COLD-CHAIN MAINTENANCE FEEDBACK FEEDBACK ON REPAIR AND MAINTENANCE FROM THE FIELD AND Important Technical Information 1
COLD-CHAIN MAINTENANCE FEEDBACK Foreword…… The refreshers training courses on maintenance & repair of WIC electrical systems, repair of Generator engine & refrigeration system provided the technician participating in the courses to exchange views & experiences thus far. This booklet 'FEEDBACK…..
COLD-CHAIN MAINTENANCE FEEDBACK COLD CHAIN MAINTENANCE- 'FEED-BACK' COMPONENT FAULT LOCATION OBSERVATION /FINDING 'Foster' (WIC) Cooling unit 1.'Gas' leak 1.Balasore 2.Bhagalpur 3.Bhopal (WIF) 1.WIC Temp.high 2.Suction pr.7.8 psi(Good unit – 20 psi) 3.Soap water testing indicated service valve on suction side leak from gland packing. 4.Bubbles with liquid in sight glass. 1.Leak in evaporator pipe. 2.No liquid in sight-glass. 3.Compressor stops on HP/LP 4.Ajmer 1.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' (WIC) Cooling unit 2.Compressor defective 1.Balasore 1.Noisy 2.Guntur 1.Unit not running 2.High compressor amps(20 amps) 3.No hum/noise 4.Relay & capacitor tested in the good compressor-OK 5.Resistance: R-C=0 ohms S-R=2 ohms Terminal Body=Infinite 1.Compressor too hot. 2.Trips at high amps on overload(after about 2 min) 3.Compressor not running, no hum/noise 4.Tried with the relay,OLP & capacitor or working unit-does not run. 1.Unit trips –off often on HP 3.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' (WIC) Cooling unit 4. Condenser fan-motor jammed. 1.Vadodara 2.Phulbani 3.Balasore 4.Parabhani 5.Gurgaon 6. Hyderabad 7.Nasik 8.Akola 9.Dibrugarh 10 Gandhi-nagar 11.Jabalpur 12.Tirunelve-lly 1.Bush /bearing jammed 2.Running slow & sometimes stops 3.Compressor may trip off on HP Bushing removed,cleaned,oiled & refitted- OK Can be replaced from spares. # 3-in-1 oil can be used for cleaning & oiling. # BUSHING MAY BE AVAILABLE LOCALLY.
COLD-CHAIN MAINTENANCE FEEDBACK time(Voltage problem-NK Low voltage protector also burnt) Coil bobbin partially deformed due to overheat & not allowing contacts to make. 5.Bikaner 6.Merrut 7.Bhopal (WIF) 7.Defrost- timer defect 8.Starting capacitor defect 9.Compressor starting trouble 10.Thermostat defect 8.Almorah 9.Bhuj 10.Ajmer 11.Faizabad 12.Bhagalpur 13.Tirunelvelly 14.Jabalpur 1.Vadodara 2.Lucknow 3.Gunjam Compressor not working. Burning smell from contactor. Contactor coil burnt.
COLD-CHAIN MAINTENANCE FEEDBACK 11.HP/LP pressostat defect 1.Vadodara Did not trip on low pressure when drier was choked & pr.was 7 psi(i.e.0.5 BAR).While pumping down also it did not cut off. 1.Both units were running 2.Drier cold 3.Suction line warm 4.Discharge line less warm. 5.Current less, about 4A. (normally=7-8 A) 12.Filter drier choked 1.Vadodara 'Foster'(WIC) cooling unit 1.No defrosting 1. Chandigarh 'Foster' Coldroom Panel 1.New type panel not received/ fitted. 1.Amritsar 2.
COLD-CHAIN MAINTENANCE FEEDBACK 2.MCB tripping 1.Gurgaon 2.Kota 3.Low voltage protector,C2 relay defect 1.Nasik 2.Balasore 3.Thane 4.Calicut 5.Guntoor 6. Chattarpur 7.Gandhi nagar MCB trips off after about one hour & becomes hot(oldpanel) Replaced- OK # If the system takes heavy current,the MCB will trip immediately. In case MCB is faulty, it will trip after sometime of putting the load ON. Confirm fault by measuring the load current.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' generator panel # Try to find locally available two-way switch with off position. One unit not Shorted contacts working Contactor temporarily. burnt. # WHEN SHOTTED LIKE ABOVE,KEEP THE SELECTOR IN THE POSITION SELECTING THE UNIT FOR WHICH THE CONTACTOR IS SHORTED. 6. Contactor defect 1.Bhopal (WIF) 7.Alarm Circuit 1. Gorakhpur Alarm 'on' when WIC temp.OK.No effect of pressing reset. Check T1 & its circuit & wirings. 1.Mains power not going to the units. 1.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' Generator Panel 3.Generator not starting T3 potentiometer turned both ways slightly & reset,it worked so also GK- OK Replaced switch-OK 1.Parbhani Auto/manual switch contacts not making 2.Nasik Auto/manual switch faulty,GK(5152)burnt. # To replace 3.Vadodara Works on Auto,does not work on manual Auto/manual switch A15 & 6 not making. To repair/replace. 4.Akola 5.Vadodara Starter bendix & flywheel ring gear teeth damaged. # To replace 6.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' Generator Panel 4.Generator panel Wiring/ component burnt 5.Generator not stopping 1.Amritsar 2.Vadodara 3.Akola 4.Ernakulam 5.Kurukhetra 6.Thane 7.Bikaner Panel wiring & stop solenoid burnt Panels required- OK.If only a few wires/components burn,the panel can be repaired easily. 8.Berhampur Stop solenoid & RH1 & RH2 burnt. 1.Amritsar Stop solenoid not drawing the plunger in Burnt wires & relays replaced-OK Rewound, worked for 3 months & burnt again.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' Generator Panel 6.Nasik 6.Automatic charging rectifier,E1 'Foster Generator Engine' (DM188) Stop solenoid coil burnt Resistors from E1 circuit came out. 1.Gurgaon 2.Vadodara 3.Bikaner 4.Bhopal 5.Ajmer 6.Gurgaon 7.Dibrugarh 8.Jabalpur Battery charge very low. Recharged externally & reconnected- OK 9.Ajmer Two resistor burnt. 10 Gandhi-nagar No charging, dry solder on resistor terminal Units not working,N1 & NK not working.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' Cooling Unit 1.F1 MCB trips when unit switched ON 2.Frost on evaporator not completely melted during defrosting 3.Thermostat defect 5.Ajmer 6.Gandhinagar Dirt & lubricant formed paste,gears jammed. Cleaned & oiled Ok 7.Akola Chart speed slow covers 2 hours division in 3 hours. Circuit breaker trips off.Varistor R7 defective, shorted. # Check your mechanism,may be defective/dirty. 1.Chandigarh (Punjab) 2.Rajkot 3.Bhubaneswar 4.Trivendrum 5.Madurai 6.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' Cooling Unit 6.Condenser fancapacitor defect 7.Evaporator fan motor 8.Condenser fan motor 13.Moradabad Mechanical jam contactor similar to NK of 'Foster' is suitable. 1.Bhubaneswar 2.pune 1.Betul 2.Patna 3.Tiruchirapalli Capacitor Burnt Replaced-OK. Winding burnt Bearing jammed Replaced-OK. Replaced bearing from another burnt motor & overhauled- OK. 4.Visakhapattan am Bearing jammed Replaced with 'Crompton' 12" exhaust fan-OK. 1.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' Cooling Unit 'Huurre'Tempe rature Recorder (old type) 2.Rajkot 11.HP/LP 1.Udaypur pressostat defect Leak from nonreturn valve on charging tube Compressor stops after running about some time. Thermostat, GasOK. 12.compressor defect 13.Vibration element for discharge line 1.Tanzania Compressor winding defect. Brust,due to compressor vibration. 2.Kunoor Leak 14.HP switch for condenser fan motor 1.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' 1.Mains power Control not extended to panel(for petrol the units engine) 2.Generator not starting 1.Pune K11 faulty,K1 coil & contacts burnt, voltage between N & E observed more than 30 volts K11 & K1 replaced.Power line checked & N-E voltage corrected. 2.Trivandrum K1 contacts fused together,coil burnt. K1 replaced. 3.Bhubaneswar 4.Surat 5.Gwalior 6.Aurangabad 7.Madurai 8.Kolhapur 9.Gwalior 10. Visakhapattanam 11.Udaypur 12.Ratlam K1 coil burnt Replaced.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' Control panel(for petrol engine 'Foster' V.M.Diesel engine 3.generator starts 1.Lucknow & stops on 'manual'but not on 'auto' Recent problem, not yet analysed. 4.generator not 1.Rajkot stopping on 2.Gwalior manual but stops 3.Raipur on Auto This problem was experienced sometime back, but later disappeared(in all the 3 cases) 5.FBI(2203.4V)transformer defect 6.Phasesequence relay defect 1.Pune 2.Bhopal 3.Bhubaneswar 1.Madurai Winding damaged/burnt 7.
COLD-CHAIN MAINTENANCE FEEDBACK 'Foster' V.M.Diesel engine 5.Oil pressure decreases after about 2 hours running 1.Phulbani 2.Vadodara 6.Engine starts 1.Bhubanswar but can not attain full speed. 7.Excessive 1.Nasik vibration 'Huurre' (New)Control Panel for Diesel Engine 1.Generator not stopping 1.Ratlam 2.Stop solenoid defect 1.Moradabad 3.K2 contactor defect 1. Moradabad 2.Betul 3.Tiruchirapalli 1.Ratlam 4.Generator not starting 2.Tiruchirapalli 5.Trickle charger 1.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' petrol Engine (Honda G-400) 1.Starting trouble 1.Trivandrum Scaling observed in the carburetor(breaks to powder),float stuck Cleaned carburetor completely, working OK 2.Japiur & several other places Sludge in fuel tank & carburetor Drained fuel tank & cleaned carburetor & fuel tank.Filled fresh fuel-OK. Probable reason: 1.Contaminated fuel, 2.Long storage without use. See suggestions #12 Replaced from local market. 2.leakage from 1.
COLD-CHAIN MAINTENANCE FEEDBACK 'Huurre' petrol Engine (Honda G-400) 'Huurre' Diesel Engine (New) ALTERNATORS 7.Speed low on load 1.Visakhapattanam 1.Starting problem 1.Tiruchirapalli ---do— Battery charge low. 2.Surat Engine can be started only after giving +ve supply to the solenoid valve in fuel line 2.Engine not stopping 1. Tiruchirapalli 3.Charging relay defect 1.Tiruchirapalli 1.No output 1.Pune(HUU) Mecc alte 2.Only 2 phases available 1.
COLD-CHAIN MAINTENANCE FEEDBACK Power Supply (MAINS 2.Ernakulum 3.Kozikode Fluctuations (150250 V) during 6-10 pm. 4.Gurgaon Fluctuations (140200 V) Maharashtra ,A.P.& U.P. In Some places voltage as low as 160 V 2.Voltage drop in Several service installations connection 'Vestfrost'MK140/142 ILRs -Aluminum conductors used -Lower size of wire used. 2 units cannot run together from power most of the time.CB of one started later trips. 3.High Line resistance 1.Jabalpur 4.
COLD-CHAIN MAINTENANCE FEEDBACK 'Vestfrost'MK140/142 ILRs 3.Filter /capillary blocked in some new units Orissa Bihar Rajastan 4.Compressor TFS 4 AT Assam= 1 No Orissa= 1 No 'Vestfrost' SB140/142 Freezers 1.Compressor defect 1.Rajastan 'Electrolux'TC W-1151 ILRs 1.Sub-zero temperature while running as ILR 2.ILR/Freezer selector switch ILRs & FREEZERs Winding resistance-OK,but compressor jammed in about 3-4. This problem occurred when equipment was changed from freezer mode to OLR mode. 1.
COLD-CHAIN MAINTENANCE FEEDBACK ILRs & FREEZERs # Try inserting a capacitor(40-60 µF,220V)between No.11 & 13 of starting device. Knock the compressor body during starting process with a handle of a hammer,at different places. These actions may free the jam. # CANNOT BE REPAIRED. #Test the unit as per recommended test procedure & complete the Test-Certificate. 3.Internal leak in condenser evaporator -Temp goes down 2-3 days. -Formation of more frost on inner liner joint. -Abnormal liquid flow sound.
COLD-CHAIN MAINTENANCE FEEDBACK other end of the above cable is to be connected to the points 11 &12 of the 'new' panel. SUGGESTION #3 One'new' panel, one two-core cable, one Aux.contact & one T1 timer(yellow,with two pot.on(ront)dispatched to all WIC/F locations in end 1986. Please locate them & connect in place of 'old'panel,as detailed in suggestion #2 above.
COLD-CHAIN MAINTENANCE FEEDBACK SUGGESTION #8 The reason of fuse S1 blowing off in 'Foster'generator panel is mostly due to any of the 3 protections diodes shorted.they can be replaced by locally available diodes,viz: BY 127/BY126/IN4007/BY100 etc. SUGGESTION #9 RH1 7 RH2 in 'Foster'generator panel & km1 & km2 of 'Huurre'control panel (new) for Diesel engine are similar. All can be interchanged.
