0100_t5 Draft Technical Specification

8/2/2019 0100_t5 Draft Technical Specification

1/26

lR;eso Tk;rsHkkjr ljdkj jsy ea=ky;Hkkjr ljdkj jsy ea=ky;Hkkjr ljdkj jsy ea=ky;Hkkjr ljdkj jsy ea=ky;

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

vuqla/kku vfHkdYi ,oa ekud laxBuvuqla/kku vfHkdYi ,oa ekud laxBuvuqla/kku vfHkdYi ,oa ekud laxBuvuqla/kku vfHkdYi ,oa ekud laxBujsy ea=ky;jsy ea=ky;jsy ea=ky;jsy ea=ky;

RESEARCH DESIGNS AND STANDARDS ORGANISATIONMINISTRY OF RAILWAYS

vkjvkjvkjvkj----MhMhMhMh----,l,l,l,l----vksvksvksvks----@ih@ih@ih@ih----bZbZbZbZ----@Lisd@Lisd@Lisd@Lisd----@ih@ih@ih@ih----,l,l,l,l----@0100 iqujh@0100 iqujh@0100 iqujh@0100 iqujh{{{{k.k & ^k.k & ^k.k & ^k.k & ^1111* &2008* &2008* &2008* &2008

RDSO/PE/SPEC/PS/ 0100(REV. 1)-2008

DRAFT TECHNICAL SPECIFICATION FOR DOUBLE-CAPPED TUBULAR T5

FLUORESCENT LAMPS, T5 LUMINAIRE & ELECTRONIC BALLAST

S

N

Date of

Amdt. & No.

Rev. Reason of amendment

1. 11.01.2010

Amndt-1

0

i) Clause 2.6 of Section - IA, IB and IC, clauses 4.3, 4.4 and 4.5 of Section-IAclauses IIC & IID of Section-II, and clauses IIIA and IIIB of SectionIIdeleted.

ii) Clauses 2.4 and 6.1 of Section IA, IB and IC, clauses 5, 12 & 16 of SectioIIA and IIB, clauses 7, 8, & 9 of Section-III- D (i) & (ii), and clauses III-C III-E of Section-III amended.

iii) Clause 3.1, Annexure-A 19, Ballast Description Table, clauses 17, 18, 19 20 of Section-IIA, and clauses A1, A2, A3, A4, B1 and B2 of Section-IIIadded.

2. 05.07.2011 1 This revision has rationalized the spec and has introduced major editorichanges to improve its readability and clarity.

Approved by

Executive Director (EM)


2/26

Page 2 of 26 Effective from ____ RDSO/PE/SPEC/PS/0100(REV 1)-2008

DRAFTTECHNICAL SPECIFICATION FOR DOUBLE-CAPPEDTUBULAR T5 FLUORESCENT LAMPS, ELECTRONIC

BALLAST & T5 LUMINAIRES

0.0 Foreword

The T5 lamp is an increasingly popular development in fluorescentlighting and it is being used worldwide. The T5 technology offersadvantages of higher illumination, life, efficiency and reliability. The aimof this specification is to standardize the T5 fluorescent lamp, ballast andluminaires for adoption on the Indian railways (IR).

1.0 Scope

This specification covers the design, manufacturing and testing of14W/24W/28W/54W T5 tubular fluorescent lamps complete withluminaires, mounting accessories and electronic ballast for workingunder the operational and environmental conditions encountered duringservice on the IR.

The following is a section-wise list of items covered by this specification:

Section I: T5 Lamps (14/24/28/54W)

Section II: High frequency electronic ballast for T5 lamps

Section III: Luminaires for T5 lamps (luminaire types are listed below)

(i) Luminaire with PVC housing channel with/without Acrylic cover

(ii) Powder coated CRCA sheet luminaire

(iii) Mirror optic luminaire

(iv) Enclosed luminaire

(v) Luminaires suitable for streetlights

2.0 Reference standards

IEC-60081 Double-capped T5 Tubular FluorescentLamps Performance specification.

IS: 2418 (Pt. I to IV) Specification for T5 Tubular Fluorescent

Lamps for General Lighting Services.

IEC 60061-1 Lamp caps and holders together with gauges

for the control of interchangeability and

safety Part 1: Lamp caps.


3/26


IEC 61195 Double-capped T5 Tubular Fluorescent

Lamps Safety specifications.

IS: 5081 Specification for glass tube for fluorescent

lamps.

EN 50 285 Specification for energy efficiency

Council Directive

98/11/EC

Annex IV For energy efficiency

EN 61000-3-2 Harmonics

EN 61547 Immunity

EN 61347-2-3 Safety

EN 60929 Performance

IEC 68-2-6FcIEC 68-2-

9Eb

Vibration & bump test

IEC 60598-2-1 Fixed general purpose luminaire

IEC 60598-1 General requirement and tests

CISPR 15, EN

55015/BS 55015

Limit and methods of measurement of radio

disturbance characteristics for RFI


4/26


Atmosphere Extremely dusty and desert weather

and desert terrain in certain areas.

The dust content in air may reach

values as high as 1.6mg/cum.

Coastal area The equipment shall be designed to

work in corrosive atmosphere,

keeping in view, the following

conditions:

ph value: 8.5

Sulphate: 7 mg/litre

Concentration of chlorine: 6 mg/litre

Conductivity: 130 micro siemen/cm

Annual rainfall Ranging between 1,750 to 6,250 mm

with thunder storm

Altitude Not exceeding 1200 m (altitude may

vary up to 2000 m in J&K area.)

Vibration and shocks Maximum vertical acceleration 3.0g

Maximum lateral acceleration

3.0g Maximum longitudinal

acceleration 3.0 g (g being the

value of acceleration due to gravity)

3.2 The T5 Tubular Fluorescent Lamp including its fitting completewith luminaires, mounting accessories and electronic ballast shall besuitable for rugged service throughout India, in the above mentionedvarying climatic conditions. The design of fittings, including allaccessories, shall be suitable to work in the vicinity of 25KV, 50 Hztraction system.

3.3 The complete luminaire for outdoor application shall be protectedagainst dust and water as per IP-65. All other types of luminaires shallconform to IP-20.

3.4 The specification lays down a minimal list of type and acceptancetests. But this will in no way limit the right of RDSO/ purchasersrepresentative to call for any additional tests, if the same is considerednecessary for ensuring quality.


5/26


SECTION I

SPECIFICATION FOR T5 TUBULAR LAMPS

A. Specific requirements for T5 tubular fluorescent lamps

1.0 Dimensions

Rated wattage 14 W & 24W 28 W & 54W

Nominal dimensions 550 mm x 16 mm 1150 mm x 16 mm

Base phase to base

phase

549.0 mm max. 1149.0 mm max.

Base phase to end of

opposite cap pins

556.1mm max.

553.7mm min.

1156.1mm max.

1153.7mm min.

From ends ofopposite pin

563.2mm max. 1163.2mm max.

Diameters 17.0mm max. 17.0 mm max.

Cap G-5 G-5

2.0 Mechanical

2.1 The dimensions of caps on a finished lamp shall conform to IEC60061-1.

2.2 Both the pins (excluding flanges) of the two caps of a finished lampshall pass simultaneously, freely without winding, through parallel slots,suitably spaced longitudinally to receive the lamp. The slot shall be 2.87mm wide.

2.3 The caps shall be attached to the tubes strong enough towithstand torsion test in accordance with IEC: 61195, with a torsionmoment of 0.5 Nm applied gradually.

2.4 The shell of the lamp shall be of leadfree glass. The caps shall beresistant to atmospheric corrosion. Certificate to this effect should be

submitted by the manufacturer.

2.5 The lamp shall be environment friendly and mercury content of thepill used should be less than or equal to 3.2 mg.

2.6 It shall have a highly efficient single-layer 3-band tri-phosphorfluorescent coating specially designed for operation with electronic gearand suitable for dimming.


6/26


3.0 Electrical and cathode characteristics

3.1 The initial reading of the power dissipated by a lamp shall not

exceed the rated wattage, specified on the relevant lamp data sheet, bymore than 5 % + 0.5 W.

3.2 The insulation resistance between the shell and the contacts of capshall not be less than 2 mega ohms measured with a 500V DC megger.

3.3 The contacts shall be evenly pin punched to ensure satisfactoryengagement and electrical contact in the appropriate holder.

3.4 T5 lamps should comply to the following Cathode characteristicsas per IEC 60081:-

Property / Lamps 14 W 24 W 28 W 54 W

Test current, A 0.160 A 0.350 A 0.160 A 0.480A

Resistance

ateach cathode,

in ohms ( )

Rated 40 12 40 8

Minimum 30 9 30 6

Maximum 50 15 50 10

3.5 T5 lamps should comply to the following Electrical characteristicsas per IEC 60081:-

Property/Lamps 14 W 24 W 28 W 54 WFrequency, kHz 20 - 26 20 - 26 20 - 26 20 - 26

Rated lamp voltage

(r.m.s.)

86 V 77 V 166 V 120 V

Min.lamp voltage (r.m.s.) 76 V 69 V 149 V 110 V

Max.lamp voltage (r.m.s.) 96 V 85 V 183 V 130 V

Rated lamp current 0.165 A 0.295 A 0.170 A 0.455 A

4.0 Colour and photometry

4.1 Rated luminous flux and colour with reference ballast shall be asfollows (the details in respect of reference ballast can be seen in sub-section 4.3):-

T5 lamp of color 4000K at 25

degree C

T5 lamp of color 6500K at

degree C

Lamps 14 W 24 W 28 W 54 W 14 W 24 W 28 W 54 W


7/26


Rated

Luminous

Flux

1200

lumens

1715

lumens

2600

lumens

4450

lumens

1100

lumens

1560

lumens

2400

lumens

4050

lume

Colour

Designation

Cool

white

Cool -

white

Cool -

white

Cool -

white

Day

Light

Day

Light

Day

Light

Day

LighColour

Temperature

4000

deg. K

4000

deg. K

4000

deg. K

4000

deg. K

6500

deg. K

6500

deg. K

6500

deg. K

6500

deg.

Colour

Rendering

Index (Ra)

> 80 > 80 > 80 > 80 > 80 > 80 > 80 > 80

Chromaticity

Coordinates

x

0.380

x

0.380

x

0.380

x

0.380

x

0.313

x

0.313

x

0.313

x

0.31

y

0.380

y

0.380

y

0.380

y

0.380

y

0.337

y

0.337

y

0.337

y

0.33

4.2 The maximum luminous flux for T5 lamps shall be obtained at anambient temperature of 34C to 38C. Typical luminous flux values at35C are as follows:-

Sr.No. Colour

temperature

in K

14W 24W 28W 54W

1 4000 1350lumens

2000lumens

2900lumens

5000lumens

2. 6500 1250lumens 1850

lumens

2700

lumens

4550

lumens

The manufacturer should submit certificate for complying the abovementioned values.

4.3 The Reference Ballast, complying to IEC 60081, should have thefollowing characteristics :-

T5 lamp at 25 degree C

Lamp 14 W 24 W 28 W 54 W

Frequency, kHz 20 - 26 20 - 26 20 - 26 20 - 26

Rated Voltage, V 167V 150V 329V 235V

Calibration current, 0.170A 0.300A 0.170A 0.460A


8/26


A

Resistance in ohms

()

500 250 950 255

5.0 Rated luminous flux

It is the quantity derived from radiant flux by evaluating the radiationaccording to its action upon the CIE standard photometric observer. Theunit of luminous flux is lumens.

5.1 The initial reading of the luminous flux of a lamp shall be not lessthan 92 % of the rated value.

5.1 The initial reading of the chromaticity co-ordinates x & yshall be

within 5 SDCM (Standards Deviation for Colour Matching) from thestandardized rated value as per Annex. D of IEC 60081.

5.2 The initial reading of the general colour-rendering index (Ra) shallnot be less than the rated value decreased by 3.

5.3 The lumen maintenance of the lamp shall not be less than 95% ofthe initial lumen after 2000 burning hours, 91% of the initial lumen after6000 hours, and 90% of the initial lumen after 12,000 hours.

6.0 Rated life

It is defined as the number of burning hours after which 50% of thelamps survive under controlled burning conditions.

6.1 Rated life shall not be less than 15,000Hrs on a preheat/warmballast and IEC cycle (a three hours cycle i.e. 165 minutes on, 15minutes off). The lumen maintenance and life test shall be done as perAnnexure C of IEC 60081-97.

7.0 Starting

7.1 Starting test shall be conducted as per Annex A of IEC 60081-97.

7.2 T5 lamps should comply to the following Starting characteristics asper IEC 60081:-


9/26


T5 lamp at 25 degree C

Lamp 14 W 24 W 28 W 54 W

Frequency, kHz 20 - 26 20 - 26 20 - 26 20 26

StartingAid Distance, mm 6 6 6 6

Preheat Current, A 0.210A 0.440A 0.210A 0.720A

Preheat Time, sec 2 2 2 2

Open Ckt Voltage (r.m.s), V 230V 250V 375V 520V

Starting Time, sec 0.1 0.1 0.1 0.1

B. General requirements for all lamps

1.0 Safety

All the lamps shall comply with the safety requirements as per IEC61195. The manufacturer should submit a certificate for this.

2.0 Tests

Sampling for tests (type, acceptance and routine) shall be done as per IS-2418. The tests shall be conducted by consignee/ purchaser orrepresentative of consignee/ purchaser at firms premises. The list oftests to be conducted are summarized in a table that follows. For certaintests, previous type test reports/conformance certificates can be relied

upon. However, the manufacturer cannot demand this as a matter ofright.

Sl.

No.

Name of test Type

Test#

Routine

Test

Acceptance

Test

Method

1.0 GENERAL

a) Visual

Examination

b) Dimension IEC 60081

Clause 1.5.3

c) Pin Punching

d) Burn-in Test

2.0 MECHANICAL

a) Mechanical

Strength: Torsion

IEC 61195

b) Lead Free Glass -----

c) Mercury Content & & -----


10/26


3.0 ELECTRICAL and

CATHODE

a) Insulation

resistance

between Shell &Contacts of Cap

IEC 61195

Clause 2.4.1

b) Cathode

Resistance

IEC 60081

Clause 1.5.5.

& Annex. Bc) Initial Lamp

Voltage

4.0 COLOUR &

PHOTOMETRY

a) Rated Luminous

flux

IEC

60081Clause

1.5.6 &Annex. B

b) ColourTemperature

c) CRI

d) Lumen Output at

25 Deg C

5.0 RATED

LUMINOUS FLUX

a) ChromaticityCoordinate

IEC 60081Clause 1.5.6

& Annex. Bb) Initial CRI Value

c) Lumen

maintenance* IEC 60081

Annex. C

6.0 RATED LIFE

a) Rated Life * IEC 60081Annex. C

7.0 Starting

a) Starting Test IEC 60081

Clause 1.5.4& annex A.

# Until the railways are able to issue their vendor list, they may in the interim periodinvite tender/ place order with the provision of acceptance test alone, in instanceswhere such recourse is considered necessary. In absence of any mention to thecontrary in the tender and purchase order, it will be deemed that both type-test aswell as acceptance test will need to be carried out


11/26


* Normally, type-test certificates shall be accepted for the same. But RDSO reserves itsright to ask for this type-test to be repeated and to witness the same

& Conformity Certificate to be submitted

3.0 Marking

The following information shall be distinctly and indelibly marked on thelamp.:-

i) Trademark and/or name of manufacturerii) Rated wattiii) Colour designation/temperatureiv) Rated luminous flux in lumen or marking to indicate the

luminous flux as per manufacturers catalogue

The manufacturer should also indicate the following on the cover of thepacking of each T5 lamp.:-

i) Indian Railway Insigniaii) Month/Year of manufactureiii) Rated luminous flux in lumens.

4.0 PACKING

Packing of the lamps should be in individual sleeves

5.0 Technical details to be furnished by the purchaser in hisrequisition are given in Annexure A and technical data to befurnished by the tenderer in his offer are given in Annexure B

*********


12/26


SECTION II

SPECIFICATION FOR ELECTRONIC BALLAST FOR T5 LAMPS

This section prescribes the requirements of electronic ballast foroperation of T5 fluorescent lamps without the need of starters, chokesand capacitors.

A. Specific requirements for high frequency electronic ballast forT5 lamps

To have better reliability, there shall be a separate ballast for each lampi.e. a 2X28W luminaire will have two ballasts and 4x14W luminaire willhave 4 ballasts dedicated for each lamp. The following table summarizes

the requirements of various ballasts covered by the spec.:

Table 1

S.No. Description Type of Ballast

14W 24W 28W 54W Integrated

for 1X28W

1. Rated

Voltage

240V ac/ 50Hz

2. Rated

Current(max.

0.08A 0.12A 0.18A 0.28A 0.18A

3. Input voltage 180 to 265V AC

4. Power

consumption

a) Ballast

(Max.)

3W 4W 4W 7W 4W

b) Power

output to

the lamp

from

ballast

>=13W >=23W >=27W >=52

W

>=27W

5. Power Factor 0.98 0.98 0.98 0.98 0.97

6. Temperature

range

-10oC to 50oC

1. Power consumption - Power consumption of ballast shall be aslow as possible and not higher than the values specified in table 1.


13/26


Conversely, the power output to the lamp from ballast shall not be lessthan the values specified in the table.

2. In case of mains voltage fluctuation within 92% to 106% of rated

voltage, the luminous flux shall not change by more than of 2%.

3. The ballast shall withstand over voltage for 48 Hrs at 320V. Itshould also withstand 350V at 60oC for 2 hours. During last 15 minutes,the circuit shall be switched ON (at 350V) /OFF at least 10 times andthere shall be no malfunctioning of the ballast and the ballast shallfunction normally. The aforesaid test will be a type-test. Duringacceptance tests, the ballast should be tested at 350V for 2 hours at60oC and the circuit shall be switched ON (at 350V)/ OFF at least 10times during last 15 minutes and there shall be no mal-functioning ofballast and the ballast shall work normally.

4. There shall be an automatic restart after lamp replacement or witha voltage dip down to 30% in duration of 10 mains cycles.

5. The operating frequency of output voltage shall be greater than 40KHz and waveform shall be quasi-sine wave.

6. Operating Voltage The operating voltage range on which theballasts should work shall be 135V to 300V. The ballasts should be ableto comply all requirements mentioned in the table 1 for the input voltagerange 180V to 265V.

7. Illumination efficiency The ballast factor shall be more than0.95.

8. Abnormal condition protection: The ballast shall have protectioncircuit in case faulty lamp of same wattage is connected.

9. Moisture resistance & insulation protection - After storage of48Hrs at 91-95% relative humidity and 20-30C, the insulationresistance shall be >2 M ohm with 500V DC megger.

10. Surge/Immunity/Dips/Burst test: The ballast shall comply withIEC 61547.

11. Power factor The power factor of ac electronic ballast shall begreater than specified in the table.


14/26


12. Starting time: The ballast shall be warm start ballast as per IEC60929. Ignition time shall less than 2 seconds.

13. Total harmonic Distortion: The ballast shall conform to IEC

61000-3-2 and have input current harmonic distortion of < 10%.However, the ballast shall meet the individual harmonics requirementsas per IS: 13021 (Pt.-2).

14. Safety:The electronic ballast shall be complying with IEC 61347-1for safety and IEC 60929 for performance standards.

15. The ballast shall be designed for a max case temp of 75 C.

16. Construction: The ballast shall be of light weight steel sheet(powder coated) or plastic/fiber of fire retardant UL94-V0 grade.

17. The Fast switching cycle (average, 1min/3min on/off) shall be>=6000 times (for 1 burner) at rated voltage.

18. The lamp current crest factor shall be less than 1.7.

19. The section of internal wiring shall exceed or equal to 0.5mmsquare.

20. PCB used in the ballast shall be min 1.2mm thick glass epoxy or1.5mm FR-1 sheet.

21. Abnormal conditions

21.1 Removal of Lamp

During operation of the electronic ballast with fluorescent lamp, the lampwill be removed from the fitting for a period of one hour withoutswitching OFF the supply. At the end of this period the lamp shall bereconnected and shall start and operate normal. For reset of ballast,switch off for 30s is permissible.

21.2 Lamp fails to start (cathode intact electrically)

With the appropriate dummy cathode resistor connected in place of eachlamp cathode, electronic ballast shall operate at the maximum value ofthe voltage range for one hour. At the end of this period, the resistorshall be removed and the specified lamp shall be connected and it shall


15/26


start and operate normally. For reset of ballast, switch off for 30s ispermissible.

21.3 Incorrect Wiring

There shall be no ballast failure in case of incorrect wiring at lampside.

21.4 Electrode Broken/Emitter Exhausted

The electronic ballast shall have a safety feature of a stop circuit in caseof electrode being broken or emitter exhausted. For reset of ballast,switch off for 30s is permissible.

21.5 The electronic ballast shall be designed to withstand short circuit

across the ac output terminals, overload and failure of electroniccomponents without any fire hazards. For reset of ballast, switch off for30s is permissible.

21.6 The current drawn from the supply at any of the voltages in thevoltage range, shall not be more than 115% of the value obtained at therated voltage.

B. General Requirements for all type of electronic ballast

1.0 All ballasts/PCBs must have batch number, make and month &

year printed on them.2.0 Tests

Sampling for acceptance tests shall be done as given in Table-10under column (N1+N2) of IS-1534/part-1. The tests shall beconducted by consignee/ purchaser or representative ofconsignee/ purchaser at firms premises. The list of tests to beconducted are summarized in a table that follows. For certaintests, previous type test reports/conformance certificates can berelied upon. However, the manufacturer cannot demand this as amatter of right.

S.

No.

Description Type

Test#

Routine

Test

Acceptan

ce Test

Method

1. Visual Examination

2. Rated Current (max.) As per IEC 60929


16/26


3. Power consumption As per IEC 60929

4. Power Factor As per IEC 60929

5. Operating frequency

of output voltage and

wave form

As per Clause 5 of

Section II Part A

6. Illumination efficiency As per IEC 60929

7. EMI As per CISPR 15

8. Surge/Immunity/Dip

s/ Burst test

As per IEC 61547

9. Starting time As per IEC 60929,

60081

10. Total harmonic

Distortion and

individual harmonics

As per IEC 61000-

3-2, IS 13021 Part 2

11. Crest factor As per IEC 60929

12. Moisture resistance &

insulation

@

As per IEC 61347-1

13. Provisions for

protective earthing

As per IEC 61347-1

14. Protection against

accidental contact

with live parts

As per IEC 61347-1

15. Electric strength As per IEC 61347-1

16. Abnormal condition

protection

16.1 Removal of lamp As per IEC 61347-1

16.2 Lamp fails to start

(cathode intact

electrically)

As per IEC 61347-1

16.3 Incorrect Wiring As per IEC 61347-1

16.4 Electrode

Broken/EmitterExhausted

As per IEC 61347-1

16.5 Short Ckt, etc (one

sample

per lot)

As per Clause 21.5

of Section II of specs

17. Creepage distance &

clearance

As per IEC 61347-1


17/26


18. Resistance to heat,

fire & tracking

As per IEC 61347-119. Resistance to

corrosion

As per IEC 61347-120. Change of Luminous

Flux

As per Clause 2 ofSection II of

specification

21. Overvoltage

withstanding

(2%

sample)

As per Clause 3 of

Section II of

specification

22. Fast Switch Cycle (one

sample

per lot)

As per Clause 18 of

Section II of

specification

23. Operating voltage

range

As per Clause 6 of

Section II of

specification

24. Endurance @ As per IEC 60929

25. PCB material and

thickness

$

# Until the railways are able to issue their vendor list, they may in the interim periodinvite tender/ place order with the provision of acceptance test alone, in instances

where such recourse is considered necessary. In absence of any mention to thecontrary in the tender and purchase order, it will be deemed that both type-test aswell as acceptance test will need to be carried out.

@Type test certificate to be produced in lieu of test

$Certificate of conformity with regard to material of PCB is required to be furnished inlieu of test

3.0 Technical details to be furnished by the purchaser in hisrequisition are given in Annexure A and technical data to befurnished by the tenderer in his offer are given in Annexure B

*******


18/26


Section III

This section prescribes the requirements of different type of luminairesfor T5 fluorescent lamps. In the market, various types of luminaires are

available and new types will get added from time to time. Further, theusers will have different type of requirements for different environments.Keeping this in view, general requirements for luminaires have been laiddown and in addition requirements have also been prescribed for specifictypes of luminaries. In their indents, railways will need to mention thespecific luminaire type required by them.

A. General requirements for T5 luminaires

1. It shall be luminaire suitable for T5 fluorescent Lamp.

2. The gear along with the other accessories shall have in builtelectronic ballast, which may be a separate ballast or integratedballast with luminaire as per requirement.

3. The type of fitting or housing channel shall be specified by users e.g.PVC channels, CRC channel, with reflector, without reflector etc.

4. The Lamp holder shall be G5 type.

5. The material used in rotor holders for contact with pins of lamps

should be made of phosphor bronze.

6. The fixing clamp shall be sturdy to avoid its falling during vibrationsor sudden pressure of wind generated during passage of train, etc.

7. Base, end caps and other caps shall be made of fire retardant andheat resistant material which meet the requirements specified inIEC/ IS specifications.

8. Fitting shall be provided with an insulated cable for mains

connector.

9. Suitable mounting arrangement as specified by user shall beprovided. The mounting instructions shall be provided along withevery luminaire.

10.The fitting shall be packed in a poly bag, besides the outercard board box.


19/26


11.The luminaire shall confirm to IEC 60598-2 with regards toapprobation.

12.The photometric results obtained during type testing shallremain the benchmark for any photometric tests done laterfor that type of luminaire of same manufacturer.

B. Additional features for luminaires of T5 fluorescent tubularlamps with PVC housing channel with/without Acrylic cover.

1. The housing channel shall be sturdy, non conductive and made upof corrosion and rust free PVC.

2. The fitting shall conform to electrical insulation class II whicheliminates the necessity of separate earthing.

3. Fitting shall be suitable for mounting on wall, ceiling, as well assuspension.

C. Additional features for powder coated CRCA sheet luminaire ofT5 fluorescent tubular lamps

1. Luminaries shall be made of a 0.5mm CRCA channel wired with

electronic ballast inside.

2. All the sheet metal parts shall be pretreated by seven tankprocess and powder coated using epoxy polyester powder. Themanufacturer shall submit a certificate to this effect.

3. The housing channel shall be powder coated with coatingthickness of 45-65 micron (test certificate to be submitted by themanufacturer) and colour shall be gloss white.

4. The powder coated CRCA sheet channel should have speciallydesigned plastic end supports for lamp holders.

5. The fitting shall conform to electrical insulation class I withprovision of separate earthing bush.

6. Fitting shall be suitable for mounting on wall, ceiling, as well assuspension.


20/26


7. Termination: The luminaire shall be complete with control gearsand pre-wired upto a terminal block.

8. The luminaires shall have replaceable ballast.

D. Additional features for mirror optic fitting for T5 Tubularlamps

1. Mounting: The luminaire shall be suitable for surface mounting aswell as suspension/recess mounting

2. Termination: The luminaire shall be complete with control gearsand pre-wired upto a terminal block.

3. Optical System - High efficiency mirror assembly of highquality pre anodized Aluminium with faceted side reflectorand diffused white lamella. For ease of re-lamping it shall befixed with the housing by specially designed springmechanism so that it can be hinged also from one side.

4. Mounting - There shall be a provision for suspension/recessmounting through 19mm dia conduit via 2 nos. EVA grommets ordirect fixing by screws on ceiling.

5. The optical compartment shall comprise of a special gear covercum reflector that enhances efficiency.

6. The optical system shall be fixed on the luminaire by a speciallydesigned robust clip-on mechanism and can be hinged to thehousing during re-lamping / maintenance.

7. Housing of luminaire shall be rigid.

E. Additional features for enclosed luminaire suitable for T5linear fluorescent lamps (outdoor application)

This type is generally suitable for the Indian Railways platforms/openareas.

1. The luminaire shall be able to withstand functional shock,vandalism, dust and be water jet proof.


21/26


2. The housing shall be made of polycarbonate with min thickness of1.6mm.

3. Cover shall be of UV stabilized polycarbonate with min thickness of

1.3mm. The cover shall be of clear polycarbonate and haveserrated patterns.

4. The luminaire shall have an IP rating of IP65.

5. The luminaire shall have a impact resistance of IK08 level

6. All external hardware including toggles shall be of stainless steel

7. The reflector shall be of powder coating for better reflectivity.

8. The gear tray containing all the accessories shall be made of0.5mm cold rolled rust free stainless steel and shall be replaceable.

9. The gear tray shall accommodate all electrical accessoriesincluding electronic ballast.

10. Mounting shall be decided based on requirement.

F. Additional features for T5 luminaires suitable for streetlights

1. It shall be made with CRCA sheet as per sub-section C.

2. The housing shall be fabricated from deep drawn sheet aluminumstove enameled white or powder coated with coating thickness of45-65 micron .

3. The end caps may be made of impact-resistant engineering plasticfor sturdy and excellent corrosion-resistant construction.

4. The Gear tray cum reflector shall be made of CRCA sheet steelepoxy powder-coated white.

5. The Gear tray shall accommodate all electrical accessoriesincluding electronic ballast.

6. The Acrylic cover shall be made from clear methyl methacrylatesheet.


22/26


7. Six or more numbers of toggles shall be provided for fixing theacrylic cover on to the canopy of the luminaire.

8. It shall be suitable for side mounting with the help of U clamps

provided on the canopy for pole diameter of max. 28mm outer diaor pipe mounting arrangement or pipe fixing.

9. The luminaire shall be protected against ingress of dust andmoisture with rubber gaskets provided in the housing.

10. The gear tray shall accommodate all electrical accessoriescomprising of electronic ballast.

11. It shall conform to IP65.

G. Tests

Sampling for tests (type, acceptance and routine) shall be done asper IS-10322. The tests shall be conducted by consignee bypurchaser or representative of consignee by purchaser at firmspremises. The list of tests to be conducted are summarized in atable that follows. For certain tests, previous type testreports/conformance certificates can be relied upon. However, themanufacturer cannot demand this as a matter of right.

S.

No.

Description Type

Test#

Routine

Test

Acceptance

Test

Method

1 Visual

Examination

2 Provision for

Earthing

As per IEC 60598-

1

3 Protection

against Electric

Shock

As per IEC

60598-1

4 Resistance to

dust, objects

and moisture

As per IEC

60529

5 Insulation

resistance

As per IEC

60598-1

6 Electric strength As per IEC

60598-1

7 Endurance test As per IEC

60598-1


23/26


8 Thermal test

(normal)

As per IEC

60598-1

9 Thermal test

(abnormal)

As per IEC

60598-1

10 Resistance to

heat

10.1 Ball pressure

test

As per IEC

60598-1 Clause

13.2

11 Resistance to

flame and

ignition

11.1 Needle-flame

test

As per IEC

60598-1 Clause13.3

11.2 Glow-wire As per IEC

60598-1 Clause

13.3

12 Resistance to

tracking

As per IEC

60598-1 Clause

13.4

13 Resistance to

corrosion

As per IEC

60598-1 Clause4.18 /clause 8 of

IS 10322(part 4)

14 Photometry 15 Powder Coating

thickness of

housing channel

(applicable to

CRCA fittings)

As per clause 3sub-section C of

Section III

# Until the railways are able to issue their vendor list, they may in the interim periodinvite tender/ place order with the provision of acceptance test alone, in instanceswhere such recourse is considered necessary. In absence of any mention to thecontrary in the tender and purchase order, it will be deemed that both type-test aswell as acceptance test will need to be carried out.


24/26


H. Technical details to be furnished by the purchaser in hisrequisition are given in Annexure A and technical data to befurnished by the tenderer in his offer are given in Annexure B

****


25/26


Annexure - A

Technical details to be furnished by the purchaser in his requisition

1. Lampa) Wattage of lampb) Color temperature (in degree Kelvin)c) Material to be accepted on type or acceptance test reports

2. Ballast (if required separately)

a)The T-5 lamp wattage for which ballast is requiredb) Material to be accepted on type or acceptance test reports

3. Luminaire

a)The T-5 lamp for which luminaire is required i.e. please mention28W, 54W, etc.

b)Type of fitting (e.g. 1X28W, 2X54W, etc.)c) PVC/ CRCAd) If it is PVC, then will it be with/ without batwings(reflector) or

with/ without acrylic covere) Mirror optic fitting (Yes/ No)f) Wall mounted/ Hung/ Recessedg) Enclosed luminaire is required for outdoor applications as per

Sub-section E of Section III of the spec. (Yes/ No)h) Streetlight is required as per Sub-section F of Section III of the

spec. (Yes/ No)i) Material to be accepted on type or acceptance test reports


26/26


Annexure - B

Technical data to be furnished by the tenderer in his offer

1. Lampa) Make and model no.b) Lamp Wattagec) Color temperatured) Lumen outpute) 15000 hours life (Certificate from accredited national/

international laboratory to be attached)f) Lumen maintenance after 2000, 6000, 12000 and 15000

burning hours (Certificate from accredited national/international laboratory to be attached)

g) Mercury content

2. Ballast

a) Make and model no.b) Ballast for which type of lampc) Rated current (max.)d) Operating voltage rangee) Power consumption of ballastf) Power consumption of complete assembly, if relevantg) Power factorh) Max. case temperature

i) Operating frequency

3. Luminaire

a) Make and model no.b) Luminaire for which lamp has been offered i.e. please mention

28W, 54W, etc.c)Type of fitting (e.g. 1X28W, 2X54W, etc)d) PVC/ CRCAe) If PVC, will it be with/ without Acrylic coverf) Mirror optic fitting (Yes/ No)

g) Wall mounted/ Hung/ Recessedh) Enclosed luminaire offered for outdoor application as per Sub-section E of Section III (Yes/ No)

i) Streetlight offered as per Sub-section F of Section III (Yes/ No)

Documents

0100_t5 Draft Technical Specification