RDSO/PE/SPEC/AC/D/0180-2014(Rev-0)

~~
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION FOR EMERGENCY LIGHT UNIT FOR
SELF GENERATING CONVENTIONAL AC & NON AC COACHES
OF INDIAN RAILWAY
I S. N°·1
Date of amendment
'~ d
31jJiI
APPROVED
Cbllfcpl~ Pl~~Cb11ft ~
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ED/PS &EMU
I Prepared
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By ~\,~.
ADE(T~ro)t~~~
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Design)
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Clause No.
DESCRIPTION
Page
No.
1
Foreword
3
2
Scope
3
3
Scope of Supply
3
4
Operating
3
5
Governing
6
Technical
7
General
8
Inspection
9
Marking and packing
15
10
Training
16
11
Infringement
12
Service engineers
16
13
Warranty
16
14
Schedule
15
Cartel formation
16
Operating
17
Testing arrangement
18
Enclosure
Annexure
and service Conditions
4
Specifications
4
requirements
9
requirement
10
and Testing
of technical
16
16
manual
for checking the working status of ELU in coach
I
I--
I
17
17
A
Performa
Annexure
B
Sample waveform
Annexure
C
Temperature
Annexure
D
Sketch for name plate for Indication
Distribution
i
16
requirement
and maintenance
i
I
16
of patent right
for undertaking
against cartel formation
of power supply in coach
cycle for Burn in test
list
18
19-21
22
LED
23
24
I
Prepared By ~
\ \ 0 \ 1-0 \ ~
ADE(TL-AC &System Design)
The general lighting inside the coaches is provided by 11OV dc or 11OV ac supply. The supply
system is backed up by battery system of 11OV dc for self generation type coaches. During
extreme emergencies like derailment, 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 (ELU) has been
developed to provide illumination during failure of all other power supplies inside the coach.
These emergency lights are provided inside the coach and on doorways which would switch
'on' automatically in the event of failure of normal supply system. Hence reliability of
Emergency Light Unit is of paramount importance.
2.1
The specification covers general guidelines for design, manufacture, tests, supply and after
sales service of emergency light unit (ELU) to be used in self generating conventional AC
and non AC coaches.
2.2
The emergency light should switch 'on' automatically in case normal battery supply system of
the coach fails during any unforeseen circumstances.
2.3
When the normal supply fails, the Emergency Lighting system shall deliver required
illumination, as stipulated in clause 6.15.
Item
Quantity per coach
Emergency Light Unit with 12V , 7 Ah capacity
sealed maintenance free battery.
4 nos. ELU per coach
Firm shall provide one copy of operation & maintenance cum trouble shooting manual with supply lot
up to 100 units. For supply lot above 100 units, one copy of operation & maintenance cum trouble
shooting manual for every 100 units will be supplied. One number Dome key as per clause 7.14 per
four number of emergency light unit shall be supplied.
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
v)
Atmosphere
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Prepared By
Extremely dusty, foggy, and desert terrain in certain
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ADE(TGAC&System
Design)
normally to
areas. The
dust concentration in air may reach at
high value of 1.6mg/cubic 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
: 8.5
: 7 mg/liter
: 6 mg/liter of chlorine
: 130 micro Siemens/cm
The equipment, system and their mounting arrangement
shall be
designed
to withstand
satisfactorily
the vibration
and shocks
encountered in service as specified below:
(a) Maximum
(b) Maximum
(c) Maximum
IEC 60571
IEC 61000
IEC 61373
IEC 60529
IS 513 - 94
ROSO SPEC. NO.
ELRS/SPEC/SI/0015
(Rev -1 )Oct 2001
vertical acceleration
lateral acceleration
longitudinal acceleration
: 3.0 g.
: 3.0 g.
: 5.0 g.
Electronic equipment used on rail vehicles.
EMC/EMI Compatibility test.
Vibration and shock test
Oeqrees of protection provided by enclosures
Cold rolled low carbon steel sheets and strips
Reliability
of Electronics
(IP code)
used in rolling stock application
6.1
The input power to the Emergency Light unit is 110 Volts DC which
143 V DC for self generating conventional AC and Non AC coaches.
6.2
The emergency
supply.
6.3
Each emergency unit will contain Sealed Lead Acid Maintenance Free type (SMF) Battery of
7 Ah capacity. The battery shall be 12 Volt, 7 Ah of M/s Exide I M/s TAFE (AMCO) / M/s
Amar Raja/ M/s HBL make .The battery older than six months from date of manufactured
should not be used.
6.4
The batteries shall be purchased from OEMs only. Purchase certificatelWTC
be enclosed along with the inspection
certificates
issued by RITES etc."
6.5
The battery of emergency light should be driven by Microprocessor
current and voltage controller for cluster of LEOs.
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unit shall function
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ADE(TL-AC &System Design)
may vary from 85 V DC to
not less than 12 hours in the absence
of coach
battery
from OEM shall
/ microcontroller
based
i.
The emergency light unit shall consists of battery back up 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 13.5 Volts +/- 0.1Volt in floating mode and
14.4Volts +/- 0.1Volt 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 shall stop working as soon as the battery voltage reduces to
10.5V, to prevent deep discharge of the battery in order to keep the battery in healthy
condition during its codal life
In this condition
amber LED flashes as per clause no. 6.6(vii) and battery
discharge
continues
below10.5 battery voltage to provide current to Amber
indication
LED and Red indication LED. Thus battery may reach to very low
voltage. To avoid the further
deep discharge of battery the circuit should not
allow the further discharge from the battery.
All cluster LED and indication
LED will be deactivated automatically
after reaching to 9.0 volts of battery. The
battery of ELU should be able to re-charge the battery from 9.0 V DC , when the
input supply 110V DC is available to ELU ."
6.6
iv.
Whenever the battery voltage reduces to 10.5 Volts, the battery shall be charged at
14.4 Volts +/- 0.1Volt with current limit as recommended by the battery manufacturer.
After the terminal voltage of the battery on charge reaches 14.4Volts, the charging
shall be switched over to trickle charge mode at 13.5 Volts +/- 0.1Volt.
v.
The system should provide the electronic component i.e. ICs duly burnt with
embedded software wherever is necessary. The Required software or tools for
loading soft code into microcontroller
may be developed by the firm or fir may
use of licensed free compilers. If the software is procured then it should be
procured
in the name ofthe manufacturer and not in the name of any individual.
The following indications shall be provided, which should be clearly visible, when mounted
on the coach.
SN
Parameter
Unit Battery connection intact ( normal
Charl:!ino or Discharoinl:! )
IT. Unit Battery discharging @ 20% during
15 days cycle
III. Failure of 11OV DC Coach Supply
IV. Charging Circuit Failure
V. Unit Battery Unhealthy and needs
replacement (Refer clause 6.9 )
VI. Microprocessor Failure
VII. Unit Battery Voltage is less than 10.5 V
L
Green
ON
Red
Amber --
Flashing
ON
ON
Flashing
ON
Flashing
The LEDs shall be similar to the following types and make or equivalent type and
other make with prior approval of RDSO:-
Prepared By
~\,~10
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ADE(TL-AC &System Design)
Colour of
indication
LED
Nichia make
Seoul
semiconductor
make
Green
NSPG 500 S
LT620
Red
NSPR 510 AS
Amber
NSPY 500 S
Avago
make
Cree make
LR 530A
Green 525 mm Lamp CB
series, HLMP-CM series
Red 626 HLMPEG08- series
C503B- series
C503B- series
LY520 A
Amber 590HLMP EL08 series
C503B- series
6.7
The control circuit of the emergency light unit shall be designed in such a way that the current
drawn by LEOs shall be minimized to give maximum duration of lighting. The actual current
drawn by LEOs shall be such that AH drawn from the battery shall not exceed 5.5 AH for new
emergency light unit. However to compensate the temperature and aging factor of the battery,
the battery used shall be of 7 AH capacity, so that the emergency light will work at least 12
hours during the life of the battery as per Lux requirement stated in clause 6.15.
6.8
The manufacturer shall submit the calculations showing the actual AH drawn from the battery
during the prototype test.
6.9
There should be a provision for cyclic discharge of battery by 20% of its rated capacity to a
maximum time of 4/5 hours automatically by its control circuit at a regular interval of 15 days
to improve the life of the battery. The discharge of the battery shall be carried out by using
either resistance or electronic method without switching 'on' LEOs. This discharge shall be
done during the day time only from 07.00 A.M to 12.00 P.M of every 1st date and 16 th date
of the month,
so that it can be recharged during the remaining period of the day and ready
for use during night in case of emergency situations. If the coach battery fails during such
discharge, the emergency light should switch over to normal mode for readiness as per the
requirement stated in clause 6.16. If resistor is provided for heat dissipation during this cyclic
discharge then the resistor shall be kept inside the housing of emergency light unit.
This condition shall be checked during type test by simulation
method
program by changing the date to 1st or 16th of that particular month.
using computer
U
6.10
The current drawn from the unit battery in idle condition shall be minimum and designed in
such a way that the unit battery will not go below 10.5Volts even after 6 months of storage
without use.
6.11
The emergency unit should switch 'on' its White LED cluster
automatically when supply
voltage drops to 80 Volts DC or below when connected with 110 Volts DC supply.
6.12
In case the microprocessor of the unit fails, the emergency light unit shall work as normal
during emergency situations. The necessary hardware back up arrangements
shall be
incorporated in the 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)
Prepared By
Trickle charging mode should work
ON/OFF as per Para 6.11
Lux level at 20 Lux for 12 hrs.
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6.13
The microprocessor
should have an auto reset facility through an independent
supervisor circuit. In case the microprocessor
is stuck due to EM I, surges
software stuck fault, it should be able to restart by the separate hardware
supervisor circuit.
The power supply circuit of the emergency light unit should have a provision of
case of the following faults.
a) Power supply output over current fault
b) Power supply short circuit fault
c) Stuck against transient & surge fault
d) Input over voltage fault ( over 200 volts)
6.14
watch dog I
or spikes or
watch dog I
auto reset in
The LED shall be arranged
in three clusters as shown in the RDSO drawing
no.
RDSO/PE/SK/AC/0180-2014(
Rev-UO"). Left and right cluster each will have 12 nos. LED and
Middle cluster will have 30 nos. LED. which will meet the Lux requirement stipulated in clause
6.15.
with fully
charged battery
Not less than 250 Lux at 0.5 M
Not less than 100 Lux at 1.0 M
(3)
Not less than 30 Lux at 2.1 M
for the first 2 hours starting with the fully charged
Not less than 20 Lux at 2.1 M
for further 10 hours
(4)
battery
The above values shall be measured at a surface perpendicular to the light rays from middle
cluster of LEDs and when all the clusters are in ON condition. At the start of illumination test,
the battery voltage shall be kept on 13.0-13.5 volts and Lux level as above shall be
maintained up to battery voltage of 10.5 volts.
6.16
The Super Bright White high intensity LEDs shall be from anyone of the following
per type mentioned to meet the Lux requirement as per Para 6.15 :
SN
1
Make of LED
Mis Nichia Corporation,
2
Mis Osram, Germany
3
Mis Seoul Semiconductor,
4
Mis Avago,
Part no. of LED
NSSW156T -P3 or equivalent
Japan
Korea
OEMs as
to above
DURIS
E3 LUWJNSH.EC
BRBT/BSBU
equivalent to above.
HW331 A or equivalent to above
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Singapore
ASMT -UWB 1-ZX3B2
or equivalent
to above
I
Any other make or other part no of above make meeting the parameters
be used with prior approval of RDSO.
(1)
(2)
(3)
(4)
Prepared By
It shall be Super Bright White high intensity and Industrial
Minimum luminous efficiency = 100 ImlW at 25°C,
Life time (L70) = minimum 50000 hrs at T J=70 °C.
View angle = Minimum 100
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ADE(TL-AC
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I Checked
By
of specification
grade type.
may
(5)
(6)
6.17
The following documents shall be submitted for LED by manufacturer of emergency light unit
during prototype test and firm has to provide the copy of record maintained of these
documents by firm during acceptance test , when ever demanded by inspecting
authority:
1)
2)
3)
4)
5)
6)
6.18
Colour temperature = 5000-7000K
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
The emergency light unit will be fitted on the roof ceiling I partition wall of the coach. The
battery portion of the light fitting will be concealed and only LED portion of the light fitting will
be projecting outside. Hence selection of battery and its housing shall be suitable flat
arrangement such that leakage of battery shall not be occurred. The battery should be fitted in
such a way that it can be easily replaced by railway person.
d)
The resistances shall be preferably
loading versus rating shall be 3.
e)
Switching devices such
temperature of 150°C.
g)
The protective-cum-adhesive
coating used on PCBs should be clear and transparent and
should not affect colour code of electronic component or the product code of the
component.
h)
The heavy components
with good finish.
i)
The electronic circuits, PCB and components should also meet the RDSO Spec. No.
ELRS/SPEC/SI/0015
- OCT.2001 (Rev.1) Specification for Reliability of Electronics used
in rolling stock application.
j)
The electronics
specification.
Prepared By
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ADE(TL-A
as transistors,
MOSFETS
should be properly fixed.
and
IGBTs
The shoulder
rating. The actual
shall
have junction
connection
should be
covered for this equipment shall pass all the tests called for in the above
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made of metal film of adequate
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ystem Design)
6.20
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.
6.21
The health of the unit battery shall be monitored using dv/dt characteristics of the battery
during 20% discharge cycle. Any abnormality in dv/dt from its reference value at 20%
discharge rate shall mean that the battery is unhealthy and needs replacement. This shall be
indicated by Red LED flashing which shall continue till the battery is replaced.
The criteria for deciding defective battery shall be decided after discharging the battery
on 1sl and 16th of every month, the battery will be charged for a consecutive 12 hours.
Then the charging will be kept off and discharge resistor will be brought into circuit for
about 5 seconds. At this time the battery voltage shall be more than 12.2 V. If it falls
below 12.2 V within 5 seconds then it may be declared as defective battery."
6.22
Emergency light unit shall be designed with SMPS working on 85 Volts dc to 143 V dc power
supply.
6.23
Emergency light unit shall be designed with battery (U- ion cell) mounted on PCB for back
up to Real time clock (RTC)
7.1
The complete emergency unit will be of compact design with mounting dimensions and overall
dimension as per the enclosed RDSO drawing no,. RDSO/PE/SKIAC/0180-2014(Rev"O")(Sheet 1 and Sheet2) Antitheft arrangement shall be as shown in sheet 2 of this drawing.
The complete emergency unit will be of compact design with mounting dimensions and overall
dimension as per above drawing . Clamp length shall be 172 mm (max) . Length of central
clamp shall be as per dimension of battery hence is not shown in drawing sheet 2 , but the
central clamp will be required to hold the battery in running train. The housing with the hinged
cover assembly shall be of robust and reliable construction. The housing shall be deep drawn
from 0.8 mm thick CRCA sheet to IS 513-94, Grade DD. The hinge should not be visible from
outside.
7.2
The hardware shall confirm to IS 1364 - 92 "Specification for hexagonal head bolt, screws and
nuts". The minimum size of the hardware shall be M5 and the hex. head slotted screw shall
work on tapped frame arrangement.
7.4
The enclosure of the unit shall consist of a top frame and bottom frame and these shall be
deep drawn from 0.8 mm thick CRCA sheet to IS 513- 94 grade DD. The mounting plate
thickness shall be 1.6 mm. The top and bottom frame shall be secured properly to form the
enclosure. Suitable holes for fasteners to be provided for fitment of the unit in the coach.
Holes of 6 mm size for cooling of the unit shall be provided on both side of enclosure for
cooling of battery.
7.5
The enclosure shall be powder coated to a minimum thickness of 60 microns to GREY colour
of MIs. MAR POL shade card No. 7605 or equivalent with prior approval of RDSO.
The battery shall be fixed inside the unit properly to avoid movement in vertical as well as
horizontal direction and taking care of the vibration encountered in service. The battery
mounting shall be suitable for horizontal direction. The battery shall be kept horizontally
I
Prepared By ~~\\O\
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ADE(TL-AC &System Design)
inside the cabinet with its positive and negative terminal facing to the PCB side of the
cabinet of ELU such that battery shall not be inverted after fitted in the coach. Gap
between PCB and battery should be maintained
to keep safe the PCB inside the
cabinet.
7.7
The size of the fixing screws with locknut / washer shall be M5 hexagonal head with slot head
wherever used for the assembly inside the unit.
7.8
Other enclosures of the unit shall be fixed to the member channel arrangement
for easy removal and attending to the battery, PCB etc
7.10
Fire retardant Transparent V-O grade UL-94 polycarbonate sheet of thickness 0.75 mm to 1.5
mm shall be provided for protection of LED from external damage and ingress of dirt.
7.11
Terminals with terminal designation ofWago
for 11 OV dc with blue 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.
7.13
Fire retardant white colour soft wool felt 3 mm thick to specification
all around the fitting.
7.14
Dome key type captive screw to be provided for fixing the cover. Dome key one no. per four
units shall be supplied.
8.1.1
Only after the detail drawings and the design have been approved and the clearance given to
this effect, the manufacturer shall take up the manufacture of the prototype. It is to be clearly
understood that any changes, required to be done in the prototype or any additional tests
other than specified herein are required to be conducted on the prototype unit or its
components, they shall be done expeditiously.
8.1.2
Subject to agreement
between user and manufacturer, ROSa shall repeat some or all type
tests once in three years on sample basis, so as to confirm the quality of the product to meet
the specified requirements.
8.1.3
The type tests shall be carried out by ROSa representative on prototype unit either totally or
in part under the following conditions without any additional cost:
a)
b)
c)
d)
e)
8.1.4
type 261-102
with provision
shall be provided on the top hood
IS 1719 - 88 to be glued
A manufacturer undertakes to manufacture for the first time.
An important change in design details of machines has been introduced.
Specification is modified necessitating re-designing of equipment.
Unsatisfactory performance reported from. user Railways.
Resumption of production after an interruption of more than two years.
Investigation tests are intended to obtain additional information regarding the performance
the production. They shall be specially requested either by the user or by the manufacturer.
Prepared By
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ADE(TL-AC
\'~\ Vl\
&System Design)
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of
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 carried out at the works of the manufacturer in presence of Indian Railway
representative on the prototype unit of the Emergency light unit as per relevant governing
specifications
modified or amplified. The manufacture shall have all possible necessary
arrangement for testing of emergency light unit . Tests
for which
facilities
are not
available with 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 ELU 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 equipmenUcard(s) of the same type and subject it to all
tests or the testes) in which failure occurred. No failure shall be permitted in the repeat testes).
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.
8.3
Acceptance test:
Each offered lot of supply shall be subjected to acceptance tests as per ROSa approved
sampling plan or as per sampling plan specified in IS 2501, at manufacturer's
works.
Acceptance test shall be witnessed by inspecting official nominated by purchaser/ROSO.
Manufacturer on demand by inspecting official shall produce the internal/routine test report
carried out by manufacturer.
S
N
1)
2)
3
4)
Acceptance
test
Visual Test
Checking
of document
of purchase
of
batter
Checkin of document of urchase of LEOs
Checking of bill of material of test sample /
design document
Oielectric Test
Insulation Test
Reverse olarit Test
Performance
test with 7 Ah
batt~
9
Software burn- in test
10 Test for batter
erformance
11 Checking the functioning of Microprocessor
controller
6.17
As per approved bill
of material
during
t pe test b ROSa.
8.8
8.9
8.10
8.11,6.12,6.15
5)
6)
7)
8)
Prepared By
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ADE(TL-AC
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To
conducted
be
8.12
8.13
6.5 ,6.6 ,6.7 , 6.9,
6.10, ,6.13 and 6.15.
12 Mechanical and Electrical Endurance Test
13 Chromaticity and dispersion angle test
14 Performance test in case of Microprocessor
failure
15 Temperature rise test (Dry heat run test)
16 Temperature rise test (Damp heat test)
17 Vibration and Shunting Shock test
18 PCB Burn in cyclic test
19 Surges,
electrostatic
discharge
and
transient
burst susceptibility
tests and
Radio frequency test
"0)
8.6
Fire retardant test
polycarbonate sheet
on
soft
wool
and
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v
v
v
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for one ELU
of every lot
of 50 Nos.
Below
50
nos at least
unit
one
shall
be
checked
for
this test
As per 6.12 during
type test only.
x
x
x
x
x
x
8.14
As per approved
by
LED datasheet
ROSa.
6.12
x
x
x
x
x
x
x
x
x
x
x
x
8.15
8.16
8.17
8.18
I 8.19
7.10and7.13
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 enclosed in packing of unit.
The unit should be checked visually for dimensions as per approved drawing. The general
workmanship should be good with all the component properly secured and sharp edges
rounded off. Visual check for all possible physical verification of compliance of all clause
mentioned in this specification shall be done.
The dielectric test shall be conducted as per the relevant clause of IEC 60571 (latest)
RMS value of test voltage as 1000 Volts AC.
with
The insulation resistance of the" unit between earth and all current carrying parts shorted
together shall be more than 100 Mega ohms at an ambient temperature
measured with
500 Volts Insulation Tester (Megger).
Prepared By
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ADE(TL-A
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stem Design)
Y
The unit shall remain functional after applying 200 Volts dc at 11OV volts dc input terminal
for one minute in correct polarity as well as in reverse polarity.
The emergency light unit shall be tested for its functioning at upper voltage limit, lower voltage
limit and rated voltage of supply system. The unit should work satisfactorily for 12 hours at
room temperature with 7 ah battery. The illumination level shall also be measured during the
performance test and the level shall not be less than 250 Lux at 0.5 meters, 100 Lux at 1
meter and 30 Lux and 20 Lux at 2.1 meters as stipulated in clause 6.15. The illumination
achieved on both side of centre of Emergency light unit at 2.1 m should be uniform or vary
within +/- 10% though it will
not be as good as at the centre and lux requirement
stipulated in clause 6.15 will be for the centre location only not for the sides.
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 shall be noted. Battery capacity shall be calculated by
following formula: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 unit will be subjected to 5000 switching operations with 30 seconds 'ON' period and 30
seconds 'OFF' period in locked chamber with automatic recording arrangement. None of the
unit component should show sign of damage/deterioration.
The tests shall be carried out as per latest IEC 60571- on the complete electronic assembly in
closed condition as during normal operation, on full load, placed in test chamber where
temperature is progressively raised from ambient from 70°C for 6 hours as per clause
no.12.2.5 of lEe 60571: 2012 or latest.
Prepared By
~vf' \'D \ VO 11
ADE(TL-~m
Desi n)
The temperature rise test (Damp heat test) to be conducted as per clause no. 12.2.6 of IEC60571: 2012 or latest.
Functional
random vibration
test conditions
shall be as per clause
category 1 class B Body mounted Figure 3 of IEC 61373:2010 or latest
Table
Simulated long life test as per clause no. 9 Table 2 Category
Figure 3 of I EC 61373:2010 or latest.
1 class B Body mounted
Shock test as per clause
61373:2010 or latest.
B Body
no. 10 Table 3 Category
It shall be done in accordance
(Rev-1) Oct -2001.
I.
no.8
with ROSa
1 class
specification
mounted
1
of IEC
No. ELRS/SPEC/SI/0015
Burn-in test shall be undertaken between - 25 0 C to +700 C as per temperature
in Annexure-1 of ROSa specification No. ELRS/SPEC/SI/0015.
cycle given
II.
Test is to be conducted continuously for 45 hours i.e. 6 cycles of 7.5 hours on populated PCB
of emergency light unit.
III.
Test shall be conducted during energized condition of PCB card in each cycle during positive
& negative temperature peak as under.
(a)
+12V DC is applied on the populated PCB at B+ terminal of PCB and LED cluster
PCB connected through jumper like arrangement
so that both PC B can be tested
during burn in test. "
(b) The critical most output is of LED cluster drawing power which is measured at LED+
terminal PCB ground and the same should be between +13.5 V to 16.5 V.
(c) The glowing of LED cluster during Burn in test on populated PCB shall be checked
to ensure the energizing condition
of PCB.
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.
Prepared
By
ADE(TL-AC
.~\f\!\
~\\O
\'),t\~
&System Design)
8.19
Surges, electrostatic
frequency test
discharge
and
transient
burst
susceptibi
lity
tests
and
Radio
These test shall be conducted as per clause 12.2.8 and 12.2.9 .Qf IEC - 60571:2012
latest.
a. Surges test as per clause no. 12.2.8.1 of IEC 60571-2012 or latest.
9.1
b.
Electrostatic
discharge
60571-2012 or latest.
c.
Transient
latest.
d.
Radio frequency
latest.
immunity
e.
Radio frequency
latest.
emission
susceptibility
burst susceptibility
test
test
as per clause
no. 12.2.8.2
or
of IEC
as per clause no. 12.2.8.3 of IEC 60571-2012
or
test
as per clause no. 12.2.9.1 of IEC 60571-2012
or
test
as per clause no. 12.2.9.2 of IEC 60571-2012
or
The Emergency Light Unit shall be provided with a name/rating plate on the enclosure. The
following information shall be available by either etching process or by engraving or screenprinted.
i)
ii)
iii)
iv)
v)
vi)
Manufacturer's name and address. It will be clearly printed on the enclosure such
that it can be seen after fitting in 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)
Prepared By
Component outline in the proximity of the component through
etching/screen
printing on PCB;
ELU manufacturer's name through etching/screen
printing.
SMD LED assembling sub vender name shall be indicated on PCB through etching
or sticker.
Version number of Hardware through etching or sticker.
~11
ADE(TL-AC
o)'1D ,'--1
&System Design)
I Checked
By
DSE(TL-AC
& System Design)
a)
b)
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 Annexure D. Dimension given in annexure D may be as
treated as maximum but format of name plate shall be same and name plate should be
legible.
9.5
The equipment and its sub assemblies shall be packed in thermo Cole /corrugated
boxes
and the empty spaces shall be filled with suitable filling material. Before keeping in the thermo
Cole/corrugated
box, the equipment shall be wrapped with bubble sheet. The equipment
shall be finally packed in a wooden /corrugated
boxes case of sufficient strength so that it
can withstand bumps and jerks encountered in a road/rail journey.
TRAINING:
10.0
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 guarantee/warranty
obligation of the complete Emergency light including
as per IRS condition of contract.
battery shall be
Firms shall have to comply to ROSa STR no. RDSa/p E/STR/AC/0034-2012
(rev-O) with
additional Chromo meter to measure Lux as well as coordinates of LED 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.
Prepared By
~~"D\2A)1
ADE(TL-AC &System Design)
~
The firm shall not engage cartel formation with other firms and shall also submit a declaration
in this regard as per annexure attached of this specification.
The manufacturer
Railway containing:
shall
submit
operating
& maintenance
manual
to ROSO
and the
user
a) Bilingual (Hindi and English) instructions for operation, maintenance and troubleshooting
b) Power & control electrical diagrams showing various connections to Emergency light unit.
c) Write- up on the working of Emergency light unit.
Production units and Zonal railways 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
(ELU) as per ROSO Modification sheet no. ROSO/PE/MS//0047-2009(Rev-0)
issued by ROSO
vide letter no. EL/6.46 dated 27.01.2010.
18.1
Performa for undertaking against cartel formation
to be furnished by the manufacturer
Prepared By ~
l (\\' . I
·~\,tl
\
VO\ l\
ADE(TL-AC &System Design)
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 Registering Authority i.e. RDSa may delist the name of our firm from the Master List of Approved Vendors if complaint is received about such
cartel formation from any of the Railways/Production Units.
Seal and Signature
(Authorised signatory of the firm)
Prepared By
~\IO\'1.t'
y
ADE(TL-AC &S stem Desi n)
iv~it;g~'
Waveform
at
; DC bus bar at No
I
Load. ERRU off and
: lnvertors off.
t-----
_ --.
i Voltage Waveform
at
DC bus bar • ERRU
; off and poth
lnvertors on with full
RMPUload.
Prepared By
~\t~'?P'\"\
ADE(TL-AC &8 stem Design)
Voltage Waveform
at
DC bus bar at No
load.
ERRU ON and
single inverter ON.
It-
-'-'-------------'---
I Voltage Waveform at
DC bus bar at full
RMPU load. ERRU
ON and single
inverter ON.
Prepared By
~h
\ "'"
'v.,v
l\\,{~ \ 0
y-=--'5'1
,\
ADE(TL-AC
f'I\1
"1
&System Desi n)
I
~--_
...•.••.•.... ,..•_•.•..
110VACline
waveform at
secondary of
415V/ll0V
transformer of
control panel
110V AC line
waveform at
secondary of
415V!110V
I
transformer
of
control panel
(After Filter)
Prepared
By ~
IID\'),1>\ II
ADE(TL-AC &System Design)
BURN-IN TEST
emperature
in Degrees
14
5.2
2.1
5.5
91
9.4
12.5
13.2
12,57
13.12
15
Time (Hrs)
0.1=10 Min
5.27
1.55
On
Off
Prepared By
~'t!\.'
~O\ 1»IY
ADE(TL-AC &Svstem Design)
5.42
9,17
932
14.41
'iLh ~'"
Blink
e5J
.0<
"V
Red
U$~
p.)
I\)
g
01 ••••• -oJ
tD-' 111
gg
I\)
p.)
o
Amber
iii' tD
i!
!.
;j'
o
Amber
ila
!~.
Prepared By
• r'\
\.~("
~~,''t)l
\UI~
ADE(TL-AC &System Design)
0
0
b
0
CHIEF ELECTRICAL ENGINEER:
.
1
Northern Railway, Baroda House, New Delhi - 110 001.
2
Central Railway, II Floor, Parcel office. CST Mumbai - 400001.
3
Eastern Railway, Fairlie Place. Kolkata - 700 001.
4
South Eastern Railway, Garden Reach, Kolkata - 700043
5
Southern Railway, Park Town. Chennai - 600003.
6
Western Railway, Churchgate, Mumbai - 400 020.
7
South Central Railway, Rail Nilayam. Secunderabad - 500 371.
8
East Central Railway, Dighi Distt- Vaishali, Hajipur Bihar- 844101
9
North Central Railway, Balmiki Crossing, Nawab Yusuf Road, Civil Lines, Allahabad- 211 001.
10
South Western Railway, 1" Floor, DRM Office, Hubli 580 020
11
South East Central Railway, Bilaspur.495004
12
North East Frontier Railway, Maligaon, Guwahati - 781001
13
North Eastern Railway. Gorakhpur - 273001
14
North Western Railway, Jaipur-
15
West Central Railway, JabaJpur - 482001
16
East Coast Railway, Bhuvneshwar, Orrisa - 751016
17
Konkan Railway, Belapur Bhavan, Sector-11, Belapur, Mumbai - 400614
302006
18
Metro Railway, 33/1 J.L. Nehru road, Kolkata- 700071
19
Integral coach factory, Perambur, Chennai - 600038
20
Rail Coach Factory, Kapurthala (Punjab) - 144 602
CHIEF WORKS MANAGER:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Matunga Workshop, Central Railway, Mumbai 400 019.
Liluah Workshop, Eastern Railway, Howrah
C&W Workshop, Northern Railway, Alambaqh, Lucknow-226 05
C & W Workshop,N. Rly., Jagdhari - 135 002
Mechanical Workshop, NER, Gorakhpur - 273 012
Carraige Workshop, Southern Railway, Perambur, Ayanavaram, Chennai - 600023.
SCR, Lallagudda Workshop, Lallaguda, Secunderabad - 500017
Carriaqe Workshop, Western Railway, Lower Parel, Mumbai-400013
CRWS, W. C. Railway, Nishatpura, Bhopal-462010
Carriaqe Workshop, NW Rly,. Aimer - 305001
Carriage Repair Workshop, Gadag Road, SWR, Hubli - 580 020
Carriaqe Workshop, S.W. Railwav, Mvsore Vishwanath.
Carriage Workshop, SE Rly., Kharaqpur - 721301
New Bongaigaon . Railway Workshop, Dangtal, Distt. Bongaigaon, Assam-783380
15
16
17
18
Carriage and Wagon Workshop,
Carriaqe and Waqon Workshop,
Carriaqe and Waqon Workshop,
Carriage and Wagon Workshop,
Carriage and Wagon Workshop,
Central Workshop, Golden rock,
19
20
OTHERS:
1
2
3
N. C. Rly., Jhansi - 248003
WC Rly., Kota - 324002
Eastern Rly., Liluha - 711204
W. Rly., Pratap Nagar, Vadodara - 390004
N Rly., Amritsar -143001
S. Rly., Trichi - 620004
Director, IRIEEN, Nasik Road IMaharashtra). - 422101
Senior Professor (Elect.). Railway Staff College. Lalbaug, Vadodara. - 390004
Director, IRCAMTECH, Maharajpur, Gwalior - 474 020.
172
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J
M.S.SIlEET
IS 2062·99
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REF No.1 PART NO. DESTRIPTION
REF : EL/6.4.6
NOTE;·
*
[)T·I
D
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10072014
"I
I A.KS~
I MMS---i'lI)'17JM.--
I. ALL DrMEN.\IONS
TInE:·
IN mm. AND TOLERANCE SHALL BE AS PER IS 2102
2. ALL ITEMS SHALL BE GIVEN SURFACE TREATMENT FOR ANTIRUST
BEFORE FINISHING WITH BROKEN WHITE POWDER COATING.
&
ANTICORROSION
I DETAILED
DRG NO.
E3®
I
NOIEACH PCS.
SCALE:
MATL.
I
ANTI THEFT HOLDING CLAMP
FOR BATTERY OF EMERGENCY LIGHT HOUSING
(Rev "0")
1079
SPEC.
*
*
*
*
REMARKS
APPROVED BY :
DRA WING FOR THE
RDSOIPElSKfI1.I0180·2014
1341·BI
Sheel2 of2
FIRST ISSUED
10.07.2014
SUPERSEDES: NIL
SUPERSEDED BY: NIL
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IS: 5270-69
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CAPTIVE
2
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IS: 2062-99
,
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SCREW
CONNECTOR
(·w
(/'.15)
)
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2
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2
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I
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IS:SI3·94(GR.[;D)
mm)
(O.im.m Thk.)
REF N0.1 PART NO. DESTRJYnON'DEIAILEDDRGNO. NOHCH PeS.
I ALL DIMENSIONS
~. ITDf
rN r:'lm TOlERASeE
I &:! SHOULD
l \Th'TIL"TING
BE DRAWN
SH.~ll
Ill: .-'\5 Pl:R IS~OI~ L~lESSSPEaFJED.
AND ~OrF:\BRIC\fED.
HOlES 1\", BE PROVIDFDO~
TIlE SIOE$OF
mE
FmED.
* 4. 9EFORE
ITEMS SIH.lL BE GIH:N SUHAC'E fRE.\ThIENT fOR ANTIRUST ., ANTICORRO$ION
HNISIONG \\1m SMOKE GR..,:, roWDER
MARPOlE 7605.
All.
S DOM.E KEY SHALlOE
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$l-L\U
REF: EL'6A.6
TITLE:-
EJ-@
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ISCALE:
MATL.
I
*
*
SPEC. REMARK
FIRST ISSUED
10.07.2014
~UPERSEDES: NIL
BE INSJOE l~'TT
(Rev "0")
!J41·01
SIJ-94 IGR-DD)
APPROVED BY :
-- _
ORA WING FOR THE
EMERGENCY LlGlIT UNIT HOUSING
FOR CONV. TYPE TUAC CC:.{'}!ES
RDSOIPElSK!fUOI~fl..2014
GAlVO
WAGOMAKE
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(~61·IO~.
Sheet I
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Sl'PERSEDED
BY: NIL
I

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