RDSO specIPS

8/8/2019 RDSO specIPS

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Page 1 of 50 Issue date 01.04.2006 RDSO/SPN/165/2004 with Amd. 5 Version 2

DRAFT SPECIFICATION

OF

SMPS BASED INTEGRATED POWER SUPPLY

VERSION 2.0

Number of Pages 50

SPECIFICATION NO. RDSO/SPN/165/2004

SIGNAL DIRECTORATE

RESEARCH, DESIGNS & STANDARDS ORGANISATION

LUCKNOW - 226011


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DOCUMENT DATA SHEET

Designation

RDSO/SPN/165/2004

Version

2

Title of Document

SMPS based Integrated Power Supply (IPS)

Authors:

Name: Shri Vipul GoelDesignation: Joint Director / Signal

Approved by:

Name: Shri G.D.BhatiaDesignation: Sr. Executive Director/Signal, RDSO

Abstract

This document defines Draft Specification of SMPS based Integrated Power Supply(IPS)


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Document control Sheet

Designation Organization Function Level

Joint Director/Signal RDSO Member Prepare

Sr.ED/ED/Signal RDSO - Approval


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AMENDMENTS

Version Chapter/ Annexes Amendments Issuedate

Ver.1.0 First issueRDSO/SPN /165/2000

January2000

Amendment 1 Certain Clauses modified/ amended/included for typographical errors,regrouping/inclusion of tests and othertechnological requirements etc.

November2000

Amendment 2 Clause 4.27 4.27.1 and 5.1.25included/modified for incorporatingprovisions for lightning & surge devicesand battery charging

Modified / added. April 2002

Ver. 2.0 (i)Clause 2.1, 3.3, 3.4, 3.5, 3.7, 4.5,4.21, 5.1.1,5.4.10 included/amended inview of the approval of RB on therecommendations of 77th SSC.

(ii) Clause 2.3, 3.6, 3.9.2, 3.10.1, 3.14,4.1, 4.25, 4.30, 5.1.4, 5.1.19, 5.1.24.3,5.2.4, 5.3.24, 5.4.8, 5.4.12, 8.4 included/ amended in view of the field problemsand RB approval on recommendation of9th MSG.

(iii) Clause 4.12, 4.22, 4.28, 4.29, 5.1.6,5.1.16, 5.1.17, 5.1.28.6, 5.2.15, 5.4.13,5.4.17, 5.5.26, 6.0, 5.6.3, 5.7.2, 5.8.3,10 modified/included for typographicalerrors / re-grouping / inclusion of

various tests, incorporating provisionsof manuals and up-gradation oftechnology.

Revision and issueRDSO/SPN/165/2004

June 2004

Amendment 1 Nomenclature for Alarms andindications in clause 4.1.23.1, 4.2.4.1,4.2.4.2, 4.3.9, 4.5.5, 4.6.13, 4.8.1 hasbeen standardised.

Modified March2005

Amendment 2 Severities for Change in Temperaturecycle, Dry heat & Cold test (Clause10.7.1) has been modified.

Modified March2005

Amendment 3 Cl. no. 3.1.5, 3.2.2, 3.2.3, 4.1.16, 4.3.8,4.3.14, 9.2(f), 9.3.1(j), 10.7.1 &

Annexure 1 (SN 3) has been modifiedto increase the system reliability.New clause 3.3.16 has been added toprovide ventilation for individualmodules.Clause 9.2 has been deleted.

Modified/Added/Deleted

May 2005

Amendment 4 Clause 2.1, 2.2.4, 3.3.1, 3.3.4, 3.12.1,3.13.2, 3.14, 4.5.7, 4.8.1, 6.9 & 10.2modified for renumbering of Annexures,design improvement in DC-DCConverter and incorporation of versioncontrol.

Modified/Added July 2005

Amendment 5 Cl. 3.12 related to Class B,C & D typeLightning & Surge Protection modified

Modified Jan 2006


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Table of Contents

Para No. Item Page No.

Abbreviations used 6

0. Foreword 71.0 Scope 82.0 General Requirements 9-15

3.0 Technical Requirements 15-29

4.0 Performance Requirements 16-30

5.0 Indenting Description / Information to be supplied bythe Purchaser

29

6.0 Labeling and Marking 29-307.0 Documentation 30-31

8.0 Packing 31

9.0 Test and Requirements 31-32

10.0 Test Procedure 33-36

11.0 Sampling Procedure for Acceptance Test 36Drg. No. SDO/IPS

/SMPS/PI/NRE/001(Annexure1-A)

IPS for up to 4 lines without AFTC Non- RE Area 37

Drg. No. SDO/IPS/SMPS/PI/RE/002

(Annexure 1-B)

IPS for up to 4 lines without AFTC RE Area 38

Drg. No. SDO/IPS/SMPS/PI/NRE/003

(Annexure 1-C)

IPS for up to 6 lines without AFTC Non-RE Area 39

Drg. No. SDO/IPS/SMPS/PI/RE/004

(Anexure 1-D)

IPS for up to 6 lines without AFTC RE Area 40

Drg. No. SDO/IPS/SMPS/PI/RE/NRE/005

(Annexure 1-E)

IPS for up to 4 lines RE/Non-RE Area with DC litLED Signal

41

Annexure-II Spare list of components 42

Drg. No. SDO/IPS/PI/Layout/007(Annexure-III)

Layout of IPS Cabinets 43

Annexure-IV Main components of the SMPS based IPS 44-45

Drg. No. SDO/IPS/LA/006 (Annexure-V)

Connection for Lightning Arrestors 46

Annexure-VI Version Number 47-48Annexure-VII Value of Insulation Resistance at different

temperature & Relative humidity49


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Abbreviations used

AFTC Audio Frequency Track Circuit

AVR Automatic Voltage Regulator

AMF Panel Auto Mains Failure Panel

ASM Assistant Station Master

ACDP AC Distribution Panel

DSA Distribution Switching & Alarm Unit

DG Set Diesel Generator Set

DCDP DC Distribution Panel

DOD Depth of Discharge

EMI Electromagnetic Interference

FRBC Float Rectifier Cum Boost Charger

IPS Integrated Power Supply

IS/IEC Indian Standard/ International Electrotechnical Commission

LEMP Lightning Electromagnetic Impulse

LCD Liquid Crystal Diode

LED Light Emitting Diode

MTBF Mean Time Between Failure

MOV Metal Oxide Varistors

PI Panel Interlocking

PF Power Factor

PWM Pulse Width Modulation

RE Railway Electrification

RFI Radio Frequency Interference

SMPS Switch Mode Power Supply

SSI Solid State Interlocking

SPD Surge Protection Devices

VRLA Valve Regulated Lead Acid


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GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

(RDSO)INDIAN RAILWAY DRAFT SPECIFICATION

FORSMPS BASED INTEGRATED POWER SUPPLY SYSTEM (IPS)

FORSIGNALLING INSTALLATIONS ON INDIAN RAILWAYS

(RDSO/SPN/165/2004, Ver. 2)

0. FOREWORD

0.1 This specification is issued with the fixed serial number followed by the year of adoption asstandard or in case of revision, the year of latest revision.

0.2 This specification requires reference to following specifications:

IRS: S 88/93 orlatest

Low Maintenance Lead Acid Battery

IRS:S 93/96(A) Valve Regulated Lead Acid Sealed Maintenance FreeStationary Battery

RDSO/SPN/144/2004* Safety & reliability requirements of electronic signallingequipment.

IS:9000* Basic environmental testing procedure for electronic andelectrical item

IRS:S 23* Electrical Signalling & Interlocking Equipment.

IEC-61643* Surge Protective Devices connected to low-voltage powerdistribution systems

IS: 3043 Indian standard code of practice for Earthing

EN 55022 European Standard for Information Technology EquipmentMIL HBDK 217F Military hand book "Reliability Prediction of Electronic

Equipment"

IEC 61312 Protection against Lightning Electromagnetic Impulse

IEC 61024 Protection of structures against Lightning

VDE 0675 Surge Arresters for Use in AC Supply SystemsVDE 0100-534 Instructions for Installations and using of Over Voltage

Arrester Class B (type I) to main power supply distributionboards.

IRS:S 74/89 with latestamendment

Voltage Regulator-Ferro Resonant

EN 50129 Railway Application Safety Related Electronic System ForSignalling

*Or equivalent recognised international standard. The manufacturer/ supplier shall submit acopy of the same for verification.

0.3 Whenever, reference to any specification appears in this document, it shall be taken as areference to the latest version on that specification unless the year of issue of thespecification is specifically stated.

0.4 This specification is intended chiefly to cover the technical provisions and does not includethe necessary provisions of a contract.


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1. SCOPE

1.1 This specification covers the technical requirements of SMPS based integrated powersupply system (IPS) suitable for wayside signalling installations upto 6 line without AFTC(orupto 7KVA total signalling load) in RE/Non-RE areas. The PI/ SSI stations have beencovered in the specification.

1.2 The IPS system is suitable to work with either Low Maintenance cells as per IRS: S 88/93(latest) or with VRLA Maintenance Free cells as per IRS: S 93/96(A).

2. GENERAL REQUIREMENTS

2.1 The SMPS based Integrated Power Supply (IPS) system is meant to give continuoussupply to both AC & DC signalling circuits. The general configuration of SMPS based IPSsystem of 4 & 6 line for RE / Non RE areas are shown in Sketch No. SDO/IPS/SMPS/001,002, 003 & 004 (Annexure I-A, I-B, I-C & I-D). Sketch No. SDO/IPS/SMPS/005 (Annexure I-E) is suitable for DC lit LED signals up to 4line RE/ Non RE station. The SMPS based IPSsystem consists of the following:

2.1.1 SMPS based Float cum Boost Charger (FRBC) Panel

This panel consists of FRBC (float rectifier cum boost charger) module, Distribution/Supervisory control / Alarm (DSA) unit and metering section.

2.1.2 AC Distribution Panel

This cabinet consists of Inverters, Ferro-Resonant based Automatic VoltageRegulator (AVR), transformers and metering section.

2.1.3 DC Distribution Panel

This panel consists of all DC-DC converters and common Digital voltmeter formeasurement.

2.1.4 Status Monitoring Panel for ASMs Room

This panel consists of status indications and critical alarms of IPS to be provided inASMs room. The monitoring panel shall be of wall mounting type. DC-DCconverters for Block Tele may also be accommodated in Status Monitoring Panel.

2.1.5 Battery Bank

IPS system is suitable for charging 110V battery bank of Low Maintenance cells as perIRS:S 88/93 or VRLA Maintenance free cells as per IRS:S 93/96(A). Battery bank is part ofthis specification and the same shall be supplied and commissioned along with IPS.Manufacturers shall give an undertaking regarding use of battery grade acid and de-mineralised / distilled water for initial charging.

2.1.6 Battery racks (MS) for VRLA batteries / wooden rack for low maintenance batteries, alongwith its accessories duly approved by purchaser, shall also be supplied with battery bank.

2.1.7 The battery is to be installed in a separate room. Low Maintenance batteries are to becharged at the site by IPS manufacturer/supplier. A test certificate of initial charging/capacitytesting shall be submitted by manufacturer/supplier to Railways.

2.1.8 A tool kit containing all types of tools required for maintenance of IPS shall be supplied alongwith IPS and shall be placed inside the IPS rack in a suitable bag.


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2.1.9 An exhaust fan of about 12 size shall be supplied and commissioned in the IPS room byIPS supplier at the time of commissioning. The exhaust fan shall run with commercial ACsupply.

2.2 Standard Configurations

2.2.1 Details of Sub system of SMPS based IPS for wayside PI /SSI Station upto 4 & 6 lines

RE/Non-RE are as per Sketch No.SDO/IPS/SMPS/PI-4L/NRE/001, SDO/IPS/SMPS/PI-4L/RE 002, SDO/IPS/SMPS/PI-6L/NRE 003 & SDO/IPS/SMPS/PI-6L/RE 004 respectively.SDO/IPS/SMPS/005 provides a typical arrangement for 4 line RE/Non RE station with DC litLED signals.

2.2.2 The DC-DC converter for Axle Counters, SSI and Data loggers are optional. Purchaser hasto specify whether optional DC-DC converters are required or not. In all cases, thedistribution cabinet shall have provision for accommodation of optional DC-DC converters.

2.2.3 For 60V operated metal to metal relay installation, the ratings of DC-DC converter for relayinternal & relay external shall be 60-66V /5A in lieu of 24-32V /5A modules.

2.2.4 A set of spares shall also be supplied along with IPS as per Annexure-II. All the sparemodules shall be accommodated in the IPS rack as cold standby. Other spares shall besupplied along with IPS and shall be placed with IPS in a suitable bag/ box.

2.3 Indoor Environmental condition

The SMPS based IPS system is intended for use in most tropical climate in India where themaximum temperature may reach upto 50C with relative humidity reaching upto 95%.

3.0 TECHNICAL REQUIREMENTS

3.1 Electrical Requirements

3.1.1 The IPS shall be suitable for operation for a nominal input voltage of 230V AC,50Hz single phase power supply derived from Electricity Board or Railway Tractionsupply or 7.5/10/15 KVA diesel generator set with AMF control of appropriatequality. The system shall work satisfactorily with input voltage variation from 150to 275V AC and frequency variation from 48Hz to 52 Hz.

3.1.2 In case of local supply, it shall be ensured that the feeder is capable of feeding30A at 230V AC to the IPS system.

3.1.3 The DG Set used for feeding IPS shall be capable of taking 10% overload forperiod of one hour during any 12-hour period. It should be ensured that waveform

of DG set is near sine wave.

3.1.4 The accidental short circuit at input feeder shall not cause any interruption to theIPS sub system. The accidental over voltage shall not cause any damage to IPSsystem.

3.1.5 There shall be an automatic arrangement for disconnecting the mains within 500ms to the rack whenever the input voltage is beyond the specified operating limitswith suitable alarm indication. The IPS shall resume normal working automaticallywhen the input is restored within the working limits. A self storing type static switchshould be provided at the input.

3.2 Module replacement time and MTBF

3.2.1 The mean time to replace a faulty module of IPS shall be less than 20 minutes.


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3.2.2 The designed MTBF of FRBC, Inverter, DC-DC Converter, Supervisory control unit & ASMPanel shall not be less than 35,000 hours.

3.2.3 The DC fan provided should have MTBF better than 70,000 hours at 40oC. The fan shall becovered with grill..

3.3 Construction

3.3.1 The individual cabinets shall be within the overall dimensions of 2000-mm max.Height 750 mm. max. Depth and 750 mm max. Width. In case all DC-DCConverter modules cannot be accommodated in one DC distribution panel, then asecond DC distribution panel shall be provided instead of making oversized panel.The height and depth of all cabinets shall be of equal size. Each cabinet will havemin 10-mm thick anti-vibrating pad and 75 mm x 5-mm bottom channel as persketch no. SDO/IPS/Layout/007 (Annexure III).

3.3.2 The spares (other than modules used for redundancy) may be placed at bottom ofany rack as per the availability of space.

3.3.3 The rack structure and the module frame shall be made up of rigid framework ofsteel profiles. The front door shall be of hinged type. The rear panel shall beprovided with proper ventilation arrangement. DC fan shall be provided at racklevel for forced cooling. The operation of such fan shall be continuous.

3.3.4 The racks and module cabinets shall be of robust construction. They shall behoused in self-supporting cubicles made of cold rolled closed annealed mild steelsheet of thickness not less than 1.6mm. The rack shall be adequately ventilated.The ventilating opening shall be less than 3mm size for protection against entry oflizard's etc. The rack shall conform to IP31 type of protection as specified in table1 of specification no. IS 2147-1962.

3.3.5 The racks and the modules shall be treated with zinc chromate primer followed byelectrostatic epoxy powder coating paint finished, passivation shall be donethrough seven stage process/sand blasting. Small metal parts such as nuts, boltsand washers shall be chrome plated. All other metal parts of the rack shall beplated for protection against corrosion.

3.3.6 The racks and the module cabinets shall be free from sharp edges & sharpcorners.

3.3.7 Provision of doors are optional, the cabinet sides shall have 3mm louvers coveredwith wire mesh. However, if the doors are not provided, the sub system shall haveproper enclosures so that any reptile/ insect shall not enter in the IPS cabinet. The

magnetic latches/handle shall be provided on the doors.

3.3.8 The racks and the modules shall be designed for easy maintenance andinstallation.

3.3.9 Facility shall be provided at the top of the rack to connect external AC power andlightning arrestors (if provided inside the rack). Where cables pass through metalpanels, suitable rubber grommets shall be provided to protect cable from damage.

3.3.10 The modules shall be of modular type. The module shall be easily mounted orremoved from the front side of the rack. The module shall be designed to slideinto the rack on a suitable mechanical arrangement. Suitable arrangement shall be

made for pulling out each module separately. The associated AC input, DC outputconnection, control/alarm & interface cable connecting the module shall bedisconnected/installed easily without causing any interruption/damage to supply &working module.


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3.3.11 All materials and workmanship shall be of professional quality to ensure the MTBFrequirements.

3.3.12 The input and output terminals shall be accessible only when the cover of thecubicle is removed. All the terminals shall be clearly, neatly and indelibly markedto correspond with the wiring diagram for easy identification.

3.3.13 Input and output connections of SMR, DC-DC converter, inverter, AVR and stepdown transformer shall be made using plug & socket of adequate rating havingpower pins with locking arrangement. The male connector shall be mounted onthe device and the female connector shall be terminated on the cable. Use ofterminal blocks for input and output connections is not accepted.

3.3.14 The finish of steel and panels shall conform to relevant IS specification. Thecolour scheme shall be as follows:

a) Rack & doors Pebble Grey RAL 7032b) All IPS modules shall harmoniously match with rack colour

3.3.15 AC/DC distribution cabinet shall have proper identification marking/protection for AC/DCmonitoring points to avoid any misuse and protection against any accidental short circuit.

3.3.16 Baffles to be provided at the rack level for forced ventilation of individual modules.

3.4 Components

3.4.1 ICs and other components used in the equipment shall be of industrial grade. Discretecomponents like diodes, Transistors, SCR etc. should conform to HIREL programme ofCDIL or equivalent. Components shall conform to relevant IS/IEC specification. Resistorsand capacitors shall meet relevant provisions of latest RDSO/SPN/144/2004.

3.4.2 Solid state components suitably de-rated to not more than 50% of the rated value shall beemployed for mounting on the printed circuit boards. Any deviation regarding de-rating ofcomponents shall be validated with proper justification at the time of type approval.

3.4.3 Semi-conductor power devices used shall not be operated at more than 50% of the ratedmaximum peak voltage and at not more than 50% of the rated maximum average currentunder any prevailing conditions specified in this specification. Manufacturer shall submitdesign details, component datasheet and justification for any deviation in this regard at thetime of type approval.

3.4.4 The manufacturer shall declare the peak reverse voltage, current rating and working

temperature of the rectifier element under ambient conditions, the number of elements usedand the manner of their connection. The peak reverse voltage rating should not be lessthan two times the expected reverse voltage across the devices.

3.4.5 The recommended list of major components and their make is given in Annexure-IV.

3.5 Printed Circuit Board

Printed Circuit Board shall generally conform to relevant provisions of latestRDSO/SPN/144/2004 for safety & reliability requirement of Electronic signalling equipment.

3.6 Cables & Wiring

3.6.1 All the cables and wires used for wiring and inter connections of modules shall conform tospecification No. IRS: S 76-89/IS 694 of grading 1100V. Aluminium wires shall not be used.


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The gauge of wiring shall be such that the current density does not exceed 3 amperes/mmsquare.

The colour scheme employed for the rack wiring shall be as below:

AC line : YellowAC neutral : Black

Earthing : GreenDC positive : RedDC negative : BlackControl wiring : Grey

3.6.2 All connections shall be made through crimped eyelets and shall be numbered with PVCcable marker rings corresponding to the numbers/letters shown in the schematic wiringdiagram. Soldering shall be used only where use of crimped eyelets is not possible.

3.6.3 All non-current carrying metal parts shall be bonded together and adequately earthed.

3.6.4 All wiring shall be neatly secured in position by bunching /strapping & adequately supported.

Where wires pass through any part of metal panel or cover, the hole through which theypass shall be provided with rubber grommets.

3.6.5 There shall not be any exposed wiring outside the cabinet.

3.7 Transformers and chokes

3.7.1 Power Transformers and chokes used shall be class B or higher grade. Thetransformers & chokes shall be wound with copper & adequate insulation shall beprovided.

3.7.2 The transformer shall be double wound and shall conform to Category 3 (clause

3.1) of IS: 6297 (Part I 1971 and Grade II (Table 1) of IS: 6297 (Part II) of 1973.The transformer shall be vacuum impregnated and Copper wires conforming to IS:4800 (Part IV) shall be used for winding of the transformers, unless otherwisespecified. The current density of the winding wire shall be less than 2A/mm. Sq.

3.7.3 The transformer shall be air-cooled and so constructed as to provide adequateprotection against specified weather conditions.

3.7.4 All exposed metal parts of the transformer including laminations shall be protectedagainst corrosion.

3.8 Potential free contacts

3.8.1 Following potential free contacts shall be provided for extension of alarms at remote place:

a) Inverter 1 failb) Inverter 2 failc) FRBC faild) DC-DC converter faile) Mains failf) Call S & T staffg) Battery low (50% Deep discharge)

3.9 Meters

3.9.1 Accuracy of 3 D Digital meters used in the IPS cabinets shall be 1%, 3 D orbetter.


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3.9.2 Meter shall be provided on top of the FRBC, ACDP and DCDP panel as perSketch No. SDO/IPS/Layout/007.

3.10 Fuses & Connectors

3.10.1 All plug- in connectors shall be non-interchangeable. Connectors as per IEC 947

shall be provided.

3.10.2 Fuse holder identification shall include details of fuse rating and type.

3.10.3 All power fuses shall confirm to specification IS 13703 / IS 9224.

3.11 Noise and Vibration

3.11.1 Fully equipped rack at full load shall not contribute more than 15dB (weighted) tothe ambient noise level takenas 45dBA. It shall be measured at a distance of 1meter from the unit and 1.25 meter above the floor level in the full audio rangeupto 3.4 KHz. The correction factor for total noise when the ambient noise level is

more than 45dBA shall be as given below:

Ambient Noise(dBA)

Correction Factor(dB)

Ambient noise(dBA)

CorrectionFactor (dB)

45 0 53 2.07

46 0.18 54 2.43

47 0.39 55 2.82

48 0.61 56 3.25

49 0.86 57 3.69

50 1.12 58 4.1751 1.41 59 4.68

52 1.73 60 5.21

Note: The correction factor shall be added to the limit of 60dBA to arrive at the limitwhen the ambient is greater than 45dBA.

3.11.2 The IPS sub-systems shall be suitably screened and immune to any kind of EMIinterference. The sub-system shall not produce any hum in the peripheral devices.

3.12 Lightning and Transient Protection:

3.12.1 The IEC standards 61312, 61024, 61643, 62305 and VDE 0100-534 pertaining to protectionagainst lightning and surges shall apply for all electronic equipment to withstand staticelectricity, electric fast transient and surge voltage.

The power line of electronic signalling equipment shall have Class B & C type 2-stageprotection in TT configuration. Stage 3 protection is also required for protection ofpower/signalling/data lines. Class B & class C type protection devices shall preferably bepluggable type to facilitate easy replacement.

3.12.2 Stage 1 Protection (Power line protection at Distribution Level)

The protection of class 'B' type, against Lightning Electromagnetic Pulse (LEMP) &other high surges shall be provided at the power distribution panel. Whereveravailable, the modules shall have an indication function to indicate the prospectivelife and failure mode to facilitate the replacement of failed SPDs. The device shall be

spark gap type and certified as per the VDE 0675 A1/A2 & IEC 61643. It shall beprovided with a 63 Amp fuse in phase line. The protection shall be in compliance ofIEC 61312, IEC 61024 & VDE 0100-534 with the following characteristics:


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LimitsSN Parameters

Line & Neutral Neutral &Earth

1 Nominal Voltage (U0) 230V 230V

2 Maximum continuous operating voltage (Uc) 255V 255V

3 Lightning Impulse current between R, Y, B & N

(Imp)

50KA,

10/350s foreach phase

--

4 Lightning Impulse current between N & E (Imp) -- 100KA,

10/350s

5 Response time (Tr) 100 s 100 s

6 Voltage protection level (Up) between L &N

1.3KV --

7 Voltage protection level (Up) N & PE -- 1.5KV

8 Short circuit withstand and follow up currentextinguishing capacity without back up fuse (Isc)

10KA --

9 Operating temperature / RH 70O C / 95% 70O C / 95%

10 Mounted on din rail din rail

3.12.3 Stage 2 Protection (Power line protection at Equipment Level)

The protection of class 'C' type against low voltage surges shall be provided at theequipment input level connected between line & neutral. This shall have anindication function to indicate the prospective life and failure mode to facilitate thereplacement of failed SPDs. This shall be thermal disconnecting type andequipped with potential free contact for remote monitoring. The device shall be asingle compact varistor of proper rating and in nocase a number of varistors shallbe provided in parallel. This protection shall be in compliance of IEC 61643-12,61312 & 61024 and VDE 0100-534 with the following characteristics:

SN Parameters Limits

1 Nominal Voltage (U0) 230V2 Maximum continuous operating voltage

(Uc) 300V

3 Nominal discharge current betweenR,Y,B & N (In)

10KA, 8/20s for each phase

4 Maximum discharge current betweenL & N (Imax)

40KA, 8/20s

5 Response time (Tr) 25 s

6 Voltage protection level (Up) at In 1.6 KV

7 Operating temperature / RH 70O C / 95%

8 Mounted on din rail

3.12.4 Stage 3 protection (Protection for Power /signalling / data lines)

All external Power/signalling/data lines (AC/DC) shall be protected by usingpreferably pluggable stage 3 surge protection devices which consists of acombination of varistors/suppressor diodes and GD tube with voltage and currentlimiting facilities.

3.12.4.1 Power line Protection (Class D)

The device for power line protection shall be of Class D type. This shall have an

indication function to indicate the prospective life and failure mode to facilitate thereplacement of failed SPDs. This shall be thermal disconnecting type andequipped with potential free contact for remote monitoring. This protection shall bein compliance to IEC 61643-1 and VDE -0675 Pt. 6 with following characteristics:


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Nominal Voltage (U0) 24V 48V 60V 110V 230V

Max. continuous operatingvoltage (UC)

30V 60V 75V 150V 253V

Rated load current (IL) 16A 16A 16A 16A 16A

Nominal discharge current (In)

8/20 s700A 700A 700A 2.0KA 2.5KA

Max discharge current (Imax) 8/20

s2KA 2KA 2KA 5KA 5KA

Voltage protection level (UP) 200V 350V 500V 700V 1100V

Response time (Tr) 25 s 25 s 25 s 25 s 25 s

Note: Minor variations from above given parameters shall be acceptable.

3.12.4.2 Signalling/Data line protection

These devices shall preferably have an indication function to indicate theprospective life and failure mode to facilitate the replacement of failed SPDs. If thedevice has any component which comes in series with data/ signalling lines, themodule shall have "make before break" feature so that taking out of pluggable

module does not disconnect the line. This protection shall be in compliance to IEC61643-21 & VDE 0845 Pt. 3 with the following characteristics:

Nominal Voltage(U0) 5V 12V 24V 48V

Arrester Rated Voltage(UC) 6V 13V 28V 50VRated load current(IL) 250mA 250mA 250mA 250mA

Total discharge current, 8/20 s( In) 20KA 20KA 20KA 20KA

Lightning test current 10/350 s 2.5KA 2.5KA 2.5KA 2.5KA

Voltage protection level (UP) 10V 18V 30V 70V

Note: Minor variations from above given parameters shall be acceptable.

3.12.4.3 If power supply /data / signalling lines (AC/DC) are carried through overhead wires or cables

above ground to any nearby building or any location outside the equipment room, additionalprotection of Stage 2 (Class C) type shall be used at such locations for power supply linesand Stage 3 protection for signal / data lines.

3.12.5 Note:

1. Coordinated type Class B & C arrestor shall be provided in a separate enclosure in IPSroom adjacent to each other. This enclosure should be wall-mounting type.

2. Length of all cable connection from input supply and earth busbar to SPDs shall beminimum possible. This shall be ensured at installation time. The connections shall beas per Sketch no. SDO/IPS/LA/006 (Annexure V).

3. Stage 1 & Stage 2 (Class B & C) protection should be from the samemanufacturer/supplier. IPS manufacturer shall provide Stage 1 & Stage 2 protectionalong with IPS. Stage 3 protection shall be got provided by Railways separately.

4. The cross sectional area of the copper conductor for first stage protection shall not be


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3.13 Earthing

3.13.1 The IPS systems and its individual modules shall haveearth terminals and shall beproperly earthed to the IPS cabinets.

3.13.2 Zonal Railways shall provide earthing arrangement as per IS:S 3043 anddirections issued by RDSO for Lightning & Surge protection for signallingequipment vide letter no.STS/E/SPD dt. 22.6.2004. The earth resistance shall notbe more than 2 ohm. Earth provided shall preferably be maintenance free usingearth resistance improvement material.

3.14 Installation & Commissioning

Installation and commissioning shall be done by the manufacturer only as per installationand commissioning manual.

Zonal Railways and manufacturers shall ensure the compliance to Pre-

commissioning checklist issued by RDSO.

4. PERFORMANCE REQUIREMENTS

4.1 SMPS BASED FLOAT CUM BOOST CHARGER (FRBC)

4.1.1 FRBC modules of 110V/20Amp rating shall be provided as per standardconfiguration.

4.1.2 The number of FRBC modules as required for meeting a particular load shall behoused in (n+1) parallel configuration in a single rack where n is the actualrequired number of FRBC modules. One additional FRBC module (spare)shall be

provided as a cold standby in the rack.

4.1.3 The SMPS based FRBC should be based on High Frequency (20 KHz and above)Switch Mode techniques.

4.1.4 Resettable Fuses shall be provided, wherever appropriate, to protect the moduleagainst failure of control / sensing circuit.

4.1.5 The design shall have suitable time delay / hysterisis to avoid hunting duringswitching ON and OFF of the system. The module shall disconnect at 150V andreconnect at 170V.

4.1.6 Switching ON and OFF the fan shall be temperature controlled.

4.1.7 In case of fan failure the module shall have automatic protection to switch off themodule above 70 deg centigrade and restore automatically with reduction intemperature. It shall not cause any fire hazard. The fan shall also be protectedagainst short circuit by providing a fuse.

4.1.8 The FRBC modules shall have forced cooling and only DC fan shall be used.

4.1.9 Screen-printed procedure for adjustment of float voltage, boost voltage, batterycurrent limit and other adjustment required to be done in the field shall beprominently visible for ready reference of maintenance staff.


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4.1.10 Meter

4.1.10.1 The following digital meter of 3 digit with LCD/LED display having 12mmnumerical display height shall be provided on the front door of the rack.

a) AC volt / ampere meter to read AC input voltage & current.

b) DC volt/Ampere meter to read system voltage, battery voltage, system totalcurrent and battery current.

4.1.10.2 In case of AC failure the battery discharge current shall be displayed on DCAmpere meter with negative sign irrespective of selector switch.

4.1.11 DC Output Characteristics

The module shall be capable of operating in Auto Float cum-Boost chargermode. It shall be programmed to operate as a float rectifier or a Boost chargerdepending on the condition of the battery being sensed by the switching/controlunit.

4.1.11.1 Auto Float Mode

a) Float voltage of each rectifier module shall be set as given in the following table:

No. of cells Auto Float mode voltage Auto Boost mode voltage

VRLA Cells Conv. LA Cells VRLA Cells Conv. LA Cells55 123.8V 118.25V 126.5V 133.1V

Normal Float & Boost voltage for VRLA battery is 2.25V and 2.3V/Cellrespectively. For conventional battery it shall be 2.15V and 2.42V/cell,respectively. The module should have a range from 2.0 2.3V/cell in float mode &

2.2 2.5V/cell in boost mode to meet the requirement of VRLA as well asconventional batteries.

b) The DC output voltage shall be maintained within 1% of the half load pre-set voltage inthe range 25% load to full load when measured at the output terminals over the full specifiedinput range.

4.1.11.2 Auto Boost Charge Mode

In auto boost charge mode, FRBC shall supply battery and equipment current till terminalvoltage reaches 2.3V (VRLA battery) /2.42V (Low Maintenance battery) per cell and shallchange over to Auto Float mode after a defined delay of 0, 1, 2, 4 hours adjustable, to be set

as per battery manufacturers specification.

4.1.12 Efficiency

The efficiency and Power factor of the FRBC in auto float and auto boost mode shall be asfollows:

Nominal input, output & fullrated load

150-275V input, 25% to 100%load

Description

Efficiency % PF Efficiency % PF

110V / 20A >90 >0.95 to unity >85 >0.9

Note: Active power factor correction circuit shall be adopted.


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4.1.13 Total Harmonic Distortion

4.1.13.1 The total line harmonic voltage distortion shall not be more than 10%.

4.1.13.2 The total current harmonic distortion contributed by FRBC at the input shall not exceed 10%for all input condition and load 50% to 100% of the rated capacity.

4.1.14 Current Limiting (Voltage Droop)

4.1.14.1 The current limiting (Voltage Droop) shall be provided for Float/Boost Charge operation.The float/boost charge current limiting shall be continuously adjustable between 50 to 100%of rated output current between 2.0 V to 2.5 V/cell.

4.1.14.2 The float and boost charge current limit adjustment shall be provided on the front panel.

4.1.15 The FRBC modules shall be fully protected against short circuit. It shall be ensured thatshort circuit does not lead to any fire hazard. It shall resume normal function automaticallyafter the short is removed. In case the problem still persists, it shall not be possible to switch

ON. It shall be possible to switch ON again only after removal of fault/ cause by pressing areset push button. The maximum short circuit current shall not exceed 105% of their rating.The tripping OFF of such a faulty module shall not affect the normal working of othermodules.

4.1.16 Battery path current shall be automatically controlled by the input current in such a way thatinput current shall not exceed the set limit. The set limit shall be adjustable anywherebetween 75 to 100% of full load input current. Provision shall also be made for full utilizationof power when DG set is operated.

4.1.17 Soft Start Feature

4.1.17.1 Slow start circuitry shall be employed such that FRBC module output voltage shall reach itsnominal value slowly within 10 to 20 seconds, eliminating all starting surges.

4.1.17.2 The maximum instantaneous current during start up shall not exceed the peak value of therectifier-input current at full load at the lowest input voltage specified.

4.1.18 Voltage Overshoot/Undershoot(with battery disconnected)

4.1.18.1 The FRBC modules shall be designed to minimise output voltage overshoot/undershootsuch that when they are switched ON, the DC output voltage shall be limited to 5% of theset voltage and return to its steady state within 20 millisecond for any load of 25% to 100%.

4.1.18.2 The DC output voltage overshoot for a step change in AC mains from 150V to 275V shallnot cause shut down of FRBC module and the voltage overshoot shall be limited to 5% ofits set voltage and return to steady state within 20 millisecond.

4.1.18.3 The modules shall be designed such that a step load change of 25% to 100% or vice- versashall not result in DC output voltage overshoot/undershoot of not more than 5% of the setvalue and return to steady state value within 10 millisecond without resulting the unit to trip.

4.1.19 Electrical Noise

4.1.19.1 The FRBC module shall be provided with suitable filter on the output side.

4.1.19.2 A resistor shall be provided to discharge the capacitors after the FRBC module has stoppedoperation and the output is isolated.


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4.1.19.3 The psophometric noise (e.m.f. Weighted at 800 Hz) ,with a battery of appropriate capacityconnected across the output should be within 5 mV, while delivering the full rated load atnominal input (230V single-phase supply). For test purpose this shall be taken asequivalent to 10mV when the battery is not connected.

4.1.19.4 The peak- to- peak ripple voltage at the output of the rectifier module without battery

connected shall not exceed 300 mV at the switching frequency measured by a storageoscilloscope of 50-60 MHz band-width.

4.1.20 Radio Frequency Interference Suppression

The SMPS charger shall be designed to minimise the level of Electromagnetic Interference(EMI/RFI), both conducted & radiated, in the vicinity of SMPS charger. The radiated &conducted noise shall be within the limits specified in International Specification No.EN-55022. The firm shall submit certificate to this effect from national/international test house atthe time of type test.

4.1.21 Parallel Operation

4.1.21.1 The FRBC modules shall be suitable for operating in parallel on active loadsharing basis with one or more modules of similar type, make and rating.

4.1.21.2 The current sharing shall be within 10% of the individual capacity of each FRBCin the system when loaded between 50 to 100% of its rated capacity.

4.1.22 Protection

4.1.22.1 DC Over Voltage Protection: In case output DC voltage exceeds 2.37V/2.5V per cellrespectively for VRLA/ low maintenance battery, the over voltage protection shall operate &shut off the faulty module. This shut off can be restored through reset push button, which

shall be provided on the front panel of FRBC module.

4.1.22.2 Shutting-off faulty FRBC module shall not affect the operation of other FRBCs operating inthe rack.

4.1.22.3 The circuit design shall ensure protection against the discharge of the battery through FRBCmodule. In any case, the discharge current i.e. reverse leakage current, shall not be morethan 100 mA.

4.1.22.4 The over voltage protection circuit failure shall not cause any safety hazard.

4.1.22.5 Fuse / circuit breakers shall be provided for each FRBC module as below

a) Live AC input line: Class C type MCB as per IS. 13947b) DC output: HRC fuse / MCB

4.1.23 Alarms & Indication of FRBC

4.1.23.1 The following indications, controls & measuring points shall be provided on thefront panel of FRBC

A) Status Indication:

Description Nomenclature Indicationa) FRBC on Auto Float mode FLOAT Green

b) FRBC on Boost Charge mode BOOST Green

c) Mains available MAINS Amber


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B) Alarm Indication

Description Nomenclature Indication

a) Rectifier module over voltage OVER VOLTAGE Red

b) Rectifier module under-voltage UNDER VOLTAGE Red

c) DC output fail OUTPUT FAIL Red

d) FRBC Overload/ short circuit OVERLOAD/SHORT CIRCUIT

Red

e) Fan fail FAN FAIL Red

Note: Provision shall be made for stopping the audio alarm with a non-locking push button.

C) Control Potentiometers

a) Float voltage adjustment (float)b) Boost voltage adjustment (boost)c) Overload current setting (OL)

D) Digital ammeter of 3 digit, 1% Accuracy with LCD/LED display having12mm numerical display height shall be provided on the front panel of themodule for measuring module output current.

E) Voltage monitoring point suitable for measurement by standard multi meter.

F) Reset button for resetting the alarm as per clause 4.1.23.1

4.1.23.2 All the above indications may be derived on a microprocessor based control andsupervisory unit and may be displayed on an LED / LCD type alphanumeric display.

4.1.24 Terminations

a) The AC input connection to the FRBC module shall be by means of plug and socketarrangement as per specification No. UL 248 & DIN 41576.

b) The DC output connection should be taken through irreversible plug and socket havingpower pins with locking arrangement.

c) The output of each FRBC in the positive lead shall be taken through the HRC fuse of1.5 times of rated capacity of FRBC.

d) In all cases, the male connector shall be mounted in the FRBC module and thefemale connector shall terminate the cable.

e) To prevent hazards or damaging conditions, all plug-in components shall benon-interchangeable.

f) All the connections between DSA unit and FRBC shall be through proper ratedcables only.

g) Circuit breakers at the input of each FRBC shall be easily accessible and ratedto 25A for 110V/20A module.

h) Proper termination for AC at the input of the circuit breakers and its output tothe FRBC.


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4.2 DISTRIBUTION/SUPERVISORY CONTROL /ALARM (DSA) UNIT

All the power plant racks shall be provided with a distribution/ supervisory control /alarm unit for the ultimate rack capacity as indicated in clause 1.1.

The unit shall comprise of the following:

a) Termination for the batteries.b) Termination for the load (DC-DC converter & Inverters).c) Termination for AC input to the rack.d) Termination for AC and DC to FRBC modules.

4.2.1 Accessibility

4.2.1.1 The termination points shall be easily accessible from front or rear.

4.2.1.2 AC and DC terminals shall be separated by physical barriers to ensure safety.

4.2.1.3 All the terminals except AC earth shall be electrically isolated.

4.2.2 AC termination arrangement

4.2.2.1 The input terminals shall be clearly marked as L & N for mains supply voltages.

4.2.2.2 AC input termination shall be suitably protected against accidental touch/contact with theworking staff for their protection and shall also have clear and prominent DANGERMarking.

4.2.3 DC terminations

4.2.3.1 Connection between the FRBC and DC distributions shall be through a proper rated luggedcable.

4.2.3.2 The DC output to battery and load shall be through bus bar or cable.

a) Battery fuse shall be of 1.5 times of maximum current that passes to / from battery.b) Fuse at the O/P of FRBC rack shall be of 1.5 times the designed O/P current required forthe system.

4.2.3.3 All the AC, DC and Control/Alarm cabling shall be supplied with the rack.

4.2.3.4 All DC positive & negative terminals shall be clearly marked and shall be suitable forminimum 10-sq. mm cable size. All conductors shall be properly rated to prevent excessiveheating.

4.2.4 Alarms & Indication of DSA Unit

4.2.4.1 Status Indication

Description Nomenclature Indication

a) Mains available MAINS Amber

b) Mains fail MAINS FAIL Red

4.2.4.2 Alarm Indication

Description Nomenclature Indicationa) Load voltage high OUTPUT VOLT HIGH Red

b) Mains out of range MAINS VOLT LOW /HIGH Red

c) System overload OVERLOAD Red


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d) Mains on/battery discharging MAINS ON & BATTERY ONLOAD

Red

e) Low voltage battery disconnection BATTERY DISCHARGED &DISCONNECTED

Red

f) Battery / load fuse fail FUSE FAIL Red

g) Temperature compensation fail TEMP. COMPENSATION FAIL Red

All the above indications may also be derived on a microprocessor based control andsupervisory unit and may be displayed on an LED / LCD type alphanumeric display.

4.2.4.3 All alarm circuits shall be provided with suitable delay to ensure that they do not operate withtransients.

4.2.4.4 All the protection/alarms shall be within tolerance of 0.012V per cell for voltage and 1% incase of current.

4.2.4.5 Every alarm condition shall be accompanied with audio alarm with auto cut off after 120seconds. Provision shall be made for stopping the audio alarm with a push button switch.

4.2.5 Battery Health Monitoring

4.2.5.1 Battery Health Monitoring in Auto Mode: To keep the battery in healthy state,the battery condition shall be continuously monitored. On restoration of AC mainsafter an interruption, depending on the battery condition sensed, the system shallchange over to Auto Boost Mode to charge the battery at higher voltage of2.3/2.42V/cell for VRLA /Low Maintenance battery respectively till the battery isfully charged. It shall come back to auto float mode as defined in clause 4.1.11.1.

4.2.5.2 Battery Current Limiting Circuit: To ensure the availability of required loadconnected and safety of the battery in auto mode, the battery charging current limitshall be settable (5 15% of battery AH capacity) as per requirement.

4.2.5.3 Battery under voltage isolation: The system shall have provision for batteryisolation using DC contactor. The battery isolation shall be effective at

i) For VRLA Battery: 1.80V/cell ( 0.012V/cell)ii) For low maintenance lead acid battery: 1.85V/cell ( 0.012V/cell)iii) Battery under voltage adjustment shall be provided inside the switching control

unit. This setting shall be adjustable from 1.80 to 2.0V/cell. Battery shall getreconnected after restoration of mains.

4.2.6 Temperature Compensation for Battery: There shall be provision for monitoringthe temperature of battery and consequent arrangement for automatic temperaturecompensation of the FRBC output voltage to match the battery temperature

dependent charge characteristics. Output voltage of the FRBC shall decrease orincrease as per the type of the battery used by the purchaser. Failure oftemperature compensation including sensor shall create an alarm and shall notlead to abnormal change in output voltage.

4.2.7 Battery Reverse Polarity Protection: Protection for battery reverse polarity shallbe provided in the system. The reverse polarity indication shall be provided nearthe battery terminal.

4.2.8 The system configuration shall be made either with cable or bus bar. Bus bar ofhigh conductivity electrolytic copper strips with purity of 99.9% as per BIS 613latest issue and shall be able to withstand maximum load and battery current. The

bus bar/cable sizes shall be sufficient to cater current density upto 2 Amps persq.mm. The size of bus bar shall not be less than 25mm x 5mm in any case.


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4.3 INVERTER

4.3.1 The inverter shall be of Pulse Width Modulation (PWM) type.

4.3.2 The inverter shall be protected against overload and short circuit with auto reset facility.Whenever the failure condition persists, it shall trip and restart automatically after about 10-

20 seconds. But if the problem still persists, the protection shall permanently get latched andinverter shall not be switched ON again unless the fault is cleared followed by pressing ofreset push button switch. Inverter overload indication shall appear at 110% of rated load.

4.3.3 Inverter shall be designed for continuous operation for an input voltage of 98V to 138V DCat a nominal of 110V DC, and shall be rated for an output of 230V AC.

4.3.4 The output of both the inverters shall be linked in such a way that on failure of one inverter,the other shall supply to load automatically within 500milli seconds. The failure of anyinverter shall be indicated using LED at appropriate common place.

4.3.5 The inverter shall be switched ON without any requirement of manual pre-charging and

shall be suitable for on-line application.

4.3.6 The input & output of inverter shall be isolated from each other.

4.3.7 Each inverter shall be provided with suitable DC MCCB/MCB at the input for connecting theDC input.

4.3.8 The DC fan, if provided, should have MTBF better than 70,000 hours at 40C. Theswitching ON & OFF the fan shall be with temperature control.

4.3.9 The following LED indications shall be provided on front panel:

Description Nomenclature Indicationa) Mains ON MAINS Amber

b) Output OK OUTPUT Green

c) Inverter fail INVERTER FAIL Red

d) Inverter ON load' ON LOAD Green

e) Fan fail indication(In case of forced cooling) FAN FAIL Red

4.3.10 Voltage overshoot and under-shoot in the first cycle for complete load shut off shall berestricted to 20%

4.3.11 The output voltage waveform shall be sine wave. Total harmonic distortion of the outputshall not exceed 8% under any condition specified in clauses 4.3.14.

4.3.12 The no-load current at rated input voltage shall not exceed 10% of the full load input current.

4.3.13 The inverter shall be capable of delivering 125% of rated full load for a period of 24 hours. Itshould be capable of delivering 200% of the rated full load for a period of 300 ms in order tocater for the high in-rush current at the time of switching ON of the inverter.

4.3.14 The output of inverters shall be regulated to 230V 2% for an input variation of 90V-138VDC and for a simultaneous load variation of 25% to 125% of the rated capacity.

4.3.15 The overall watt efficiency of the inverter shall not be less than 85% at full load for the entireinput range of 98V to 138V DC.

4.3.16 The unit shall be capable to withstand 20 cycles / hrs of 1.5 minute each ON and OFF atrated load.


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4.4.14 The response time of regulator for sudden changes of 50 V AC input voltage orload variation from 25% to 75% of the rated load shall be such that the outputvoltage should settle at 230V 1% within 3 cycles/60m seconds.

4.4.15 The no load current shall not be more than 25% of the rated input current and theno load power shall not be more than 10% of the rated output power at nominal

input voltage of 230V at 50Hz.

4.4.16 The overall watt efficiency shall not be less than 85%.

4.4.17 The total harmonic distortion measured at the output of the regulator shall notexceed 8% under any working conditions specified in Clauses 4.4.11, 4.4.12 &4.4.13.

4.4.18 The voltage regulator shall be capable of handling any load from unit power factorto 0.8 lagging, without degrading total harmonic distortion and regulation.

4.4.19 When continuously operating at full load at any ambient condition specified in

clause 2.3, the regulator shall withstand short-circuit on output side for one hourwithout any damage or deterioration to the regulator or any of its components.

4.4.20 The resonant voltage across the capacitor bank shall not exceed 480V at all inputvoltage and frequency conditions i.e 160-270V & 47.5Hz to 52.5Hz at no load.

4.4.21 Suitable surge voltage protection shall be incorporated in the circuit, preferablywith high isolation between primary and secondary sides.

4.4.22 Ferro resonant voltage regulator shall be switched into operation in case of failureof both inverters within 500 ms. "Switching in" of voltage regulator shall be madeby using heavy-duty 3-pole Contactor by using one pole at input and two poles at

the output of the regulator. It shall switch off automatically as soon as one of theinverter becomes healthy.

4.4.23 In case of failure of contactor, provision shall be made for manual bypass ofcontactor through a manual change over switch.

4.5 DC-DC CONVERTER

4.5.1 The DC/DC converter covered under this specification shall work satisfactorilymeeting all the prescribed parameters as long as the DC input voltage is within98V to 138V.

4.5.2 DC- DC converters shall be connected in the following order:

i) Relay internalii) Relay externaliii) Axle Counteriv) Block local UPv) Block Local DNvi) Panel indicationvii) Block Line UPviii) Block Line DNix) Block Tele UPx) Block Tele DN

4.5.3 All components dissipating 3W or more power shall be mounted so that the body is not incontact with the board unless a clamp, heat sink or other means are used for proper heatdissipation.


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4.5.4 Each converter shall be provided with a proper plug in arrangement for DC input & output. Atoggle switch shall be provided for switching ON/OFF the unit.

4.5.5 The converter shall be provided with means for protection and visual indication on frontpanel for the following:

Description Nomenclature Indicationi) Input Power ON indication INPUT Amber

ii) DC-DC Converter output OK OUTPUT Green

iii) DC-DC Converter fail FAIL Red

4.5.6 All modules except block Tele shall work on active load sharing basis without master /slaveoperation, Failure of any module shall not cause malfunction in other modules. The currentsharing shall remain within 10% for 50% to 100% load.

4.5.7 The unit shall be provided with over-load protection, over-voltage protection and output shortcircuit protection with fold back characteristics. The over-load protection shall be effective at105% and output short circuit protection shall be effective at 110% of the rated current.

The DC over voltage protection shall be auto tracking type. Over voltage trip shall be set atapproximately 110% of the set output voltage. For example in a 24V-32V DC-DC Convertermodule if output is set at 25V, over voltage shall be set at 25x1.1=27.2 approximately andso on.

The output voltage settability of the converter shall be within the -2% of the minimum ratedvoltage and +2% of the maximum rated voltage of the converter.

4.5.8 The output shall be free from overshoot because of "Turn on /Turn off" or power failure orwhen the battery charger is switched ON/OFF.

4.5.9 In case of failure of DC-DC converter the output voltage shall not exceed beyond pre-setvalue. Manufacturer shall submit fail-safety validation report in this regard by an approvedassessor at the time of initial approval / any design change.

4.5.10 The no load input current shall not be more than 10% of the rated input current at maximumfull load for all setting of output voltage and input voltage variation from 98V to 138V ofnominal input voltage for DC-DC Converters of 50 VA and above.

4.5.11 The overall efficiency of the converter at full load shall not be less than 75% for convertersrating from 50VA to less than 150VA at rated load and 80% for converters of 150VA ormore rated output at 98V to 138V of nominal input voltage. . For converters of rating 10VA 50VA, overall efficiency shall be greater than 50%. The efficiency shall be measured at the

maximum output voltage of the specified range.

4.5.12 Each DC-DC converters shall be of modular type which shall be fitted in main rack. Theinput and output connections shall be made using irreversible plug in connectors ofappropriate rating.

4.5.13 The DC-DC converter of 12-40V, 1A for block line circuit has been catered in thisspecification, which will be suitable for double line block instrument. Purchaser may selectthe voltage range for other type of block instruments from any of the following ranges:

a) 40-60Vb) 60-100Vc) 100-150V

4.5.14 The DC-DC converter for relay internal and relay external is catered for 24V, 5Aoperated metal to carbon relays. For 60V operated metal to metal relay system,DC-DC converter shall be used in n+2configuration for relay internal. Where 'n' is


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4.6.7 The size of the core shall be as small as possible commensurate with the electricalcharacteristics required by this specification.

4.6.8 The core of the transformer shall be such that its Electro-magnetic property will not beaffected due to ageing.

4.6.9 The body of the core is required to be earthed and one earth terminal shall be provided forthis purpose. Suitable marking shall be made near the earth terminal.

4.6.10 The efficiency of the transformer at rated load with nominal input shall not be less than 90%.

4.6.11 The appropriate voltage shall be legibly & indelibly engraved near the input and outputterminals.

4.6.12 An HRC fuse of appropriate rating shall be provided at the input of transformer.

4.6.13 The following LED indications shall be provided on the front panel:

Description Nomenclature Indicationa) Input ON INPUT Amberb) Output ON OUTPUT Green

c) Tx. fail FAIL Red

4.6.14 230V AC at 50 Hz shall be applied on primary side between terminals 0 and 230V and thevoltages across different tappings on the secondary side shall be measured, which shall bewithin 1.5% of the nominal value.

4.6.15 The open circuit secondary voltage and the primary no load current of the transformer shallbe measured with the primary winding connected to 230V, 50Hz supply and the secondarywinding open circuited. The open circuit secondary voltage at different tappings of the

secondary windings shall be within 1.5% of the nominal values. The primary no loadcurrent shall not exceed 10% of the rated full load primary current for all transformers.

4.6.16 The percentage voltage regulation shall not be more than 5%.

4.6.17 Induced High Voltage Test: - The transformer shall withstand without break down, when440 volt 100 Hz AC is applied to the primary winding, with secondary winding open-circuited. The voltage shall be raised from one third of the maximum value to maximumvalue as rapidly as is consistent with accurate reading of the indicating instrument. The fulltest voltage shall be maintained for one minute and shall then be reduced to the one third ofthe value before being switched off. At the end of the test the transformer shall be tested forthe following:

a) Insulation resistance (Clause 10.2)b) Open circuit test (Clause 4.6.15)

4.6.18 The transformer shall withstand without any damage short circuit of secondarywindings momentarily when primary is fed with 230V AC at terminals 0V and230V. The test shall be carried out after bypassing the fuse.

4.6.19 Applied high voltage test as per clause 10.3 shall be repeated after short circuittest.

4.7 Common Requirements of SMPS based FRBC Panel

4.7.1 The following 3 D digital meters with LED/ LCD display having 12mm numericaldisplay shall be provided on top of the charger panel. The selector switch for metershall not be at a height of more than 1800 mm from the ground.


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Instruction Condition LED Ind. Remark

A Run Gen set 50% DOD RED Audio / visual alarm. Alarm can beacknowledged for audio cut off.

B Emergency start

generator

60% DOD RED -do-

C System shutdown

70% DOD RED Signal feed cut off and all DC-DCconverters to work. Audio alarm willcontinue till Generator is started.

D Call S & T staff Equipmentfault

RED Failure of any module will give thealarm in ASM's panel. Alarm canbe acknowledged for audio cut-off.

E Stop Gen Set FRBCchange

over to floatmode

GREEN Audio /Visual alarm

Audio alarm in case of A, B & C shall be of one type of tone and there shall be different tonefor the case of D & E cases.

4.10.1.1 In A, B & C conditions, the visual LED indication will remain lit until fault is cleared or the DGset is started as the case may be until reset push button is pressed. In case of D condition, iffault is not cleared, the LED will continue to glow, even if reset push button is pressed.

5.0 INDENTING DESCRIPTION / INFORMATION TO BE SUPPLIED BY THEPURCHASER:

Indenting description / information to be supplied by the Purchaser for the IPS

system configuration covered under clause 2.2.1 are as under:

"Supply, installation and commissioning of SMPS based integrated power supplysystem for Panel Interlocking/SSI station in non-RE /RE area as per table.

A Specification No. RDSO/SPN/165/2004 withlatest Amd.

B Configuration As per clause 2.2.1C Applicable sketch No. As per clause 2.2.1

D Type of Battery Low Maintenance /VRLA*

E DC-DC converter for Axle Counter/SSI/Data-logger

Required / not required.

F DC-DC converter for block line working 12-40V/ 60-100V /100-150V*

G Type of Internal & External relays 24V/ 60V*

H Distance between IPS Room & ASM Panel(in meters)

I Distance between IPS rack & battery (inmeters)

J Earthing Requirement Drg. No.

* Strike out whichever is not applicable.

6. LABELLING AND MARKING

6.1 Each electrical/solid state component should be possible to be located by the layout/circuitdrawing. The wiring shall be clearly and permanently identified with a designation or a colour


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code, which corresponds to the equipment circuit diagram. Where non-standard coloursare used, cable functions shall be clearly and permanently labelled at both ends.

6.2 A screen printed cabling / wiringdiagram shall be placed on the inside of the front door orany other convenient place for ready reference of maintenance staff.

6.3 Screen-printed Dos & Donts, adjustment procedures and operating instructions shall be

provided at convenient place on front panel of the IPS cabinets. One laminated blockdiagram shall also be provided at convenient place inside the cabinet.

6.4 The layout of the components and wiring shall be such that all parts are easily accessible forinspection, repairs and replacement.

6.5 All markings shall be legible and durable. Where the marking is by use of labels, they shallbe metallic or screen-printed. These shall be firmly struck and shall not be capable of beingremoved by hand easily. They shall be placed in the vicinity of the components to whichthey refer.

6.6 All cubicles belonging to one IPS shall be identified with a common serial number.

6.7 Each cubicle shall be identified with the following appropriate name plates/labels:

i) SMPS IPS-AC distribution panelii) SMPS IPS-DC distribution panelIII) SMPS IPS- SMPS based FRBC panel

6.8 Each FRBC, Inverter, AVR, DC-DC converter shall be marked with its name &rating on its front panel. The placement for particular module in respective rackshall be clearly marked with its application for the purpose of appropriatereplacement.

6.9 Every SMPS based IPS shall be provided with a rating plate fixed outside at aconspicuous place in IPS cubicle. It shall be clearly and indelibly etched,engraved or screen printed and shall show the following minimum information:

a) Name and trade mark of the manufacturerb) Specification No.c) Nominal AC input voltage and frequencyd) Serial number and year of manufacturing.e) Version number as per Annexure VI.

.6.10 All input and output terminals shall be clearly identified by using proper name

tags/labels.

7. DOCUMENTATION

7.1 Two copies of the user's instruction manual shall be supplied along with each unit.The manual has to include dimensional layout drawings, detailed circuit andschematic diagrams, PC card layouts and detailed interconnecting drawing of allsub systems. Details on testing and adjustment procedures, initial checks onreceipt at site, detailed installation and commissioning procedures, maintenanceprocedures, proposed routine maintenance test, actual test results obtained for theparticular unit at the factory and detailed trouble shooting chart shall be outlined inthe manual. Feed back format is also to be included in the instruction manual.

7.2 The instruction manual is to be prepared using good quality paper with clear crispprinting. All the drawings in clear printing shall be attached to the handbookbinding. One set of flow chart drawings necessary for trouble shooting shall be


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provided with lamination with each manual. The handbook shall have a thickpolythene sheet cover with plastic winding or comb winding.

7.3 The manufacturer shall submit certificate of the equipment for its satisfactoryperformance for 24 months from the date of commissioning. During the warrantyperiod, any defect should be repaired free of cost.

7.4 The joint pre-commissioning checklist and post commissioning loadmeasurements shall be a part of instruction manual. The system shall becommissioned, as per specification and representatives of manufacturer andpurchaser/railways shall sign this jointly.

8 PACKING

8.1 Complete IPS shall be packed in suitable wooden boxes/crate, strong enough,without additional packing to prevent damage or loss to the unit during transit.Loose space inside the box/crate shall be filled up with suitable packing material.

8.2 FRBC module, DC-DC converters, inverters, AVRs & Step down Transformers

shall be separately packed. These shall be wrapped in bubble sheet and thenpacked in thermocole boxes and empty space shall be filled with suitable fillingmaterial. All modules shall be finally packed in wooden case of sufficient strengthso that it can withstand bumps and jerks encountered in a road / rail journey.

8.3 Each box shall be legibly marked at one end with code numbers, contents,quantity and name of manufacturer/ supplier. The upside shall be indicated with anarrow. Boxes should have standard signages to indicate the correct position andprecaution "Handle with Care" with necessary instructions.

9. TEST AND REQUIREMENTS

9.1 Inspection & tests shall be carried out to ensure that requirements of this specification arecomplied. All tests, unless otherwise specified, shall be carried out at ambient atmosphericconditions on all the modules of SMPS based IPS system. For inspection of material,relevant clauses of IRS: S 23 and RDSO/SPN/144/2004 shall apply unless otherwisespecified.

9.2 Initial type approval:

Manufacturer shall furnish following information at the time of initial type approvalof IPS system.

a) Details of protection provided and their effectiveness / proposed set values and

range and working principle.b) Bill of material for racks and modules. Details of semi conductors devices used

and its specification and data sheets.c) Safety margins in voltage, current, thermal (for junction temperature) along

with the limit value for power devices, inductors and transformer etc.d) Installation & commissioning manual, Quality Assurance Plan and Service

manual (consisting of indications and fault diagnostics, Do's & Dont's etc.)e) Design approach for the IPS system and salient features through which

required MTBF has been achieved..

9.2.1 While granting initial type approval, it shall be ensured that the system conforms toall the clauses and passes all type tests as mentioned in clause 9.3.1and other

relevant guidelines of RDSO.


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9.3 Maintenance type approval

Before expiry of validity period, manufacturer shall submit prototype samples asper guidelines of RDSO. The IPS system must pass all type tests as per Clause9.3.1.

In case of design changes, RDSO may call for fresh sample in the intermediatestage. In such cases, manufacturers shall submit all the information as per clause9.2.

9.3.1 The following shall comprise the Type Tests:

a) Visual Inspection (Cl. 10.1)b) Insulation Resistance (Cl. 10.2)c) Applied high voltage test (Cl. 10.3)d) Temperature rise test (Cl. 10.4)e) Performance test (Cl. 10.5)f) Test for protective devices (Cl. 10.6)

g) Environmental & Climatic Test (Cl.10.7)h) Functional test (Cl. 10.8)i) Vibration test on modules as per RDSO/SPN/144/2004.

j) Static discharge test as per RDSO/SPN/144/2004. Electrostatic discharge testshall be carried out as per international standard IEC 61000-4-2 or itsequivalent with 150 Pico Farad charged capacitor of 7KV and should bedischarged through 330 ohm resistor.

Note:(i) Test for protective devices and performance test shall be carried out before andafter climatic test. There shall not be any significant deviations in the observationsrecorded.

(ii) Vibration & Static discharge test shall be conducted on one module of FRBC along withDSA unit, ASM panel, Inverter and DC-DC Converter.

9.3.2 The following shall comprise the Acceptance test:

The acceptance test shall be carried out as per the sampling plan given in Clausein 11.0.

a) Visual Inspection (Cl. 10.1)b) Insulation Resistance (Cl. 10.2)c) Applied high voltage test (Cl. 10.3)d) Temperature rise test (Cl. 10.4)

e) Performance test (Cl. 10.5)f) Test for protective devices (Cl. 10.6)g) Functional test (Cl. 10.8)

9.3.3 The following shall comprise the Routine test:

The routine test shall be carried out on every module of the IPS system and theresults will be submitted by the manufacturer to the inspecting authority at the timeof inspection.

a) Visual Inspection (Cl. 10.1)b) Insulation Resistance (Cl. 10.2)

c) Applied high voltage test (Cl. 10.3)d) Performance test (Cl. 10.5)e) Test for protective devices (Cl. 10.6)f) Functional test (Cl. 10.8)


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10. TEST PROCEDURE

10.1 Visual Inspection

Test for visual inspection shall be carried out as per relevant clauses of this specification andRDSO/SPN/144/2004.

10.2 Insulation Resistance

Insulation resistance (I.R) test shall be carried out:a) before the high voltage testb) after the high voltage testc) after climatic test

The measurement shall be made at a potential of not less than 500 V DC. The insulationresistance shall be measured at module level / rack as follows:

i) Input line terminals and the body of the equipmentii) Output line terminals and the body of the equipment

iii) Input line terminals and output line terminalsiv) Between rack and earth

Value of the insulation resistance shall not be less than 10 M.ohm for the rack /equipment and 1000 M.ohm for the transformer/CVT when measured at atemperature of 40C and relative humidity of 60%. There shall not be appreciablechange in the values measured before and after high voltage test and after thetemperature rise test.

After completion of climatic test, the values shall not be less than 5 M.ohm for theequipment and 500 M.ohm for the transformer/CVT when measured at atemperature of 40C and relative humidity of 60%.

Note: - In case, temperature and humidity prevalent at the time of the abovemeasurements of insulation resistance are different from those specified above,the values of I.R. shall be obtained from Annexure-VII.

10.3 Applied High Voltage test

The module shall withstand the application of 2000 V AC rms for one minute withoutpuncture and arching. The test voltage shall be approximately sine wave and of anyfrequency between 50 and 100 Hz. The high voltage shall be applied between the following:

a) Input and earthb) Output and earth

c) Input and output

Note:i) For FRBC, (b) above shall be tested at 1000V AC rmsii) DC-DC Converter shall be tested for a), b) & c) at 1000V AC rms.iii) The test shall be carried out after removing surge arrestors /MOVs or any other surge

absorbing components.iv) In routine test, only one module of each type shall be tested.

10.4 Temperature rise test

Temperature rise test should be logged during functional test of IPS after 8 hours, either with

the help of thermo-couple or with resistance method on one module of each type.

10.4.1 While conducting the test with the help of thermo-couple, the temperature ofMOSFET/IGBT, heat sink, diode, Transformer/ Ferrite Transformer, Core, Booster choke,


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Internal ambient, Inside cabinet and outside cabinet shall be recorded at every one hour forfirst four hours and every half hour for next four hours. During this test, the temperaturecompensation probe shall be disconnected.

10.4.2 The temperature rise of heat dissipating components above the ambient measured directlyand at heat sink shall not be more than

a) Transformer and chokes : 65C for B type and 90 oC for F type insulationb) Thyristor & diodes : 70C or as per component specification.c) IGBT/MOSFET : 50C

10.5 Performance test

10.5.1 Performance test for FRBC shall include following and other relevant clauses of thisspecification.

i) The FRBC shall be tested for its output performance (efficiency, power factor, harmonicdistortion, psophometric noise and ripple voltage) at the AC input voltages 150V, 230V and275V at different load currents by connecting a variable resistance load across the output

terminals for the auto float mode and auto boost mode respectively.

ii) In auto float mode, readings shall be taken for float voltage setting of 2.15 V/cell &2.25V/cell for low maintenance lead acid batteries & VRLA batteries, respectively at loadcurrent in the ranges 25% load to full load.

iii) In auto boost charger mode, readings shall be taken for boost voltage setting of2.42V/cell & 2.3 V/cell for conventional lead acid batteries & VRLA batteries respectively atload current in the ranges 25% load to full load.

iv) During the performance test, the system shall fulfil the requirements of efficiency, powerfactor, psophometric noise, harmonic distortion, ripple voltage etc. as given under clauses

4.1 of this specification.The test report from National /International test house of RFI/EMI shall be submitted by themanufacturer as per clause 4.1.20.

v) The current sharing of the module working in parallel shall be tested as per clause4.1.21.2.

10.5.2 Performance test on DSA unit, Inverter, Ferro Resonant Voltage Regulator, DC-DCConverter and Step down Transformer shall be carried out as per clause no. 4.2, 4.3, 4.4,4.5 & 4.6 respectively.

10.6 Test for protective devices:

10.6.1 Test for protective devices for FRBC shall include following and other relevant clauses ofthis specification.

i) Short circuit: During this test, system shall be connected to AC input voltage of 275V.Output terminals shall be short-circuited through a suitable arrangement. Steady short circuitcurrent shall be measured. It should not exceed rated current + 5%. There shall not be anydamage to charger. Working of over load/ short circuit indications/ alarms will also bechecked on the FRBC. This shall be achieved by controlling output current and voltageunder short circuit condition and not by switching off the input/ output voltage under shortcircuit condition.

ii) Reverse battery connection: A fully charged battery shall be connected in reverse polarityto output terminals of charger. There shall be no emission of smoke of undue temperaturerise of any component of charger. Working of corresponding indication/ alarm shall also bechecked.


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acceptance test & 4 hours during routine test with frequent ON and OFF condition of ACMains alternately, after every 30 minutes.

10.8.2 All the sub systems of IPS shall be connected. The output of all sub systems shallbe checked. The switching over from mains to standby and vice versa of FRBC,inverters and DC-DC converters shall be checked. Switching over of Inverter &AVR shall also be checked. Indication of working and faulty condition of FRBC,

inverters & DC-DC converters shall be checked.

10.8.3 All alarms and indications of ASM status monitoring panel shall be checked for its properfunctioning.

11. SAMPLING PROCEDURE FOR ACCEPTANCE TEST

Visual inspection / compliance shall be carried out on one of the IPS unit of eachtype. The modules shall be tested for insulation resistance, high voltage test,temperature rise test, performance and protection tests as per the sampling plangiven below:

Test Description Ins.Res.

HVtest

Temprise

Performancetest

Protectiontest

SMPS (FRBC) N/2 N/2 N/2 N N

Inverter N/2 N/2 N/2 N NAVR N/2 N/2 N/2 N N

DC-DC Converter (ofeach type/ rating)

N/2 N/2 - N N

Transformer N/2 N/2 N/2 N N

Battery Bank -10 hrs discharge test for capacity: Sample shall be taken as perClause 11.1 of IS: 8320-1982. Cells shall be taken from all banks of IPS.

N = Denotes the no. of samples, N/2, shall be rounded off to the next number. Incase of any failure during acceptance test, the lot shall be rejected.

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Annexure II

SPARE LIST OF COMPONENTS USED IN THE IPS SUB SYSTEMS

SN Sub system Spare components Qty

1 SMPS Charger Module Module (as cold standby) 1 Module2 Inverter Module Module (as cold standby) 1 Module

3 DC-DC Converter a) 24-32V, 5A or 60-66V, 5A (ascold standby)b) 12-28V, 5A (as cold standby)c) 12-40V, 1A or as ordered forblock line (as cold standby)

1 Module

1 Module

1 Module

4. Ferro-resonant type

Automatic VoltageRegulator (AVR)

AC Capacitor 1 Set

5. Fuses All type of fuses used in IPSsubsystem

1 Set

6. Transformer Module (as cold standby) 2 Modules

7. Inverter/SMR DC fan 2 Nos.8. Cells 2V Cells 5 Nos.


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Annexue- IV

SOURCES OF MAIN COMPONENTS OF THE SMPS BASED IPS SYSTEM

S.N Item Specn Manufacturer Country Indian Source

1. Distribution Fuse

& Fuse Bases

Glass(Slo

w Blow)& HRC

1) S&S

2) GEC3) DF

India

IndiaIndia

S&S

GEC AlsthomAPS, Gurgaon

2. MCB/MCCB Class C 1) Merlin Gerlin(Telemecanique)

2) Siemens3) Schneider4) ABB

India

India

Telemecanique

ABB3. Terminal Flame

proof TBtype

1) Phoenix2) Wago

India New Delhi, Noida

4. Lighting & Surgeprotection device

Class B,C & D

type

1) Phoenix

2) OBO

3) Schirtec4) DHEN (Only for

Class D type)

Germany

Germany

AustriaGermany

Phoenix Contact,New Delhi

Cape ElectricCorpn. NagercoilMcML, BangaloreAdhunik PowerSystem, Gurgaon

5. ContactorDC(LVD)

SPST DCoperated

1) ABB2) Albright/Phoenix3) Andrewoyulu4) Telemecanique5) Siemens

IndiaUKIndiaIndia

APS Gurgaon

6. Contactor AC 1) Telemecanique2) L&T

3) ABB4) Siemens

IndiaIndia

India

APS GurgaonL&T

ABB, Delhi

7. DC /AC DigitalMeter

LCD 3 D 1%Acc.

1) A.E2) PLA3) Nippen4) Self made

IndiaIndiaIndia

AEPLA

8. Relays - 1) PLA2) OEN3) Omran

IndiaIndiaJapan

PLAOEN, BangaloreAPS, GurgaonOmran ND

9. Neon Lamp -- 1) Panasonic2) Vinaic

3) Vaishnav4) Elcon5) Gillard

IndiaIndia

IndiaIndiaIndia

----

------

10. LED -- 1) Agilent2) Nischia

USAJapan

Authorised dealerAuthorised dealer

11. PCB Connector 1) Phoenix2) Molex3) Wago4) Essen

IndiaIndiaIndiaIndia

12. Switches 1) Elmax2) Salzer3) Recom

IndiaIndiaIndia

SalzerRecom


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13. MOSFET/IGBT

1) APT2) IR3) Infinion4) SGS Thomson5) Intersil6) IXYS

7) Semicon8) Mittsubishi

USAUSAUSAUSAUSAIndia

Germany

14. Capacitors 1) Rescon2) Alcon3) Arcotronic4) CTR5) Philips6) Wima7) Rifa8) SICSA FCO9) NICHICO10) Webelson

India

15. Resisters 1) Thermax2) Philips3) Baychelog4) Shree Torn5) PFC

IndiaIndiaGermany

16. Connector Irreversible withlock

1) OEN2) Amphetornics3) Allied Technology4) Anderson/Wago5) Phoenix

IndiaIndiaIndia

India

17. ICs - 1) Liner Technology

2) NationalTechnology

3) Motorola4) Philips5) Unitrode6) Harris7) GI8) SGS9) General

Semiconductor10) Cherry11) NEC

12) MICRIL13) INTEL

18. Cables - 1) Lapp Kabel2) Finilex Cables3) Deltan Cable4) ECKO5) Kapi

IndiaIndiaIndiaIndiaIndia

19. Exhaust Fan 1) Kaitan2) GEC

IndiaIndia

20. SCR/Diode/Ultrafast diode

1) RIR2) HIRET3) IXYS

4) Philips

IndiaUSAIndia


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Annexure-VIVersion control of electronic signalling equipments

(Issued vide letter no.STS/E/SPN/144 dated 10/13.06.2005)

Signalling equipments are evolving and will continue to evolve so as to provide enhanced Reliability,Availability, Maintainability and Safety (RAMS) features and functionalities. It is, therefore, important to

provide a proper mechanism to ensure that as and when the design or hardware or software or acombination of these is modified/ upgraded/ improved, a proper version control is exercised by allconcerned.

1 Objective

The purpose of this letter is to implement and ensure a proper mechanism to exercise versioncontrol in case of modification/ upgradation/ improvement of signalling equipments. The followingshall be implemented.

2 Scope

2.1 The instructions contained in this letter shall be applicable to all electrical and electronicsignalling equipment and firms for which type approval or cross approval has been granted byRDSO.

2.2 Existing equipments and firms which are type approved, shall implement the new versionnumber scheme by 30.09.2005.

2.3 The format of version number is, however, not applicable to equipments which are approved onthe basis of cross acceptance and manufactured to manufacturer's specifications and verifiedand validated by accredited third party. However, it will be applicable to any module developedand manufactured indigenously to work in conjunction with equipment approved on the basis ofcross acceptance, for example, reset box for axle counters.

2.4 All type approvals granted hereafter shall comply with instructions contained in this letter withimmediate effect.

3. Version Control

2.5 The version number of any equipment shall be as per the format given below:

DXXSXXXHXX

DXX SXXX HXX

Basic Design Software Hardware

D: Design, S: Software, H: Hardware

XX and XXX are numeric two and three digit numbers respectively.

Thus the initial version of any equipment will be D01S001H01.

In every case of modification/ upgradation/ improvement of Basic Design,DXX will increment by one.

In every case of modification/ upgradation/ improvement of system Software(executive software), SXXX will increment by one.

In every case of modification/ upgradation/ improvement of Hardware, HXXw

Documents

RDSO specIPS