• Schedule : Trip /

D1 Weekly
• Schedule : Monthly ±
D2 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
The equipment wise maintenance activities of above schedules
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Check the log sheet maintained in

each AC coach and attained the
a.     
defects recorded by escorting staff
during run.

Clean all dust by vacuum cleaner or

by compressed air from the switch
b. board cabinet and tighten the cable --    
terminals, if found loose.

Replace/ connect defective/ by

c.     
passed components.
 TI M HY IOH POH
Activities (D1 (D2 (SS- (SS-
) ) (D3 1) 2)
)
e. i) Remove return air filters by opening
the
access doors of the unit. Clean these
filters with vacuum cleaner or by
compressed air after taking out the
filters and place them gently in their
places or replace with pre-cleaned/

To be replaced
To be replaced
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
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
ii) Remove fresh air filters by
opening the access doors of the
unit. Clean these filters with
vacuum cleaner or by
compressed air after taking out
e. 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/
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

f. Check looseness of --- ---   

microprocessor‟s
input/ output connections.
Check that the
g.     
microprocessor controller is firmly
mounted.
Check analogue type pressure
h. gauges for their working provided     
on switch board panel.

Check working of rotary switches by

rotating forward and backward,
i. provided on switch board panel for     
temperature selection and air control
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
Check working of set point generator
j. rotary switch provided for temperature     
setting.

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
testing, the probe of digital
k. 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
 TI M POH
Activitie HY (SS-
s IOH 2)
m. Run the plant for half an hour and then (D1) (D2) (D3)
check the current drawn by various (SS-1)
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. 
 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
 TI M H IOH PO
Activities Y (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Check visually roof &

n. condenser fan blade and --    
ensure that there is no crack on
the blade or hub.
Check and tighten mountings
of blower, compressor and
o. -- --   
blower motors and ensure that
they are in good condition.
 TI M HYIOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
Check capillary tubes provided for
HP/LP cutout for proper support/
q. --    
clamping. Their nuts should be
properly tightened.

Capillary type HP/LP cut out should

be replaced with HP/LP cutout
without capillary during IOH/POH.
r. -- --- --  
HP/LP cut out and its sensors should
be replaced in SS-4 schedule i.e.
after 72 months.
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Check for proper tightening of

s. cover provided over evaporator --    
compartment.

To be replaced
Check that earthing shunts in
t. RMPU are provided. Earthing -- --  
shunts should be earthed with
coach body.

Check canvas duct provided at

u. return & supply air. Rectify or -- -- 

d
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Run the plant in conjunction

v. with micro-processor     
controller and observe for any
abnormality.

Check anti-vibration mountings AVM

of compressors, condenser for over
w. -- --   all
motors, blower motor and over package
all package unit. Replace if unit to
required. be
replaced
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
If less cooling is noticed, check the
leakage
of refrigerant from the system by using
x. 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 standards.
Check insulation resistance of all the
motors
& compressors by the duly calibrated
1000V megger. Attend the motors, if
y. -- -- --  
insulation resistance of motor is found
less than 2M ohm.
 TI M H IOH PO
Activities Y (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Check for physically damaged/

z. --  --  
jointed cables. Replace if
needed.

Check for the physically

To be
z-i damaged conduits. Replace --  -- 
replace
them, if needed.
d

Check for proper working

z-ii -- --   
of servo drive.

z-iii Harting connector to be -- -- --  

Refrigerant Pipe Line/ Capillary

TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

a. Check for proper clamping/ -- -- --  

support.
Check for rubbing of capillary
b. with SS sheet/ channel or other -- -- --  
parts of RMPU.

Check leakage from flare nut of

c. -- -- ---  
HP/ LP cutouts with soap
solution.
Check leakage from feeler tube
Compressors
TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure holding

a. -- --   
clamps from top are properly
tightened.

Check and ensure mounting

b. -- --   
fastenings are properly
tightened.
Check leakage from
c. -- --   
suction & discharge port.

Check Accumulator
d. -- --   
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Ensure condensing area covers

e. are properly tightened & not -- --   
touching top of compressor
body.
Check electrical terminal
f. box is properly tightened & -- --   
cables are terminated with
lugs.
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Check condition of blade for its

d. fixing/ cracking/ breakage/ damage -- --   
or touching with its cover. Rectify/
replace, if needed.
Ensure proper clamping of cable
e. -- --   
conduits.

Overhauling of Blower and

condenser fan motors shall
f. includes -- -- -- -- 
the following during POH.
 The incoming motors shall
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
f.  Check bearing make and
replace with
specified make, if found defective.

 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 10 M, when
measured with 1000 volt megger.

 Winding resistance of motors shall be

measured between RY, YB & BR
phases. The winding resistance shall
be
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
f.  Check closely terminal block
and
connecting lead for any physical
damage or any flash mark over it.
Replace the same, if not
satisfactory.
-- -- -- -- 
 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
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

f.  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 –

20dB max.

(Green
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
f.  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.
 Activities TI M HY IOH PO
(SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Ensure that impellers are

g. -- -- ---  
properly tightened.

Ensure electrical terminal

h. box is properly tightened & -- -- ---  
cables are terminated with
lug.
Return/ Fresh Air Filter
TI M HY IOH PO
Activities
(SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Ensure that filters are

a.     
not damaged.

Ensure that there is a

b. provision to avoid wrong -- -- --  
fitment in the filter as well
as in RMPU.

c. Filter media to be replaced --- ---  -- ---

HP/ LP/ OHP Cutout Switch

Activities TI M HY IOH POH

(D1) (D2) (D3) (SS-1) (SS-2)
Check that the mounting fasteners
a. -- --   
are properly tightened.

Ensure proper clamping/ support

b. of capillary tube connected to -- --   
HP/ LP/ OHP cutout switch.

Ensure that flare nuts are

c. -- --   
properly tightened.
Ensure that control wires to HP/ LP/
d. OHP cutout switches are -- --   
properly clamped.
 TI M HYIOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Ensure that covers of these HP/

e. LP/ OHP cutout switch are ---    
properly screwed.

Ensure proper clamping of feeler

f. -- -- --  
tube of OHP switch.

Remove the accumulated dust

g. -- --   
over feeler tube of OHP switch.
Heater

TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

a. Ensure proper mounting of heater. -- --   

Ensure proper clamping of

b. electrical -- --   
wires to heater.

Check dust accumulation on

c. -- --   
heating element. Remove gently,
NTC Sensors
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that the sensors provided

a. at return air path, fresh air and -- --   
supply air are firmly mounted.

Ensure sensor wires are

b. -- --   
properly clamped.

Remove the dust accumulated over

c. -- --   
sensor gently.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that the bulb is not

c. -- --   
connected at the bottom of the
pipe line.

Ensure that bulb/ equalizing

d. -- ---   
line/ capillary tubes are not
chocked.

Capillary tubes /expansion valve

e. and HP/LP cut out to be replaced -- -- -- -- *
on condition basis

* on condition
Evaporator Coil

Activities TI M HY IOH PO
(SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)
Ensure that there is no damage to
a. -- -- --  
fins.

Ensure that capillaries of

distributors to evaporator coil are
b. -- -- --  
not having any sharp bend or
kinks. They should also be
clamped properly.

Ensure that air passes only

 Activities TI M HY IOH PO
(SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Clean the coil, if found dirty.

d. (i) cleaning through blower in D2. --    

(ii) Cleaning through water jet in

D3.

Check that the mounting fasteners

e. -- -- --  
are properly tightened.
Filter Drier & Sight Glass
TI M HY IOH POH
Activities
(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.

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
 Access
Doors TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Insulate service doors, lower

a. portion and side wall from inside -- -- --  
of the evaporator compartment.

Ensure that the latches to lock

b.     
the service doors are not
defective/ damaged.
Check and replace
c. -- -- --  
thermal insulation
Drip Tray
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that there is no leakage

of condensate water from drip
a. -- --   
tray to electrical box & blower
housing area.

Ensure free flow of

b. --    
condensate water.

Roof of coach should be checked

c. for Rain water leakage -- -- -- -- 
thoroughly, especially above
electrical panels.
Condenser Area
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Clean the condenser coil from

a. inside with compressed air/ water --    
jet after opening the cover of
condenser area.

Ensure that there is no

b. -- --   
damage to fins.

Check that the mounting

c. -- -- --  
fasteners are properly
tightened.
 TI M HY IOH PO
Activities (SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

Provide fire retardant

d. -- -- -- --- 
thermal insulation over
suction line.

Ensure that there is no damage/

e. -- -- --  
crack in structure frame of RMPU.

Ensure proper clamping of

f. -- -- --  
electrical conduit.
Microprocessor Controller

TI M HY IOH PO
Activities
(SS- H
(D1 (D2 (D3 1) (SS-
) ) ) 2)

a. Check control logic of -- -- -- -- 

microprocessor controller
on simulating kit.
 Minimum fresh air required for per person for AC coach
is 0.35 m³/ min.

 Measure fresh, return and exhaust air velocities with the

help of anemometer using suitable hoods to avoid
turbulence of air.

 Compute the volume of air by multiplying the velocity

with face area.

 For ideal condition, the exhaust air should be equal to

fresh air or it can be less by 10% but no reasons it
should not be more than fresh air.
2. Pre-cooling Test

This test shall be conducted to record the time taken for

cooling the coach without passenger, with fresh air
filters closed, lights switched „ON‟ and after raising the
inside temperature of air-conditioned compartment to
45°C.

Procedure:

1. Place the coach inside the shed.

2. Close all fresh air intake openings.

3. Record dry and wet bulbs temperature of ambient air.

4. A sample calculation for finding out compensating
heat load for AC chair car is given at Annexure 1.4.

5. Calculate the electrical compensating heat load from

the graph chart as per sample calculation given in
Annexure 1.4

6. Provide the electrical compensating load, as

calculated above, inside the coach. This load should
be kept in OFF condition till further instruction.

7. Raise the inside temperature of the coach to 45°C

by switching „ON‟ heater circuit in test mode.
8. Switch „ON‟ all lights. Set the temperature setting at
position no. 6th (i.e. 24.04°C) of both sides and run both
the AC package units in auto mode keeping compensating
load „OFF‟.

9. Record the timings for „cut off‟ of both the plants and
other parameters during the test as per Annexure 1.2.

10. Total time taken by each plant to cool the coach should
not exceed one hour.

11. Feeder testing on 750 volt.

12. Testing of local mains supply system.
13. Measurement of currents for AC plant.
Final Joint Inspection
• Workshop supervisor with divisional supervisor shall
jointly inspect the coach and the performance of
electrical and refrigeration equipments shall be
recorded as per Proforma at Annexure 1.6.

• A details of equipments changed with new assemblies

will also be handed over along with the coach to the
divisional representative. Any attention, if required to
the equipments shall be given before dispatch of the
coach from workshop to division.
 ELECTRICAL TEST REPORT FOR AC COACHES AFTER
SS-I
Type of
Coach
Coach---------------------
No.---------------
Date of
Railway-----------------
testing---------------------
INSULATION -
RESISTANCE
Sr. Capacity of Min. value Actual Remarks
Megger of IR value
Circuit No. used required observed
1. 750V 1000 V 05 M ohm OK / Not OK
Voltage
1. 415 V 1000 V 03 M ohm OK / Not OK
1. 230 V 500 V 02 M ohm OK / Not OK
1. 190 V 500 V 02 M ohm OK / Not OK
1. 110 V 500 V 02 M ohm OK / Not OK
1. 24 V 100 V 01 M ohm OK / Not OK
AIR CONDITIONING EQUIPMENT
Electrical load test
Sr. No. Description Specifi Actual observed
ed Load R Y B
Current

AC PLANT No. 01 (PP SIDE)

1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5. CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
AC PLANT No. 02 (NPP SIDE)
1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5 CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
Load Current for RMPU
 b) Pre cooling test ...........................................as per Annexure
„1.2‟
c) Air delivery
test:
Sr. Actual
Description Specified observed
No.
PP NPP

Air delivery-
1 Fresh Air (FA) 12.69 12.39
0.35 m / min/ passenger
3
2 Return Air (RA) 7.23 16.83
Approx. 3 x Fresh Air
3 Exhaust Air (EA) 0.50 4.63
4 Conditioned Air Equal or less than 10% of --- ---
(CA) FA Fresh Air + Return Air
a) Total Fresh Air (PP+NPP) = 20.08 Cub mtr/
min
b) Total Return Air (PP+NPP) = 49.85 Cub mtr/
min
EQUIPMENT SAFETY TESTS

SNo Equipments PP Side observations NPP Side observations

1. Blower Motor OK /Not OK OK /Not OK
2. Cond. Fan Motor 1 OK /Not OK OK /Not OK
3. Cond. Fan Motor 2 OK /Not OK OK /Not OK
4. OHP 1 OK /Not OK OK /Not OK
5. OHP 2 OK /Not OK OK /Not OK
6. Compressor-1 OK /Not OK OK /Not OK
7. Compressor-2 OK /Not OK OK /Not OK
8. LP-1 OK /Not OK OK /Not OK
9 LP-2 OK /Not OK OK /Not OK
10. HP-1 OK /Not OK OK /Not OK
11. HP-2 OK /Not OK OK /Not OK
12 CP-1 (By pass) OK /Not OK OK /Not OK
13 CP-2 (By pass) OK / Not OK OK / Not OK
AIR CONDITIONING EQUIPMENT
a) Electrical load
S No. test Description Specified Load current Actual observed
R Y B
AC PLANT NO. 01 (PP SIDE)
1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5. CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
AC PLANT NO. 02 (NPP SIDE)
1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5 CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
Load Current for RMPU
Voltage for RMPU - 415 ± 10% V
Total Power Consumption in kVA
Total Power Consumption in kW
 b. Air delivery test
```````````````````
Sr. Description Specified Actual
No. observed
PP NPP

1 Fresh Air (FA) Air delivery- 12.69 12.39

2 Return Air (RA) 0.35 m3/ min/ passenger 7.23 16.83

3 Exhaust Air (EA) Approx. 3 x Fresh Air 0.50 4.63

4 Conditioned Air (CA) Equal or less than 10% of --- ---

FA
Fresh Air + Return Air

a) Total Fresh Air (PP+NPP) = 20.08 Cub mtr/

min
b) Total Return Air (PP+NPP) = 49.85 Cub mtr/
min
c) Total Exhaust Air = 9.63 Cub mtr/
Pre Cooling Test
TEST CONDITIONS:
Coach Location
----------------
Time from ------------------ hrs. to --------------
hrs.
Ambient Temperature (DB) --------- º C. --------- º C.
(WB) Specified Actual observed
S. No. Time taken for Pre- cooling test
PP side NPP side

From 45 to 24.04 ºC Less than

1.0
(Temperature setting on position 01
6) hour
Time taken for pre-cooling ----------------------------Min/hr.
test:

Satisfactory /
Unsatisfactory
Pull Down Test
TEST
CONDITIONS
-------------------
Coach
from ---------- to ----------
Location Time hrs. hrs.
Ambient Temperature at starting (DB) ---- º C.
(WB)--- º C.
Ambient Temperature at finish (DB) --- º C.
(WB)--- º C.
Average compensation load ………………..k
Watts
S.No. Time taken for Pull down Specified Actual observed
test
PP side NPP side

From 45 to 24.04º C Not more than 02

hrs.
Pull down time to achieve 24.04 º C --------------------hrs.

Satisfactory /
Unsatisfactory
 ELECTRICAL TEST REPORT FOR AC COACHES

Equipment Safety Tests

SNo Equipments PP Side observations NPP Side observations

1. Blower Motor OK /Not OK OK /Not OK
2. Cond. Fan Motor 1 OK /Not OK OK /Not OK
3. Cond. Fan Motor 2 OK /Not OK OK /Not OK
4. OHP 1 OK /Not OK OK /Not OK
5. OHP 2 OK /Not OK OK /Not OK
6. Compressor-1 OK /Not OK OK /Not OK
7. Compressor-2 OK /Not OK OK /Not OK
8. LP-1 OK /Not OK OK /Not OK
9 LP-2 OK /Not OK OK /Not OK
10. HP-1 OK /Not OK OK /Not OK
11. HP-2 OK /Not OK OK /Not OK
12 CP-1 (By pass) OK /Not OK OK /Not OK
13 CP-2 (By pass) OK / Not OK OK / Not OK
 SAMPLE CALCULATION FOR CALCULATING
COMPENSATING LOAD

To find out electrical compensating load to be provided inside the coach

when coach is tested at other than the designed outside ambient condition
say 40º C (104 ºF) DB and 30 ºC (86º F) WB

Coach: Self generating chair car to CSC layout No. 1559 for 71

passengers. Designed (outside) conditions = 45 º C (113 º F)

DB & 25ºC (77ºF) WB Designed (outside) conditions = 25 ºC

(77 ºF) DR & 40% RH

A. Heat gain inside the coach at designed
conditions:
i. Conduction = 11,045 B.Th.U/hrs.
Formulae = Area x Overall coefficient of
heat transfer in B. Th.U/ hr/ ºF/
sq.ft x temperature difference

a) Side wall = 2 x 236 x 0.127 x = 2980.94

36 4
b) End walls = 2 x 73 x 0.127 x 31 = 667.512
partition
c) Roof = 550 x 0.134 x 36 = 2653.2
d) Floor = 514 x 0.149 x 36 = 2757.09
6
Where
e) 0.127 is the factor for=heat
Windows 2 xtransfer
69 x 0.4through
x 36 walls, 0.134 is
= 1987.2
for roof and 0.149 is for the floors. For glass windows the factor
for heat transfer has been taken as 0.4.
 ii) Solar 15193.4 B.Th.U/ hrs.
radiation=
Area x Overall coefficient of heat
Formula transfer x solar temperature difference

a) Side = = 326 x 0. 127 x 16 = 662.4

wall
b) Roof = 550 x 0.134 x 19 =
1400.3
c) Windows = 69 x 1.1 x 173 =
13130.7
Where 16.19 & 173 are the solar temperature differences as per tranes
air-conditioning manual page 314 and 315 for 30 ºC N latitude at 16
hrs.
iii) Passengers (@ 400 B. Th. = 28,400 B.Th.U /
C hr
per passenger 71 x 400)
iv) Light and fans (3.4 B.Th.U/ = 8,275 B. Th. U/
hrs per watt for lights and hr
3600 B.Th.U/hrs for small
motors)
a) Tube lights = 22 x 30 x 3.4 = 2244
b) Carriage fans B.Th.U/hr
= (8 x 35 x 3600)/ 746 = 1351
c) Blower B.Th.U/hr
= 2 x 0.65 x 3600 = 4680
motor B.Th.U/hr
v) Ventilation
=
a) = 1.1 x Nos. of person x cfm of air per person
51,365 B.Th.U/hr
Sensible x temperature difference.
= 1.1 x 71 x 12.4 x 36
= 34864 B.Th.U/hr
b) = 0.68 x No. of person x cfm of per
Latent person x difference of grains of moisture
between outside air & conditioned air. **
= 0.68 x 71 x 12.4 x (82 -
= 56)
Formula = For sensible heat gain as per tranes air conditioning
manual

page 88 and for latent heat gain formula 23 on page 150 of

carrier handbook of air conditioning and ventilation.

Total heat gain = 1,14,729 B.Th.U/hr

Adding 10% for leakage = 1,25,707 B.Th.U/hr

heat gain
B) Heat gain during test at outside ambient = 104 - 77
Conditions of 40 º C (DB) and 30 ºC = 27 º C

(WB) temperature difference

i) = (11046 x 27)/ 36 = 8284
Conduction B.Th.U/hrs
ii) = 8275
iii) Ventilation
Light & fan B.Th.U/hrs
a) Sensibl = (34867 x 27)/ 36 = 26148
e B.Th.U/hrs
b) Latent = 0.68 x 71 x 12.4 x (161-56)**
= 62861 B.Th.U/hrs
Total heat gain under actual test condition 105568
= B.Th.U/hrs
Therefore electrical load to = 125707-
be 105568
B.Th.U/hrs
provided inside the coach
to
produce heat = 20, 139
units B.Th.U/hrs
Therefore electrical load in = 20139/
kW (3.41x1000)
= 5.906 kW

** To be determined from the outside and inside conditions

on physcrometic chart.
 PROFORMA TO RECORD PULL DOWN TEST
1. Type and Coach No. : …………
2. Supply Voltage : …………V
3. Ambient ………….DB…….W
4. temperature : B
Electrical compensating heat load provided
………….kW
Temp : Time when Time Coach Time Coach
setting at Compensatin when temperatur of temperature
position 6 g Electric both e when plants when both
(i.e.24.04° Load plants both plants
C) switched switched plants cuttin switched
„ON‟ „ON‟ switched g „OFF‟
„ON‟ „OFF‟
Plant Plant Plant 1 Plant 2
Total time taken by both plants to switch
1 2
„OFF‟ PP side ………………....min.
NPP side ……………….min.
S
i
Final Checking
S.No. Description of Checks Observations / Remark
1.0 Roof Mounted AC Package Unit (RMPU)

Compressor

Make of Compressor
PP Side 1. 2.
NPP Side 1. 2.

Condition of anti-vibration mountings

PP 1. OK / Not OK 2. OK / Not OK
1.1
Sid 1. OK /Not OK 2. OK /Not OK
e
NP
P
Sid
e
Condition of terminal boxes
S.No. Description of Checks Observations /
Remark
Condenser Motors

Make of condenser motor

PP 1. 2.
Side 1. 2.

1.2
NPP
Side

Condition of terminal boxes

PP 1. OK / Not OK 2. OK / Not OK
Side 1. OK /Not OK 2. OK /Not OK

NPP
Side
S.No Description of Checks Observations /
. Remark
Evaporator Motor
Make of evaporator motor
PP 1. 2.
Sid 1. 2.
e
NP
P
Sid
e
1. OK / Not
Condition of terminal boxes
OK 2.
PP OK / Not
Sid OK
S.No Description of Checks Observations / Remark
.
Servo Motor
Make of Servo motors
PP Side 1. 2.
1.4 NPP Side 1. 2.
Condition of Servo Motors
PP Side 1. OK / Not OK 2. OK / Not
NPP Side OK
1. OK /Not OK 2. OK /Not OK
Heating Elements
Make of Heating Elements
PP 1.
1.5 Side 1.
NPP
S.No Description of Checks Observations /
. Remark
Filters

Make of Filters
Return air
PP 1. 2.
Side 1. 2.
1.6 NPP
Side 1. 2.
Fresh air 1. 2.
PP
Side
NPP
Side
Condition of Filters
1. OK / Not OK 2. OK / Not
S.No. Description of Checks Observations / Remark
Protection Devices

Condition of HP output 1. OK / Not OK 2. OK /

PP Not
Side
OK
NPP 1. OK /Not OK 2. OK
1.7 Side /Not OK

Condition of LP cutouts 1. OK / Not OK 2. OK /

PP Not OK
1. OK /Not OK 2. OK
Side
/Not OK

NPP
Side
S.No
Description of Observations
.
Checks / Remark
Condition of ESTI fusible
link OK / Not
PP Side OK OK /
NPP
Condition of OHP Not OK
Side
PP Side OK / Not
NPP OK OK /
Condition of temperature
Side Not OK
sensors OK / Not
PP Side OK OK /
NPP
Condition of humidity Not OK
sensors Side OK / Not
PP Side OK OK /
S.No. Description of Checks Observations / Remark

Refrigerant Pipe Line

1.8 Condition of Clamping of pipe

line PP Side OK / Not
NPP Side OK OK /
Not OK
2.0 Switch Board Cabinet
Condition of rotary switches OK / Not OK

Condition of MCBs for

Light OK / Not
Fan OK OK /
circuit Not OK
Other OK / Not
S.No. Description of Checks Observations / Remark

Condition of terminals OK / Not OK

Condition of contractors OK / Not OK
Condition of relays OK / Not OK

Condition of meters
Ammeters OK / Not
Voltmeters OK OK /
Pressure Not OK
Gauges OK / Not
OK
Condition of cable OK / Not OK
Condition of clamping of cables OK / Not OK
Condition of conduits OK / Not OK