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RDSO/PE/SPEC/D/ACI0181-2014
(Rev-"O")
.
0\
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~~
GOVERNMENT 0
DIA
MINISTRY OERAILWAYS
RESEARCH
DESIGN§e.ND STAN!2ARL>S ORGANISATION
MINISTR'6' OF RAIEWAYS
TECHNICAL SPECIFICATION FOR
EMERGENC'6' LIGHT UNIT
(SAFETY LIGHT UNIT - SLU)
FOR EOG COACHES OF INDIAN RAILWA '6'
ctil4ctil'~~
EO/PS &EMU
/-qr ~ ~
t ~ 1!
Page
No.
3
Training
Infri
elll~pt of patent rigQJ
e engineers
Warranty
15
16
16
16
17
Testing
for checking the working of SLU in the coach
16
18
Enclosure
Annexure A
Performa forurigertaking
Annexure B
Sample wav¢fprm of power supply in coach
18-20
Annexure C
Temperafurecycle
21
Annexure D
Sketch for name plate for Indication LED
Distribution list
16
against cartel formation
for Burn in test
17
22
23
The general lighting inside the coaches is provided by 24 V DC or 110V dc supply in EGG
coaches. The supply system is backed up by battery system of 11OV DC /24 V DC for End on
generation type coaches. During extreme emergencies like derailment and accidents etc.
sometimes these supply system fail, causing total darkness inside the coach. To facilitate
easy exist of passenger and their immediate rescue during such emergencies, this
Emergency Light unit (safety light unit-SLU) has been developed to provide illumination
during failure of all other power supplies inside the coach. These emergency light Units (SLU)
are provided inside the coach and on doorways, would switch 'on' automatically in the event
of failure of normal supply system110 V DC & 24 V DC. Hence reliability of Emergency Light
unit (SLU) is of paramount importance.
2.1
The specification covers general guidelines fpr design, man~facture,
service of Emergency Light unit (SLU) for
type coaches.
2.2
The emergency light should switch 'on'automatically in case normatbattery
the coach 110 V DC and 24 DC fail during any unforeseen circumstanc~s.
2.3
When the normal supply fails, the Emergency
illumination, as stipulated in c1au$~.6.15.
Ei'rlP
Li~ht unit (SLU)
tests, supply and sales
supply system of
shall deliver
required
Quantity
per coach
(Safety ligh~~pit-SLU ) for EGG type
capacity sealed maintenance free
4 No.
Firm shall
e copy of op§!ration & maintenance cum trouble shooting manual with supplylot
up to
For su~~!y lot above 100 units, one copy of operation & maintenance cum
trouble shootll"l9.manual for every 100 units will be supplied.
j~i"
The equipment shall be sturdy and suitable for the following service conditions
be met in service:
i)
Ambient
-5 to +55 deg Celsius
ii)
Train speed
200 Kmph
iii)
Relative Humidity
Up to 98% during rainy season
iv)
Altitude
Max 1200 meter above sea level
Prepared
By
Checked By
normally to
Extremely dusty, foggy, and desert terrain in certain
areas. The dust concentration in air may reach at
high value of 1.6mglcubic meter
Very heavy in certain areas.
The equipment shall be designed to work in humid salt
laden and corrosive atmosphere .The maximum values
of the condition shall be as under:
Maximum Ph value
Sulphate
Max concentration
Max. conductivity
The equipment, system
their~:punting
designed to with
nd satisfactorily
the
encountered in
as specified below:
(a) Maximum vertigi-'l'acceleration
(b) Maximum lateraLi'lCC!3leration
(c) Maximum longitudinq!acceleration
arrangement shall be
vibration and shocks
: 3.0 g,
: 3.0 g.
: 5.0 g.
6.0
TECHNICAL
6.1
The input power to the Emergency Ught unit (SLU)is 110 V OC+I- 30% or 24 V DC in case of
LHB EO
coaches. .
REQUIREMENTS
The
supply.
6.3
Each
7 Ah
Amar
shall
emergency unit will contain Sealed Lead Acid Maintenance Free type (SMF) Battery of
capacity. The battery shall be 12 Volt, 7 Ah of Mis Exide I Mis TAFE (AMCO) I Mis
Rajal Mis HBL make .The battery older than six months from date of manufactured
not be used.
6.4
The battery shall be purchased from OEMs only. Purchase certificate
enclosed along with the emergency light unit.
6.5
The battery of emergency light unit (SLU) should be driven by Microprocessor
and voltage controller for duster of LEOs.
from OEM shall be
based current
i.
The Emergency Light unit (SLU) shall consists of battery backup system, control
circuit for charging the battery, sensing the battery charging current, voltage etc, and
trip or cut off circuit for the unit to avoid over charging/deep discharge and give a
visual indication.
ii.
The battery shall be charged at 13.5V +/- 0.1Volts in floating mode and 14.4V +/0.1 Volts in boost mode depending on the state of the battery. The control circuit
should be very specific in terms of boost and trickle charging characteristic.
iii.
The emergency light unit (SLU) shall stop workip~ as soon as the battery voltage
reduces to 10.5Volts, to prevent deep discharg€lof the battery in order to keep the
battery in healthy condition. The battery supply shall be available up to 9 Volts
battery voltages to show the status of igdiC<;iti LED (Amber flashing) for deep
discharge of battery below 10.5 volts a~!p~r cia
o. 6.6 of this specification.
Whenever the battery voltage redu
14.4V +/- 0.1V with current limit a
the terminal voltage of the batt
switched over to trickle charge
v.
The system should
embedded software
version. The software
the name of any indivi
engineers.
attery shall be charged at
10.5 Volts, t
ttery manufacturer. After
mmended by t
the charging shall be
charge reaches 14.4
13.5V +/- 0.1 Volts.
ogic component i.e. ICs'iiduly burnt with
he software shall be of original licensed
name of the manufacturer and not in
p software within firm by software
The following
the coach.
Parameter
Unit Battery conne¢tion intact
Green LED
ON
Unit Battery discharging @ 20%
Failure of 11OVd
Unit Battery 4nhealthy
replacement
The LEOs shall be similar to the following types and make or equivalent type and other make with
prior approval of ROSO:-
Colour
of
indication
LED
Nichia make
Seoul
semiconduct
or make
Avago make
Cree make
Green
NSPG 500 S
LT620
Green 525 mm Lamp CB
series, HLMP-CM series
Red 626 HLMPEG08- series
C503B- series
Red
Amber
NSPR 510AS
NSPY500
LR 530A
S
LY520A
The equivalent indication
approval of ROSa.
Amber 590HLMP H08
series
C503B- series
C503B- series
LED of above or other
6.7
The control circuit of the Emergency Light unitCS£. shallbegesigned
in such a way that the
current drawn by LEOs shall be minimized
give maximumiguration of lighting. The actual
current drawn by LEOs shall be such t
drawn from the batt~ry shall not exceed 4 AH
for new emergency light unit. However t
pensate the temperatyfe pnd aging factor of the
battery, the battery used shall be of 7AHQ~pacity, so that the emergency light will work at
least 12 hours during the life of the battery asp~r Lux re uirement stated indause 6.15.
6.8
The manufacturer shall sUb~ittn~calculations
sh~~! ... he actual AH drawntrom
during the type test/revalidatio~,fype t~Rt/ prototypelesf.
6.9
There should be a provision for
e of battery>by 20% of its rated capacity to a
maximum time of 4/5 hours auto
trol circuit pt a regular interval of 15 days
to improve the life
e battery.
!Q¥batteryshall
be carried out by using
either resistance
nic meth
t s ifchi~~ 'on' LEOs. This discharge shall be
done during'fl1e day tim 9n'Y from
to 12.00 P.M, so that it can be recharged
during the re
'ng periodi!~{ the day an ready for use during night in case of emergency
situations. If the
ch batt~ryf~ils during sYHr discharge, the emergency light should switch
mode fgr readinessa~. per the requirement stated in clause 6.15.
X:,:, ",,:"':'::
the battery
....«;,;,;,,'~
6.10
current drawn fromth~unit
batteryiniglecondition
shall be minimum and designed in
a way that treunitbqtt~ry
will notgo below 10.5V even after 6 months of storage
use. Firm willsybmit und~rtaking in this regard.
6.11
Theehlergency unit sh0919 switchlOh' automatically when supply voltage drops to 80 V DC or
below IN
connected with 110 V DC supply.
6.12
In case the riiiQ~~proce~S9r of the unit fails, the emergency light unit (SLU) shall work as
normal during e~)~~~ency situations. The necessary hardware back up arrangements shall be
incorporated in tfie>design of the unit. This will be tested during Proto-type test/revalidation
type test by removing microprocessor from unit under test. After taking out the processor the
unit should keep on functioning as under:
a)
b)
c)
6.13
Trickle charging mode should work
ON/OFF as per Para 6.11
Lux level at 20 Lux for 12 hrs with 7 AH battery.
The microprocessor should have an auto reset facility through a separate watch dog /
supervisor circuit. In case the microprocessor is stuck due to EMI, surges or spikes or
software stuck fault, it should be able to restart by the separate hardware watch dog /
supervisor circuit.
The power supply circuit of the Emergency Light unit (SLU) should have a provision of auto
reset in case of the following faults.
a)Power
b)Power
c)Stuck
d) Input
6.14
supply output over current fault
supply short circuit fault
against transient & surge fault
over voltage fault (over 200 volts)
The LED shall be arranged in three clusters as shown in the RDSO drawing no.
RDSO/PE/SKIAC/0181-2014(
Rev-"O"). Left and right cluster each will have 12 nos. LED and
Middle cluster will have 30 nos. LED , which will
Lux requirement stipulated in
clause 6.15
Not less than 250 Lux at 0.5M
Not less than 100 Lux aL1:0M
with fully
charged battery
Not less than 30 Lux at 2.1iM
for the first 2 hours starting with the
Not less than 20 Lux at 2.1 M
for further 1
rs
The above values are measu
cluster of LEDs and when all the
the battery vol tag . shall be ke
maintained up JOb
'tpltage of 1
6.16
ace perpenqic::ular to the light rays from middle
ON conditiOn. At the start of illumination test,
volts and Lux level as above shall be
The Super Bri ht White hi~.R!ntensity L
s.shall be from any one of the following OEMs as
per type menti
meet!If:j~ Lux requirerjlent as per Para 6.15 :
PartIhb. of LED
N§SWl56T-P3 or equivalent to above
DO~IS E3 LUWJNSH.EC BRBT/BSBU
to above.
HW331 A or equivalent to above
or equivalent
Any other make or
er equivalent part no of above make meeting the parameters of
specification may be used with prior approval of RDSO.
(1)
(2)
(3)
(4)
(5)
It shall be Super Bright White high intensity and Industrial grade
type.
Minimum luminous efficiency = 100 ImlW at 25°C.
Life time (L70) = minimum 50000 hrs at TJ=70 DC.
View angle = Minimum 100
Colour temperature = 50oo-7000K
0
(6)
1)
2)
3)
4)
5)
6)
Luminous flux of LED bin shall be minimum 7 lumens at 30 mA at
Ta = 25 degree C .
OEMs certificate for purchase of LED.
Test certificate of LED by OEM.
Data sheets of LED.
Reliability test data sheet of LED.
Label details on packing: part no. , lot no. , ranking by colour coordinate,
luminous flux.
Junction temperature calculation of LED.
ranking by
6.18
The Emergency Light unit (SLU) will be fitted on t~e r90f eiling / partition wall of the coach.
The battery portion of the light fitting will be con~~led a
Iy LED portion of the light fitting
will be projecting outside. Hence selection q~!!!:!::paHery
an Its housing shall be suitable flat
arrangement such that leakage of battery s~al!iJ~bt be occurred
battery should be fitted in
such a way that it can be easily replaced I:>yralrway person.
6.19
The Industrial grade electronic component~iL'l~ed shall be as per the following:
6.20
d)
The resist
loading vrp
e)
Switching devices such as
temperature of 150°C.
t)
The devices shall
g)
The fire retaro~nt FR-4 grade glass epoxy coated PCB shall be used. The protectivecum-adhesive cqating used oJ) PCBs should be clear and transparent and should not
affrpct color code ofrp!rpctronic component or the product code of the component.
h)
The heavy componrpht§ should be properly fixed.
with gooq ~nish.
i)
The electronic cii~~.~it§,PCB and components should also meet the RDSO Spec. No.
ELRS/SPEC/Sl!0015
- OCT.2001 (Rev.1) Specification for Reliability of Electronics used
in rolling stock application.
j)
The electronics covered for this equipment shall pass all the tests called for in the above
specification.
s shall be preferably ma
rating shall be 3.
The shoulder connection
should be
No electro-mechanical components shall be used. All the control systems, Electronic circuits,
Relays, Cut-off systems, etc., to ensure automatic operation of emergency lights should be
necessarily Solid state type only.
Prepared
By
~
6.21
The health of the unit battery
during 20% discharge cycle.
discharge rate shall mean that
indicated by Red LED flashing
shall be monitored using dv/dt characteristics of the battery
Any abnormality in dv/dt from its reference value at 20%
the battery is unhealthy and needs replacement. This shall be
which shall continue till the battery is replaced.
6.22
Emergency Light unit (SLU) shall be designed with SMPS working on 90 Volts dc to 143 V dc
power supply .
6.23
Emergency Light unit (SLU) shall be designed with battery mounted on PCB for back up to
Real time clock (RTC)
7.1
The complete emergency unit will be of compa
design with mounting dimensions and
overall dimension as per the enclosed ROSa dr
no. ROSa/PE/SKlAC/0181-2014(Rev"O")(Sheet 1 and Sheet2) . Antitheft arrangementsha I be as§Qown in sheet 2 of this drawing.
The housing with the hinged cover assem
all be of robUst and reliable construction. The
housing shall be deep drawn from 0.8
k CRCA sheet to IS 513-94, Grade DO. The
hinges should not be visible from outsi
7.2
The hardware shall confirm to IS 1364 - 92 "Specification for hexagonal head bolt, screws and
nuts". The minimum size of the hardware shcillp¢!.M5!and the hexagonalhead
slotted screw
shall work on tapped frame arr
ent.
The enclosure of the unit shall co
deep drawn from 0.8 mm thick CR A
frame shall be secured properly to for
of the unit shall be provided on both si
The enclosure snaUQe po
colour of M/s. BURGER snad
e and bottom frame
and these shall be
grade DO. The top and bottom
~••Incl
ure! •••
~ nos. holes of 6 mm size for cooling
{enclosure for cooling of battery.
g1~:94
to a minimum thickness of 60 microns to Broken White
302 or equivalent with prior approval of ROSa.
7.6
THe
7.7
The size of the fixing screws with I
nut / washer shall be M5 hexagonal head with slot head
whereve
d for the as§embly inside the unit.
7.8
Other enclosut~§pf the unit shall be fixed to the member channel arrangement with provision
for easy removaI:i:ihg att$nding to the battery, PCB etc
7.10
Fire retardant Transparent V-O grade UL-94 polycarbonate sheet of thickness 0.75mm to 1.5
mm shall be provided for protection of LED from external damage and ingress of dirt.
7.11
Terminals with terminal designation of Wago type 261-102 shall be provided on the top hood
for 110 Volts dc with blue and for 24 Volts DC with Parrot green female connector.
7.12
An automotive type connector to be provided inside the unit and one part to be fixed rigidly for
connection/disconnection
of unit battery to the circuit.
battery sh~II<~e fixed!Q:ide the unitg~~perly to avoid movement in vertical as well as
hprizontal diredion ..and taKing. care of the vibration encountered in service. The battery
mounting shall be sUitable for ahdirection.
7.13
Fire retardant V-O grade UL-94
compliant White colour
specification IS 1719 - 88 to be glued all around the fitting.
7.14
Dome key type captive screw to be provided for fixing the cover. One number dome key per
four nos. emergency light units will be supplied.
7.15
The weight of complete
maximum.
8.1.1
Only after the detail drawings and the design hav~
approved and the clearance given to
this effect, the manufacturer shall take up tht;man
acture q'~he prototype. It is to be clearly
understood that any changes, required t~c~r done in the prototype or any additional tests
other than specified herein are require(jYi~o be conducted on the prototype unit or its
components, they shall be done expeditiously.
8.1.2
Subject to agreement between user and IllqQufacturt;r!yROSO shall repl(atsome or all type
tests once in three years on sqmple basis, so a.s to confirm the quality of thgproduct to meet
the specified requirements.
8.1.3
The type tests shall be carried'04tby
in part under the following condi .
a)
b)
c)
d)
e)
assembly of Emergency
soft wool felt 3 mm thick to
Light unit (SLU) shall be 4.5 kilo gram
represent~~.iMl( on prototype unit either totally or
o!Jllil,Qy additional cost:
A manufacturer undertakes to ma
ture for the first time.
An important change in design detai
achines has been introduced.
Specification is modified necessitating
esigning of equipment.
Unsatisfactory performance reported from user Railways.
Resumption of production after an interruption of more than two years.
8.1.4
Investigation tests are intended to obtain additional information regarding the performance of
the production. They shall be specially requested either by the user or by the manufacturer.
8.1.5
ROSa may conduct surprise check on manufacturing process and quality control along with
any of the tests to ensure quality of product and its conformance to ROSa.
8.1.6
The tests Shall be carrie(j 94t at the works of the manufacturer in presence of Indian
representative pn the prqtptype unit of the Emergency Light unit (SLU) as per
governing sp~eificati
modified or amplified. The manufacture shall have all
necessary arrangelll
or testing of Emergency Light unit (SLU). Tests for which
are not available WI
the firm shall be conducted at NABL accredited lab.
8.1.7
The test protocol indicating relevant clause of the test, condition of the test, specified value
and observed value of the parameter for SLLJ shall be submitted by the firm before offering
the sample for type testing.
8.1.8
The system shall successfully pass all the type tests for proving conformity with this
specification. If anyone of the equipment fails in any of the type tests, the inspecting agency
at his discretion, may call for another equipmenVcard(s) of the same type and subject it to all
tests or the test(s) in which failure occurred. No failure shall be permitted in the repeat test(s).
Railway
relevant
possible
facilities
Routine test are to be carried out on each unit to verify that properties & design of the product
correspond to those measured during type test. Proper documentation of routine tests results
should be available with the firm and should be produced before inspecting official on
demand. Tests shall be conducted as per test schedule given.
Each offered lot of supply shall be subjected to acceptance tests as per ROSa approved
sampling plan or as per sampling plan spedfied in IS 2501, at manufacturer's works.
Acceptance test shall be witnessed by inspecting offipial nominated by purchaser/ROSa.
Manufadurer on demand by inspecting official shall.pnQcjuce the internal/routine test report
carried out by manufacturer.
S No.
'/< "
Test
Type
.....
Routin
etest
Accept
ance
test
:<)j! .•
1)
2)
3)
4)
Visual Test
Checking of document
battery
Checking of document
LEOs
of
of I~r~tse
of purch~se<Qfl..J
....
Ign
docum
ent
«
9)
10)
11)
12)
13)
14)
15)
16)
17)
Prepared
Dielectric Test
Insulation Test
Reve[sePolaritv Test
Performance ...test with 7 Ah
battery
Software burn- infest
Tesf·.for battery pef(pCQ1ance
ChecKing
the
functioning
Microproq:lssor contrpll1i$r
Mechanical
Test
Chromaticity
and
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~iii:h
Electrical
,.~
>
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"\
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"\
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"{
,"
of.
Endurance
Performance
test
in
case
of
Microprocessor failure
Temperature rise test (Dry heat run test)
Temperature rise test (Damp heat test)
Vibration and Shunting Shock test
As per approved
bill of material
during type test
bv ROSa.
8.8
8.9
8.10
8.11,6.12,6.15
,
x
..J
x
8.12
8.13
To be 6.5,6.6,6.7
, 6.9,
and
conduc
6.10,6.13
ted for 6.15
6.12
a lot of As
per
50
during type test
Nos.
only.
x
8.14
..J
x
x
..J
x
x
As per approved
LED
datasheet
bv ROSa.
6.12
..J
x
x
x
x
x
x
8.15
8.16
8.17
,
and dispersion angle test
By
..J
8.7
6.4
6.17
.~
of tesf~amPlelfl~~per
Checki ng ~dt~~o~l
/ design dp
ent
5)
6)
7)
8)
~"."~
As per clause no.
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x
Checked By
~
ADE(TL-AC
&System Design)
DSE(TL-AC
& System Design)
,
ACID 181-20 14 (Rev-"O")
RDSOIPE/SPEC/DI
18)
19)
20)
21)
PCB Burn in cyclic test
Surge and Transient Test
EMI test
Fire retardant test on soft wool
polycarbonate sheet
and
.
""
"
x
x
x
x
x
x
x
x
8.18
8.19
8.20
7.10 and 7.13
8.6
The acceptance test shall be conducted by inspecting agency as per sampling plan in IS
2500 part-I. The Routine test shall be conducted by firm on each unit during manufacturing.
Firm shall keep record for individual unit & a copy shall be endosed in packing of unit.
8.7
Visual test:
The unit should be checked visually for dimensions a~ ~~~approved drawing. The general
workmanship should be good with all the component properly secured and sharp edges
rounded off. Visual check for all possible physica:!!.)(.!?~ificationof compliance of all clause
mentioned in this specification shall be done.
The dielectric test shall be conducted
RMS value of test voltage as 1000 Volts
8.10
The insulation resistance of t~r unit";.~~!Ween
~md all current carrying parts shorted
together shall be more than 20 Mega ohms §It a ambient temperature of 55°C measured with
500 V Insulation Tester (megger).
Reverse polarity t!?st:
The unit shall remain functional after
32 Volts DC
10 Volts dc input termm
reverse polarit
case the 24 Volts input
the unit should tn without any damage.
at 110 Volts dc input terminal and
one
in correct polarity as well as in
connected inadvertently to 110 Volts dc supply
be
for its functioning at upper voltage limit, lower
supply system. The unit should work satisfactorily for 12
t room temperature with
battery. The illumination level shall also be measured
during he performance test and th level shall not be less than 250 Lux at 0.5 meters, 100
Lux at
and 30l;ux and 20 Lux at 2.1 meters as stipulated in dause 6.15. The
illuminatio
sidesi!Qf centre of Emergency Light unit (SLU) at 2.1 m should be uniform
or vary within
Correct burn - in of embedded
(SLU).
software version shall be verified for Emergency
Light unit
Tests to determine the performance and capacity of battery. For proven design of battery, The
capacity test on battery shall be conducted during type test of complete unit. For this purpose
the battery shall be selected randomly. Capacity/20 or Capacity/10 discharge test as
recommended in datasheet of battery with constant discharge current using rheostat shall be
done and average room temperature
following formula:-
shall be noted. Battery capacity shall be calculated by
Battery Capacity at 27 0 C = C*T /1 +K (t-27) Ah.
C= Current in mA
T = Time taken to discharge hrs,
K= 0.0043
't = Average temperature in 0 C.
The calculated capacity of battery should exceed or match the rated capacity of battery.
Mechanical and electrical endurance test:
8.14
The unit will be subjected to 5000 switching operation~
30 seconds 'ON' period and 30
seconds 'OFF' period in locked chamber with auto
recording arrangement. None of the
unit component should show sign of damage/deter
on.
8.15
Temperature
rise tests: (Dry heat run test)
The tests shall be carried out as per IEC60571- on the complet~ electronic assembly in
closed condition as during normal ope ratiQQ, on full load, placed in test chamber where
temperature is progressively raised from ambient from 70·C for 6 hours a~per IEC 60571. At
the end of this test the performance test is repeat$g.
8.18
Burn in test On poPulated PCB: It shall b
ELRS/SBl;QISII0015 {R.~v:D Oct"2001.
Burn in test procedure on Populated PCB to be done at NABL Accredited Lab shall be under:
I.
Burn-in test shall be undertaken between - 25 0 C to +70 0 C as per temperature
in Annexure-1 of ROSO sp3cification No. ELRS/SPEC/SI/0015.
cycle given
II. Test is to be conducted gOqtinuously for 45 hours i.e. 6 cycles of 7.5 hours on populated PCB
of Emergency I"ight unit (SI.;U).
III.
Test shall be condu
& negative temperature
Gring energized condition of PCB card in each cycle during positive
peak as under.
(a) +12V DC is applied on the populated PCB at B+ terminal of PCB
(b) The critical most output is of LED cluster drawing power which is measured at LEO+
Terminal PCB ground and the same should be +13.5 V to 16.5 V.
IV.
This will be measured to ensure the proper functioning of PCB and microprocessor control.
V.
After completion of burn-in cycles the PCB shall be assembled with emergency light unit.
Full performance test as per Para 6.7, 6.12 & Para 8.6.1 shall be conducted after burn-in
test of PCB.
8.19
Surge and Transient Tests:
The test shall be conducted as per clause 5.4 of IEC - 60571 and Performance to be checked
after the test.
The Emergency Light unit (SLU) shall be designed such that there will not be any
Electromagnetic Interferences and the test shall be conducted for EMI/EMC with relevant
clauses of IEC 61000 as under:
Pulse re etition rate
Volta e eak
ii)
2.5 KHz
4KV
Surge Test
The test shall be carried oulas
Test level: 4 KV
a)
b)
iv)
er IEC: 6100Q.:4Fq; Ihstallation dass: 4,
Enclo.§:tJreconductive part-cont
Endosure insulated part- air disch
Radiated susceptibility test: As per LEC-6100Q.:4-3
v)
Earth Potential test
Body without powder coating of the ELU shall be given external voltage of 110V
performance of ELU shall not get affected
The Emergenoy Ligh
following informatiqn
printed.
i)
ii)
iii)
iv)
v)
vi)
DC
II be provided with a name/rating plate on the enclosure.
The
be available by either etching process or by engraving or screen-
Manufacturer's name and address. It will be dearly printed on the enclosure such
that it can be seen after fitted SLU in the coach.
Type / make, Specification No.
Continuous battery rating, short time rating/duration, input voltage range, output
voltage range.
Connection diagram in an anodized aluminum plate with terminal markings
Serial Number of the equipment.
Software version loaded.
Note:
The first two digits shall indicate the year of manufacture.
Next two digits month.
Next one digit for any type Model, etc.
Next three digits manufacturing serial number
a)
b)
c)
d)
a)
b)
Component outline in the proximity of the component;
ELU manufacturer's name.
Sub vendor's name that has assembled SMD components on PCB.
Version number of Hardware.
The manufacturing serial number.
Month and year of manufacture
9.4
Indication plate for meaning of Indication LED red, green and amber shall also be provided
below the indication LED as per AnnexureD.
9.5
The equipment and its sub assemblies shall be packed in thermo Cole boxes and the empty
spaces shall be filled with suitable filling material. Before keeping in the thermo Cole box, the
equipment shall be wrapped with bubble sheet. The equipment shall be finally packed in a
wooden case of sufficient strength so that it can withstand bumps and jerks encountered in a
road/rail journey.
The supplier shall arrange for training to IR personnel as and when required in maintenance
and trouble shooting of the system supplied. Firm shall arrange for training of Railway staff in
maintenance and troubleshooting of the system ..
Indian Railways shall not be responsible for infringement of patent rights arising due to
similarity in design, manufacturing process, use of similar components in the design &
development of this item and any other factor not mentioned herein which may cause such a
dispute. The entire responsibility to settle any such disputes/matters lies with the
manufacturer/ supplier.
Details / design/documents given by them are not infringing any IPR and they are responsible
in absolute and full measure instead of railways for any such violations. Data, specifications
and other IP as generated out of interaction with railways shall not be unilaterally used without
the consent of ROSa and right of Railways / ROSa on such IP is acceptable to them.
The manufacturer shall be required to make available the services of his engineer/engineers
free of cost to watch performance of the equipment in service periodically and also carry
necessary repairs or replacement under warranty obligations. The necessary spares needed
for replacement during service should be available with the service engineer at all possible
places where these coaches are maintained.
The complete unit except battery shall be guaranteed for satisfactory performance
and manufacturing defects for a period of 60 months from the date of commissioning or 72
months from the date of supply whichever is earlier. For the battery guarantee/warranty
obligation of the equipment shall be as per IRS condition of contract.
'
Firms shall have to comply to ROSa STR no. ROSa/PE/STR/AC/0034-2012 (rev-O) with
additional Chromo meter to measure Lux as well as coordinates of LEO to ascertain quality of
light. This will be considered for as compulsory requirement at the time of registration
/renewal or revalidation of registration as approved vendor of ROSa for this item.
The firm shall not engage cartel formation with other firms and shall also submit a declaration
in this regard as per annexure attached ofthis specification.
The manufacturer shall submit operating & maintenance manual to ROSa and the user
Railway containing:
a) Bilingual (Hindi and English) instructionsJor operation, maintenance and troubleshooting
b) Power & control electrical diagrams showing various connections to Emergency Light unit
(SLU).
c) Write- up on the working of Emergency Light unit (SLU).
I
Production units and zonal railway shall provide the arrangement using Push button in the
existing wiring circuit of the coach in every trip to check working status of emergency light unit
(SLU) as per ROSa Modification sheet no. ROSa/PE/MS//0047-2009(Rev-0) issued by ROSa
vide letter no. EL/6.4.6 dated 27.01.2010
18.1
Performa for undertaking against cartel formation
to be furnished by the manufacturer
We,
hereby, give an undertaking that as a Registered Vendor for
manufacture and supply of
'"
will not be a part of a cartel with other
vendors and will be quoting competitive rates in the tenders invited by the Indian Railway/PUs.
We
are aware of the fact that the
list the name of our firm from the Master List of Approved
cartel formation from any of the Railways/Production
Authority i.e. ROSa may deif complaint is received about such
Seal and Signature
signatory of the firm)
Voltage Waveform at
DCbus bar at No
Load. ERRU off and
lnvertars off.
Voltage Waveform at
DC bus bar • ERRU
off andjwth
IX bus bar at B2
!.!allO. ERRU ON and
single inverter ON.
DC bus bar at full
RI\lWU load. ERRll
ON and single
inverter ON.
~
Checked By
l1WACfirw
waveform at
secondary of
415V/UOV
transformer
of
control panel
UOVACIlrw
waveform at
415V/1l0V
transformer
<rl
control panel
(After Filter)
Prepared By
~~
BURN-IN TEST
emperature
in Degrees
Blink
C
Gl'8Bn
li$
Red
Jf$~
c ....Amber
Ii' -
It
! ii'
~'-J--.I
c:D-Ui
8·bo
C
c
Northern Railway, Baroda House, New Delhi - 110 001.
2
Central Railway, " Floor, Parcel office, CST Mumbai - 400001.
3
Eastern Railway, Fairlie Place, Kolkata - 700 001.
4
South Eastern Railway, Garden Reach, Kolkata - 700 043
5
Southern Railway, Park Town, Chennai - 600 003.
6
Western Railway, Churchgate, Mumbai - 400020.
7
South Central Railway, Rail Nilayam, Secunderabad - 500 371.
8
East Central Railway, Dighi Distt- Vaishali, Hajipur Bihar-
10
South Western Railway, l' Floor, DRM Office, Hubli
11
South East Central Railway, Bilaspur.495004
12
North East Frontier Railway, Maligaon,
13
North Eastern Railway, Gorakhpur-
14
North Western Railway, Jaipur - 302006
15
West Central Railway, Jabalpur-A82001
16
East Coast Railway, BhuvneshW
17
Konkan Railway, Belapur Bhavan
18
19
15
16
17
18
19
20
OTHERS:
1
2
10 HOLES 06 ON BOTH SIDE
150
(j)
0
0
0
0
0
0
0
0
--l
(j)
0
0
~
01
•• •• ••
1~
240
150
180
3
-$
~
01
0
I
I
D
I
-$-
I
-$
-$-
7
315
375
=
RUBBER
2
M.S.ROD
4
CONNECTOR
2
2
COVER (0.8mm Thk.)
(261-102)
2
*
DT
D
AK.S
C
M.M.S.
GALVD.
M.S.SHEET IS: 1341-Bl
MS.SHEET IS: 513-94 (GR-DD)
NOTE:-
REF NO. PART NO. DESTRIPTION DETAILED DRG NO.
1. ALL DIMENSIONS IN mm. TOLERANCE SHALL BE AS PER IS 2102
2. ffEM 1 &2 SHOULD BE DRAWN AND NOT FABRICATED.
3. VENTILATING HOLES 10 Nos., 06 mm TO BE PROVIDED ON THE SIDE OF THE FITTED.
REF : EL/6.4.6/LHB
4. ALL ITEMS SHELL BE GIVEN SURF ACE TREATMENT FOR ANTIRUST & ANTICORROSION
BEFORE FINISHING WITH BROKEN WHITE POWDER COATING OF BURGER 302.
5. DOME KEY SHALL BE SUPPLIED 1 No. FOR EACH SET.
6. FOR 110 VfDC W AGO MAKE BLUE CONNECTOR & 24 VfDC PARROT COLOR CONNECTOR.
7. RESISTOR FOR HEAT DISSIPATION UNDER 20% DISCHARGES SHALL BE INSIDE UNIT.
IS: 2062-99
WAGOMAKE
M.S.SHEET IS: 513-94 (GR-DD)
HOUSEING (0.8mm Thk.)
TITLE:-
IS: 5270-69
2
HINGE (40 mm)
405
IS: 1719-2000
GROMMET
=
=
WOOL
CAPTIVE SCREW (M5)
6
=
FELT (3mm)
NOIEACH PCS. MA TL.
SCALE:
DRAWING FOR THE
EMERGENCY LIGHT UNIT HOUSING
FOR LHB TYPE EOG COACHES
**
SPEC. REMARKS
APPROVED BY :
FIRST ISSUED
10.07.2014
SUPERSEDES: NIL
l
70
85
150
_II
I
I
t
I
I
4
U CLAMP BRACKET FOR CONNECTOR
3
MIO M.S. BUSH
2
M.S.SHEET
IS
2062-99
M.S. ROD
IS
2062-99
U CLAMP BRACKET (1.5 Thk.)
M.S.SHEET
IS: 1079
U CLAMP BRACKET (1.5 Thk.)
M.S.SHEET
IS: 1079
4
REF NO. PART NO. DESTRIPTION DETAILEDDRGNO.
REF: EL/6.4.6/LHB
NOTE:-
*
I. ALL DIMENSIONS
IN nun AND TOLERANCE
SHALL BE AS PER IS: 2102.
2. ALL ITEMS SHALL BE GIVEN SURFACE TREATMENT FOR ANTIRUST & ANTICORROSION
BEFORE FINISHING WITH BROKEN WHITE POWDER COATING.
TlTLE:-
NOIEACHPCS. MATL.
SCALE:
DRAWING FOR THE
ANTI-THEFT HOLDING CLAMP
FOR BATTERY OF EMERGENCY LIGHT HOUSING
OT.
o
A.K.S.
C
M.M.S.
SPEC.
*
*
*
*
REMARKS
APPROVED BY :
FIRST ISSUED
10.07.2014
SUPERSEDES : NIL

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