RTC) is provided to determine the date and time at which the fault
has occurred.
 Controller read the position of the Set Point Generator (7 positions) installed inside.
Figure 18: Block diagram of Control System of RMPU
 There are (8) Analog inputs designated X402 & X403. Of these eight inputs, 6 nos. are
temperature sensors (NTC type) and there is 1 no. of humidity sensor for measuring
humidity level. 1 no. of set point generator for temperature adjustment inside the
coach.
 There are (20) digital inputs designated as X701 & X702.
 The external voltage is + 110V, Digital input returns must be tied to an external return
(Input common).
 There are 20 Digital Outputs designated as X301, X302, X501 and X502.
 Digital outputs are externally sourced solid-state switches.
 Digital outputs are groups into four: each group requires one output common.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 16
Figure 19: Microprocessor Based Controller for RMPU
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9.1. LAYOUT OF LEDS IN MICROPROCESSOR CONTROL UNIT

Meaning of the individual displays and consequences for the operation of the conditioning
system:
Lamp no. Lamp no.

SID/ LHB/ Meaning of Display SID/ LHB/ Meaning of Display
Liebherr LEEL Liebherr LEEL
Glows when controller is Glows for fault in AC
K-118 01 K-119 011
healthy system
Glows when Fresh/ Glows when Fresh/
K-116 02 Recirculating Air flap is K-117 012 Recirculating Air flap is
set at Recirculating Air set at Fresh Air
Glows when Ventilation-I Glows when
K-113 03 K-114 013
is ON Ventilation-II is ON
This indication is not for Glows when
K-21 04 K-115 014
AC system Ventilation-II is ON
Glows during cooling Glows during cooling
K107 05 operation indicates K-108 015 operation indicates
bypass cooling in Unit-I bypass cooling in Unit-II
operation indicates operation indicates
K-109 06 pressure switch K-111 016 pressure switch
functional when CD 1.1 functional when CD 2.1
in Unit-I starts. in Unit-II starts.
operation indicates operation indicates
K-110 07 pressure switch K-112 017 pressure switch
functional when CD 1.2 functional when CD 2.2
in Unit-I starts. in Unit-I starts.
K-101 08 operation indicates K-103 018 operation indicates
Comp 1.1 ON Comp 2.1 ON
Comp 1.2 ON Comp 2.2 ON
Glows during Heating Glows during Heating
Heater-I, Unit-I ON Heater-II, Unit-II ON
Glows when AC system Glows when 415V is OK
K-15 I1 gets ON with switch K-16 I11
S1U4S1
Glows when winding Glows when winding
temperature of CD 1.1 temperature of CD 2.1
motor is within limit. motor is within limit.
K-1 I2 This light goes OFF when K-3 I12 This light goes OFF
winding temperature when winding
goes beyond limit & the temperature goes
motor also switches OFF. beyond limit & the
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 18
motor also switches

OFF.
Glows when winding Glows when winding
temperature of CD 1.2 temperature of CD 2.2
motor is within limit. motor is within limit.
This light goes OFF when This light goes OFF
K-2 I3 winding temperature K-4 I13 when winding
goes beyond limit & the temperature goes
motor also switches OFF. beyond limit & the
motor also switches
OFF.
This is OFF when winding This is OFF when
temperature of winding temperature of
Ventilation-I motor is Ventilation-II motor is
within limit. This light within limit. This light
K-13 I4 Glows when winding K-14 I14 Glows when winding
temperature goes temperature goes
beyond limit & the AC beyond limit & the AC
Unit-I also goes out of Unit-II also goes out of
service. service.
Glows when Glows when
temperature of Heater-I, temperature of Heater-
Unit-I is within limit. This II, Unit-II is within limit.
light goes OFF when This light goes OFF
K-17 I5 Heater temperature goes K-18 I15 when Heater
beyond limit & the temperature goes
Heater also switches beyond limit & the
OFF. Heater also switches
OFF.
Glows when LP is OK. Glows when LP is OK.
pressure at LP switch of when pressure at LP
refrigerant circuit 1.1 switch of refrigerant
goes down and switches circuit 2.1 goes down
K-6 I6 K-10 I16
off refrigerant circuit 1.1 and switches off
if the pressure remains refrigerant circuit 2.1 if
low for more then 30 the pressure remains
seconds. low for more then 30
seconds.
Glows when LP is OK. Glows when LP is OK.
pressure at LP switch of when pressure at LP
refrigerant circuit 1.2 switch of refrigerant
goes down and switches circuit 2.2 goes down
K-8 I7 K-12 I17
off refrigerant circuit 1.2 and switches off
if the pressure remains refrigerant circuit 2.2 if
low for more then 30 the pressure remains
seconds. low for more then 30
seconds.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 19
Glows when Control Glows when Control

pressure switch-1 is ON, pressure switch-2 is
which means HP is more ON, which means HP is
then 25 bar which will more then 25 bar
K-19 I8 K-20 I18
automatically run second which will
condenser motor. automatically run
second condenser
motor.
This will Glow when HP This will Glow when HP
gets more then setting gets more then setting
K-5 I9 of HP cut out switch 1.1 K-9 I19 of HP cut out switch 2.1
and the compressor 1.1, and the compressor
Unit-I will get OFF 2.1, Unit-II will get OFF
This will Glow when HP This will Glow when HP
gets more then setting gets more then setting
K-7 I10 of HP cut out switch 1.2 K-11 I20 of HP cut out switch 2.2
and the compressor 1.2, and the compressor
Unit-II will get OFF 2.2, Unit-II will get OFF
9.2. Microprocessor Control Panel
The control panel for RMPU is provided with LCD display and it works on 110 V dc ±
30%. It is installed in switch board cabinet. There is a rotary switch on switch panel for
putting the unit in manual mode in case of emergency.
One display unit (as shown below) for each control unit is mounted on the left door of
the control panel. The control display-unit functions as an interface between operator
and system. Display unit have necessary keys for the purpose.
Figure 20: Operation Panel for Air Condition System
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 20
The following functions are possible through key board.

• Setting of time, date, train no. and RMPU no.
• Clearing of the fault on display.
• Viewing of the stored faults.
• Display of digital inputs and outputs.
• Display of status of the system.
• Setting various parameters for controller by maintenance staff.
9.3. Fault Storage/ Self Diagnostic System

• A fault storage system records various tripping and faults of the RMPU along with
the instant status of various parameters like temperature setting, LP & HP
pressure and relative humidity.
• The fault messages along with trouble shooting instructions are displayed during
various fault conditions.
• The system monitors supply voltage and current and records the power
consumption of units.
10. FUNCTIONS AND MODES OF OPERATION OF RMPU

 The outside air (fresh air) is sucked in via the two fresh air screens and their air filters
on the carriage side wall. It is mixed in the unit with the outside air/ recirculating air
ratio can be set by means of air dampers, the positions of which are controlled by the
controller of the air conditioning system.
 The temperature inside the coach is maintained as per the temperature setting
selected by the operator. It is possible to alter the assigned value of temperature (in
step of 0.1° C.) through key-board on display unit.
 The difference between cut in and cut out temperature shall be 2°C. The difference of
2°C reduces the duty cycle of compressor & eventually the failures of compressors.
 Fault storage/diagnostics system: Faults are recorded automatically. Faults can be
downloaded by Laptop. Display Unit is available. Trouble shooting instructions are
displayed on the screen.
 The heater is cycled with a period of 60 seconds The ON period of the heater
is controlled by a control signal of the computer.
System monitors supply voltage and current and record the power consumption.
The Heating, Ventilation and Air Conditioning unit work in different modes depending
upon the temperatures SENSORS & Humidity level. The following are the main modes of
operation:
i. Pre-Heating Mode
ii. Pre-Cooling Mode
iii. Normal Operating mode
iv. Cooling Mode
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v. Heating Mode
vi. Dehumidification mode
vii. Shut down Mode
viii. Manual Mode
10.1. Pre-Heating Mode

⚫ If the Ambient Temperature & Room Temperature is less than 14-degree C, the
controller decides to operate in Pre- Heating mode.
⚫ In this mode the fresh air/re-circulating air flap set to 100% re-circulation air and
exhaust fans are turned off.
⚫ Heaters are operated at its maximum duty cycle (55 seconds ON and 5 seconds OFF)
⚫ This cycle runs for 30 minutes, after that depending on temperature, mode changed
to Cooling/Heating.
10.2. Pre-Cooling Mode

⚫ If the Ambient Temperature & Room Temperature is greater than 28-degree C, the
controller decides to operate in Pre-cooling mode.
⚫ In this mode the fresh air/re-circulating air flap set to 100% re-circulation air and
exhaust fans are turned off.
⚫ Both Compressor are turned ON for maximum Cooling.
⚫ This cycle runs for 30 minutes, after that depending on temperature, mode changed
to Cooling / Heating.
10.3. Normal Operation Mode

⚫ Depending on the Ambient Temperature, controller selects Heating or Cooling
mode.
⚫ If the Ambient Temperature is less than the SET temperature, then Heating mode is
selected. Ex: SET=20-degree C, AT= 18-degree C, HGS = Normal
⚫ If the Ambient Temperature is greater than SET Temperature, then Cooling mode is
selected. Ex: Ex: SET= 20-degree C, AT= 23-degree C, HGS = Normal
⚫ During Heating mode or Cooling mode, when the Humidity sensor gives a High level,
the systems enters De-humidification mode. Ex: SET= 20-degree C, AT= 23- degree C
, HGS = HIGH
10.4. Cooling Mode

⚫ During Cooling mode, the controller selects depending on the difference in
temperature between SET temperature and Room Temperature.
⚫ If the difference in temperature is less than 5-degree C and greater than 2-degree C,
Condenser & one compressor turns ON.
⚫ If the difference in temperature is greater than 5-degree C, Condenser with both
compressors ON.
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10.4.1. Temperature Regulation in Cooling Mode
⚫ Cooling
If (RT-SET) is -Ve value Cooling step sleep, only Ventilation & Exhaust ON
Ex: RT=19°C, SET=20.0°C & AT >18°C.
Step-1
Cooling Entry:
If (RT-SET)<=1, is single condenser and Compressor ON.
Ex: SET=20°C, RT=20 to 21°C and AT>20°C.
Cooling Exit (shutdown)
Ex: SET=20°C, RT<=19°C and AT>20°C.
Step-2:
Cooling Entry:
If (RT-SET) = (1 to 2°C) single condenser and compressor without BYPASS.
Ex: SET=20°C, RT=(21 to 22°C.) AT>20°C
Cooling Exit:(Shutdown)
Ex: SET=20°C, RT<=19°C and AT>20°C.
10.5. Heating Mode

⚫ During Heating mode, the controller selects depending on difference in
temperature between SET temperature and Room Temperature for one of the 3
Heating cycle duty cycles:
• Minimum duty cycle - 5 sec ON & 55 sec OFF.
• Medium duty cycle - 30 sec ON & 30 sec OFF.
• Maximum duty cycle - 55 sec ON & 5 sec OFF.
10.5.1. Temperature Regulation in Heating Mode
⚫ Heating
If (SET-RT) is -Ve value, Heating step sleep mode, only Ventilation & Exhaust Fan ON
Ex: RT=20°C, SET=19.0°C & AT <22°C.
Step-1
Heating Entry:
If (SET-RT)<=1°C, Minimum duty cycle Heater ON for 5 sec and OFF for 55 sec.
Ex: SET=19°C, RT= (17 to 18 °C) and AT<19°C.
Heating Exit (shutdown)
Ex: SET=19°C, RT>19°C and AT>20°C.
Step-2
Heating Entry:
If (SET-RT) = (1 to 3°C), Medium duty cycle Heater ON for 30 sec and OFF for 30sec.
Ex: SET=19°C, RT<18 °C and AT<17°C.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 23

Step-3
Heating Entry:
If (SET-RT)>3°C, Medium duty cycle Heater ON for 55 sec and OFF for 5 sec.
Ex: SET=19°C, RT<17 °C and AT<16°C.
10.6. De-Humidification
⚫ Dehumidification process starts, if the relative humidity of return air is more than
60%.
⚫ During 5 min cycle in this process, first compressor and heater are ON, while Second
compressor remains in OFF position.
⚫ The heater Duty Cycle is 30 sec ON and 30 sec OFF.
⚫ After 5 minutes the Relative Humidity is again monitored, and if still it is more than
60%, the cycle repeats till the RH is reached less than 60%.
10.7. Shut Down Mode

⚫ Air Conditioning system will be shut down when the Air-Con switch is turned OFF or
when there is no 400 V level supply.
⚫ Controller selects the corresponding mode at which the operating will be shut down
sequentially i.e., if it is in Heating mode / Pre-Heating Mode, Heaters are switched
OFF and if it is in Cooling / Pre-Cooling mode, compressors and condensers are
switched OFF with the time delays assigned between them.
10.8. Manual mode
⚫ The Manual mode can only be activated through serial interface and application
software with the help of laptop. This Mode makes testing of the individual outputs
of the system.
10.9. Sleep Mode Operation

 The controller automatically enters the sleep mode operation during pre-defined
night hours which can be changed to suit the requirement for different seasons and
places.
 At the start of sleep mode operation, controller gradually increases the coach
temperature in equal steps to a predefined value within specified time period and
maintains the same during the night hours.
 At the end of night hours, the processor gradually reduces the coach temperature
to selected value within pre-defined time period.
 The set temperature during night hour as well as its time period can be altered by
the maintenance staff.
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10.10. Other Functions of Controller

 The controller will continuously monitor the duty cycle of compressors. If duty
cycle of both the compressors is recorded to be less than 40% for four consecutive
cycles, only one of the compressors will be worked alternatively. Again if one
compressor is not able to achieve the desired temperature within 10 minutes,
both the compressors will start working simultaneously.
 Once the compressors are switched off, the first compressor starts after a time
delay of 2 minutes and the second compressor starts after 30 seconds of starting
of first compressor in order to control initial inrush of current.
 During winter season when the coach temperature reaches 2°C below the set
value, the heaters are switched ON. The heaters will remain ON till the set
temperature is achieved.
 In the event of any defect, malfunction or abnormality, the unit isolates the
equipment of RMPU or shuts down the system, depending upon the nature of
defect to prevent any unsafe operating condition for the RMPU.
11. PROTECTION DEVICES (MCBs AND FUSES)
NAME DESCRIPTION SUPPLY VOLTAGE

MCB (Triple Pole) 10A for Ventilation Fan Motor Unit 1
F-01 415 VAC
(Blower Motor-1)
MCB (Triple Pole) 10A for Ventilation Fan Motor Unit 2
F-02 415 VAC
(Blower Motor-2)
F-03 MCB (Triple Pole) 20A for Compressor Motor 1.1 415 VAC
MCB (Double Pole) 10A for Crankcase Heaters (for CP
F-04 220 VAC
1.1 & CP 1.2)
F-06 MCB (Triple Pole) 10A for Condenser Fan Motor 1.1 415 VAC
F-08 MCB (Triple Pole) 6A for Heater Unit-1 (NPPS) 415 VAC
MCB (Double Pole) 10A for Crankcase Heaters (for CP
F-10 220 VAC
2.1 & CP 2.2)
F-14 MCB (Triple Pole) 16A for Heater Unit-2 (PPS) 415 VAC
F-35 MCB (Double Pole) 6A for AC Compact Controller 110 VDC
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 25
HRC Fuse (63A) in R-phase for Radiator Motor, Roof

F-79 415 VAC
Extractor-1 & 2
HRC Fuse (63A) in Y-phase for Radiator Motor, Roof
F-80 415 VAC
Extractor-1 & 2
HRC Fuse (63A) in B-phase for Radiator Motor, Roof
F-81 415 VAC
Extractor-1 & 2
HRC Fuse (63A) in R-phase for Radiator Motor, Roof
F-82 415 VAC
Extractor-3 & 4
HRC Fuse (63A) in Y-phase for Radiator Motor, Roof
F-83 415 VAC
Extractor-3 & 4
HRC Fuse (63A) in B-phase for Radiator Motor, Roof
F-84 415 VAC
Extractor-3 & 4
12. CONTACTORS & RELAYS
NAME DESCRIPTION SUPPLY VOLTAGE

K-21 Contactor for Fresh Air Flap Motor 24 VDC
K-22 Contactor for Return Air Flap Motor 24 VDC
Contactor for Ventilation Fan Motor Unit-1(Blower-
K-26 110 VDC, 415 VAC
1/NPPS)
K-27 Contactor for Controller OK 110 VDC
Contactor for Ventilation Fan Motor Unit-2 (Blower-
K-28 110 VDC, 415 VAC
2/PPS)
K-31 Contactor for Condenser Fan Motor 1.1 110 VDC, 415 VAC
K-33 Contactor for Compressor Motor 1.1 110 VDC, 415 VAC
K-35 Contactor for Heater Unit 1 (NPPS) 110 VDC, 415 VAC
K-40 Contactor for Heater Unit 2 (PPS) 110 VDC, 415 VAC
U-4 Air Conditioning Control Switch Panel 24 VDC, 110 VDC
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13. THREE PHASE POWER TERMINAL FOR RMPU
Terminal no. Description Terminal no. Description

231 256
232 Ventilation-1 257 CD fan 1.2
233 258
234 Earth 259
235 260 Compressor 2.1
236 Ventilation-2 261
237 262 Earth
238 Earth 263
239 264 Compressor 2.2
240 Compressor 1.1 265
241 266 Earth
242 Earth 267
243 268 Heater-2
244 Compressor 1.2 269
245 270
246 Earth 271 Crank Heater-2
247 272
248 Heater-1 273
249 274 CD fan 2.1
250 275
251 Crank Heater-1 276
252 277 CD fan 2.2
253 278
254 CD fan 1.1 279
255 280 Exhaust fan
281
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14. ADDITIONAL FEATURES OF RMPU DOUBLE DECKER

(which are different from LHB EOG AC coaches)
RMPU capacity increased from 7 TR to 10 TR, and the refrigerant used is R 407 C, eco-
friendly refrigerant. These AC units are designed as per RDSO spec. no.
RDSO/PE/SPEC/AC/0134-2009 (Rev.0) with amendments 1, 2, 3.
• 2 nos. 60 kVA step-down transformers are provided in each coach. These are shifted
towards ends of the coach. The 750 volts, 3-phase, 50 Hz input is stepped down to
415 volts 3-phase, 50 Hz and fed to the 415 v supply system of the Double Decker
coach.
• As the space for ducting in the centre of the coach was not available, specially
designed ducting along the sidewall has been provided for upper and lower deck.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 28
CHAPTER 2
MAINTENANCE
Periodic Maintenance Schedules for LHB Coaches

 Schedule D1 : Trip / Weekly
 Schedule D2 : Monthly ± 3days
 Schedule D3 : Half Yearly ± 15 days
 Shop Schedule (SS-1), IOH : 18 Months+30 days/6 Lakh kms whichever is
earlier
 Shop Schedule (SS-2), POH : 36 Months /12 Lakh kms whichever is earlier
 Shop Schedule (SS-3), POH : 72 Months/24 Lakh kms whichever is earlier
As per RDSO’s Maintenance Schedule No. RDSO/PE/SMI/AC/0044-2011 (Rev.0) dated

02/04.11.2011 and ‘Maintenance Manual for LHB Coaches’, following maintenance
activities to be carried out on roof mounted AC package unit of LHB design coaches:
2. General
Activities TI M HY IOH POH

(D1) (D2) (D3) (SS-1) (SS-2)
a. Check the log sheet maintained in each AC     
coach and attained the defects recorded by
escorting staff during run.
b. Clean all dust by vacuum cleaner or by --    
compressed air from the switch board cabinet
and tighten the cable terminals, if found loose.
c. Replace/ connect defective/ by passed     
components.
d. Cleaning of air grills -    
e. i) Remove return air filters by opening the   
access doors of the unit. Clean these filters
with compressed air after taking out the
filters and place them gently in their places
To be replaced
To be replaced
or replace with pre-cleaned/ new filter/

filter media and close the doors properly. A
cleaning jig should be available with AMC
holders/ Railways for this activity.
Note: After this activity, the service doors shall
be latched properly in case of return air
filter. Similarly, the fresh air grill shall be
positioned and locked properly.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 29
ii) Remove fresh air filters by opening the --  

access doors of the unit. Clean these filters
To be replaced
To be replaced
with compressed air after taking out the
filters and place them gently in their places
or replace with pre-cleaned/ new filter/
filter media and close the doors properly. A
cleaning jig should be available with AMC
holders/ Railways for this activity.
f. Check looseness of microprocessor’s input/ ---    
output connections.
g. Check that the microprocessor controller is -- --   
firmly mounted.
h. Check analogue type pressure gauges for their     
working provided on switch board panel.
i. Check working of rotary switches by rotating     
forward and backward, provided on switch
board panel for temperature selection and air
control ON. Replace if required.
j. Check working of set point generator rotary     
switch provided for temperature setting.
k. Check the tripping of heaters i.e. OHP. The OHP -- --  
setting is 65°C. The testing of OHP setting shall
be done by switching off the blower. During
To be replaced
testing, the probe of digital thermometer shall
be placed near the sensor of OHP & the display
shall be kept outside.
Note: It shall be checked twice a year. In
addition, it shall also be checked as a pre-
winter precaution before the onset of winter
season.
l. Check whether ESTI cartridge is provided with -- --  
To be replaced
bulb and properly screwed.

Note : It shall be checked twice a year, in
addition, it shall also be checked as a pre-
winter precaution before the onset of winter
season.
m. Run the plant for half an hour and then check     
the current drawn by various equipment with
the help of clamp tester (tongue tester) duly
calibrated.
Normal currents for various equipments and
mode of operation are as under:
 Package unit in cooling mode - 20-23 Amps
 Compressor - 7.5 – 9.5Amps.
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 Condenser fan motor - 1.5 – 2.1 Amps.

 Blower motor - 1.5-2.5 Amps
 Package unit in heating mode -07-11 Amps
Note: The current also depends on the ambient
temperature.
n. Check visually roof & condenser fan blade and --   
replace
To be
ensure that there is no crack on the blade or
hub.
o. Check and tighten mountings of blower, -- --   
compressor and blower motors and ensure
that they are in good condition.
p. Ensure that no capillary tubes are in hanging -- --   
position.
q. Check capillary tubes provided for HP/LP cut- -- --   
out for proper support/ clamping. Their nuts
should be properly tightened.
r. Capillary type HP/LP cut out should be replaced -- --- --  
with HP/LP cut-out without capillary during
IOH/POH.
HP/LP cut out and its sensors should be
replaced in SS-4 schedule i.e. after 72 months.
s. Check for proper tightening of cover provided --    
over evaporator compartment.
t. Check that earthing shunts in RMPU are -- --  
replaced
To be
provided. Earthing shunts should be earthed
with coach body.
u. Check canvas duct provided at return & supply -- -- 
replaced
replace
To be
To be
air. Rectify or replace the same, if torn or

damaged.
v. Run the plant in conjunction with micro-     
processor controller and observe for any
abnormality.
w. Check anti-vibration mountings of overall --    AVM for
package unit. Replace if required. over all
package
unit to
be
replaced
x. If less cooling is noticed, check the leakage of --    
refrigerant from the system by using soap
solution or leak detector. If leak is detected, it
should be attended and re-charging of
refrigerant in the system shall be made as per
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 31
RDSO’s SMI ELPS/AC/SMI/14.

y. Check insulation resistance of all the motors & -- -- --  
compressors by the duly calibrated 1000V
megger. Attend the motors, if insulation
resistance of motor is found less than 2M ohm.
Important: Disconnect microprocessor
controller during this activity.
z. Check for physically damaged/ jointed cables. -- --   
Replace if needed.
z-i Check for the physically damaged conduits. -- --   To be
Replace them, if needed. replaced
during
POH
z-ii Harting connector to be replaced -- -- --  
2.1. Refrigerant Pipe Line/ Capillary

(D1) (D2) (D3) (SS-1) (SS-2)
a. Check for proper clamping/ support. -- -- --  
b. Check for rubbing of capillary with SS sheet/ -- -- --  
channel or other parts of RMPU.
c. Check leakage from flare nut of HP/ LP cut- -- -- ---  
outs with soap solution.
2.2. Compressors

(D1) (D2) (D3) (SS-1) (SS-2)
a. Check and ensure holding clamps from top -- --   
are properly tightened.
b. Check and ensure mounting fastenings are -- --   
properly tightened.
c. Check leakage from suction & discharge -- --   
port.
d. Check Accumulator holding/ mounting, if -- --   
provided.
e. Ensure condensing area covers are properly -- --   
tightened & not touching top of compressor
body.
f. Check electrical terminal box is properly -- --   
tightened & cables are terminated with lugs.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 32
2.3. Condenser Fans Motor/ Blades and Blower Motor/ Impeller

(D1) (D2) (D3) (SS-1) (SS-2)
a. Check and ensure mounting fasteners are -- --   
properly tightened.
b. Check electrical terminal box of motors is -- --   
properly tightened & cables are terminated with
lugs.
c. Ensure double earthing shunts are provided. -- -- ---  To be
replace
d
during
POH
d. Check condition of blade/impeller for its fixing/ -- --   To be
cracking/ breakage/ damage or touching with repla
its cover. Rectify/ replace, if needed. ced
durin
g
POH
e. Ensure proper clamping of cable conduits. -- --   
f. Overhauling of Blower and condenser fan -- -- -- -- 
motors shall includes the following during POH.
 The incoming motors shall be checked for
abnormal noise and vibration.
 Check bearing make and replace with
specified make,
• The IR value of motor stator shall be
measured between motor terminal and
frame before and after overhauling. The
value of IR shall not be less than 5 M,
when measured with 1000 volt megger.
• Winding resistance of motors shall be
measured between RY, YB & BR phases. The
winding resistance shall be ± 10% of
resistance declared by OEM in cold
condition.
• Check closely terminal block and connecting -- -- -- -- 
lead for any physical damage or any flash
mark over it. Replace the same, if not
satisfactory.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 33
 Perform HV (Di-electric test) on stator by

applying 1.5 kV AC supply for one minute.
During test the leakage current shall also be
measured, which shall not be more than 1.0
mA.
 Run motor on no load for 15 minutes
and check the following.
i. Bearing noise – Normal noise.
ii. Bearing temperature rise above ambient
should not be more than 10°C.
iii. SPM reading – 20dBM max.
(Green zone)
 Measure starting current of motors on no
load. It shall not be more than 10 times of
normal running current. Similarly, the running
current of motors shall be measured and it
shall not be more than 1.4A.
 Spray water over running motor by jet
having 10mm dia from all side. After spray,
check IR value. There should be no drop in IR
value.
 Ensure the continuity of TOP.
 Anti tracking varnish
g. Ensure that impellers are properly tightened. -- -- ---  
h. Ensure electrical terminal box is properly -- -- ---  
tightened & cables are terminated with lug.
i Cleaning of blower impeller -- -- --  
2.4. Return/ Fresh Air Filters

(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that filters are not damaged.     
b. Ensure that there is a provision to avoid wrong -- -- --  
fitment in the filter as well as in RMPU.
c. Filter media to be replaced --- ---  -- ---
d. Complete filter shall be replaced -- -- --  
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 34
2.5. HP/ LP/ OHP Cutout Switch

(D1) (D2) (D3) (SS-1) (SS-2)
a. Check that the mounting fasteners are -- --   
properly tightened.
b. Ensure proper clamping/ support of capillary -- --   
tube connected to HP/ LP/ OHP cut-out
switch.
c. Ensure that flare nuts are properly -- --   
tightened.
d. Ensure that control wires to HP/ LP/ OHP -- --   
cut-out switches are properly clamped.
e. Ensure that covers of these HP/ LP/ OHP cut- ---    
out switch are properly screwed.
f. Ensure proper clamping of feeler tube of -- -- --  
OHP switch.
g. Remove the accumulated dust over feeler -- --   OHP
tube of OHP switch. to
be
repl
aced
2.6. Heater
(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure proper mounting of heater. -- --   
b. Ensure proper clamping of electrical wires to -- --   
heater.
c. Check dust accumulation on heating -- --   
element. Remove gently, if required.
2.7. NTC sensors

(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that the sensors provided at return -- --   
air path, fresh air and supply air are firmly
mounted.
b. Ensure sensor wires are properly clamped. -- --   
c. Remove the dust accumulated over sensor -- --   To
gently. be
repl
aced
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 35
2.8. Expansion Valve/ Capillary Tubes

(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that the bulb is mounted in the -- ---   
suction line just after evaporator coil and in a
position corresponding to between 1 O’clock
and 4 O’ clock. Ensure that it is properly
insulated.
b. Ensure that the bulb is not connected at the -- --   
bottom of the pipe line.
c. Ensure that bulb/ equalizing line/ capillary -- ---   
tubes are not chocked.
d. Capillary tubes /expansion valve and -- -- -- -- *
HP/LP/CP cut out to be replaced on
condition basis
* on condition basis
2.9. Evaporator Coil

(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that there is no damage to fins. in -- --   
addition, combing to be done, if required.
b. Ensure that capillaries of distributors to -- -- --  
evaporator coil are not having any sharp
bend or kinks. They should also be clamped
properly.
c. Ensure that air passes only through -- --   
evaporator coils and no air is bypassed
directly to blower chamber.
d. Clean the coil, if found dirty. --    
(i) Cleaning through blower in D2.
(ii) Cleaning through water jet in D3.
e. Check that the mounting fasteners are -- -- --  
properly tightened.
2.10. Filter Drier & Sight Glass

(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that drier is installed with flow in the -- -- --  
direction of the arrow marked on the filter
drier label. Whenever replaced.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 36
NOTE:
1. Never use “Antifreeze liquids” like methyl alcohol together with a filter
drier. Such liquid can damage the filter.
2. Never re-use a filter drier.
3. To avoid chances of moisture ingress in the system, filter drier &
compressor should be installed immediately after evacuation and charging
the system.
2.11. Access Doors

(D1) (D2) (D3) (SS-1) (SS-2)
a. Insulate service doors, lower portion and side -- -- --  To
wall from inside of the evaporator be
compartment. repl
aced
b. Ensure that the latches to lock the service doors     
are not defective/ damaged.
c. Ensure that the hinges of the service doors are -- --   
not defective/damaged.
2.12. Drip Tray

(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that there is no leakage of condensate -- --   
water from drip tray to electrical box & blower
housing area.
b. Ensure free flow of condensate water. --    
c. Roof of coach should be checked for Rain -- -- --  
water leakage thoroughly, especially above
electrical panels.
NOTE: Epoxy coating of RMPU trough by mechanical staff to be ensured in SS2**
2.13. Condenser Area

(D1) (D2) (D3) (SS-1) (SS-2)
a. Clean the condenser coil from inside with --    
compressed air/ water jet after opening the
cover of condenser area.
b. Ensure that there is no damage to fins. In -- --   
adding, combing to be done, if required.
c. Check that the mounting fasteners are -- -- --  
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 37
properly tightened.
d. Provide fire retardant thermal insulation over -- -- -- --- 
suction line.
e. Ensure that there is no damage/ crack in -- -- --  
structure frame of RMPU.
f. Ensure proper clamping of electrical conduit. -- -- --  
g. Provide PU sealant/Silicon Sealant RTV on -- -- --  
lower portion of condenser.
2.14. Microprocessor Controller

(D1) (D2) (D3) (SS-1) (SS-2)
a. Check control logic of microprocessor -- -- --  
controller on simulating kit.
Table 1: IR value for different circuit voltage
Sr. No. Circuit Voltage Capacity of Megger used Min. value of IR required
1. 750V 1000V 05 M ohms
2. 415V 500V 03 M ohms
3. 230V 500V 02 M ohms
4. 190V 500V 02 M ohms
5. 110V 500V 02 M ohms
6. 24V 100V 01 M ohms
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 38
CHAPTER 3
RMPU TROUBLE SHOOTING
Sn Fault Cause Remedial Action

1 Compact control 1) 110V DC supply not 1) Ensure 110V DC supply
MCB F-35 on available 2) Replace glass fuse
microprocessor has 2) Glass fuse on 3) Replace Microcontroller
NO indication microcontroller has
blown
3) Microcontroller
faulty/defective
2 With MCB-F35 ON, 1) 415V AC supply not 1) Ensure 415V AC supply
AIR-CON switch ON, available 2) Replace glass fuse F73 or
but NO output of 2) Check NO contact of contactor K23, if defective
Micro-controller K23, replace if 3) Check and use spare
required contact of K27
3) NC contact of K27 4) Check overheating of
not working motor
4) Blower motor T.O.P
tripped
3 MCB F-35 ON, AIR- 1) Controller OK 1) Replace Micro-controller
CON switch ON, only indication not 2) Check DC supply on K-27,
BLOWERs are working glowing if supply available check
2) K-27 contactor not NC contact.
working
4 MCB F-35 ON, AIR- 1) Vent 1 & 21) Check NC contact for
CON switch ON, indication blower motor contactor
blower motor starts continuously K-26, K-28. If contact OK
and trips glowing motor tripped due to
phase over heating
5 Condenser motor 1.1 1) Condenser motor 1) TOP of condenser motor
and 2.1 not working 1.1 temperature ok tripped check and rectify
not working 2) TOP of condenser motor
2) Condenser motor tripped check and rectify
2.1 temperature ok
not working
6 a. Condenser motor 1) Control pressure 1) Control pressure switch
1.2 not working indication not defective replaced it
even if HP glowing 2) Motor tripped at TOP,
indication is 2) Temperature check for over heating
glowing on Micro- condenser motor1.2
controller not glowing
b). Condenser motor 1) Control pressure 1) Control pressure switch

2.2 not working of indication not defective replace it
even if HP glowing 2) Motor tripped at TOP,
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 39
indication is 2) Temperature check for over heating

glowing on Micro- condenser motor2.2
controller not glowing
7 Compressor not 1) Temperature 1) Set temperature setting
working selector switch set Low
at high 2) Check suction pressure
2) LP indication not and compressor current,
glowing recharge gas if required.
If LP output are ok check
LP switch, replace if
defective
3) HP indication 3) Check if second motor
glowing not working replace it,
clean the condenser unit
if found dirty.
4) Tripped due to 4) Ambient Temperature is
internal overload high or solenoid valve
not operating check the
circuit.
8 Heater not working 1) Temperature 1) Change the Temperature
selector switch set to high
at Low 2) OHP tripped or CKT may
2) Temperature be checked
heater on 3) Replace ESTI
indication not
glowing
3) ESTI fused
9 DC supply tripping as 1) Contactor coil or 1) Remove both plant
MICR output signal diode suppressor output voltage
ON may be short connectors from Micro-
circuited in controller and identify
condenser or the defective contactor
compressor by reconnecting one by
contactor one and replace the
defective contactor
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 40
ANNEXURE-1
FUNDAMENTALS OF AIR-CONDITIONING
Air conditioning is the controlling of air temperature, its humidity, its purity, noise-free and its
flow rate at a certain place to produce a comfort zone.
Ventilation is refreshing the air in a crowded place by feeding the place with amount of air at a
certain time and drawing the same amount of air to obtain a healthy environment empty of
dust, gases and bad smell.
Human’s Comfort
The human needs water, food and air for a healthy life. The healthy requirements are:
 One third of the feeding air must be fresh air and the 2 third return air after purifying.
 Entire air in the air conditioned areas must be moved at a velocity between 0.15 to 0.25
M/s. This velocity doesn’t cause a noise.
 Comfort means treatment of 5 properties of air
1. Dry bulb temperature (d.b.t) : cooling or heating
2. RH (%) : humidification or de-humidification
3. Air purity : Free from dust & bacteria
4. Ventilation : Fresh air to provide the needed oxygen
5. Air movement : homogeneous flow rate and distribution
(Static air causes temperature difference of about 8-16 degree C between the breath
level and the ceiling level)
🞂 Temperature
◦ Winter 18-21 0C
◦ Summer 23-29 0C
🞂 RH 30-70 %
BASIC TERMINOLOGIES IN AIR CONDITIONING
1. Kilo-Calorie
It is defined as the amount of heat to be added /removed to raise /lower the
temperature of one kg of water by one degree Celsius.
2. BTU
It is defined as the amount of heat to be added (removed) to raise (lower) the
temperature of one pound of water by one degree Fahrenheit.
1 Kilo Calorie = 3.97 BTU.
3. Sensible heat
It is that heat which when applied to a body, results in a rise of its temperature without
any change in its physical state. It is the heat which is sensed by a thermometer. Eg: -
Heating of water
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 41
4. Latent heat
It is that heat which when applied merely changes the state of substance, whether solid,
liquid or gas, without causing any change in its temperature. Latent heat can not be
sensed by a thermometer but can be measured by Kilo-Cal per Kg or BTU per lb.
Eg: - Melting of ice without change in temperature. Latent heat of fusion of ice 80
k.cal/kg (144 BTUs/lb).
5. Enthalpy
It is calculated property of vapour which is defined as "Total heat content ". It is the sum
of the sensible heat and latent heat.
6. Critical Temperature
There is a defined temperature for every liquid or gas, which is called it's critical
temperature, beyond which any amount of increase in pressure cannot liquefy it. The
temperature when below it's critical point, the gas can be liquefied without lowering it's
temperature but by increasing it's pressure.
7. Humidity
The amount of water vapour present in the air is called humidity.
8. Specific Humidity
The amount of water vapour present in one kg of air is called specific humidity.
9. Relative Humidity (RH)

It is the ratio of the actual amount of moisture contained to the maximum amount
required for saturation and is expressed as a percentage.
RH = Actual amount of water vapour present x 100%

Maximum amount required for saturation.
10. Temperature & Pressure Relationship

 Water boils at 100 degree C when the pressure on it's surface is atmospheric, i.e.
1.003 kg /sq cm.
 If pressure is increased to above atmospheric, i.e. more than 1.003 kg / sq cm, the
boiling temperature of water will increase, which happens in pressure cooker.
 If the pressure is decreased below atmospheric, i.e. less than 1.003 kg /sq cm, the
boiling temperature of water will decrease, which exactly happens when water
dried out in an oil centrifuging plant by creating vacuum, at a temperature of
about 70 degree C.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 42
 The same thing is also true for other liquid like various refrigerant which
evaporates at low temperature when the pressure is suddenly decreased.
11. Expansion Principal
When a gas expands, its temperature falls and when it is compressed its temperature
rises.
12. Dry Bulb Temperature (DBT)
It is the temperature of air as measured by an ordinary thermometer.
13. Wet Bulb Temperature (WBT)

 It is the temperature of air as measured by an ordinary thermometer, but it's glass
bulb is covered by a thin cotton sleeve soaked in water.
 When the sleeve is wetted, mercury column of the thermometer will be observed
to start dropping down, until it finally settles down at a definite minimum value.
Because the water in the wet bulb takes away it's latent heat, as it gets
vapourised, from the mercury.
 As a result, the bulb gets cooled and the mercury column shows a low
temperature. The drop in temperature depends upon the relative humidity of the
surrounding air.
 When air is heated, the DBT increases, WBT also increases, but at a slower rate
and therefore, the difference between DBT and WBT widens indicating a lower
humidity.
 When air is cooled, it becomes more and more humid, until it becomes fully
saturated and the difference between DBT and WBT goes reducing until it
becomes zero at saturation. Hence, at saturation the DBT & WBT are equal.
 If cooling is continued further some of the moisture contained in air gets thrown
out and will condense, since air has a limited holding capacity for moisture.
14. Dew Point Temperature (DPT)
It is the temperature of air at which the moisture of air starts condensing on the surface.
Relative Humidity at dew point is 100%.
15. Effective Temperature (ET)

 It is an arbitrary index which combines into single factor the effect of temperature,
humidity and air movement on human comfort in a noise free environment.
 This corresponds to a DB temperature of saturated air at which a given percentage
of people feel comfortable. Thus an effective temperature of 21 degree C can be
expressed as 23 degree C DB at 70 % RH or 25 degree C DB at 30% RH.
16. Coefficient of Performance (COP)
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 43
Ratio of heat absorbed from refrigerated space and equivalent heat supplied to
compressor.
17. Ozone Depletion Potential (ODP)

• Relative value that indicates the potential of a substance to destroy ozone gas as
compared with the potential of Chloro-Fluoro Carbon-11 (CFC-11 or R11) which is
assigned a reference value of 1.
• Thus, a substance with ODP of 2 is twice as harmful as CFC-11. R-22, for example,
has an ODP of 0.05.
18. Global Warming Potential (GWP)
Global Warming Potential (GWP) is a relative measure of how much heat a greenhouse
gas traps in the atmosphere. It compares the amount of heat trapped by a certain mass
of the gas in question to the amount of heat trapped by a similar mass of carbon di-
oxide.
19. Psychrometry
The measurement of moisture content in air is known as psychrometry. The air is

basically a mixture of dry air and water vapour. The relative amount of water vapour in
atmosphere is very small. Variations in amount of water vapour as well as change in
temperature are very significant and important in air conditioning.
20. Unit of Refrigeration
 The unit employed for designating Air Conditioning capacity is “Ton of Refrigeration
(TR)”.
 The capacity of a plant is said to be one ton, if it is capable to extracting heat at a
rate equivalent to that required to freeze one American ton (2000lbs) of water at
0°C into ice at the same temperature in 24 hrs.
OR
 One ton of refrigeration is the heat required to melt one American ton (2000lbs) of
ice at 0°C into water at the same temperature in 24 hrs.
1 ton of Refrigeration = 2000 lbs X 80K.cal/kg.

= 907.198 kg x 80 K.cal/kg
=72575.84 K.cal/24 Hrs
=3023.99K.cal/hrs
=3024 K.cal/hr
21. Refrigerant
Refrigerants are the fluids that change their state upon application or removal of heat
within a system and, in this act of change, absorbs or release heat to or from an area or
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 44
substance. Many different fluids are used as Refrigerants such as R-12, R-22, R-134a, R-
407c etc.
21.1 Desirable Properties of a Refrigerant

⚫ Low boiling point
⚫ Low freezing point.
⚫ Low specific heat because high specific heat decreases the refrigerating effect per
kg.
⚫ High latent heat because high latent heat at low temperature increases the
refrigerating effect per kg of refrigerant.
⚫ Low specific volume to reduce the size of the compressor.
⚫ High thermal conductivity to reduce the area of heat transfer in evaporator and
condenser.
⚫ Non-flammable.
⚫ Non-explosive
⚫ Non-toxic
⚫ Non-corrosive.
⚫ High COP in the working temperature range. This is necessary to reduce the running
cost of the system.
⚫ High miscibility with lubricating oil and it should not have reacting property with
lubricating oil in the temperature range of the system.
⚫ Should not have any bad effects on the stored material or food, when any leak
develops in the system.
⚫ The leak should be easy to detect.
⚫ High Electrical Resistance to prevent electrical short.
⚫ It should not have harmful effect on the environment i.e. Environment friendly.
(Global Warming & Ozone layer depletion).
⚫ Pressures required to be maintained in the evaporator and condenser should be low
enough to reduce the material cost and must be positive to avoid leakage of air into
the system.
⚫ Must be readily available and must be cheap.
21.2 Name of Refrigerants

• Ammonia (NH₃) : Ice making, cold storage.
• Sulphur di-oxide(SO₂) : Domestic refrigerator.
• Methyl chloride (CH₃CL) : Small Domestic refrigerator.
• Carbon Dioxide(CO₂) : For manufacturing Dry ice,
• Monoflouro trichloro Methane (F-11)
• Dichloro Diflouro Methane (F-12)
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 45
• Trifluro monochloro Methane (F-13).

• Monoflouro dichloro Methane (F-21).
• Monochloro Difluro Methane (F-22).
• Trifluro chloro Ethane (F-113).
• Tetra fluro dicloro Ethane (F-114).
• Tetra fluro Ethane (R-134a)
• R407c- Substitute for R22 Refrigerant blend containing R32, R125 and R134a
(23/25/52% by weight).
Refrigerants-Comparison
Property R-407c R -134a R-22 R-12
Chemical name Tetrafluotoe Mono-chlorodi- Di-chlorodi-

thane fluoromethane fluoromethane
Molecular mass 86.2 102.03 86.868 120.91
Boiling pt °C -46.1 -26.2 -40.8 -29.8
Freezing pt °C -142 -256 -252
Critical temp °C 86.22 102 96 112
Critical pressure 4.62 590 psia 722 psia 591 psia

MPa
GWP/ ODP 1600/0 1300/0 1700/0.05 2400
Cylinder colour Orange Light sky blue Green White
21.3 Description of R-407C

• Substitute for R22
• Refrigerant blend containing R32, R125 and R134a (23/25/52% by weight).
• Temperature glide approx 7K
• Refrigerant must be charged from liquid phase Physical and thermodynamic
properties comparable to R22.
• Non-flammable and safe to use commercially available miscible with polyol ester
oils.
• Chemical Name: Di-fluoro-methane, penta-fluoro-ethane, 1,1,1,2- Tetra-fluoro-
ethane
22. VAPOUR COMPRESSION CYCLE

Main component of Vapour compression cycle are :
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 46
i) Compressor
ii) Condenser
iii) Expansion valve
iv) Evaporator unit.
22.1 Compressor (Compression)
Refrigerant is drawn from evaporator in dry vapour & low pressure state by suction
strokes of the compressor. In compression stroke, the refrigerant pressure being
increased due to increase pressure of vapour, temperature of vapour increase and send
to the condenser unit for condensation. (Refrigerant in high pressure & in vapour form)
22.2 Condenser (condensation)
It is intended for cooling the hot gas & liquefying it. It may be air cooled or water
cooled. High temperature refrigerant in vapour state is received in condenser unit
where the heat is rejected with the help of natural air of condenser fan, which results
refrigerant returns to liquid state. (Refrigerant in high pressure & in liquid form).
22.3 Expansion Valve (Expansion)
Expansion valve is provided just before evaporator unit. After condensation, the liquid
refrigerant passes through this valve and enters this evaporator unit at low pressure &
low temperature. Its function is to control & regulate the rate of flow of liquid
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 47
refrigerant under high pressure and allow it into the evaporator under low pressure or
expended the refrigerant. The expansion valve admits more refrigerant when air
conditioning load is high & reduces it to minimum when load is low. (After expansion
refrigerant in low pressure & in liquid form).
22.4 Evaporator (Evaporation)
Expanded low pressure liquid refrigerant enters into the evaporator unit and converted
into vapour form by gaining latent heat through circulating air with the help of blower
fan thereby cooling the space and thus refrigeration cycle is completed.
This constitutes the cooling unit, in which the liquid refrigerant under low pressure
evaporates and do so, it takes away its quota of latent heat, thereby cooling the
medium surrounding the cooling coil. (After evaporation refrigerant in low pressure & in
vapour form)
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 48
REFERENCES
1. RDSO specification no. RDSO/PE/SPEC/AC/0061-2005 (Rev.1)-Dec, 2011 for Roof

Mounted AC Package Unit for LHB Variant AC Coaches.
2. RDSO specification no. RDSO/PE/SPEC/AC/0139-2009 (Rev.1)-Dec, 2011 for

Microprocessor Controller for Roof Mounted AC Package Unit for LHB Coaches
and Double Decker Coaches.
3. RDSO specification no. RDSO/PE/SPEC/AC/0134-2009 (Rev.0)- July, 2009 for Roof

Mounted AC Package Unit for Double Decker EOG type Air Conditioned Coaches
(10TR).
4. RDSO Special Maintenance Instructions no. RDSO/PE/SMI/AC/0044-2011 (Rev.0)-

Nov., 2011 for Maintenance Schedule of LHB RMPU.
5. Maintenance manual for AC EOG LHB coaches issued by CAMTECH, Gwalior.
6. Operation and maintenance manual for RMPU and Microprocessor Controller

issued by various OEMs.
7. Literature and photographs collected from various field units.
8. Suggestions and feedback received from field units of Indian Railways.
CAMTECH/E/EP-06 /2020-21/RMPU/1.0 49
CAMTECH is continuing its efforts in the documentation and up-

gradation of information on maintenance practices of electrical
assets. Over the years a large number of publications on electrical
assets have been prepared in the form of handbooks, pockets books,
pamphlets & video films etc. These publications have been uploaded
on the internet as well as rail net.
For downloading these publications please do following:
1. On internet visit :www.rdso.indianrailways.gov.in
Go to Directorates  CAMTECH  Publications for

download Electrical Engineering
2. On Railnet visit RDSO website at 10.100.2.19
Go to Directorates  CAMTECH Publications for

download  Electrical Engineering
For any further information regarding publications please
contact:
Dy. Director (Elect.) BSNL: 0751- 2470740 (O)
Rly. : 03747203
: 9752447030 (CUG)
SSE/Electrical : 9755549297 (CUG)
E-mail : direlcamtech@gmail.com
Fax : 0751- 2470841
Write at : Dy.Director (Electrical)
Indian Railways
Centre for Advanced Maintenance
technology,
In front of Hotel Adityaz,
Airport Road, Maharajpur,
Gwalior, Pin code – 474 005

Booklet On Roof Mounted Package Unit of LHB Coaches-30 - 03 - 2021

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Booklet On Roof Mounted Package Unit of LHB Coaches-30 - 03 - 2021

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(For Official Use Only)

भारत सरकार GOVERNMENT OF INDIA

End User: Electrical Coaching Maintenance Staff

Maharajpur, GWALIOR - 474 005

“We at RDSO, Lucknow are committed to maintain and update

To ensure wide dissemination of knowledge on Roof Mounted Package Units of LHB

CAMTECH Jitendra Singh

Air-conditioning of railway coaches is a priority passenger amenity for the maximum

I am sincerely thankful to Shri B. C. Agrawal, SSE/EL/CAMTECH, Smt. Sangeeta

CAMTECH, Gwalior Himanshu Maheshwari

9.3. Fault Storage/ Self Diagnostic System...................................................................................20

Figure 1: LHB Coach fitted with RMPUs at both ends................................................................1

ISSUE OF CORRECTION SLIP

CAMTECH/ E/EP-06/2020-21/RMPU/1.0/C.S. # XX date---

CORRECTION SLIPS ISSUED

It is clarified that the information given in this booklet does not

To upgrade maintenance technologies and methodologies and achieve

Contact person: Dy. Director (Electrical)

Postal Address: Centre for Advanced Maintenance Technology,

Phone: 0751 - 2470740

Fax: 0751 – 2470841

MCB Miniature Circuit Breaker

Figure 1: LHB Coach fitted with RMPUs at both ends

drawing no. RDSO/PE/SK/AC/0069-2004 (Rev.-1). The Microprocessor Controller of RMPU

2. WHY AIR CONDITIONING IN RAILWAY COACHES IS REQUIRED

3. BASIC REQUIREMENTS FOR COACH AIRCONDITIONING SYSTEM

4. SALIENT FEATURES OF RMPU FITTED ON LHB AC COACHES

 Pressure transducers for LP/ HP measurement

5. TRANSPORT AND STORAGE

6. TECHNICAL DATA (PER UNIT)

S.No. Description Details

7. Operating voltage 415 V, 3 Ø, AC, 50 Hz

Safety Devices Provided in the RMPU

Equipment Protection Specifications Remark

The AC package unit can work satisfactorily under following conditions:

Summer condition Dry Bulb Wet Bulb % R. H.

7. DETAILS OF AIR CONDITIONING SYSTEM IN LHB AC COACH

7.1. Compact Air Conditioning Unit (RMPU)

Figure 2: Compact air conditioning unit (RMPU)

Figure 3: Major Sections of RMPU

Each compressor of minimum 3.5 TR capacity at 60 Degree C condensing and 5 Degree

Figure 4: Compressors in RMPU

7.1.2. Condensers and Condenser Fans

Figure 5: Axle fans (Condenser Fans) along with motors in RMPU

Figure 6: Condenser units in RMPU

7.1.3. Evaporators (cooling unit)

Figure 7: Evaporators units in RMPU

7.1.4. Supply Air Fan and Blower Motor

Figure 8: Twin-sucking radial fans for the supply air in RMPU

7.1.5. Heating Assembly

1. Over heat protection switch for heater One

Figure 9: Heating Unit in RMPU

7.1.6. Pressure Transducers

1. Pressure switch 23/20 bar Two

Figure 10: pressure transducers (pressure switches)

7.1.8. Humidity Control

Relative humidity is controlled inside coach by RMPU and is

Figure 11: Humidity sensor

7.1.9. NTC type sensors

Figure 12: NTC type temperature sensor

Position of the Temperature

Figure 13: HP/ LP Cut Out (Cartridge type)

Figure 14: Overheat protector (Bimetallic type thermal switch)