Electronic Equipment Supplied for Passenger Rolling Stock · 2019. 5. 23. · IEC 60146 Semiconductor converters – General requirements and line commutated converters ... Equipment

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Electronic Equipment Supplied for Passenger Rolling Stock

T HR RS 00126 ST

Standard

Version 1.0

Issued Date: 27 June 2014

Effective Date: 27 June 2014

Important Warning

This document is one of a set of standards developed solely and specifically for use on the rail network owned or managed by the NSW Government and its agencies. It is not suitable for any other purpose. You must not use or adapt it or rely upon it in any way unless you are authorised in writing to do so by a relevant NSW Government agency.

If this document forms part of a contract with, or is a condition of approval by, a NSW Government agency, use of the document is subject to the terms of the contract or approval.

This document may not be current. Current standards are available for download from the Asset Standards Authority website at www.asa.transport.nsw.gov.au.

© State of NSW through Transport for NSW

http://www.asa.transport.nsw.gov.au/

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Electronic Equipment Supplied for Passenger Rolling Stock Version 1.0


© State of NSW through Transport for NSW

Standard Approval Owner: M Uhlig, Lead Rolling Stock Engineer Authorised by: D. Spiteri, Chief Rail Engineer Approved by: J. Modrouvanos, Director Asset Standards Authority on behalf of the ASA

Configuration Control Board

Document Control Version Summary of Change 1.0 First issue

For queries regarding this document

[email protected]

www.asa.transport.nsw.gov.au

mailto:[email protected]

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© State of NSW through Transport for NSW Page 3 of 18

Preface

The Asset Standards Authority (ASA) develops, controls, maintains, and publishes standards

and documentation for transport assets for New South Wales, using expertise from the

engineering functions of the ASA and industry.

The ASA publications include the network and asset standards for NSW rail assets.

This document has been developed from existing RailCorp standards and specifications and

has been issued by the ASA to provide the requirements for the conditions of operation, design,

construction, components, materials and finishes and testing of electronic equipment supplied

for passenger rolling stock.

This document supersedes RailCorp standard FE 126 General specification for electronic

equipment.

Foreword

This standard forms part of a suite of passenger rolling stock electrical standards and should be

read in conjunction with those related standards. These include the standards listed below:

T HR RS 00117 ST Electric Circuits and Equipment for Passenger Rolling Stock

T HR RS 00164 ST Electrical Cable for Passenger Rolling Stock

T HR RS 01701 ST Mounting and Installation of Electric Equipment for Passenger Rolling

Stock

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Table of contents

1. Introduction........................................................................................................................................... 6 2. Purpose.................................................................................................................................................. 6

2.1 Scope.................................................................................................................................................. 6 2.2 Application......................................................................................................................................... 6

3. Reference documents .......................................................................................................................... 6 4. Terms and definitions .......................................................................................................................... 7 5. Operating conditions............................................................................................................................ 8

5.1 Rail operations environment............................................................................................................ 8 5.2 Ambient temperature conditions..................................................................................................... 8 5.3 Power supply..................................................................................................................................... 8 5.4 Vibration and Shock ......................................................................................................................... 9

6. Design of electronic equipment .......................................................................................................... 9 6.1 Fire performance............................................................................................................................... 9 6.2 Equipment reliability....................................................................................................................... 10 6.3 Component ratings and de-rating ................................................................................................. 10 6.4 Adjustable components ................................................................................................................. 10 6.5 Component tolerances and ageing ............................................................................................... 10 6.6 Protection......................................................................................................................................... 10 6.7 Interference...................................................................................................................................... 10 6.8 Ventilation........................................................................................................................................ 11

7. Construction of electronic equipment.............................................................................................. 11 7.1 Component mounting..................................................................................................................... 11 7.2 Electrical connections .................................................................................................................... 12

8. Identification........................................................................................................................................ 13 8.1 Equipment labelling ........................................................................................................................ 13 8.2 Unit and sub-unit mounting position ............................................................................................ 13 8.3 Termination of screened cables .................................................................................................... 13

9. Component requirements .................................................................................................................. 14 9.1 Discrete semiconductor devices................................................................................................... 14 9.2 Fixed resistors................................................................................................................................. 14 9.3 Variable resistors ............................................................................................................................ 14 9.4 Capacitors........................................................................................................................................ 14 9.5 Power transformers ........................................................................................................................ 15 9.6 Other transformers and inductors ................................................................................................ 15 9.7 Reed relay coils............................................................................................................................... 15 9.8 Hermetically sealed relays ............................................................................................................. 15

10. Component identification .................................................................................................................. 15 11. Documentation.................................................................................................................................... 16

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11.1 Drawings....................................................................................................................................... 17 11.2 Circuit diagrams .......................................................................................................................... 17 11.3 Component lists .......................................................................................................................... 17 11.4 Component layout ....................................................................................................................... 17 11.5 Logic diagrams ............................................................................................................................ 18 11.6 Block diagrams............................................................................................................................ 18 11.7 Cubicle wiring diagrams............................................................................................................. 18 11.8 Interconnection diagrams........................................................................................................... 18 11.9 Equipment drawings ................................................................................................................... 18 11.10 PCB graphics patterns................................................................................................................ 18

12. Testing ................................................................................................................................................. 18

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1. Introduction This standard states the performance standards required of electronic equipment supplied for

passenger rolling stock.

2. Purpose This standard details the requirements which must be met by electronic equipment for use on

TfNSW passenger rolling stock.

This standard aims to satisfy the need to maximise passenger safety and minimise risk to life in

the event of fire, especially those which occur underground.

2.1 Scope This standard covers the conditions of operation, design, construction, components, materials

and finishes and testing of electronic equipment supplied for passenger rolling stock.

2.2 Application This standard shall apply to new passenger rolling stock and the refurbishment or modifications

of existing rolling stock assets. Pending a direction otherwise from the TfNSW contract

administrator (or applicable equivalent), contracts and tenders for new or modified passenger

rolling stock released before the standard effective date shall be exempt from the requirements

of this standard.

3. Reference documents Australian standards

AS 1046 Letter symbols for use in Electro technology

AS 1100 Drawing practice

AS 1102 Graphical symbols for Electro technology

AS 60417.1 Graphical symbols for use on equipment – Overview and application

AS 60529 Degrees of protection provided by enclosures (IP Code)

AS/NZS 4383 Preparation of documents used in Electro technology – General requirements

International standards

BS 6853 Code of practice for fire precautions in the design and construction of passenger trains

EN 50128 Railway applications – Software for railway control and protection

EN 50155 Railway applications – Electronic equipment used on rolling stock

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EN 60068 Series Environmental testing (IEC 60068 series)

EN 60352-2 Solderless connections Crimped connections. General requirements, test methods

and practical guidance

IEC 61287 Railway Applications – Power convertors installed on board rolling stock – Part 1:

Characteristics and test methods

IEC 60146 Semiconductor converters – General requirements and line commutated converters

– Part 1-1: specification of basic requirements

IEC 60605 Equipment reliability testing; Tests for the validity and estimation of the constant

failure rate and constant failure intensity

IEC 61188-1-1 Printed boards and printed board assemblies

TfNSW standards

T HR RS 00117 ST Electric Circuits and Equipment for Passenger Rolling Stock

T HR RS 00164 ST Electrical Cable for Passenger Rolling Stock

T HR RS 01701 ST Mounting and Installation of Electric Equipment for Passenger Rolling Stock

4. Terms and definitions The following definitions apply in this document:

ac alternating current

AFAIRP as far as is reasonably practical

approval is the process whereby an authorised person certifies that engineering outputs have been verified as meeting input specifications and requirements, and that the engineering output

has been completed in accordance with relevant regulations and standards, prior to progressing

to the next stage

authority is the allocation of responsibility which allows you to act

cubicle is any enclosure for housing electrical or electronic equipment

dc direct current

printed board is the base material cut to size containing all holes and bearing at least one conductive pattern

printed board assembly is the printed board with electrical and mechanical components

PCB polychlorinated biphenyls

surge is a non-periodic and relatively short positive or negative (or both) variable (voltage or current) between two steady states

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5. Operating conditions All electrical power, control, signal and communication cables shall meet the performance

requirements appropriate for the installation, under the following conditions:

the rail operations environment

ambient temperature conditions

power supply system

vibration conditions

5.1 Rail operations environment Rail vehicles operate in suburban and outer suburban areas which include tunnels and elevated

track.

The operating and design categories shall be approved by the authorised contract

representative.

5.2 Ambient temperature conditions All equipment shall operate and comply with the ambient temperature class 'T1', defined in

section 4.1.2, Ambient temperature of EN 50155. The ambient temperature ranges for 'T1' class

are detailed in Table 1 below.

Table 1 - Ambient temperature

Ambient temperature outside vehicle °C

Internal cubicle temperature °C

Internal cubicle over-temperature during 10 min °C

Air temperature surrounding the printed board assembly °C

-25 +40 -25 +55 +15 -25 +70

For existing non air-conditioned fleets; where fluorescent lighting ballasts are located close to

the roof. Fluorescent light inverter ballasts shall operate satisfactorily at 90° C.

5.3 Power supply Electronic equipment shall be designed to operate from the vehicle dc control voltage.

Electronic equipment shall be designed to operate with supply voltage variations and transients.

5.3.1 Power supply voltage variations Where the equipment makes use of the vehicle dc control voltage, it shall perform its functions

to specification between 80% and 120% of the nominal voltage value and shall operate normally

for a minimum of 10 seconds at 50% of nominal supply voltage.

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5.3.2 Power supply transients The equipment must not be damaged or malfunction in the presence of spikes and surges on

the supply, across input and or output terminals.

All electronic equipment shall withstand surges, electrostatic discharge and transient burst

susceptibility tests as specified in EN 50121-3-2 in accordance with EN 50155 clause 12.2.7.

5.4 Vibration and Shock Equipment shall be tested for vibration and shock in accordance with the requirements detailed

in EN 50155 clause 12.2.11.

6. Design of electronic equipment All electronic equipment shall be manufactured and designed in accordance with;

EN 50155 Railway applications – Electronic equipment used on rolling stock

Software shall be developed in accordance with;

EN 50128 Railway applications – Software for railway control and protection

Design of electronic equipment shall meet requirements for the following:

fire performance

equipment reliability

component ratings and derating

adjustable components

component tolerances and ageing

protection

interference

ventilation

6.1 Fire performance All new equipment shall comply with the fire protection requirements and recommendations of

BS 6853 Code of practice for fire precautions in the design and construction of passenger trains

in its design, material selection and testing.

All fire performance design categories and operating conditions shall be as documented in

BS 6853.

The operating and design categories shall be approved by the TfNSW authorised contract

representative.

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6.2 Equipment reliability The required reliability will be specified in the individual specification and the manufacturer shall

provide reliability data on the equipment together with any supporting evidence of figures used.

In general, no maintenance shall be required to achieve the stated reliability figures.

Reliability shall be evaluated in accordance with IEC 60605 Equipment reliability testing; Tests

for the validity and estimation of the constant failure rate and constant failure intensity.

6.3 Component ratings and de-rating Component ratings and de-rating shall comply with the requirements of EN 50155 clause 8.2.4

6.4 Adjustable components The use of adjustable components shall be avoided, unless inherently essential. Designs that

incorporate stable fixed components are preferred.

Where an adjustable resistance is necessarily incorporated in the design, multi-turn trimpots

shall be used, which shall not have accessibility for general maintenance.

6.5 Component tolerances and ageing The design of the circuits used shall be such that cyclic and non-cyclic changes in component

values and parameters which may occur during the operational life of the equipment are either

inconsequential or are compensated for. Such compensation shall not necessitate the use of

adjustable controls.

The combined effects of all tolerances, within a single component and between components

shall be allowed for by taking all tolerances in all worst case combinations produced by

environmental and operational conditions.

Other statistical assumptions that only certain combinations of tolerances will occur shall not be

made, unless the relevant parameters involved are invariably interdependent.

6.6 Protection As far as possible all circuits shall be designed so that in the event of a component fault

consequential damage is confined to a minimum.

Outgoing cables shall be rated above the current limit value.

Additionally EN 50155 clause 7.2.2 shall be applied.

6.7 Interference Equipment shall meet requirements for the following types of interference:

self-generated interference

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external interference

radio interference

6.7.1 Self-generated interference Equipment shall not generate any type of electrical, mechanical, magnetic, audible or near

audible sonic interference or noise, at a level which could be detrimental to the performance of

any other equipment or which could cause annoyance, discomfort or health risk to any person.

Individual components of the equipment shall not exhibit harmful resonance, or perform any

unscheduled operation, with particular reference to relays, and also standard miniature circuit

breakers.

6.7.2 External interference Where the performance of any equipment could be susceptible to interference it shall be

shielded from such interference.

6.7.3 Radio interference Radio interference testing shall be conducted in accordance with the requirements of:

EN 50155 clause 12.2.8

6.8 Ventilation Forced cooling is not preferred.

See EN 50155 clause 9.10 for further guidance

7. Construction of electronic equipment All electrical equipment shall be constructed to the requirements of EN 50155 clause 9;

Construction.

Additional construction requirements exist for the following:

component mounting

electrical connections

7.1 Component mounting Component mounting shall conform to IEC 61188-1-1 Printed boards and printed board

assemblies.

Additionally the following shall apply:

all components weighing 14 grams and over shall be adequately supported and secured

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components shall be mounted so that no adverse effects will result from the fixing method

7.2 Electrical connections All connections shall comply with the requirements of EN 50155 clause 9.1.4.

Additional requirements exist for the following connection types and attributes:

crimped connections

soldered connections

internal wiring

printed circuit boards

protective finishes

encapsulation

ventilation

7.2.1 Crimped connections Crimped connections shall comply with the requirements of:

EN 60352-2: Solderless connections Crimped connections. General requirements, test methods

and practical guidance

7.2.2 Soldered connections Soldered connections comply with the requirements of:

EN 50155 clause 9.3.1

7.2.3 Internal wiring Internal wiring shall comply with the requirements of:

EN 50155 clause 9.4 and clause 9.5

7.2.4 Printed circuit boards Additionally printed circuit boards shall comply with the requirements of IEC 61188-1-1 Printed

boards and printed board assemblies.

Edge connectors for printed circuit boards shall not be used without a concession to this

standard.

7.2.5 Protective finishes Protective finishes shall comply with the requirements of:

EN 50155 clause 9.7

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7.2.6 Encapsulation The methods of making connections through the encapsulant shall not permit the ingress of

moisture.

The encapsulation process shall, AFAIRP, ensure that the finished product is free from cracks,

air pockets and any weaknesses due to any components which are too near the surface.

7.2.7 Multi-pole circular connectors The design and arrangement of multi-pole circular connectors shall be such that incorrect

mating cannot occur. Where more than one connector is available, incorrect insertion is to be

prevented.

Gold plated mating pins and sockets to a minimum thickness of 2 microns shall be used.

8. Identification All electronic equipment and its installation shall be identified through the following:

labelling of equipment

identification of mounting position

identification of components

8.1 Equipment labelling Labelling of equipment shall facilitate routine testing and maintenance. All labels shall be clear,

bold, concise, durable and securely fixed.

Each detachable unit shall be either marked so as to enable it to be identified with the parent

equipment, or else marked with the manufacturer's name and type number or code number and

where definable its function.

Each printed circuit board shall carry its circuit function title and serial number.

8.2 Unit and sub-unit mounting position Each mounting position shall be marked to indicate the type of unit or sub-unit to be located in

that position. Additional markings may be required for apparently identical units or sub-units

having different pre-set characteristics.

8.3 Termination of screened cables Where screening is employed solely for noise suppression, the screen shall be terminated at

one end only. The unterminated end of the screening shall be adequately insulated.

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9. Component requirements Specific requirements exist for the following components:

discrete semiconductor devices

fixed resistors

variable resistors

capacitors

power transformers

other transformers and inductors

reed relay coils

hermetically sealed relays

9.1 Discrete semiconductor devices Attention is drawn to the need to comply with the requirements of IEC 61188-1-1 Printed boards

and printed board assemblies

9.2 Fixed resistors Fixed resistors shall be tested in accordance with EN 60068 Environmental testing.

9.3 Variable resistors Wherever pre-set potentiometers are used on the printed circuit boards these shall be of the

multi turn cermet type. A staggered pin arrangement is preferred to a 3-in-line arrangement.

Open type skeleton variable resistors shall not be used.

9.4 Capacitors Wherever possible, capacitors shall be of a type other than aluminium electrolytic capacitors.

9.4.1 Aluminium electrolytic capacitors Where aluminium electrolytic capacitors are used they shall be of the long life type, and

particular attention shall be paid to ripple and pulse rating.

9.4.2 Variable capacitors Unsealed variable capacitors shall not be used.

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9.5 Power transformers Windings on power transformers shall be vacuum impregnated or encapsulated and shall

terminate on a terminal board mounted on the item. Secondary windings shall be isolated from

the primary windings.

An electrostatic screen with provision for earthing shall be fitted between the primary and

secondary windings.

9.6 Other transformers and inductors Inter-stage, oscillator and similar transformers, together with inductors shall have vacuum

impregnated or encapsulated windings. Where possible, leads shall be terminated on a terminal

board.

Pulse and other small PCB-mounted transformers may have pin terminations for direct

mounting on to the printed circuit board. The pin terminations shall be polarised.

Transformer cores shall be clamped and mounted in an approved manner.

9.7 Reed relay coils Reed relay actuating coils shall be either vacuum impregnated or encapsulated.

9.8 Hermetically sealed relays The coils and contacts of hermetically sealed relays shall preferably be sealed into separate

compartments.

Where the coil and contacts are sealed into a single compartment, evidence shall be provided

that contact contamination will not occur.

10. Component identification Component reference numbers shall be marked adjacent to the components. On closely packed

circuits the reference may be placed such that it can be seen when the component is removed.

The following shall be marked in all instances:

fuses – the type rating and the circuit identification of each fuse shall be marked adjacent

to the fuse base

control and indicating devices – the function of each control and indicating device and its

mounting position

pre-set controls – the circuit reference and if possible the function shall be marked

adjacent to each pre-set control and in a position where it will be clearly visible while the

adjustment is being made

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connectors – the diagram reference number shall be marked on or adjacent to each

connector

test points – the diagram reference number prefixed by 'TP' shall be individually marked

adjacent to the test point

polarised devices; for example. diodes and transistors – the polarity of any polarised

devices shall be indicated

heatsinks – the polarity (that is A or K) of heatsinks shall be identified adjacent to device

fixing

11. Documentation All documentation shall be supplied in accordance with EN 50155; clause 11.

Documentation shall also consider the requirements of the following standards:

AS 1046 Letter symbols for use in Electro technology

AS 1100 Drawing practice

AS 1102 Graphical symbols for Electro technology

AS 60417.1 Graphical symbols for use on equipment - Overview and application

AS/NZS 4383 Preparation of documents used in Electro technology – General

requirements

The number of copies required will be specified in the contract.

Documentation shall be provided for all modifications made during the warranty period. Such

documentation shall include changes to all relevant sections of the literature.

Additional requirements apply to the following types of documentation:

drawings

circuit diagrams

component lists

component layout

logic diagrams

block diagrams

cubicle wiring diagrams

interconnection diagrams

equipment drawings

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PCB graphics patterns

11.1 Drawings All drawings provided shall bear an appropriate drawing number and title indicating the

particular item shown and the class of drawing.

All drawings and components lists shall have an issue or revision number and a record of

modification.

11.2 Circuit diagrams Circuit diagrams are required for each unit, sub-unit and plug-in board in the complete

equipment.

Where practicable, all circuit diagrams shall be drawn so that the main sequence of events on

the signal path is from left to right, and where necessary for arrangement purposes, from top to

bottom.

The circuit diagram for any one unit shall be completely self-contained, self-explanatory, and

readily-related to other circuit diagrams, and shall include such information as supply voltage

values and interconnections. Components external to a unit or sub-unit but essential to its

operation shall be shown in dotted outline on the circuit diagram and be appropriately identified.

All component symbols shall be marked with their circuit references. The nominal value of

components shall be marked on the circuit diagrams where the component list is not included

on the diagram. Polarised components and those with three or more connections shall have the

connection points identified.

The function of all controls, switches and indicating devices shall be indicated in accordance

with the inscriptions on the equipment. The symbols for rotary controls shall be marked with an

arrow indicating the direction of rotating of the spindle when viewed from the operating end.

Relays shall always be shown in the de-energised position. Spare contacts fitted to relays and

switches shall be shown on the diagram.

11.3 Component lists Component lists shall state the value, tolerance, rating, type number, manufacturer and second

source, catalogue numbers, and equipment suppliers, number for each component together

with the circuit reference number, and space for user's references.

11.4 Component layout Component layout drawings shall show the location of each individual component used in a unit,

sub-unit and plug-in card marked with its circuit reference number, outline and polarising details

where necessary.

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11.5 Logic diagrams Logic diagrams shall be provided for digital systems and shall show all logic functions, not

necessarily in graphical form. Alternatively, a completely algebraic form may be used consisting

of a list of logical equations.

11.6 Block diagrams Block diagrams shall show the flow of information between the identifiable parts of a system,

with thickening of lines where necessary, to show the main flow of information.

11.7 Cubicle wiring diagrams Cubicle wiring diagrams and charts shall show the inter-unit wiring within cubicles in addition to

miscellaneous services provided, that is supplies, distribution and alarms.

11.8 Interconnection diagrams Interconnection diagrams and charts shall show the necessary labelling, connections, between

cubicles of equipment and all items connected to the equipment by means of external cables.

The interconnection diagrams and charts shall also show the type of cable to be used for these

connections and any special arrangements for terminating.

11.9 Equipment drawings Equipment drawings shall show the layout of equipment on racks, the disposition of units and

sub-units within a cubicle, and the essential mechanical features of all racks, cubicles, units and

sub-units.

11.10 PCB graphics patterns Full-size reproducible PCB patterns shall be provided for all cards.

12. Testing Where not otherwise specified within this standard, all testing shall be in accordance with

EN 50155 clause 12; Testing.

Electronic Equipment Supplied for Passenger Rolling Stock T HR RS 00126 ST Standard Standard Approval Document Control

Preface Foreword Table of contents

1. Introduction 2. Purpose 2.1 Scope 2.2 Application

3. Reference documents 4. Terms and definitions 5. Operating conditions 5.1 Rail operations environment 5.2 Ambient temperature conditions 5.3 Power supply 5.3.1 Power supply voltage variations 5.3.2 Power supply transients

5.4 Vibration and Shock

6. Design of electronic equipment 6.1 Fire performance 6.2 Equipment reliability 6.3 Component ratings and de-rating 6.4 Adjustable components 6.5 Component tolerances and ageing 6.6 Protection 6.7 Interference 6.7.1 Self-generated interference 6.7.2 External interference 6.7.3 Radio interference

6.8 Ventilation

7. Construction of electronic equipment 7.1 Component mounting 7.2 Electrical connections 7.2.1 Crimped connections 7.2.2 Soldered connections 7.2.3 Internal wiring 7.2.4 Printed circuit boards 7.2.5 Protective finishes 7.2.6 Encapsulation 7.2.7 Multi-pole circular connectors

8. Identification 8.1 Equipment labelling 8.2 Unit and sub-unit mounting position 8.3 Termination of screened cables

9. Component requirements 9.1 Discrete semiconductor devices 9.2 Fixed resistors 9.3 Variable resistors 9.4 Capacitors 9.4.1 Aluminium electrolytic capacitors 9.4.2 Variable capacitors

9.5 Power transformers 9.6 Other transformers and inductors 9.7 Reed relay coils 9.8 Hermetically sealed relays

10. Component identification 11. Documentation 11.1 Drawings 11.2 Circuit diagrams 11.3 Component lists 11.4 Component layout 11.5 Logic diagrams 11.6 Block diagrams 11.7 Cubicle wiring diagrams 11.8 Interconnection diagrams 11.9 Equipment drawings 11.10 PCB graphics patterns

12. Testing

Documents

Electronic Equipment Supplied for Passenger Rolling Stock · 2019. 5. 23. · IEC 60146 Semiconductor converters – General requirements and line commutated converters ... Equipment