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GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

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RESEARCH DESIGNS AND STANDARDS ORGANISATIONMINISTRY OF RAILWAYS

FUNCTIONAL REQUIREMENT SPECIFICATION (FRS) FOR DESIGN,DEVELOPMENT AND MANUFACTURING OF 30 KW PERMANENT

MAGNET ~ ALTERNATOR WITH CONTROLLER FOR 110V DC SGAC I LHB COACHES

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EU7.1.38/2w.eJ December 2012

FUNCTIONAL REQUIREMENT SPECIFICATION (FRS) FOR DESIGN,DEVELOPMENT AND MANUFACTURING OF 30 KW PERMANENT MAGNET (PM)

ALTERNATOR WITH CONTROLLER FOR 110V DC SG AC I LHB COACHES

In LHB type coaches, FIAT bogies are used with Disc brakes. In these bogies theexisting 25kW alternators can not be fitted due to space constraint. Permanent Magnet(PM) alternators are smaller in size and can be fitted in these bogies. As further detailsregarding manufacturing and standardisation of permanent magnet alternators are notavailable with Indian Railways, this FRS has been proposed for 30kW permanentmagnet alternator and controller.

0.1 As these functional requirements are defined for development of the PermanentMagnet Alternator with controller, better specifications / parameters may be acceptedfor trial/ testing by Indian Railways.Deviation in the specified parameters may also beconsidered by Indian Railways on merit and mutual agreement basis. However,manufacturer must note that once the product is developed and stabilised, IndianRailways reserves the right to freeze / standardize any particular design or mayprovide its own design which shall be binding on all the manufacturers.

1.1 This specification covers the design, development, manufacture, testing and supply of30 'r0N 'V'-belt driven bogie mounted permanent magnet brushless alternator requiredfor LHB broad gauge air-conditioned coaches.

1.2 The permanent magnet brushless alternator covered by this specification shall nothave any windings on rotor.

1.3 The scope of supply for each set shall include the following unless or otherwisestipulated in the tender: -

i) 30 kW permanent magnet alternator, complete with one/two'V' grooved alternator pulleys on one/both side

ii) Safety chainsiii) Belt tensioning device completeiv) AXle-pulleys complete with rubber pads and hardwarev) Suspension pin complete with hardwarevi) Maintenance manual including trouble shooting details

3 No.1/2 Nos.1/2 Nos.1 No.1 copy

For the purpose of this specification, the following definitions shall apply:-

2.1 Alternator - An axle driven power-generating machine mounted on the bogie of coach.

2.2 Axle pulley- A pulley fitted on the axle of the coach to drive the alternator by 'V'-belts.

2.3 Alternator pulley - A pulley fitted on alternator and driven by axle pulley through 'V'-belts.

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EU7.1.38/2w.e.f December 2012

2.4 Cut-in speed - The alternator speed in rev./min. at which rectified out-put is 110V at noload.

2.5 Minimum speed for full output - The minimum alternator speed in rev./min at which itgives full rated output current of 230A at rated voltage of 130V. This will henceforthbe termed as MFa speed.

2.6 Voltage and current detector - A device to limit voltage and current of alternator to thepre-set values.

2.7 Control Unit - Electronic unit to rectify the AC output of the alternator with controlelectronics to keep voltage and current within specified range.

2.8 The fully air conditioned sleeper coaches, composite coaches and chair cars with roofmounted package units will normally be equipped with two roof mounted packageunits and two sets of 30 t0N permanent magnet alternators. Other types of air-conditioned coaches e. g. First class AC coaches may be equipped with only one setof 30 t0N permanent magnet alternators. The DC output of the alternator will normallysupply coach loads consisting of air-conditioning control unit fed from inverter,incandescent and fluorescent lights, air-circulating fans, pantry loads etc. and inaddition to charge a bank of 56 Nos. 650Ah VRLA battery at a nominal voltage of 110V DC.

2.9 The battery is connected to the alternator through control unit, which converts ACoutput of alternator into regulated DC and prevents the reverse flow of current from thebattery to alternator during periods of non-generation. The inverters and coach fansare connected across the main positive and negative. The light fittings are alsosimilarly connected across the main positive and negative. Some of the coaches arefitted with AC fans and lights, which are connected across the AC output of inverter.

2.10 Control unit shall also have provision for feeding 3 phase AC from external supply forbattery charging and precooling of the coach in yards/station. Incase of externalsupply, back feed to Alternator is to be prevented and similarly in case of running train,voltage availability at external supply input points should be prevented for safety.

3.1 The alternator shall function satisfactorily in the ambient temperature range from _5° Cto 55° C and 98% relative humidity and will be subjected to vibration, dust and rainwater in service when installed in the under frame of the coaches. The control unitshall be designed for mounting on the bogie transom and shall be suitable for workingin a heavily dust laden atmosphere which may also contain brake block (conducting)dust. The design and construction of Alternator with controller shall be suitable towithstand the above service condition. The vibration levels generally are 3g, 3g & 59.

3.2 The coaches are expected to run up to a maximum speed of 175 kmph in the varyingclimatic conditions exiting throughout India. All accessories to be mounted on thecoach under frame shall be designed to withstand service vibrations and buffingshocks.

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3.3 The design of alternator shall be suitable for use with any make of controller andshould have

a) Maximum reliability.b) Long life with minimum maintenance by the use of components not liable to wear.c) Universal applicability within the speed range.d) High power-weight ratio.e) Low initial cost as well as low annual maintenance cost.f) The installation shall also be able to operate without battery.g) Well protected against extraneous interference and pilferage.h) Self-exciting

4.1 The standard rating at the DC output terminals of the controller (control unit) shall be130V &. 230A.

5.1 The mounting arrangement and drive for the alternator shall be generally as perexiting arrangement. The alternator and axle V-grooved pulleys shall be of theextended groove type for alternator & axle pulley. In the manufacturing of the pulleys,special care shall be taken for strict adherence to the tolerance given in the abovementioned drawings. Pulleys may be out sourced from RDSO approved vendors, ifrequired. The alternator and axle pulley for 30 kW permanent magnet brushlessalternator shall generally conform to RDSO Specification No. ELPS/SPECITLI 13March 1998 or latest. However, dia of the pulley and number of grooves can bedecided by manufacturer.

5.3 The coach wheel diameter is 915 mm when new and 813 mm when fully worn out.New wheel diameter shall be considered for making calculations of speed of the trainin Kmph corresponding to cut-in-speed and MFO speeds of the alternator.

5.4 The "V"-belts shall be suitable to run at 175kmph. Number of belts shall be suitabilychosen by the manufacturer and calculation and the same shall be submitted toRDSO. However, at 175kmph, worn wheel dia shall be considered for calculation ofalternator speed in rpm.

5.5 The tensioning device consisting of compression spring limiting pipe etc. Punching ofcapacity i.e. 30 KW along with name of manufacturer shall be done on indicator plate.

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EU7.1.38/2w.e.f December 2012

6.1 The cut-in speed and MFO speed of the alternator shall be as low as possible andconsistent. New wheel dia shall be considered for calculation of cut-in and MFO inkmph.

The alternator shall be capable of working at maximum speed of 175kmph. Nonegative tolerance is permitted on the voltage and current for measuring cut-in-speedand minimum speed for full output (MFO).

6.2 The alternator output voltage in conjunction with control unit shall be within thetolerance of ± 2% of the voltage setting for any load form 10A to 230A over the speedrange of MFO to maximum speed i.e. 2500 rpm. The alternator shall be dispatchedwith the voltage setting of 129±0.5V at 115 A at 1500 rpm. The current limiting shallbe set between 274A to 278A and voltage shall not drop to less than 120V at 269A.

6.3 Efficiency Test: The efficiency of the alternator with controller taken together shall notbe less than 90% at 130V, 230A and 110kmph.

7.0 GENERAL CONSTRUCTIONAL FEATURE OF ALTERNATORS AND ITSCOMPONENTS.

7.1.1 The alternator shall be of robust construction suitable for the rough usage to be metwithin rolling stock application, including vibrations, impacts during shunting operationetc. Alternator shall be protected against the ingress of solid foreign bodies and waterin accordance with IS: 4691-1985. The degree of protection shall be IP-55.

7.1.2 a) The rotor and alternator pulleys shall be dynamically balanced separately on abalancing machine. The residual unbalance shall not be more than 2.5 gm-cm/kg in any case.

b) Permanent magnets shall be fitted mechanically on the rotor. In such a mannerthat they do not become loose during life of Alternator

c) The field of permanent magnet shall not have any magnetism/effect outside ofalternator body.

7.1.3 The mating of the alternator pulley with the shaft shall not be less than 80%. Thealternator number shall be punched on the pulley so that it remains a matched set.

b) The bearings shall be of ROSa approved sources.

c) Finite Element Analysis (FEA) of bearings

d) In addition to provisions of the required interference tolerances on bearinghousings, the bearings covers shall grip the bearing faces to prevent outer racerotation in the housing for fixed bearings

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e) Simple gap type seals with labyrinth and two or more grooves in the bearingcovers shall be provided to ensure proper retention of grease.

7.1.5 Special care shall be taken in regard to design and manufacture of rotor shafts. Themanufacturer shall institute checks to ensure that the raw-material for the shaft is EN-24 manufactured by the forging process (hardened and tempered). At change ofsections, smooth ground finish should be obtained after giving maximum possibleradius with form tool. Finished shafts shall be subjected to ultrasonic (100%) test todetect internal as well as surface defects / discontinuities.

7.1.6 Each alternator shall be supplied complete with two safety chains of approved designconforming also to IS:2429-1967. The overall factor of safety of the chains shall not beless than 4. Allowance shall be made for the stress in the chains due to impact of thefalling alternator.

7.1.7 Safety chains fitted to the alternator shall not in any way restrict the scope of itsadjustments to provide adequate tension for stretched belt. The clearance maintainedfrom rail level when the alternator is hanging freely by safety chains shall not infringethe maximum moving dimensions, Le. 178 mm from rail level. The design of safetychain shall be such that it will not rub any of the bogie / alternator while in service.

7.1.8 The alternator terminal board details shall incorporate the following essentialfeatures:-

a) The terminal block shall not be loose when tightening or loosening the terminalscrews.

b) Incoming socket shall be connected to one terminal post and outgoing socket shallbe connected to second terminal post ensuring the flow of current through lugs &copper strips avoiding threaded screws and nuts.

c) The temperature rise of any terminal shall not exceed 50 degree centigrade aboveambient at continuous rated current.

f) The terminal block shall be fixed with terminal box with slotted head hexagonalscrews instead of counter sunk screws.

g) Leads coming out from alternator windings to alternator terminal board shall bethrough independent holes for each lead to avoid any contact with the frame.Holes should be sealed with RTV silicone sealant.

h) Terminal box shall have fuse in each lead. Fuse rating, model & type should besuitably chosen to given trouble free service for the complete range of operation.

7.1.9 Cable from alternator to controller shall be of e-beam type conforming to ROSO'sSpecification ELRS/SPEC/ELC/0019 Rev-2 of Feb 2011 supplied by the manufacturer.

7.1.10 Cleat has to be provided on the alternator frame to support the outgoing cables.Material of cleat shall be non-hydroscopic insulation material with fire retardantproperties such as EP2-IS: 10192

EU7.1.38/2w.e.f December 2012

Dual coated enameled winding wires as per IS: 13730-13-1993. Dual coat means thatbase coat with polyesterimide enamel MT533.39A & topcoat with Allothem 602.35 ofDr. Beck & Co. only.

The enamel thickness shall comply with IS: 13730 PT. 0 Section M (i) & (ii) mentionedabove.

a) The test on enameled winding wires shall be conducted as per IS: 13778 Part 1 to6. Separate documentation for these tests shall be maintained by themanufacturers, indicating the winding wire supply particulars.

b) Impregnation: Vacuum pressure impregnation (VPI) process shall be adopted,with Dr. Beck & CO.'s solventless unsaturated polyestermide (UP) impregnatingresin Dobec-on FT1052/2005 or 500 EK. The winding shall be subjected topressure impregnation as per the recommended procedure of varnishmanufacturer.

(c) Winding of Coil Overhang: The star point of the winding shall be formed inside thestator overhang. The star point shall be adequately brazed and insulated ensuringbest workmanship. On the brazed joint, RTV silicon-sealent and tape with twolayers I half lap Nomex tape (20xO.05mm) shall be applied. The joint should beinsulated with fiber glass silicon elastomer sleeve of suitable diameter and securedproperly by tying with glass cord.

Coil overhangs in the stator winding shall be adequately secured with glass cordand stagger taped and each soil emerging from the slot shall be covered with %lap impregnated glass tape of size 0.3 x 20 mm. Alternatively, coil separatorsimilar to the phase separators may be provided between adjacent coil emergingfrom the slot.

(d) Slot linter-phase insulation: Nomex-Kapton-Nomex shall be used for slot liner andwedge separator. Uncalendered Nomex (Nomex 411) shall be used for inter layerand inter-phase insulation. Epoxy bonded glass fibre laminate shall be used forslot wedges. The tenderer shall state in his offer the brand names of the insulatingmaterials proposed to be used which is suitable for "H" class.

The air clearance between un-insulated live parts and body of alternator shall not beless than 10 mm. The minimum clearance between the un-insulated live parts shallnot be less than 4 mm.

The stator windings between two phase wires shall have nominal resistance, 0.040 ±0.010 ohm max.

Colour of Alternator - The equipment shall be finished in the colour code No. 796dark violet of IS: 5-2007 "Colours for ready mixed paints & enamels". Painting shallbe in accordance with the specification and "Code of Practice" issued by RDSO forraw materials, hardware and anti-corrosive treatment of train-lighting equipment

Alternator serial no. and manufacturers name shall be punched on both thesuspension bracket of alternator.

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7.1.16 For dimensions and mounting of the alternator and controller, manufacturers areadvised to study FIAT bogie I LHB coaches at RCF.

7-2.1 The Microprocessor based alternator control unit shall be protected against theingress of solid foreign bodies and water in accordance with IS: 4691-1985. Thedegree of protection shall be IP-65. After these tests the unit should worksatisfactorily

7.2.4 Subject to the condition that total current of alternator is less than the rated currentoutput, the regulator unit shall regulate the output voltage of the alternator so as tomaintain a preset voltage subject to the tolerance indicated in clause 6.2 of thisspecification at the rectifier terminals under the following conditions:-

7.2.5 a) Current limiting protection shall be provided to limit the output current to the ratedvalue and with tolerance of 5%.

b) Over voltage a separate protection, solid-state type shall be provided. Settingshall be 145±2V.

7.2.6 The OC output voltage shall be capable of being set from 124V to 130V at 110kmph ata reference load of 115.5Amps.

7.2.7 The semi-conductor devices and other components used shall conform to "ReliabilityAssurance specification for Electronic Components used in Rolling stock" -ROSOspecification nO.ELPS/SPEC/SI/0015 OF October 2001 unless or otherwiseapproved by ROSO.

7.2.8 The cut-in speed and MFO speed of the alternator working in conjunction withcontroller shall be as low as possible consistent with economical design. Thecontroller shall be capable of working at maximum speed of 175kmph. Nonegative tolerance is permitted on the voltage and current for measuring cut-in speed and minimum speed for full output.

7.2.9 The DC output voltage at full load shall be suitable for setting from 120 V to130V.

Similarly, the current limiting setting of DC output current, battery charginglimit shall also be possible to adjust within 20% of above values. Normally,the above settings shall be adopted for the controller of 30 kW ratings.

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No load DC Output voltage

DC Output Voltage setting

Voltage regulation

Efficiency at full load at 1800 rpm

Voltage ripple

Current ripple

Load variation

Speed variation

Voltage at 10% over load

Current limiting

Battery charging current limits (max)

135 V (Maximum)

129 ±0.5 V, 115 at 1500 rpm

±20.10of set voltage

95% (minimum)

within 2%

within 10%

10 A to 232 A

o to 175kmph

120 V (minimum) at 255 A

250A (maximum)

130A

Controller shall have IP-65 SS-304 or better cubical. All the connectors/couplersshall be IP-68.

Controller shall have separate positive output for battery charging (BC+) and onepositive (DC+) and one negative (DC-) output for feeding the load. In case of nogeneration, load shall be fed through DC+ and BC+ from battery.

The pre-cooling mode shall be designed for the following rating and otherparticulars:

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. ! voltage or constant current mode while charging theI Battery exclusively. When, the unit shall be used for II pre cooling purpose, it shall act on constant voltage. II Separate mode selection for exclusive battery charging II and for pre-cooling mode shall be provided. Interlock!I shall be prov.ided so that when unit is on exclusive II, battery charging mode, Roof Mounted Package Unit ,.

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7.3.2.1 Constant Voltage: Under this mode of working, the charger shall give a DC outputvoltage to 2.35 V per cell. The value of output voltage shall be maintained within±2% of the set value over the entire range of input AC supply variation and thecharging current output variation.

7.3.2.2 Constant Current: Under this mode of working the unit shall be capable ofdelivering the output current whose magnitude shall be selected. The current shallbe maintained within ±2% of the set value for charging of fully discharged battery tofull state of charge with the input voltage 415 V ±15%.

7.3.3 EFFICIENCY: The efficiency of the unit shall not be less than 85% at half load andnot less than 90% at full load for entire input voltage range. However, efforts shall bemade to achieve more than 93% efficiency at full load.

7.3.4 RIPPLE CONTENTS: The unit shall be designed in such a way that the outputvoltage ripple factor to less than 2% r.m.s. of the set value of voltage and currentripple factor to less than 3% r.m.s. of the set value of the current, at all loads whenmeasured across a resistive load.

7.3.5.1 Over voltage (Constant voltage mode charging): Over voltage protection shall beemployed to avoid the unit giving high voltage beyond the set level. The trippingshall be set at 2.35V per cell for charging of VRLA batteries.

7.3,5.2 Current limit (in case of constant voltage) : During charging mode, the unit outputcurrent shall be limited to 220A.

7.3.5.3 Over current protection: The unit shall be protected against over current at DCoutput by limiting the output current to a maximum of 115% of its rated current in precooling mode.

7.3.5.4 Input protection: A 100Amps MCCB (current setting at 63 amps) shall be providedat input side.

7.3.5.6 Input overl under voltage protection: Input over/ under voltage protection shall beprovided at 350 V and 480 V AC with an audiovisual alarm. The unit output voltageshall automatically be available as and when the AC voltage is within 350 V to 480V.This should be prominently displayed with audio/ visual indication.

The unit shall be provided with the following minimum controls:i) AC input circuit breaker for emergency shut down.ii) Unit ON/OFF.iii) Trip reset push buttoniv) Mode selection:a) Pre cooling cum chargingb) Battery charging: Constant voltage mode for VRLA Batteries

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7.5 For pre-cooling, suitable connectors/couplers for 3-phase, 3-wire supply shall beprovided. Protection shall be provided that power is not available on terminals ofalternator in pre-cooling mode. Similarly, in self generation mode, voltage should notbe available on pre-cooling connector / coupler.

a) Prototype Tests: Prototype Tests: A prototype test is the test which is to becarried out on an alternator declared as a prototype under the followingconditions:-

The prototype tests shall be carried out at the works of the manufacturer by ROSa.Manufacturer shall submit the details of alternator to ROSa as per Annexureenclosed for information before offering the machines for prototype testing. Thesetests are to be carried out at manufacturer's premises.

b) Type Tests: A type test is to be carried out by the manufacturer and the inspectionauthority on Alternator/control unit equipment picked up at random to ensurecompliance with specifications in details as declared by the manufacturer andapproved by ROSO.

c) Routine Tests: The routine tests are to be carried out by the manufacturers attheir premises on every alternator manufactured, to ensure compliance withspecification declared by the manufacturer and approved by ROSa.

d) Acceptance Test: These tests are to be carried out by an inspecting authoritynominated by the Purchaser at Manufacturer's premises to ensure compliance withthe specification on alternator/s.

In addition, the manufacturers shall submit the following test results to theInspecting Officer at the time of offering the machines for his inspection.

i) Type test results.ii) Routine test results.

The inspecting officer can ask for repetition of any / all tests, if he so desires.However, Inspecting officer shall witness 'type tests' at least on one machine.

These alternators are used on air-conditioned coaches where high reliability is tobe ensured. Therefore, machines are to be accepted after completing all tests

e) Revalidation I Renewal tests: For renewal of firm, the following tests shall bedone at firm's premises after certain time interval as decided be ROSa/IR fromprevious date of registration / renewal.

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The prototype approval shall be valid for a period of three years from the date ofissue of approval letter unless specified otherwise. Before expiry, themanufacturer shall have to apply for revalidation of approval. However. RDSOmay conduct the type tests at short interval in case of need for implementation ofdesign related modification or ensuring reliability.

While applying for renewal of type test approval, the following information shallbe given by the manufacturer.

I. Deviations from the bill of material, QAP approved by RDSO earlier.II. Implementation of all maintenance/reliability improvement modifications

issued by RDSO.iii. Addition/Deletion of machinery and plant.iv. Details of purchase orders executed in last three years i.e. PO No., Qty.,

Rate (including taxes), Date of supply, consignee.

Retype tests shall be done as per clause 8.1 for revalidation. Followingverification shall be done:i) QA Pii) Matching of alternator pulley with shaft as per Clause 7.1.3Iii) Approved make of bearing as per Clause 7.1.4 (b)IV) Properties of alternator shaft as per Clause 7.1.5v) Winding details as per Clause 7.1 11

Renewalof Type

TestNo

I ~~. Type of TeSC- ..··-·m···-r cl~se·r·~~~~r~~fr·R~~~~eTAcc~~~~nce Iii' I test I I I I!M. 1. I Verification of dimensi-o-n-s-o-f-al-I-···-·--1.-8...1..fT. '1es···\ Yes··r-yes ! Yes!I , assemblies and sub- assemblies I I I I 'I

I 2. I Measurement of stator 'res'(stance ~.·8~f.:U_'y'~,?_._!Ye.?_J Yes Yes' Yes'I' 3. i Temperature rise test of alternator, I 8.1.3 1 Yes !Yes i No No i Yes

I Electronic rectifier-cum-regulating i ! I I I, , I I II I equipment !!' I I

I~ Insulation resistance test of I 8.1.4 ! Yes. r, Yes I Yes Yes I Yes. i alternator ! . __ L----+. I

5. High voltage test I 8.1.5 Yes i Yes ! Yes Yes!,6. Open circuit test I 8.1.6 I Yes"T No ! No No I

I. 7. ,* Load test .. _...__-==.======--l-8·~1~7-tYes·1_i~~=-~Y~s Yes I

f-: II ;'~~i~~:~:,"~:;;::~::e;:~'GOf_l_:;+~:;f:: I ~: . ·t-ve~I induced voltage test . .. I . i .. . . I .. I I I IW Short circuit characteristic test----r·S·:1"-:1"cfT·Ye-s· ..r-No·i No II No I, No I~-~ Maximum voltage.Generati.on test 1"8-:f11=l':Y~~=1Yes I No i No I NNoO I,

12. ! Surge protection t~s.t..___ I 8.1.12 +_Y:~?~..x.~?~J}\I()_ ...+---.l'J.o __ .~ __ ~.

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I rotor and pulley j Iii I I I15. 'I Verification of controller overaIT-·-·-i·-·S:2T-r"Yesfyes--t-· Yes ! Yes I. Yes I1 i . , ,

! dimensions and visual check I -L.---L---J.-_. I I I, Temperature rise test oJ:!..~ontro"e...r:.__J- 8.2.?....-I-. Yes I Yes-l-_ Yes I Yes ~ Yes IL18li~~~~~:::=::r:~~I :~~ ~~h:J:::I ::: l:::I

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I 19. I "Load test on controller .~~ 8.2.5j Yes -t--Yes ! Yes Yes

I~~.I~~:~~~~~;~~~;n~~~~lfe~==i!ti-~~~=H!!! ~:!~:!~ Environmental test oncontroller~~1 8.2-:-10i-YesT Yes-I Yes Yes

I I i I I I I iI I I useT I I I II s. I Type of Test i-clause .Proto-rTYpef Routine I Acceptance i1 No. ;1 I ~~o I type I Test I Test I' Test ,Ii! test I I . .I 24. i Total DC isolation test (both I 8.2.13 i Yes I Yes IYes I Yes i

~Positive & negative) for SMPS __ +__-----L L_ I .L II 25. I Pe.rformance test on pre-cooling I 8.3.3 I Yes ! Yes I Yes I Yes Yes

i 26. I ~~~rtcircuities!on pre-coolingunit+-B:3.4-rves -I-Yes - r- Yes Yes! YesI . on pre-cooling unit i I I I i; 27. I Surge test on pre-cooling unit i 8.3.5~yes -t_yes I Yes Yes ~ Yes: 28. Dielectric test ~--_--_--t--43.6_t' _Ye~_ 1 __ Yes_' :ies_j~ Ye~_+---.."!es-------jL 29. I ~nsula_tionresi~~C!!1_~ . -+---~~3:L- Y~s_J Y~~_ r Y~~+--.--Y.~ ----t-- Yes!I 30. i Output current limit. I 8.3~_.L_Y~~L.ies .+-Yes I Yes I Yes 'I 31. i Ripple measurement .... h~}·9_L'l"~_+ Yes i No Ii No NoI 32. I Endurance test I 8.3.1Q..LYes --!-...1'J0 I No No No

33. I Power loss Determination_._ ..._._. +~:].JL_.~..~e.§-~.-y~~+_- Yes Yes Yes34. Dry heat & dam heat I 8.3.12 j Yes 1 No I No I No No35. I Salt mist test 8.3.~_'y'es_J--_~9 , No I No I No

RH!i;!~J!~~~~~~---rt!iti=~:~-I-~t·~!t~ti Hi! 39. 1 Load break test ==_=_r8.3.-17rY~iTY8-s-r Yes ! Yes I Yes

40. jlnput UN & ON transient 1 8.3.18 -t! Yes I Yes+ Yes i Yes I Yes41. Acoustic noise _ ~3.19 .l--i~J-Ye~ I Yes Yes I Yes42 'High frequency transformer. I 8.3.20_1.. Y~_l-.Y~~]:..Yes_l.. Yes ! Yes

Renewalof Type

TestYes

Tests marked with star ( " ) are to be conducted in both directions of Alternator rotation. The difference in voltage developed in clockwise and anticlockwise direction shall notbe more than 1 V during all conditions of load test

8.1.1.1 This test is to check the dimensions of assemblies and sub-assemblies as perspecifications and constructional details thereof to ensure that they are consistent withgood engineering practice. Interchangeability aspects of alternators with differentElectronic control unit in current use should be ensured.

Stator resistances shall be measured either by voltmeter ammeter method by suitableresistance measuring device when the alternator is at ambient temperature. Ambienttemperature at the time of carrying out the test shall also be recorded. The statorresistance at 20 degree centigrade shall be averaged for first 5 machines. Theresistance of any stator winding shall not vary by more than ±5% from the prototypevalue.

Pr~pared By

ELl7.1 .3812 I RDSO/PE/FRSI AC/0003-2012 .-~w.e.f December 2012 I ~______________ .. _ .. __ ._. ._ ......L...... ... _ .. _ ... •. __ ... ...._ .. _ ....

8.1.3.1 The alternator in conjunction with the control unit shall be run at rated current &voltage at 2500 rev.lmin. speed till the temperature stabilizes as evidenced by threeconsecutive readings of frame temperature at an interval of fifteen minutes betweeneach other, under forced air-cooling of 6m/sec. for alternator. The air velocity at thelocation where the alternator is to be located for tests shall be adjusted to 6m/sec.prior to mounting of control unit in position under test. The control unit shall be placedin position after obtaining the required ambient conditions Temperatureof the stator Windings, bearings, terminals and frame of alternator shall be measured.The temperature rise above the ambient of 55 degree centigrade shall not exceed thefollowing values under full load condition (130V, 230A) or one hour over load (267 A)conditions: -

The temperature rise of terminals, frames etc. shall be as low as possible. Themaximum bearing temperature at the highest ambient temperature of 55 degreecentigrade shall not exceed 80 degree centigrade. The temperature measurements onall locations shall be made by point contact pyrometers unless otherwise specified oragreed to.

8.1.3.2 The temperature rise test shall be repeated at minimum speed for full output, underwhich also the temperature rise shall not exceed the above values.

8.1.3.3 While accepting the first lot of the machine, after the approval of prototype,temperature rise test shall be carried out on 5 machines and the temperature rise shallbe averaged. This average, temperature rise shall serve as basis of acceptance orrejection of subsequent machines. The temperature rise of the windings ofsubsequent machines shall be regarded as satisfactory if it does not exceed by morethan 8% from the average temperature rise value or 10Ge, whichever is higher butwithin the limits specified in clause 8.1.3.1 for the class of insulation used. If after theproduction has stabilized and consistency in production and performance has beenachieved and with the approval of ROSO, the temperature rise test is not conductedon all the machines, the temperature rise shall not exceed by 8Ge above the avera~etemperature. Further if the temperature rise is observed to be less by more than 5 ein 3 lots continuously, re-averaging of temperature rise shall be done by conductingtemperature rise tests on five machines again and the revised values shall hold goodfor subsequent lots.

8.1.3.4 After conducting temperature rise test at rated current as stipulated above, machineshall be subjected to overload at 267 A for 1 hr. in continuation to heat run at normalload (at MFO and 175kmph). The temperature rise shall not exceed the specifiedvalue for 'H' class of insulations used on the machine.

8.1.4.1 The insulation resistance ( IR )shall be measured before and after high voltage testbetween all live terminals shorted together and body with a 500V De Megger andthese values shall not be less than 20 mega Ohm.

[ Prepared BY-~ --'-. I Checked-Sy---" ~", ~ . I~ . ..._... ... 'IO'~~_ig_rlj_..__.....__... ._._ ... _. pi~&Metro I

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8.1.5.1 Immediately after the temperature rise test, an AC potential of 1500 V rms at 50 Hzshall be applied between all external terminals of the alternator shorted together andthe frame for a period for 1 minute. The test shall be commenced at a voltage of lessthan one third the test voltages and shall be increased gradually to the full test voltage.During acceptance test, the test voltage of 1500V for a period of 5 seconds shall beapplied without conducting temperature rise test. The leakage current shall notexceed 30mA for the above tests.

8.1.6.1 The alternator shall be run at not less than five speeds viz. 500, 900, 1500, 1800,2500 rpm covering the entire speed range. The output voltage at the alternatorterminal corresponding to each setting of field excitation shall be recorded and curvesplotted. The selected speed during the test shall be kept substantially constant.

The alternator shall be run in conjunction with the control unit. The test shall beconducted with a resistive load and or with battery. Preferably, this test shall beconducted with resistive load and full coach set of battery consisting of 56 VRLA cellsof 650Ah capacity. All characteristic tests are to be done at a setting of 129V at 115.5A at 1500 rev. / min.

The test shall consist of the following: -a) No load testb) Speed vs. output voltage characteristic testc) Current versus voltage characteristics test.

In this test, the speed shall be varied covering the entire working range of speed andcorresponding DC voltage available at control unit output terminals shall be noted.The voltage variation shall not exceed 2% of the preset voltage. The cut-in-speed shallalso be noted in this test. The speed shall be adjusted at minimum speed for fulloutput - 1500, 1800 and 2500 rev./min. This 'no load' test may be conducted at 10Abase load.

It shall be done at full rated current and 50% of full rated current. The speed shall bevaried from minimum speed for full output to maximum speed. The voltage shall notvary more than ±2% of the pre-set voltage.

Current versus voltage characteristic test shall be carried out at 1800 rev./min Thecurrent shall be varied from 10 Amp to rated value of 232 Amps, keeping the speedconstant. The voltage variation shall be within ::1::2%of the pre-set value.

Page 16 of 35 II

, I-' -------,._-~~-

EU7.1.38/2 RDSO/PE/FRS/AC/0003-2012 iw.e. f l?~c~f!1Rei_~Q.12___L .__ .__ _ _ _ --.J

After the current versus voltage characteristic test, Current limiting test shall be carriedout. At the point when the load is increased and current does not increase, the valueof current shall be treated as the limit of current setting. Current limit shall not exceed275 Amps. Load shall be increased till the output voltage dropped to below 70V.

Note: The difference in voltage developed at dispatch setting shall not be more than1.5 V in both the direction of rotation during all conditions.

The test is to be conducted as soon as possible after the temperature rise test or loadtest, while the alternator is still hot. The alternator shall be run for a period of 2 mts. ineach direction with the stator winding open-circuited at the level corresponding to 185kmph. No part of the alternator shall show any sign of damage deterioration.

The output terminals of the alternator shall be short circuited with an ammeter in circuitbefore starting this test. The test shall be carried out at various speeds coveringcomplete speed range. The speeds selected for this test shall be the same asselected for open circuit test. Curves shall be plotted at different speeds for fieldcurrent versus short circuit current. This test shall be carried cut on a 'cold machine'.

8.1.11.1 Alternator shall be run at cut-in, MFO and 175kmph speed in both the direction.Voltage measurement at alternator terminals shall be done with moving iron voltmeter,digital multi-meter and oscilloscope at No-load, base load, half load, full load and 20%overload. Measured voltage shall not exceed 500V Waveforms shall be taken for allthe measurements.

8.1.12.1 This test is to be conducted on alternator in conjunction with control unit. A speed 01800 rev/min. shall be adjusted with full load which shall be thrown off and the outputterminal voltage rise shall be noted. The terminal voltage may rise to any value butshall not damage the alternator. Again, only 10A resistive load shall be kept in circuitand balance load shail be suddenly thrown off and output terminal voltage of thealternator shall not rise beyond 400V and shall drop to normal value in less than 5 sec.

8.1.13.1 The enclosure of control unit shall be protected against ingress of solid foreign bodiesand water in accordance with 18:4691-85. After these tests the equipment shall worksatisfactorily. This shall be conducted in accordance with.IP-65.

8.1.14.1 Alternator pulley shall be checked for mating on shaft. The area in contact shall not beless than 80%. The test shall be conducted using plug and ring gauges and Persianblue as Media.

Page 17 of 35 EU7.1.38/2 I RDSO/PEIFRS/AC/0003-2012 I______ ...__ ~~~.!J::>ecemb_er__20._1_2__ .J._ .. . ~ . .-----------l

The dynamic balancing of rotor and pulley shall be checked individually on a balancingmachine. The residual unbalance shall not exceed 2.5 gm-cm/kg. in an case.

8.1.16 Measurement of MFO speed at cold and hot condition of alternator. The minimumspeed of full output of the alternator both in cold and hot condition shall not be morethan 800 rev./min.

The alternator shall be run at a speed of 600 rev.lmin. The current at 130 V outputsetting shall be measured. It shall not be less than 50% of rated current. The speed atwhich 50% rated current is available shall be measured.

8.1.18.1 The terminal board of brushless alternator shall be tested for resistance to spread offlame in the manner given below:

A piece of terminal board of brush less alternator material measuring about 150x25mm shall be subjected to the luminous bat swing flame, preferably supplied by aBunsen burner. The specimen shall be held with the flat side up at an angle of 45degree to the horizontal. The flame shall be 25 mm in width across the tips.

The flame shall be applied to the specimen at the lower end for 30 seconds andremoved for similar period and then applied again to the same end for a second periodof 30 seconds and thenagain removed. This test shall be carried out with the decorative surface facingupward and also the decorative surface facing downwards. Should the specimen getignited, it shall not continue to burn for more than 50 second after the flame has beenfinally removed.

8.2 TEST ON CONTROLLER:8.3

This is to check the dimensions of assemblies and sub-assemblies i.e. overalldimensions of controller box, terminal arrangement and layout of aux.Equipment as per specifications and constructional details thereof to ensurethat they are consistent with good engineering practice. Inter-changeabilityaspects shall also be ensured "Sound engineering practices should be followedin the manufacturing of controller. Care should be taken for avoiding sharpbend to cables, ensure good welding quality with smooth finish, Use ofstandard hardware, avoiding sharp edges, proper bunching, routing andsupport to the cables."

Prepared By

Page 18 of 35 EU7.1.38/2 I RDSO/PE/FRS/AC/0003-2012_. I,V~~Dec~!!1E~L~~.J_ . . . _..__._. .. --.------J

8.2.2.1 The temperature rise test shall be conducted with the same capacity alternator andcontroller, with forced air cooling of 6m/sec. for alternator and 4m/sec. for controller.

The temperature rise test shall be conducted on controller in conjunction withalternator of same capacity at MFO and at 160kmph speed at rated capacity until thebody temperature of alternator gets stabilized as evident from three consecutivereadings of frame temperature at half an hour interval. The air velocity at locationwhere the alternator and controlier are to be iocated for tests shall be adjusted asmentioned in above para prior to mounting of equipment in position. For 30 kw, aftereach temperature rise test at MFa and 160kmph speed, one hour over load test shallbe conducted at 267 Amps.

8.2.2.2 While conducting acceptance test, in case of 30 kw controller, only at 160kmph atrated output and one hour overload test at 267 Amps shall be conducted whereastemperature rise test at rated condition.

i Capacity Maximum Minimum---r Ratedvo-Itage--r--Rated currentkw speed rpm speed rpm -L--- Volts. . Amps.

~_3_0_kw_~ __ 3_2_5._0_~__ M_FO__ ~I 1~Q... ~_. 230

One hourall Amps.267 Amps

8..2.2.3 Temperature of Controller components shall be recorded for every one hour up tofour hours and thereafter for every half an hour, readings shall be recorded. Threeconsecutive half an hour readings indicate stabilisation of the body temperature ofalternator.

i) Diode/IGBT base temperatureii) Transformer I ChokeHi) Hall effect sensorsiv) HRC fusev) Bleeder Resistancevi) Heat sink of controllervii) Bus barviii) Fusesix) Ambient inside the controller

8.2.2.5 In regard to control unit equipment, the temperature rise of IGBT/Power diodes, Hallsensors, HRC fuses, bleeder resisters, current transformer, bus bars etc, , shall beless than designed temperature limits of each component under worst operatingconditions. The temp. Rise of electronic devices i.e. IGBT, auxiliary diodes, auxiliarypower supply module etc. shall not increase more than 30 deg. C above the ambientof 55 degree C. The ambient temperature rise inside the box shall also be recordedand it shall not exceeding 30°C.

8.2.2.6 The temperature rise of IGBT/Power diodes, ISO-Packs, Hall Sensors, ExcitationTransformer (if used),bus-bars etc. Shali not be more than 50 deg. C above theambient of 55 deg.C. There shall be consistency in the quality during lot productionof the equipment whereby achieving consistency in various test parameters such asregulation, temp. Rise etc.

( Pr~p~r~d8yi

Page 19 of 35 ii

EL/7.1.38/2 RDSO/PE/FRS/AC/0003-2012 iw.e1-}2.e_c_em_b~~912_._-L_. .__ ..._~. __ ._._._~. ._. __ ..---J

The insulation resistance shall be measured before and after high voltage testbetween all live terminals shorted together and body with a 500 V DC Megger andthese values shall not be less than 20 meg ohm for control unit.

Immediately after completion of heat run/performance tests, an AC potential of 1500V rms at 50 Hz shall be applied between all live terminals shorted together andhousing of the equipment The test shall be commenced at a voltage of less thanone third of the test voltage and shall be increased gradually to the full test voltage.The test voltage of 1500 V for a period of 60 seconds shall be applied afterconducting temperature rise test The leakage current shall not exceed 10 mA forthe above tests.

8.2.5.1 The alternator shall be run in conjunction with the control unit of same capacity. Thetest shall be conducted with a resistive load and with battery. Preferably, this test shallbe conducted with resistive load and a battery bank of adequate capacity.

8.2.5.2 All performance tests shall be conducted at the set voltage of 129 V at half load of 116A. The voltage setting of the control unit shall be done at 1500 rpm after the heat runtest. The alternator frame temperature shall be 40 deg. C above the ambient.

8.2.53 The test shall consist of the following:

a) No load test

b) Speed versus output voltage characteristic test

In this test, the speed shall be varied covering the entire working range of speed andcorresponding DC voltage available at equipment output terminals shall be noted. Thevoltage variation shall not exceed i:2% of pre-set voltage for the speed range from theMFO speed to 160kmph. The cut-in-speed shall also be noted in this test. The speedshall be adjusted at 800, 1000, 1200, 1500, 2000, 2500 rev/min and 160kmph. Thistest shall be conducted at 10A for 30 kw Alternator as base load.

8.2.5.4.1 No load test at 0 A shall be conducted for the above conditions and the no loadvoltage shall not exceed 135 V.

8.2.5.4.2 Speed versus DC output voltage graph shall be plotted for 'Base Load' and zero Ampi.e. No load.

IiPrepared By~

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Page 20 of 35 EL/7.1.38/2 ; RDSO/PE/FRSI AC/0003-2012 i__ ~ w_.~~Decernb~.r:~012_~. .______________ . -----.--J

It shaH be done at overload, full rated current, 75%, 50% and 25% of full rated current.The speed shall be varied from MFO to maximum speed as per speeds mentionedCI.8.15.4. The voltage shall not vary more than ±.2% of pre-set voltage for the rangefrom the MFO speed to 160kmph at these loads.

Current versus voltage characteristic test shall be done at 110kmph rev/min. Thecurrent shall be varied from OA to rated value of 232 A for 30 kw keeping the speedconstant. The voltage variation shall be within 2=.2%of the pre-set value. The current -Vs-voltage shall be plotted for the load variation.

8.2.5.7 CURRENT LIMITING CHARACTERISTIC TEST OF ALTERNATOR AND CONTROLUNIT:

8.2.5.7.1 After the current voltage characteristics test, current limiting test shall be done. At thepoint when the load is increased and current does not increase, the value of currentshall be treated as the limit of current setting. The DC out put voltage shall not be lessthan 120 V at 267 A load. The current limiting shall not exceed 275A ratings.

The current-vs-voltage shall be plotted for the load variation including overloading ofthe controller.

Note: The difference in voltage developed in clockwise and anticlockwise directionshall not be more than 1 V during all conditions of load test and current vs voltagecharacteristic test.

i) Total battery charging current (BCG) in AC coach shall be limited to 130±.5 ampscorresponding 20% of the C10 capacity of charging current i.e. 650 x 0.2 = 130Amps maximum, when two controllers are in parallel.

ii) BC +ve terminal shall be loaded with resistive load to check the battery chargingcurrent limits.

iii) The total load connected across the DC output and BC +ve terminal of thecontroller shall not exceed the overload rating of the alternator at any given timeenroute.

iv) The BC terminal voltage shall be recorded for the load variation from OA to thebattery charging limits keeping the DC +ve terminal without any load. Thebattery charging current versus DC output voltage shall be plotted.

v) Total DC output current versus DC output voltage shall also be plotted

Page 21 of 35 EL/7.1.38/2 "--i-- RDSO/PEIFRS/AC/0003-2012 iI I

__________ w_.e .~ ..[)_~~~r:!'b_~?..9J? L_. ._ ._.._ _.. _.. . ---.------J

8.2.6 Ripple content test:The ripple content in dc output shall not exceed 3 % and ripple content shall becomputed from oscilloscope measurements as under

Format A (1 minute)Time Controller-1 c6ntrolfer-2-~! C-harging I Dischargin

, I Current . 9 Current1 I ._-"--,- j ! j

Output I Output i Output i Output I! Vo'tag~:d_-g~~~rentI Voltage I Current Ii-----~-~---~ i -----r---------'--T-~--·---_·-~-:----------

I ! ! _~ ~ ~

8.2.78.2.7.1

V max- V minRipple content = --------------------- x 100

Where V maxVmin.

V max + V min= Maximum voltage= Minimum voltage

INDICATION BOARD TEST:The indication board working shall be checked for the following:

i) Capacity of alternatorii) Healthiness of controlleriii) Over voltage Protectioniv) Fuse failurev) Overload faultvi) Downloading of the recorded data as per format given in Clause 8.2.7.8*

* If stoppage is for more than one hour - non-generation time shall not be countedand generation and non-generation time in hours shall be recorded in three digit.

During battery charging/discharging test, check shall be conducted to verify theAmp. Hours of discharge/charge indicated on the indication board. A dischargedbattery of a battery set, preferably of 650 Ah capacity shall be charged/dischargedfor five hours. The indicated reading shall not vary ±3% over the calculated reading.

The attachment and detachment of the indication board should be checked for easeof maintenance and proper contacts. If the indication board is removed, theperformance shall not be affected.

Data shall be downloaded by USB Pen Drive of reputed make. Down loading datashould be directly openable in MS Office applications like ExcellWord. It should bepossible to down load data of at least 24 coaches in one go i.e. without the need tocopy the data on laptop.

Memory shall have sufficient capacity to contain minimum 7 days data with aresolution of one minute apart from cumulative data of last 7 days and fault data.

Transferring of the Journey data: Normally, the data stored in the portable USB pendrive unit shall be transferred directly to the PC or laptop having USB port.

Reporting Format: Recording interval shaH be one minute and minimum duration ofrecording shall be seven days. The formats of reporting shall be as follows:

AlternatorRPM

Pr~par~d By

Page 22 of 35 EU7.1.38f2 ------ RDSO/PEfFRS/AC/0003-2012 I.. . ._.__ ~ __ .._w .~:!J2.ec~f!lbe!_?Q_)? l ....__._. .__._____ J

Cumulative GenerationCharging Ah Discharging Ah time

NonGeneration

time

___ D_a_te T_,i_m_e I .__ Type of F_a_u_l.t_s -+-R_e_m_a_r_ks----<i

~----~---"-_ ..__._-_._! -~--------_. __..._----~-"...,.~-""-"-----------------~----~

I No supply from alternator or altematortajTure----=_-=-._-_· ---'L9ver voltage generation ..._. . . ----<

l controller Failure . .. I~g~:e~::~r~~~t-. =---------........ ..__.. _ _._ _1~rt-ci-rcu-it -.--._=- __-:.-==~===_ =- --. . .•••~~~= .. .__ JI Battery voltage low .. .._ .__.__ ___... ._. I

The design of the controller shall be provided with a provision of data logger to logboth alternators DC output currents, DC voltage/battery voltage, batterycharging/discharging current with respect to real time. USB interface shall beavailable enabling to down load in any commercial pen drive and analyse recordeddata directly in MS Office application. The controller shall also be provided with aLCD/alpha-numeric display to indicate its various parameters as given below:

'----' . --._-_ .._-_ ..._-- ..__ .._--- ._---- ..._.-.__ ...-._----------------

I Parameter --L Recording frequency CumulativeI Total distance traveled by the particular ! 1 hour YesI coachi Alternator rpm , 1 minute NoI ----------------+--- I I

LI::;~~;~~;~~~~e_~:~~t~~~~~:~·--=_~__J-----~~~~~-e----l-------~-JI Output voltage Controller -1 ! 1 minute I No iI Output current Cont~~lIer~J_. ===_~=-----=t-- ..- }IllJ':1_ute_ j No II Output voltage Controller -2 i 1 minute No"! Output current Controller -2 i 1 minute No

I i !

rsatfery charging current------ ....--t---1mmute No I

I Battery discharging current·----t----- 1 minute No!ICharglngAh--- .-------- ·-----T-..-1hou-r-- -·----Y-e ..s1roISChargmgAh-----_= ===-~-=-=-___L - '1'h-our Yes

EL/7.1.38/2 RDSO/PEIFRS/AC/0003-2012 Iw.e.f DeCerTlbe_r2012~ ~ ~_._. ~_. ._~ __ ~.__. ._ ...J

Please note the following points:i) Cumulative data summary must be available at the end of journey.ii) Output voltage will display battery voltage when train is not running.iii) At the end of journey if waiting period is more than one hour, then that period

shall not be counted as non generation timeIV) If external charging is done, then, it should not be counted towards cumulative

charging ampere hour.v)It shall be possible to download the data using any commercial USB pen drive fromController to PC. in case memory becomes full, earlier data should be automaticallydeleted and data for last seven days should be retained.

It should be possible to downloaded data of at least 24 coach trains without need oflaptop. Downloading data should open directly in MS-Office.

All the above parameters shall be displayed by manual selection arrangement on thedisplay unit.

8.2.8 Hose Proof Test:a) The enclosure of controller shall be protected against ingress of solid

foreign bodies and water in accordance with IS: 4691-1985 After thesetests the equipment shall work satisfactorily. This shall be conducted inaccordance with IP-65 as per lEG 60529 with latest amendment andworked satisfactorily.

b) Alternator shall be protected against the ingress of solid foreign bodies andwater in accordance with IS: 4691-1985. This shall be conducted inaccordance with IP-55 as per lEG 60529 with the latest amendment.

8.2.9.1 Ripple content test: The voltage and current ripple content in dc output shall notexceed 2% and 10% respectively in the battery charging load and DC output at 800,1800,2500 rpm and 175kmph for 25% ioad, half load and full load. Ripple contentshall be computed from digital storage oscilloscope having interface with theprinter/PC. It shall be calculated as under:

(V max - V min)Ripple content = ------------------------ X 100

(V max + V min)

Where V max = Maximum voltageV min = Minimum voltage

To arrest the ripple, suitable filter circuit may be incorporated in regulator withelectronic component of the highest reliability.

SHORTING OF POWER DEVICES: The Alternator with control unit shall be run at1800 rpm at full load with pre-setting the full load. Stop the alternator, anyoneIGBT/Power diode shall be shorted and the alternator 'v'Jithrectifier regulator shall berun at 1800 rev.lmin. The pre-set full load shall be connected across DC outputterminals for 2 minutes. After the test, no component of alternator or rectifierregulator shall get damaged. DC output voltage & current shail be recorded .

.._" .. _"~. _ ..~""" .._--"--\ Prepared By ~~. I Checked ByL__ ~_~_.__ ..__ ..________~_.__:.._~'"_~s~g!1L__""..'.."""'...'."'.""""'.

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OPENING OF POWER DEVICES: The alternator with control unit shall be run at1800 rpm and pre set the full load in three steps. Stop the alternator, then anyonepower diode of any of the IGBT/Power diode modules shall be opened andalternator with rectifier regulator shall be run at 1800 rev./min at no load for 2minutes and then the full load resistance shall be applied gradually in three stepsand run for 2 minutes. After the test, no component of alternator or rectifier regulatorshall get damaged.

COMPUTATION OF JUNCTION TEMPERATURE OF SEMI-CONDUCTORS USEDIN CONTROL UNIT:

The junction temperature of power diode/ISO-Packs and auxiliary diodes shall becomputed. The temperature of the junction shall not exceed 110 degree centigradeas specified in Specification No. ELRS/SPEC/SII0015-0ct 2001. The loading of thevarious electronic components and other tests shall be as per this specification.

EFFICIENCY TEST: The efficiency test shall be conducted at the 800, 1800, 2500rpm and 175kmphat rated load, half load and quarter load for output terminals ofcontrol unit Load versus efficiency curve shall be plotted for different speeds asmentioned above. The efficiency of Alternator and controller taken together at 110Kmph at full load shall not be less than 90%.

Efficiency test shall be done by measurement of input and output powers at thecontrol unit input and output terminals.

OVER CURRENT (SHORT CIRCUIT) PROTECTION: Short the DC+, DC- and BCCterminals at the control Unit output. Run the alternator at 11Okmph for two minutesand then increase the speed to 175kmph and run for two minutes. During the test,AC fuses or field fuses may blow. No damage to alternator, controller or UVC shouldoccur.

FIRE RETARDANT TEST FOR TERMINAL INSULATORS: The terminal insulatorsof control unit shall be tested for resistance to spread of flame in the manner givenbelow:

A terminal post insulator shall be subjected to the luminous bat swing flame,preferably supplied by a Bunsen burner. The specimen shall be held at an angle of45 degree to the horizontal. The flame shall be 25 mm in width across the tips. Theflame shall be applied to the specimen at the lower end for 30 seconds and removedfor similar period and then applied again to the same end for a second period of 30seconds and then again removed. Should the specimen get ignited, it shall notcontinue to burn for more than 50 seconds after the flame has been finally removed.

ENVIRONMENT TESTS: The test shall be conducted on control unit equipment onlyas per IEC-60571-SECTION FIVE-TESTS", this shall include the following te5t5:-

a. Temperature rise test (dry heat)

b. Temperature rise test (damp heat)

c. Vibration, shock and bump test.

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8.2.10.1 Dry heat and damp heat test: - The dry heat and damp heat test shall be conductedon all PCBs as per latest IEC-60571.

8.2.10.2 The control unit shall be subjected to vibration and shock testing as per IEC61373 -1999_

a) Random vibration test as per clause 8 Table-1 , category 1 Class B

b) Simulated long life test as per clause 9, Table-2 , category 1 Class B

c) Shock test as per clause 10, Table-3, category 1 Class B

To ensure the reliability of the components, all the controller cards fitted withcomponents used in the inverter are subjected to 45 HiS. burn-in tests as per ROSOspecification no. ELRS/SPEC/SI/0015 for reiiabiiity of electronics used in rolling stockapplication. Bum-in tests shall be repeated on every 100th cards and records of thetests shall be maintained for all the cards and shall be produced before therepresentative of the inspecting agency at the time of testing. Also this test may beconducted randomly by the ROSa on the selected cards from the running lot

EMIIEMC test shall be conducted as per relevant clauses as mentioned in the IEC61000 for the following:-

i. RFI RADIATED TEST: as per IEC 61000 - 4 - 3II. RFI CONDUCTED TEST: as per IEC 61000 - 4 - 6iii. ELECTRICAL FAST TRANSIENTS TEST: as per IEC 61000 - 4 - 4iv. POWER FREQUENCY MAGNETIC FIELD: as per IEC 61000 - 4 - 8

No degradation of the system & malfunctioning shall be allowed during or after thetest.

This test shall be performed by a 500Volts Megger instrument, connectingbetween DC negative and positive shorted together at one end and UVC,SMPS ground shorted together with all terminals of SMPS together. Theminimum permissible insulation resistance shall be more than 20 Mega Ohms.

Page 26 of35 EL/7.1.38/2 T~_~ ~ __ w_.e_.f~~eceml>er~Q.1~ __" L ~_" .. . .~ _

8.3.1 The unit shall include the following minimum protective features in the precoolingmode:

• AC MCCB at input side.• Input /output fuses with fuse blown indication.• Supply over voltage set at 480±1 V with audio visual alarm,• Supply under voltage set at 350±1 V with audio visual alarm.• Output short circuit protection shall preferably be with firing pulse block.• DC output over voltage set at 2.35 V per cell incase of VRLA batteries and for pre

cooling mode the voltage may be set at 130V preferably by blocking the firingpulses.

• Over load protection and single phase protection.• Thermal over load of semi conductors and transformers.• Capacity to withstand input of 510V AC for two minutes without any damage to any

part of the unit.• Complete electrical isolation between input and output

8.3,2 The unit shall have the provision of the following indications. Three indications i.e.'Input AC ON', 'Pre-cooling Unit ON' & Mode of charging shall be provided on 'OnBoard' display unit through LEOs. Fault shall be displayed with audio signal, ifoccurred.

I Failure Indication Other Indication-------.--.-----.----t--! Rectifier Block Fault ! Input AC on 3 Phase.---.--'.-" -- ..~-- ..'i - - --.- ..-- --- ..i Firing pulse Block __ . . . l£~E3~ool!£19...U__n__it_"O_N_" _I Fuse failure (for input fuses [ Pre cooling Mode "ON".! Earth Fault ~--"----I~Batte,:y charging moder-::--::::--- '~"'--------"---- -.,.... ~---_.-._-.- .. ----._- .. ------.-I AC Input over voltage ... . ..+__VR~A l..hea_d_A_c_i_d_b_a_tt_e~ry _I AC input under voltage . 1.Constant Current charging "ON"~ .__ ._. __ ~[...Qonstant'yoltage charging "ON"

Connect the unit to the AC input and record the following parameters at low, nominaland high input voltages of 350 V, 415V and 480 V respectively for 10%, 50% and100% loads. Record input Watts, input pf, DC output Volts, DC amps, r.m.s & peak-to-peak ripple for voltage and current, % regulation, frequency, firing signals andefficiency in constant voltage, constant current and pre-cooling mode. The valueshould conform to Clause 7.3 of this specification.

Set the unit to constant voltage working mode by logging through external keyboard and set voltage to 2.3V icell and record parameters as mentioned above forline and load variations at 350V, 415 V and 480V and at 10% load, 50% load. fullload. .

rrcpur~dBy ~\=-. Checked By-·-------

~esign

---------------_._-~---,.~--_._'~-_ .._------------Page 27 of 35 EU7.1.38/2 I RDSO/PE/FRS/AC/0003-2012

____________ w.__ ._e_.fDecember __2012__ j ..._.._.__. .__

Set the unit to constant current mode by means of logging through external keyboard and set the output voltage to 2.35V 2.75V ICell and load the unit to fullcapacity. By adjusting the current to set value by logging through external keyboard, without disturbing the load, reduce the output current to 80%, 50% and35% of the rated capacity and record the change in output

current setting for the input voltage of 350V, 415V and 480 V AC and record theparameters as mentioned above. The variation in set current shall not exceed by ±1.5 % of the set value. Manufacturers shall endeavor to achieve regulation within±2%.

Set the unit at pre-cooling mode by using the controls and measure theparameters for 10%,50% and 100% load for input voltages of 350,415 and 480 VAC.

Type test: Short the output terminals and switch ON the unit at low, nominal and highinput AC voltage and measure the short circuit currents. On removal of short, thecharger shall start automatically.

Type test: This test shall be conducted as per IEC-60571 (clause 22) and record thewaveforms through storage oscilloscope.

Routine test: Connect the unit to 375 V AC input supply and a fully dischargedbattery. Immediately, on switching 'ON' of the AC supply, switch 'OFF' and ON thebattery for 10 times with interval of 5 seconds between ON and OFF. After the test,check the components for their healthiness.

When the unit is cold, dielectric test shall be carried out after disconnecting capacitorsand shorting power semiconductor devices, primaries of trigger equipment, pulsetransformers earthed and disconnecting special card, if necessary, before applyingdielectric voltage corresponding to the voltage given below: -

i) 415V AC circuitsl 2000V r.m.5, sine wave, 50 Hz for 1 minute.ii) 110V DC circuits, 1500V rms, sine wave, 50 Hz for 1 minute.iii) Below 110V DC circuits 1000V rms, sine wave, 50 Hz. for 1 minute.

Test is considered satisfactory if there is no flash over or tripping of dielectric testequipment set at 50 mA leakage current is experienced.

\

DirekMetro I

EL/7.1.38/2 I RDSO/PEIFRS/AC/0003-2012w.e.f December 2011_J_.___________ . ~-------~--_._---.---

This shall be done with the help of 1000 V megger prior to the starting of all the testsand after heat run. Insulation resistance shall not be less than 10 M-Ohms for allcircuits

Load the unit at nominal AC input Voltage to its 100% capacity in charging mode andnote down DC Voltage and load the unit beyond 100% and record the droop in outputvoltage.

Routine Test: Measure the ripple of the output by using a true RMS multi-meter. Itshall not be more than 2% r.m.s of set value for voltage and 3% rms of set value forcurrent.

Type test: The waveform shall be recorded through storage Oscilloscope (havingsuitable interface with PC or printer for recording the waveform) across precision shuntfor 10%, 50%, 100% resistive load at max, min, nominal input voltage. Record r.m.sand peak to peak ripple .

• The unit shall be sUbjected to test as per IEC60947-1• The firm shall do rigorous test of the battery charger for minimum 52 Hrs.

continuously at full load i.e. 267 Amps battery/simulated load.

The losses at "No load", "Light load", "Full load" and 'half load' losses shall berecorded for both complete unit and transformer separately. The efficiency shall becalculated and it shall not be less than 85% at half load and more than 91% at full loadfor the complete system. The tolerances on losses shall not exceed +10% ofguaranteed value.

The dry heat and damp heat test shall be conducted as per clause 24 and 25 ofIEC60571 on the electronic module.

8.3.13 Salt Mist:

The efficiency shall be measured soon after temperature rise test. The efficiency of theunit shall be measured with wattmeter at full and half load at input supply of 415 V, 50Hz with a resistive load. The efficiency requirement should conform to Clause 4.3. Theoutput voltage should also be recorded.

Page 29 of 35 EL/7.1.38/2 I RDSO/PEIFRS/AC/0003-2012 i~~~ .w.eJ ~~cem~~s~g12_.J_.~. __...__._.~. .._._~_. .__ ~._ ..--J

This test shall be conducted in accordance to clause IS: 2020 at full load with 350 VAC input supply. The pre cooling unit shall be deemed to have reached thermalstability when three consecutive readings of temperature are more or less same. Theunit shall be set on pre-cooling mode during this test.

The object of this test is to verify that the firing pulses comply with the design and themanufacturers shall furnish the details. The blocking of firing pulses as mentioned inclause 8.16.1 shall also to be checked.

A contactor shall be connected in series with the load. After the rated current has beenflowing in load for 1 min. the load shall be broken through the contactor. The test shallbe repeated three times. No damage shali occur to any part of unit.

The input voltage shall be reduced below 350V and check that unit switches "OFF"prior to 345 volts and automatically switches "ON" after the input voltage exceed 352volts.

The input voltage shall be increased beyond 480 V AC and check that unit switches"OFF" at 482 Volts and automatically switches "ON" when the voltage reduces to 475V. The input voltage is raised to 510V AC and maintained for two minutes. There shallbe no damage of any nature to any of the components of the unit. The unit shallautomatically switch "ON' after the voltage is decreased below the set value.

The design shall incorporate necessary feature of suitable time delay/ hysteresis of 5Vto avoid hunting for both under voltage and over voltage tripping. Transient voltagetest shall be conducted as per clause 22 of IEC-60571.

The sound pressure level shall be measured in order to ensure that it is not exceedingthe limit value of 65 dB (A) at a distance of 1 meter away from the equipment in all thedirections. Tests shall be performed at no load, 50% load and full load; however, themanufacturer shall endeavor to reduce the noise level below 60 dB (A).

All the tests as mentioned in the relevant standards shall be carried out on the highfrequency transformers used in the system Certificate to be produced for the above tothe inspecting authority ROSa/Purchaser reserves the rights to witness / repeat thetests. However, Temperature-rise test shall be conducted by resistance methodseparately.

p_a_9_e__3__o_0_f_3_5_~ __ w_._e ..f ~~~~~~~?-012 __J .___,~~~~P~F __R__S_/_A_C,/_O__O_O_3-_2_0_1_2_. __ ~

Firm should submit maintenance manual specifying the minimum maintenancerequired by the unit. Firm should bring design improvements to reduce themaintenance requirement further Bearings of alternator should require greasing after36 months of service. Maintenance Manual shall be approved by ROSa before givento purchaser by the firm.

i0.1 The alternators shall be provided with suitable name plates, on which the followingshall be marked / engraved.

a) Maker's name and trade mark;b) Rated capacity of the alternator;c) Voltage and current ratingd) Class of insulation.e) Weight of alternator

Space should also be provided on the name plate for the purchaser to mark theRailway Administration's Code initials and serial No.

First two digits Year of manufactureNext two digits Month of manufactureNext two / three digits No. of machine manufactured in the particular monthe.g. Serial No. 120701512 - 201207 - July015 - Serial No. of machine manufactured in July Serial number of the alternatorshall be punched at suspension bracket.

I ~;~":~:ication i Q~feaCh typeof alternatorcoveredin a purchaseorder I

! \ Qty. upto 49-1 Fro'in 50t~-1~9-r~om~,50 to 299 I ;g~v~nd II ~~~~typedlAs_sP~ifie'l~R[)~- -- ~--3- ---T ~I Ii Routine : All ----1 . .-1'-1L ~ AI~_ I IL6~ceptalJ~§__~ 1.. ,~ __ A_II 1__ __AIL_ _, ~,___.hll_~ L 6IL_.J

Note: Acceptance test will be carried out on 10% of the lot quantity offered bymanufacturer for Part.-II Regular Supplier.

Page 31 of 35 I EL/7.1.38/2 T RDSO/PE/FRS/AC/0003-2012 Iw.e.f December201~_~ .. ._. __ ._. _._ .. i

I Classification ! STAGE !i ~.-._------_._._-----_._--~_._--,----_ ...._-_.,--_._--.-._._--~-._.- -.--.-I---.-···-.-~

I of test i I I II i III I>---.-_ ..i__ . . •. _ _ ....•....,,_,.._,",..,_ ".,,,,,,,_ ,,,,,,,", ...1.- .•••.... __••• ,,,"",.- .• __.• ".,,,, ...••.. ,-,, ..- •....•..• ,,_.,, •••.••••...... __ .-., --" •.• -_ ••....... --.- ••. ".--.----- ••. ,---.----'--- •• •· .• __ 1I Proto- I The machines shall not be cleared for regular manufacturing til! it II type I passes all the tests. Quantity as specified by ROSa i! Type I Qty. as per I Twice the no. of alternators ! If any alternatorI I CI. 13.1 ! which failed in any of the i fails in the III ,i I th ., j : tests at stage - I I' stage e entire

i I i lot shail beIi. I ._. ._ I rejected.I Acceptance I Qty. as per I If any machine fails in any I The failedi CI. 13.1 i of the test in the j machines shall! i Test as per sub II - stage, test shall be I be re-offered for

i clause 1,2,5,6,9 ! carried out on 100% I inspection in theI & 10 of Clause i machine for part I & I! i subsequent lotI 12.1.4 I suppliers. I after rectification.I Qty. as per i Twice the no. of alternators ! If any alternatorI Cl. 13.1 I which failed in any of the I fails in the IIi Test as per sub i tests at stage I I stage the entireI clause 3,4,7 & 8 I 1 lot shall be

~ ~I_o_f._C_I_a_u.s_e__1_2:.:L.'LL. ._. . . I rejected.

12.1 The manufacturer shall submit details like make, type, reliability, grade, rating andloading of various Electronic components used in the circuit along 'vVith reliabilityprediction, calculations based on actual loading of various components.

122 The manufacturer must submit the following information before manufacturing ofprototype unit in printed form and neatly compiled in a booklet form as well as in softcopy.

(a) Clause by Clause compliance to specification.(b) Detailed specification of the offered Alternator and controller.(c) Details of protections provided and their effectiveness/proposed set values and

range and working principle.(d) Circuit diagrams along with bill of materia! and circuit description and ""Jarking

principle.(e) Safety margins in voltage, current.(f) Declared output voltage wave-form, power factor and regulation.(g) Drawings and details of dimensions, mounting arrangement and weight.(h) Detailed description/explanation of circuit adopted and its salient advantages.(i) Duty cycle considered for alternator/controller design for continuous and short

time ratings.U) Service experience for the similar units based on the design offered(I) Temperature rise of the various components under the most adverse conditions

shall also be declared.

I

._.!?j~...2!lPE&Metro I

i Page 32 of 35 EL/7.1.38/2 1--- RDSO/PE/FRS/AC/0003-2012 Il w_·~.LQecemb~_20g~_L~ ~ .__._. ~.~_.._~.__._J

After completion of prototype test manufacturer shali submit foliowing documents inbound booklet in two copies as well as in soft form. One copy duly approved shall bereturned to manufacturer. This booklet should be made available to the inspectingagency. Booklet should contain:

1) ISO certificate2) Design details3) Circuit diagrams and detailed drawings of alternator.4) Bill of material.5) Quality assurance plan.6) Prototype test results and field trial reports.

i) Diagram of electrical connections together with assembly drawing showing fullparticulars of stator and field windings, dimensions, shape, size and number ofturns; sections; weight and length per coil.

ii) Detailed schematic and circuit diagram along with working principle for controllerii) Dimensioned part drawings with full details of tolerances of dimensions, finish,

material specification.iii) Draft maintenance manual and spare parts.ivy Shaft stress calculationv) Bearing life and lubrication interval calculation

13.2 The drawings mentioned in this standard are issued by Research; Designs & StandardsOrganisation, Lucknow - 226 011. Manufacturer has to comply schedule oftechnical requirements No. RDSO/PE/STRJTU0004-2004 (Rev.1) or latest,RDSO/PE/STRlTU0017-2007 (Rev.O) and RDSO/PE/STRJAC/0013-2004 (Rev.O)or latest. The manufacturers are requested to refer to the latest version of thedrawings only. Manufacturers are advised to submit their manufacturing drawing /detailed drawing before starting manufacture of prototype and after approval fromRDSa. the manufacture shall be undertaken.

At the time of tendering the purchaser shali define the scope of supply withreference to Clause 1.3.

15.1 Guarantee I warranty shall be applicable for a period as mentioned in IRS conditionof contract or tender conditions as given be purchaser.

15.2 The supplier shall make arrangements for careful study of all units failure reported inservice. Periodic reports containing analysis of the failures and remedial measuresproposed shall be furnished by the manufacturer to ROSa, ICF and user railways.Such failures will also be periodically reviewed at MSG (TL & AC) Meeting organizedby RDSa periodically. Manufacturer should prepare preventive and corrective actionplan by visiting Railway workshops based on failure data.

EU7.1.38'1-2---'T RDSO/PE/FRS/AC/0003-2012 Iw.e.f December 2012 ! .________ ~ __ . ,_.__ . . ...__ ~ __ ... .L............ __ .~ __ ,__ .... .....__ .. .._._._. __ ._. .. ,__ ._.._"~_,,_J

16.1 The manufacturer shall submit their internal quality assurance process beingfollowed by them. Certificates of the OAP will also be given with each lot ofalternator to Inspecting Authority.

16.2 The material purchased form outside agencies shall conform to the relevantStandard Specification as specified in ROSa / IS Specification. The certificateconforming to ROSa liS Specification should also be made available for each lot ofmachines. It is also preferred that in-house test facilities for purchased items shouldbe developed by the firm so that testing of these materials can be done within thefactory premises so that as check can be exercised by the Inspecting Authority incase necessary, otherwise, the testing of these materials should be done byGovernment recognized Testing Houses conforming to ROSa / IS Specification.

16.3 The Ultrasonic testing shall be conducted on each rotor shaft and certificate of thesame shall be attached with each lot at the time of Inspection.

17.1 Manufacturers shall submit complete detail of components used for alternator alongwith information as per Appendix/Annexure enclosed before offering the machine forprototype testing.

18.1 Indian Railways shall not be responsible for infringement of patent rights arising dueto similarity in design, manufacturing process, use of similar components in thedesign, development of the Alternator and any other factor not mentioned hereinwhich may cause such a dispute. The entire responsibility to settle any suchdisputes/matters lies with the manufacturer

182 The firm shall have ISO 9000 accreditation or equivalent certification to ensure itsconformance to Quality Systems iaid down in the standard for design, manufacturingprocesses, raw material, testing, quality control at different stages etc.

I.. Prepared Bv ~~-- i. Checked Bvi 1 J " ' \ ~

i ElDes\' on i, • '0 I.~----------- ._. , .L . . .. _

EU7,-f38/2 ,.- -'RDSa/PE/FRS/AC/0003-2~-!w.eJ December 2012 i ~__________ ..__ ...__ . . .---.L.. .__. . . _

--!,i. Specification/IS-- T- ... Make

r------------'1)--rJils-Calcutta IronUdyog, kolkata! RDSa Specification No. ! 2) MIs Vinayak Founders kolkataI ELPS/Spec i 3) MIs KEL,Kundarai ITU13 March 1998 I 4) Mis Rine Engineering Baddi! ; or, other RDSa approved source.

Rubber Pads** --iRDSODrg.No SKEL=----i 1) MIs Basant Rubber Factory Ltd., Mumbai.I 4021 alt.2 I 2) Mis AKlndustries, Kolkata

'3) MIs Manish Rubber Industries MumbaiI 4) MIs Faively Transport India Ltd., Hosur! 5) MIs De Engineering Works, Howrahi 6) Mis M.G.rvt Rubber Company, KolkataI 7) MIs Elora rubber & Plastic Industries, Kolkatai 8) MIs. Ray Elastomer, Mumbaii 9 MIs Swan Rubber Industries, Kolkata

--T1) -MlsSwarnagiri Wire Insulation Pvt. Ltd. ---~! 2) MIs Ram Ratan Wires: 3) Mis GK Winding wires! 4) MIs ALCa wires producti 5) Mis Precision wiresI 6) MIs Mimani wores! 7) MIs Khaitan winding wiresi 8) MIs K. Patel, Mumbai

I Varnish for \lpl-----h,1 v2--0a-Orn5-i/s5h-0-oFETk·10520r-----r~+--~j~-~~~~~k~~~~-D£3_m

_a

rl,

! -4-________: or, other RDSa approved source.

I ~~::~e~:;~n~------I ;r-~~~;:~(i~~~~~~)i---- -~...---...--_ i i 3) MIs. NSK (imported)i 6. I,: Grease ..rAP~fRR3&-LL'3--r g-- ~~~~~tr()I----- -----.-

J '~_--i __.'_. ~ __...., .. ,.....i 3) MIs Balmer Lawrie& CO.Ltd.i 7 I Silver Brazing -- I Grade BACu-P5asper'lsT1f--~JlIsESABlild~--------- ---! I electrode i 2927-1975 i 2) MIs L & Ti ; i 3) MIs Advani aerlikon

_I _._' . i . ._._ L1L..0th~RDSa approved sour~ .--J

! S.N.i i.

I Descriptioni Alternator I axlei pulley **I

,I

Ij

-,,-~

!,

**Alternator manufacturer is responsible for ensuring quality of pulleyslRubber Pads from theirsub-vendors as shown above.

i Prepared By0' ctorlPE&Metro I- ------ :'.J

Page 35 of 35 EL/7 .1.38/2-·-~~ ! ~~-'-RDSO/PE/FRS/AC/0003-2012 !._. .__ ~:.~}.J)e~~m~!~..?.9.12__ .__1 ._. .__._...____~ ._._...__~._.J

Annexure -IIBill of material for 30 'r'0N control unit specifying make of important items

IiI ISO Packs bridgei block diode

~! 10.

!

Specification I Make I-~-_..-~.--.1_.~__ .__.",,"_.__~. ~._-.," " .,__.....-L,_--..~_._-_.__...._._._ .._---~~ __ ._~ __ ,,~

I power . i. MIs IXYS i

i. MIs International Rectifier Ltd. '[I

i. MIs Hind Rectifiers Ltd.• MIs. Semikron. I

: i· MIs. Ruttonsha International I! 2. IThyristor ....; ..~·"--·-··-···-·-~--'1;-~i~\~~sLtd. ---~III Ii· MIs. Semikron !

i i. MIs International Rectifier Ltd. I. I, If3-:----1 HallEffect Senso;=--- ---+---'-'~~"~'-"~~-'-l-~-'M/s ABS ~

~-b~. ----:-.~--..... f4>· _Mj~,=£M. - - ...-----~ II 4. ! LCD Display !. MIs. Oriole Electronics iI ! I· MIs. Lampex Ii,'

I ! I 1. MIs. Noritek,---,."t--:.'"'---.--'-"'- ....--."-.-------"---""- ..~----"._~,------'-----~-.,--~_._-'---~ --'~--'"---------_._--i

: 5. I IGBT i. MIs IXYS 'I

I I. Mis Semikron

Ii. MIs International Rectifier Ltd. III,:',

',. MIs. SiemensI. MIs. ABBI. MIs. Infineon

'-------r- _ .--f. MIs. Mitsubishii. MIs EPCOS!. MIs Alcon

• MIs. Kendeil1[. MIs. Nippon Chemi-Con I

h~---·+con-n-ector..-···---··· ..J .-- IP 65/681 : .·~~~:it,i~~~l_---·-·---·_·---1I I " :,J. MIs. Amphenol '! i .-~~- Ir 8. I HRC Fuse ... -.---.-.j--------.- ..----.- --··-r~-·--M!sCooper Bussman ii I I· MIs English Electric Co. II--·-+---:·~--·-·--·· ,:-- .-.,-.-..-----.---. ·-t·-~...lI.i1!?~t'_~_E3 --~--~~I 9. i Thimble Copper all sizes I. Mis. Kiipon [! I :. MIs. Tyco

, i. MIs. Jensoni

i i :. Mis. DowellI Control cables (Sealed-·1-~- ..--·_-:---------I-;·-M;s·.- Hu-b-e-r--&-S'u-h'-n-e-r'- ....--.~I I !i Cable) ! !. M/s_ NEXANi , i. Mis. TEFKOTI ! ... __ . J.....~Any RDSO approved source

16.,!

I! Capacitor!