Hkkjr ljdkj jsy ea=ky; - rdso. · PDF fileREGULATED BATTERY CHARGER FOR LHB COACHES 0.0 FOREWORD: At present, 6.5kW „ON Board‟ type Regulated Battery Chargers (RBC) are being provided

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

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RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

SPECIFICATION FOR 4.5kW UNDERSLUNG TYPE CONSTANT VOLTAGE

REGULATED BATTERY CHARGER FOR LHB COACHES

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SPECIFICATION No. RDSO/PE/SPEC/AC/0183(REV ‘0 1’) – 2015 2017

SN Date of

Revision/amendment

Revision/Amendme

nt

Page no. Reasons for revision

1. -- Rev „0‟ 20 First issue

2. -- Rev „1‟ -- To change the outline of display

cubicle with the same overall

dimension, to increase the fuse rating,

to revise the temperature of

transformer, revision of facilities at

the firm and some other minor

changes.

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Approved

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Executive Director/ Power Supply & EMU

Page 2 of 23 RDSO/PE/SPEC/AC/0183 (Rev. „1‟)-2017

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I N D E X

CLAUSE

No.

DESCRIPTION PAGE

No.

1.0 SCOPE 3

2.0 SYSTEM OPERATING DETAILS 3

3.0 GOVERNING REFERRED SPECIFICATIONS 4

4.0 SERVICE OPERATING CONDITIONS 4

5.0 TECHNICAL SPECIFICATION 5

6.0 GENERAL REQUIREMENT 6

7.0 PROTECTIONS AND INDICATIONS 8

8.0 CABLES 9

9.0 TESTS 10

10.0 DETAILS OF TESTS 11

11.0 TEST SCHEMES 14

12.0 TESTING FACILITIES SCHEDULE OF TECHNICAL

REQUIREMENTS

15

13.0 GUARANTEE WARRANTY 16

14.0 PRE-COMMISSIONING AND COMMISSIONING TESTS 16

15.0 SAMPLING 16

16.0 SPARE AND MAINTENANCE MANUAL 16

17.0 INFORMATIONS TO BE SUBMITTED 16

18.0 APPROVAL OF DESIGN/DRAWINGS 17

19.0 FAILURE DURING GUARANTEE WARRANTY PERIOD

OR UNDER MAINTENANCE CONTRACT

17

20.0 TRAINING 18

21.0 DEVIATIONS 18

ANNEXURE-1 (Bill Of Material) 19

ANNEXURE-2 (RCF‟s Drg.) 20


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SPECIFICATION FOR 4.5kW UNDERSLUNG TYPE CONSTANT VOLTAGE

REGULATED BATTERY CHARGER FOR LHB COACHES

0.0 FOREWORD: At present, 6.5kW „ON Board‟ type Regulated Battery Chargers (RBC)

are being provided in the LHB coaches inside the switch board cabinet to charge the 70

Ah/120 Ah batteries and to feed the supply to Emergency light, PA system & sanitary

system. Failures of existing battery charger are reported to be very high due to improper

thermal management because of space constraint. It is; therefore, decided to use natural

cooled „Underslung‟ type Regulated Battery Chargers (RBC) in LHB coaches. This

specification is prepared for 4.5kW Underslung type Regulated Battery Chargers herein

after referred as „RBC‟ to suit the VRLA batteries and requirement of load connected to

it.

1.0 SCOPE

1.1 This specification covers the design, manufacture and supply of Natural cooled IGBT

based and DSP controlled Battery Charger suitable for Underslung mounting on LHB

type coaches working on a nominal input 3-phase supply of 415 volts±15%, 50Hz±3%

from generator power car or locomotive.

1.2 Coach Display Panel cubicle shall be suitable for on-board mounting comprising of 3-

phase MCB at input, HRC fuses at output with indication for protection and LCD display

for different parameters such as current, voltage and fault diagnostics etc.

1.3 All the equipment/component used in the system shall be of proven design and suitable

for rolling stock applications.

1.4 RBC shall also include the following and any other equipment essential for its proper

functioning:

S.N. Description Quantity

i Input and output cable‟s terminal lugs 1 set

ii Coach display panel and wire from Coach display panel RBC to

display panel Underslung cubicle along with connectors

1 set

2.0 SYSTEM OPERATING DETAILS: The RBC shall be suitable for 3-phase, 415

volts±15%, 50Hz±3% AC supply receiving from three-phase generator of power car or

from locomotive converter. This charger, incorporating galvanic insulation from the

mains, and shall provide power supply in the coach at for 110 volts DC load and at the

same time to charge the VRLA battery with capacity of 70 Ah/120 Ah.

The input shall be provided with MCB and the output shall be protected with HRC fuses,

replaceable from the front. The charger Underslung cubicle shall be designed for IP-65

protection class. The heat generated by the power components shall be dissipated

through suitable heat-sinks. All the electrical terminals shall be made of IP-67 protected

circular shell connectors.

The charger RBC shall be designed to measure battery current internally within the unit

and battery voltage at a separate battery connection output terminal of the unit. There


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shall be no damage to any of the power semiconductor devices in either the input or

output circuits due to short circuit at the output. The manufacturer shall furnish complete

design details of the charger along with the internal test results while offering for

prototype testing.

2.1 PROPOSED SCHEME: The three phase 415 volts±15%, 50Hz±3% AC supply

shall be processed to required voltage in a controlled way using latest IGBT with Digital

Signal Processor (DSP) based electronics for control & protections so as to meet

performance the requirement of the specification. RBC shall have and having galvanic

isolation between input and output

The unit RBC shall work without human intervention except arrangement of input AC

power supply and switching „ON‟ and „OFF‟ the unit. The unit RBC shall be free from

maintenance by design.

There shall be a an on-board Coach display panel which shall be mounted on-board in

the coach. RBC shall be so designed so as to work with or without the display panel.

3.0 GOVERNING REFERRED SPECIFICATIONS: The equipment covered shall

generally comply with the relevant clauses of the following specifications with latest

version and as modified by this specification:-

i) IGBT IEC:60747/IS: 3700

ii) Semiconductor fuses IEC:60269-4

iii) Meters IS:1248

iv) Paints IS:8662

v) Degree of protection IEC:60529

vi) Danger Notice Plate (Anodizes aluminum) IS:2551

vii) Steel for general purpose- SS 304 IS:2062

viii) Method of random sampling IS:4905

ix) Low voltage switch IS:8623

x) Railway applications- Electronic

equipment used on rolling stock

IEC:60571

xi) Power inductors IEC:60310

xii) Power Capacitor for power electronic IEC:61071

xiii) MCB IEC:60947

xiv) Power converter installed on board rolling

stock

IEC:61287

xv) E-beam cables ELRS/SPEC/ELC/0019 Rev. 2

xvi) Reliability of electronics Used in rolling

stock Application

ELRS/SPEC/SI/0015-Oct-2001

xvii) EMI/EMC compatibility IEC:61000

xviii) Vibration & Shock test IEC:61373

Note: Latest version of the above specifications/IEC shall be applicable.

4.0 SERVICE OPERATING CONDITIONS: The equipment shall be sturdy and generally

suitable for the following service operating conditions normally to be met in service.


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4.1 Environmental conditions

i) Maximum ambient air temperature 55°C

ii) Minimum ambient air temperature -5°C

iii) Max. relative humidity 98%

iv) Coastal area The equipment shall be designed to work

in coastal area in humidity, Salt laden and

corrosive atmosphere.

The maximum value of the condition in the coastal area will be as under:

a. Max. pH value 8.5

b. Sulphate 7 mg/litre

c. Max. concentration of chlorine 6 mg/litre

d. Max. Conductivity 130 micro Siemens/cm

e. Annual rainfall Ranging between 1750 to 6250 mm with

thunder storm

v) Altitudes Not exceeding 1200m

vi) Dust Extremely dusty and desert weather and

desert terrain in certain areas. The dust

contents in air may reach as high values as

1.6 mg/m3

4.2 Vibrations: The equipment shall withstand satisfactorily comply the vibration and

shocks as per IEC-61373. Normally vibrations encountered in service are as indicated

below:

(a) Maximum vertical acceleration : 3g

(b) Maximum longitudinal acceleration : 3g

(c) Maximum transverse acceleration : 3g

(„g‟ being acceleration due to gravity)

4.2.1 The vibrations are of sine wave form and the frequency of vibration is between 1Hz to

50Hz. The amplitude „a‟ expressed in „mm‟ is given as a function of frequency (f) by

equation.

a=25/f for value between 1Hz and 10Hz

a=250/f2 for values between 10Hz and 50Hz

Because of track irregularities, level of shocks and vibrations to which RBC are exposed

are far more than actually given in IEC for underslung mounting arrangement. Measured

data of vibration levels at critical locations of underslung cubicle and its mounting

arrangement of existing fittings, which can be used for design and in case of any doubt,

the manufacturer must carry out instrumented trials on existing stock for measurement of

shock and vibrations in consultation with RDSO, Lucknow at design stage only. The

fitting and its mounting arrangement shall be so designed that the performance is not

adversely affected due to such high vibrations and shocks.

5.0 TECHNICAL SPECIFICATION:


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5.1 The RBC shall be designed for the following rating and other particulars:

i) Type Constant voltage with current limiting

ii) Input

Nominal voltage 415 V AC 3-phase, 3-wire system

Operating voltage range 415 V ±15%, 3-phase AC, 50 Hz ±3%

iii) Output

DC output Voltage 110V to 135 volts (settable with the help of Key

pad)

Output current DC 35A Maxm

a) Battery charging current 10A to 20A (settable with the help of Key pad)

b) Other Loads 15A

Operating Modes Constant voltage

5.2 REGULATION: The RBC shall give supply a DC output voltage of 122 volts to battery

for charging during normal operation. The value of output voltage shall be maintained

within 2% over in the entire range of input AC supply variation and the charging

current output variation.

5.3 EFFICIENCY: The efficiency of the unit RBC shall not be less than 85% at half load

and not be less than 92% for at full load for in the entire range of input voltage range.

5.4 RIPPLE CONTENTS: The unit RBC shall be designed in such a way that the output

voltage ripple factor (r.m.s.) to shall be less than 2% of the set value of voltage and

current ripple factor (r.m.s.)to shall be less than 3% of the set value of the full load

current at all loads when measured across a resistive load.

5.5 PROTECTIONS:

5.5.1 Over voltage: Over voltage protection shall be provided employed to avoid the unit

equipment giving supplying high voltage beyond the 135 Volts. Tripping of the RBC

should be at higher than required charging voltage i.e.135 V DC.

5.5.2 Current limit: The battery charger shall have current limiting feature for battery

charging and shall be limited to set value (10-20Amps) and total output of the unit RBC

shall be limited to 35 Amps.

5.5.3 AC input: A 20 Amps three-pole MCB suitable for rolling stock application shall be

provided at input side.

5.5.4 Output fuse: There shall be 2X20 32 Amps HRC fuse in each positive path on output

side i. e. for battery and other load.

5.5.5 AC over / under voltage protection: AC under / and over voltage protection shall be

provided at below 350 V and beyond 480 V AC respectively with an audiovisual alarm.

The unit RBC output voltage shall automatically be available as and when the AC


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voltage is within 350 V to 480V. This shall be prominently displayed with audio / visual

indication.

5.5.6 Controls: The unit RBC shall be provided with the following minimum controls:

i) AC input MCB

ii) Unit ON/OFF

iii) Trip reset push button

6.0 GENERAL REQUIREMENT

6.1 Choke and transformer may be provided in a separate compartment/cubicle (if required

for better thermal management) but shall be provisioned provided within overall size as

specified herein after. The cable entry holes for the above shall be made at the top. Cable

glands along with low halogen, low smoke fire retardant (UL94V0) conduit confirming

to IEC: 61386 of suitable size of reputed make confirming to IP-67 shall be provided.

6.2 High frequency natural cooled transformer with H-class insulation shall be used to step

down the voltage and to provide isolation. Designer Manufacturer is free to use the

transformer core as common as to input filter inductance also to reduce the overall size.

6.3 IGBTs shall be used as power devices and shall be selected based on the switching

surges either from input supply or through output. Actual measurement selection may be

carried out by manufacturer and shall be incorporated in design calculations.

6.4 The underslung cubicle for Regulated battery charger shall be made of minimum 2.0 mm

thick, SS304 grade stainless steel sheet conforming to IS: 10632 Pt-3 with suitable anti-

chipping and antirust painting (Black/Grey) on outer side with a coating thickness of not

less than 80 microns and suitable painting on inner side. Details and Proof of used anti-

chipping and antirust paint including procedure of painting shall be submitted by the

manufacturer along with internal test result.

For on-board display cubicle, minimum 1.6 mm thick metallic cold rolled closed

annealed (CRCA) sheet steel conforming to IS: 513 shall be used. The housing shall be

powder coated with grey colour to a coating thickness of not less than 60 microns.

6.5 All material used in manufacturing of unit the RBC shall be fire retardant. All the

electronic component shall be used of industrial grade (minimum) and the Electrolytic

Capacitors shall be of 1050C category with extra long life.

6.6 The electronics of the equipment shall be reliable and shall conform to RDSO

Specification No. ELRS/SPEC/SI/0015-Oct-2001 or latest for reliability requirement

assurance. Over all and fixing mounting dimensions shall not exceed the approved

specified limits. The enclosure shall be designed for natural cooling.

6.7 Suitable low smoke fire retardant (UL94V0) gaskets of neoprene rubber shall be

provided on the covers to prevent ingress of water, dust and moisture.


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6.8 Components‟ /equipments rating, type and makes as approved by RDSO (wherever

applicable) shall be used. Final design documents shall be approved by RDSO based on

the prototype test results report and observation/ feedback noted during service trial. No

deviation in Approved make/grade of components/grade/sourcing shall not be changed

without obtaining prior approval of RDSO.

6.9 Only virgin core shall be used in high frequency transformer. Released core shall not be

used in any condition.

6.10 All the replaceable components such as fuses, indicating LEDs and switch modules etc.

shall be mounted at the front side of the display for easy maintenance.

6.11 All the studs for fuses and terminals shall be provided on FRP/SMC terminal boards

made with adequate clearance and creepage distances.

6.12 Minimum values of adequate creepage distance and clearance shall be maintained from

the live terminals to earth and between live parts as per IS: 13947.

6.13 A rating plate (marking plate) made out of 1 mm thick aluminum sheet shall be riveted to

the inspection outside the cover of the underslung cubicle unit with letter etched painted

white in black background.

6.14 All the hardware including those used for electrical terminals shall be stainless steel

hexagonal head screws and nuts conforming to SS-304. Plain and spring washers shall be

used as per the requirements of fastening arrangement. Screws used for mounting of the

components shall preferably be on tapped holes, wherever necessary.

6.15 Two Nos. tinned copper earthing pad with tapped hole and brass M10 bolt with flat

surface & spring and flat washers shall be provided on front side of the unit underslung

cubicle frame member conforming to IS: 2062 (latest edition) and two nos. of 300 mm

long 16 sq. mm bare copper braided cables duly crimped on both ends to be supplied

with each unit RBC.

6.16 Suitable terminal arrangement shall be made to connect 3-phase, 415V incoming power

supply to the RBC unit with the help of suitable size of cable glands circular connectors

suitable for rolling stock application as per MIL-5015H with pin identification depending

on the circuit requirement of the product, having IP-67 protection and fire retardant

(UL94V0), low smoke halogen free flexible conduit.

6.17 Terminal markings R, Y, B, DC+, DC-, and BC+ and BC- shall be engraved on

Terminal board. The termination of internal connections shall facilitate palm-to-palm

connections.

6.18 Caution Danger plate as per IS: 2551 (latest edition) made out of 1 mm thick and 100

mm x 100 mm size aluminum sheet shall also be riveted to the inspection outside the


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cover of underslung cubicle the unit worded as approved by RDSO with letter etched and

painted white in red background.

6.19 The complete unit RBC shall be free from maintenance.

6.20 Size and weight of the RBC charger unit shall be as small as possible. The size of the

battery charging unit underslung cubicle shall not be more than 900 mm (L) X 755mm

(D) X500mm (H) suitable for underslung mounting and the weight of the battery charger

shall not be more than 75 Kg. The mounting dimension of underslung cubicle shall be

850 mm(L) X 300 mm(D). The maximum possible envelope for RBC size of Coach

display panel cubicle is 440 mm(L)X400mm(D)X325mm(H).However, the size of the

Coach display panel with mounting shall not be more than 300 mm (L)(H) X 250mm (D)

X500mm (H) (L) with four elliptical mounting holes, each having dimension

ɸ10mm(L)X15mm(H). The mounting dimension of Coach display panel shall be

470mm(L)X250mm(H). However, RDSO reserve the right to change the dimensions at

the time of design approval or prototype approval.

Dimension for mounting shall be at 300mm leaving 50mm from both the ends and shall

generally confirm to RCF drawing No. LS71104 (Tentative) enclosed as Annexure-2.

6.21 Use of silicon coated wire wound resistors and metal film resistors are recommended.

All the PCBs used shall be of FR-4 having with good workmanship.

6.22 Manufacturer shall provide a screen-printed single line diagram inside the front opening

cover of underslung cubicle at suitable place on charger unit.

6.23 Equipment cubicle / body shall not be connected to any circuit / PCB and shall not be

used for any type of earthling or shielding.

6.24 The connectors shall be located left side of the underslung cubicle. Cable connection

shall be in front in Coach display panel.

6.25 The cubicles shall be designed for natural cooling.

7.0 PROTECTIONS & INDICATIONS

7.1 The underslung cubicle/unit RBC shall include the following minimum protective

features:

Protection against ingress of dust and water shall be IP-65 and IP-20 for underslung

cubicle and Coach display panel respectively.

AC MCB of suitable rating at input side on Coach Display panel (CDP)

Output fuses on CDP

Input supply over voltage set at 480±1 V.

Input supply under voltage set at 350±1 V.

Output short circuit protection shall preferably be by blocking firing pulse block.

Output overvoltage trip at beyond 135Volts.

Over load protection


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Earth fault.

Thermal over load of semiconductors. and transformers.

Capacity to withstand input of 510V AC for two minutes without any damage to any

part of the RBC unit.

Single phase protection and functioning at reduced load: The RBC shall be protected

against the single phasing at the input side. However, the RBC shall be able to

function normally and shall deliver 35% of the full load even when one phase is not

available at input.

Reverse polarity protection

Output current / voltage limit

7.2 INDICATIONS: The Coach display panel cubicle of RBC on CDP shall have the

provision of following indications through LEDs. Fault shall be displayed with audio

signal, if occurred.

Input AC on (3-Phase) – R, Y, B

Battery charging “ON”

Faults indications

Fuse failure (for output fuses)

AC Input over voltage

AC input under voltage

Reverse polarity

Earth fault

Output over voltage

7.3 FAULT DIAGNOSTIC: The RBC shall have following features for fault diagnostics

with LCD display and key pad on Coach display panel:-

i. The battery charger RBC shall be provided with following faults with brief description

for voltage/current.

Input under voltage <350Volts

Input over voltage >480Volts

Reverse polarity

Output short circuit

Over Temperature

Output overvoltage >135V

Over current

ii. Port for down loading of faults – The RBC shall be provided with self-checking

feature and facilitiesy to down load data through USB port on commercially available

USB pen drive. Diagnostic system shall be capable of recording at least last 300 latest

faults with real time clock with override feature i.e. first come first out FIFO). Any

There shall not be provision for deletion or clear the data/faults. shall not be provided.

iii. Format for the downloading data shall be as follow (for illustration purpose):


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Date Time (24:00:00hr) Brief Description Fault values

From To

11/11/16 15:09:56 15:10:05 Over Temperature Temperature of … item 95ºC

8.0 CABLES

8.1 The number of wires/cables to be used shall be reduced to minimum. The use of

insulated copper busbar is preferable. The wires/cables below 10 Sq.mm. shall be PTFE

and higher than 10 Sq.mm. that e-beam cables as per RDSO Specification No.

ELRS/SPEC/ELC/0019 (Rev „2‟) with latest amendment shall be used. The use of PVC

cables/wires is not acceptable. Outer sleeves, if used, for bunching the control wiring

shall be low smoke halogen free fire retardant. Fire retardant heat shrinkable sleeves

shall be provided at the termination point of the cable.

8.2 All the connections including incoming and outgoing connections of transformer shall be

of crimped type sockets and numbered/ferruled with cable markers corresponding to the

wire numbers of the schematic diagram and neatly bunched over suitable insulated

stiffeners with fire retardant ties.

8.3 The RBC shall be provided with connectors suitable for rolling stock application as per

MIL-5015H with pin identification depending on the circuit requirement of the product.

The Connectors shall be provided with IP-67 protection, corrosion resistant., fretting

corrosion resistance and pins shall be accessible for making connections at the time of

commissioning /replacement.

8.4 The supply of connectors shall be within the scope of manufacturer. Adequate

clearances/isolation shall be ensured between the various terminals of different voltage

levels in the terminal box.

8.5 Five core Inter-connecting control communication cable between ON Board Coach

display Panel and underslung RBC cubicle along with their end connections of suitable

IP protection of and suitable length will form a part of supply against the order for

supply of Under Slung the RBC.

9.0 TESTS: Separate type, Acceptance, Routine and Investigation tests for the RBC

assembly and complete unit installed on a coach will be conducted. Resistive(R)-L load

of 4.5 kW (with overload, if any) shall be arranged at the manufacturers‟ premises by the

manufacturer for the purpose of testing. Various tests shall be performed by simulating

the combination of inductive and resistive load of adequate capacity matching the rating

of the RBC.

RDSO may conduct surprise check on manufacturing process and quality control along

with any of the test to ensure quality of product and its conformance to RDSO's

specification.

9.1 PROTOTYPE TEST: Prototype of the RBCunits will be inspected / tested by RDSO at

manufacturer‟s premises. All the tests shall be carried out on one prototype sample (first


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unit equipment) of the RBC developed by the prospective manufacturer in the presence

of representative from of RDSO to establish the conformity of the product with the

specification. This prototype sample shall not be commissioned in the field, however, the

same shall be kept in the premises of the manufacturer for future references.

9.2 TYPE TESTS: Type tests shall be carried out on one RBC unit of given design to verify

that product to meet the requirements specified and agreed between user and

manufacturer. Subject to agreement between user and manufacturer some or all the type

tests shall be repeated whenever required by RDSO on sample basis, so as to confirm the

quality of the product to meet the specified requirements. In addition, the manufacturer

shall repeat the type test to be witnessed by representative of RDSO or purchaser either

totally or in part in following cases without any additional cost: -

Modification of equipment likely to affect its function.

Repeated failure of equipment or variations established during routine tests

Resumption of production after an interruption of more than two years.

In any other condition where RDSO/Purchaser felt necessity of the type test.

9.3 ACCEPTANCE TESTS: The acceptance tests are to be conducted in the presence of

Railways nominated representative on the samples selected at random or on all as agreed

between purchaser and manufacturer to establish conformity of the lot to be supplied

with the requirements of the specification. Purchaser has the right to insist acceptance

tests on each unit equipment in the presence of his nominated representative.

9.4 ROUTINE TESTS: These tests are to be carried out to verify that the properties of the

product RBC corresponding to those measured during prototype / type tests. Routine

tests are to be performed conducted by the manufacturer on each equipment and all the

records of test results shall be maintained with traceability. The same shall be produced

before the railway inspecting officer / representative to verify the routine test results.

9.5 INVESTIGATION TESTS: Based on the performance, field experience, in case of

critical failures in the system or in view of the improvement measures, investigation tests

shall be carried out at no extra cost. These tests shall be specially requested either by

RDSO or user or by the manufacturer.

10.0 DETAILS OF TESTS:

10.1 Visual Inspection: The various approved drawings, QAP, Bill of Material (BOM) of the

assembly/sub-assembly components used in the equipment and approved after prototype

tests shall be checked along with aesthetics, design, workmanship and general

construction of the unit equipment.

10.2 Performance Test: Connect the RBC to the AC input and record the parameters at low,

nominal and high input voltages of i.e. 350 V, 415V and 480 V respectively for 10%,

50% and 100% loads. Record Input Voltage (r.m.s), Input Current (r.m.s), Input Watts,

Input pf, DC Output Volts Voltage, DC Output Current (Amps), r.m.s & peak-to-peak

ripple for Voltage and Current, percentage regulation and efficiency.


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10.3 Short Circuit Test: Short the output terminals and switch ON the unit RBC at low,

nominal and high input AC voltage and measures the short circuit currents. On removal

of short, the charger shall start normally after reset.

10.4 Surge Test: This test shall be conducted as per IEC-60571 and record the waveforms

shall be recorded through storage oscilloscope.

10.5 Dielectric Test: When the unit RBC is cold, dielectric test shall be carried out after

disconnecting capacitors and shorting power semiconductor devices, primaries of trigger

equipment, pulse transformers earthed and disconnecting special card, if necessary

before applying test dielectric voltage. corresponding to the voltage given below: -The

test voltage for different type of the circuits are as under:

i) 415V ac circuits- 2000V (r.m.s), sine wave, 50 Hz for 1 minute.

ii) 110V dc circuits- 1500V (r.m.s), sine wave, 50 Hz for 1 minute.

Test is considered satisfactory if there is no flash over or tripping of dielectric test

equipment set at 30 mA leakage current.

10.6 Insulation Resistance: This shall be done with the help of 500V megger prior to the

starting of all the tests and after heat run. Insulation resistance shall not be less than 10

M-Ohms for all circuits.

10.7 Weight: Weight of the underslung cubicle charger unit shall not exceed 75 kgs and that

for Coach display panel shall be as less as possible.

10.8 Output Current/ Voltage Limit Test:

Set the current limit at 14 Amps through key pad and load the unit RBC at nominal

AC input Voltage to its 100% capacity. Note down DC Voltage. Now, load the unit

RBC beyond 100% and record the droop in output voltage. Now, set the current limit

at 20 Amps using keypad and repeat the test.

Set the voltage at 122 Volts through key pad and load the unit RBC at nominal AC

input Voltage to its 100% capacity. Note down DC Voltage. Now, load the unit RBC

beyond 100% and record the droop in output voltage. Now, set the voltage at 128

Volts using keypad and repeat the test.

10.9 Ripple Measurement: Measure The ripple of the output shall be measured by using a

Cathode-Ray Oscilloscope (CRO). It shall not be more than 2% r.m.s of set value for

voltage and 3% r.m.s of set value for current at all loads.

The waveforms shall be recorded through storage Oscilloscope (having suitable interface

with PC or printer for recording the waveform) across precision shunt for 10%, 50%,

100% resistive(R)-L load at max, min, nominal input voltage. Record Both the r.m.s. and

peak to peak ripple shall be recorded for each load.

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10.10 Vibration and Shock Test: The complete RBC (Underslung unit and Coach display

panel) together with its mounting arrangements (including shock-absorbing devices, if

provided) shall comply be subjected to the vibration and shock testing (for category 1) as

per IEC: 61373, category-1 class-A.

10.11 Endurance test: The manufacturer shall conduct rigorous test of the RBC for minimum

52 Hrs. continuously at full load of 35 Amps i.e. 20 Amps battery load and 15 Amps

resistive load. The input supply voltage shall be at minimum i.e. 350-355 V.

10.12 Dry Heat and Damp Heat Test: The dry heat and damp heat test shall be conducted as

per relevant clauses of IEC: 60571 on all the electronic modules cards/PCBs used in the

system RBC.

10.13 Salt Mist: Salt mist test shall be conducted as per IEC:60571 on all the electronic

modules cards/PCBs used in the system RBC.

10.14 Efficiency Test: The efficiency shall be measured soon just after temperature rise test at

full and half load at input supply of 415 V, 50 Hz with a resistive (R) load. The

efficiency shall be as per clause No. 5.3 of specification. The efficiency of the unit shall

be measured with the help of Power meter or oscilloscope at full and half load at input

supply of 415 V, 50 Hz with a resistive and inductive (R-L) load. The output voltage

shall also be recorded.

10.15 Temperature Rise: The unit RBC shall be loaded to full load current corresponding to

35 A DC rating of unit with minimum input voltage of 350V AC± 5volts. The

temperature rise shall be recorded with the help of temperature recorder having at least

12-14 sensors mounted at the specified reference points (by using thermal imaging

camera to detect hot spot) on the body of semiconductors, transformer, filter capacitors

and other components. The maximum-recorded temperature under worst loading

conditions shall be corrected for 55ºC and compared with maximum permissible

temperature (for power semiconductor devices at junction). The thermal margin available

shall be compared with the safety margin declared by the manufacturer. Under loading

conditions as specified above, the corrected temperature of the power semiconductor

devices shall have a safety margin of minimum 100C.

Temperature of the transformer shall not exceed 100 155 ºC when corrected to 550 C.

The unit shall also be subjected for short time rating after continuous loading to ensure

the temperature rise is within the permissible limit.

The maximum temperature rise of the electronics devices on the PCBs shall not exceed

200C, when measured at half inch away from identified critical components.

The charger unit RBC shall be deemed to have reached thermal stability when three

consecutive readings of temperature are more or less same.

The temperature rise in the inductors/choke windings shall also be measured by

resistance method.


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10.16 Test for IP protection (Water proof-ness test): The water proofness test shall be done

on the underslung cubicle by dipping the equipment in water for one hour under de-

energised condition leaving 135mm from the top. Water shall not enter into the RBC

undeslung cubicle and thereafter the RBC shall function normally.

Water if any accumulated in the inductor cubicle if designed as a separate cubicle /

compartment will be drained out through drain plug to be provided by the manufacturer

and the inverter RBC shall function normally.

10.17 Trigger Equipment Test: The object of this test is to verify that the firing pulse comply

with the design. and the manufacturers shall furnish the details. The blocking of firing

pulse for output short circuit shall also to be checked.

10.18 Load Break Test: A contactor or a DC knife switch shall be connected in series with

the load. After the rated current has been flowing in load for 1 min. the load shall be

broken through the contactor. The test shall be repeated three times. No damage shall

occur to any part of unit the RBC.

10.19 Input under Voltage/ Over Voltage: The input voltage shall be reduced below 350V

and check that unit the RBC shall switches- “OFF” prior to 345 volt and automatically

switches “ON” after the input voltage exceed 352 350 volts. The input voltage shall be

increased beyond to 480 V AC and check that unit the RBC shall switches “OFF” prior

to at 482 480 Volts and. The voltage shall be further raised to 510V AC and maintained

for two minutes. There shall be no damage of any nature to any of the components of the

unit RBC. The unit RBC shall automatically switch “ON‟ when the voltage shall be

reduced below 480 V AC but, prior to 475 V.

The design shall incorporate necessary feature of suitable time delay/ hysteresis of 5V to

avoid hunting for both under voltage and over voltage tripping.

10.20 Acoustic Noise Measurement: The sound pressure level shall be measured in order to

ensure that it is not exceeding the limit value of 60 dB (A) at a distance of 0.5 meter

away from the equipment in all the four directions. Tests shall be performed at no load,

50% load and full load. However, the manufacturer shall endeavor to reduce the noise

level below 60 dB (A).

10.21 Tests on High frequency Transformer: Temperature-rise and efficiency at operating

frequency shall be conducted at the works of manufacturers. Necessary test results shall

be submitted at the time of testing.

10.2221 BURN-IN TEST: To ensure the reliability of the components, Burn-in tests as per

RDSO specification No. ELRS/SPEC/SI/0015 for reliability of electronics used in

rolling stock application shall be conducted on every card in energised condition.

10.2322 EMI/EMC Test: EMI/EMC test shall be conducted as per relevant clauses as

mentioned in the IEC: 61000 for the following:-


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i. RFI RADIATED TEST: as per IEC 61000 – 4 – 3

ii. RFI CONDUCTED TEST: as per IEC 61000 – 4 – 6

iii. ELECTRICAL FAST TRANSIENTS TEST: as per IEC 61000 – 4 – 4

iv. POWER FREQUENCY MAGNETIC FIELD: as per IEC: 61000 – 4 – 8

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

test.

10.2423 MARKING: The unit shall be marked/screen printed with the following information:-

Type /Make

Contract No.

S.No- 8 digit i.e. Month (2digit)/Year(2digit)/Eqpt. No.(4 digit)

Month & Year of manufacture

Input operating voltage range

Output voltage range

Wattage

Output current

Frequency

In addition to this the make shall also be embossed on cubicle with the help of

additional plate duly welded from all the side on the body of the cubicle which shall be

legible and lasting till equipment life.

10.2524 Over load protection: Over load protection shall be inbuilt in the design and tested.in

the complete operating voltage range. An over load capacity as per IEC 61800-2

(Clause No. 5.2.2-a) shall be inbuilt in the design. and tested as per IEC 61800-2

(Clause No. 7.3.2) for over current capability.

Over load protection shall be inbuilt in the design and tested at nominal voltage of input

supply i.e. 415V AC. An over load capacity of 10% of full load for 30 seconds shall be

inbuilt in the design. The feature of overload protection shall be by current limiting at

output.

10.2625 Single phase protection and functioning at reduced load: The battery charger shall

be protected against the single phasing at the input side. However, the battery charger

shall be able to function normally and shall deliver 35% of the full load even when one

phase is not available at input. The feature of the protection shall be by tripping the

RBC.

10.2726 Reverse polarity protection with indication at battery terminal.

Reverse polarity protection: Reverse polarity protection shall be provided with

indication at battery terminal. The RBC shall trip and reverse polarity indication appear

as soon as the RBC shall sense the reverse polarity.

10.27 Output over voltage protection: Over voltage protection shall be provided to avoid the

equipment supplying high voltage beyond the 135 Volts. Tripping of the RBC should be

at higher than the required charging voltage i.e.135 V DC.


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11.0 TEST SCHEMES:

S.

No.

Type of Test

Clause

No.

Prototype

Test

Prototype/

Type test

Acceptanc

e test

Routine

Test

1 Visual Inspection 10.1,

10.24

Yes Yes Yes Yes

2 Protection & Indication 7.0 Yes Yes Yes Yes

3 Performance test 10.2 Yes Yes Yes Yes

4 Short circuit test 10.3 Yes Yes Yes No

5 Surge test 10.4 Yes Yes No No No

6 Dielectric test 10.5 Yes Yes Yes Yes

7 Insulation resistance 10.6 Yes Yes Yes Yes

8 Weight 10.7 Yes Yes Yes Yes

9

Output current/voltage limit 10.8 Yes Yes Yes Yes

10 Ripple measurement 10.9 Yes Yes No No

11 Vibration & shock test 10.10 Yes Yes No No No

12 Endurance test 10.11 Yes Yes No No

13 Dry heat & damp heat 10.12 Yes Yes No No No

14 Salt mist test 10.13 Yes Yes No No No

15 Efficiency test 10.14 Yes Yes Yes Yes

16 Temperature rise test 10.15 Yes Yes *Records

to be

verified No

Every

50th Unit

equipme

nt

17 Water proofness test 10.16 Yes Yes No No No

18 Trigger equipment test 10.17 Yes Yes No No

19 Load break test 10.18 Yes Yes Yes Yes

20 Input U/V & O/V Test 10.19 Yes Yes Yes Yes

21 Acoustic noise 10.20 Yes Yes No No

22 Tests on Transformer 10.21 Yes* Yes* No No

23

22

Burn-in test 10.22 Yes Yes No *Records

to be

verified

Every

50th card

equipme

nt

24

23

EMI/EMC 10.23 Yes Yes No No No

25

24

Marking 10.24 Yes Yes Yes Yes

26

25

Over load protection 10.25 Yes Yes Yes No

27

26

Single phase protection and

functioning at reduced load

10.26 Yes Yes Yes No

28

27

Reverse polarity test 10.27 Yes Yes Yes No

28 Output Over voltage

protection

10.28 Yes Yes Yes Yes

29 Paint and coating thickness 6.4 Yes Yes Yes No

*Records from Manufacturers to be obtained.


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12.0 SCHEDULE OF TECHNICAL REQUIREMENT:- TESTING FACILITIES:

Following facilities/machinery and plant are considered essential at the developmental

stage in the premises of the manufacturer for quality and reliable product:-

SN FACILITIES SN FACILITIES

I Digital multi meter xvi Dust free environment for the assembly of PCBs

ii Mill volt meters xvii Component lead forming machines/fixture

iii Weighing machine xviii Water tank for carrying out water dip IP test

iv Dry heat test chamber xix Variable load bank with 0.8 power factor.

v Power analyzer meter xxi Multi-channel temperature scanner and thermometers

vi Surge tester xxii Functional testing of PCBs preferably with computer

vii High voltage tester xxiii Complete test bench for measuring the different parameters

viii Megger- 500Volts xxiv Automatic/light beam guided component insertion machine

for PCBs

ix Storage type

Oscilloscope

xxv Digital/analog meters for measuring voltage, current, power,

frequency, resistance, power factor etc

x Temperature controlled wave-soldering machine with auto-fluxing facilities

xi Testing jigs along with measuring instruments for the testing of assembled PCBs for

different parameters

xii In circuit testing machine for checking the correctness of component inserted PCBs

xiii Noise level meter (dB meter).

xiv Electro static discharge protection in line with IS: 10087-1981.Work procedure for

following ESD practices needs to be submitted

xv ISO 9001 certification.

Note: The facilities mentioned at SN. x), xvii) & xxiv), if not available with the firm then

the related activity can be outsourced to the other ISO 9001 firm having these facilities.

However, the firm shall have an MOU with that firm. Outsourced firm should comply the

requirement of xiv).

1. Dust free environment with ESD protection for the assembly of PCBs.

2 Testing jigs for the functional testing of assembled PCBs alongwith computer for

different parameters.

3 Component lead forming machine/fixture.

4. Temperature controlled automatic wave-soldering machine with auto-fluxing facilities.

5. Automatic/light beam guided component insertion machine for PCBs.

6 Surge tester

7. Burn-in testing chamber.

8. Digital multi meter

9. Digital power analyzer

10. Digital storage oscilloscope

11 Megger- 500/1000 Volts

12. High voltage tester

13 Water tank for carrying out water dipping test.

10. Variable load bank up to 4.5 kW (with overload, if any)

11. Multi-channel temperature scanner minimum 12 channel

12. Complete test bench for measuring the different parameters

13. Noise level meter (dB meter).


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14. Weighing machine.

All the above facilities are considered essential at the developmental stage itself and shall

be verified by RDSO/ Indian Railways as the case may be before considering the firm for

development of item. However, the facilities mentioned at SN. 3, 4 & 5 for PCB

assembly may be outsourced with the sub vendor, who shall have all the facilities in-

house as mentioned under item no. 1 to 5. RDSO may visit the premises of sub-vendor

engaged by the firm for PCB assembly. The firm shall arrange the visit to the sub-

vendor‟s premises.

13.0 GUARANTEE WARRANTY:. The complete RBC shall be guaranteed warranted for a

satisfactory performance for a period of 60 months from the date of commissioning or 72

months from the date of supply whichever is earlier. Any design defect, defective

material, underrated component used, etc. have to be corrected and merely replacement

of defective parts will not be considered adequate. Complete investigation report of each

defect/failure shall be submitted to RDSO and purchaser for each case.

14.0 PRE-COMMISSIONING AND COMMISSIONING TESTS: Unpack the RBC unit

and check that it is not damaged. Energize the RBC and check for the performance tests

by energizing the unit and connecting resistive load before fitment on the coach. Mount

the assemblies of the unit RBC on the coach and conduct the following: -

- Proper mounting of the cubicles and its rigidity

- Insulation and dielectric test.

- Performance test at nominal voltage and full load.

- Proper functioning of protections, indications, meters and data fault logging by

simulation method and operating switches.

- Ensure operation of earth fault

Above tests shall be conducted in presence of the engineers / representatives nominated

by the competent authority of the purchaser / railways.

15.0 SAMPLING: The sampling and rejection shall be done as per IS: 4905.

16.0 SPARES AND MAINTENANCE MANUAL: A list of spares required for a period of

five years maintenance shall be submitted in printed form and neatly compiled in a

booklet form at the time of supply prototype testing. The supplier shall supply free of

cost maintenance manuals to purchaser / Railways. The maintenance manual shall

consist of introduction, working principle, description, schematic drawings, cubicle

drawings, instructions for installation and troubleshooting, precautions while trouble

shooting, list of components replaceable with brief specifications and their makes.

The operating and maintenance manual giving instructions for installation, maintenance

and circuit diagram with voltages at salient points to locate faults, list of components

with brief specifications and manufacturers etc. Trouble shooting and after repair testing

procedure of major assemblies and electronic cards shall be supplied. In addition to

above, working principle, precautions to be taken, fault diagnostic upto component level,

component testing before its fitment, component handling etc. shall be included in the

maintenance manual. The original numbers on IC, transistors and other components shall

not be erased or painted.


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17.0 INFORMATIONS TO BE SUBMITTED AT THE TIME OF PROTOTYPE

TESTING: The manufacturer must submit the following information along with the

internal test results in printed and neatly compiled booklet form: and soft copy when

offer for prototype testing. Incomplete information may not be considered.

a) Detailed specification of the offered RBC along with all the components fitted.

b) Details of protections provided, and their effectiveness/proposed set values, and

range and working principle.

c) Details of semi-conductor devices used, and their specification and data sheets.

d) Circuit diagrams, along with bill of material along with detail specification of the

major components, their quantity and makes, and circuit description and working

principle.

e) Safety margins in voltage, current and thermal (for junction temperature for

semiconductor ) alongwith the limit values for power semiconductor devices,

inductors and transformer etc.

f) Declared Output voltage wave-form power factor and regulation.

g) Cubicle drawings and details of dimensions, mounting arrangement and weight.

h) Details of operating panel Coach display panel, and function of each switch,

indications and fault diagnostic features.

i) Detailed description/explanation of circuit adopted and its salient advantages.

j) Burn-in procedure followed for components / assembled cards if applicable.

k) Duty cycle considered for the RBC battery charger design for continuous and short

time ratings.

l) Service experience for the developed unit or similar units.

m) A set of different coloured photographs of the RBC clearly showing the outside and

inside details in different photographs.

n) Quality assurance plan for the product RBC.

18.0 APPROVAL OF DESIGN / DRAWINGS BEFORE MANUFACTURING OF

PROTOTYPE: The manufacturer shall submit working principle, schematic diagrams,

detailed design calculations, specification of components and dimensional & fitment

cubicle drawings proposed to be used in the system to RDSO for provisional approval

before manufacturing the prototype unit.

Based on provisional approval of design/drawings, the prototype unit shall be

manufactured after incorporating all the modifications found necessary during inspection

/ testing without any additional charges.

The manufacturer shall also submit details like make, type, reliability, grade, rating and

loading of various electronic components used in the circuit along with reliability

prediction, and calculations based on actual loading of various components. The

temperature rise of the various components under the most adverse conditions shall also

be declared. The battery charger shall be accepted for prototype test only if the

reliability prediction calculations show that MTBF is not less than 4x10 4.

19.0 FAILURES DURING GUARANTEE WARRANTY PERIOD OR UNDER

MAINTENANCE CONTRACT: The under warranty failures shall be attended by the


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supplier. The details of failures, action taken, investigation report, failure analysis and

action to be taken to arrest prevent re-occurrence of similar failure in future if any ,

failure report, investigation report and failure analysis are to shall be submitted to RDSO

and purchaser / Railways.

In case of repeated failures, necessary changes in design on the units put in service or in

production line are to shall be made by the manufactures after approval of RDSO. Any

investigation tests, if considered necessary, are to shall be arranged / conducted by the

manufacturer.

20.0 TRAINING: The contractor supplier shall undertake to train the few supervisors of the

Railways free of cost the supervisors of the Indian Railways for operation & mainte-

nance., fault finding, repair of the offered equipment under the guidance of skilled

engineers during the first year of the service of the equipment. The purchaser shall pay

the wages and allowances of each Railway Supervisor nominated for training. The

purchaser shall bear the cost of the passage to and fro from the place of training for the

Railway supervisors.

21.0 DEVIATIONS: The clause wise comments compliance shall be submitted and

deviations, if any, shall be brought out reported clearly while offering for witnessing the

prototype testing.


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ANNEXURE-1

BILL OF MATERIAL FOR REGULATED BATTERY CHARGER

SN Item Description Make Remarks

1 DSP (Digital Signaling Processor) designed

for motor control/ Battery charger/Converter

application

Texas USA/

Microchip/Motorola

-

2 Electrolytic Capacitor for load life of 10,000

hrs at 1050 C

EPCOS/ALCON/

Hittachi / Nippon/

Philips

3 IGBT (High Frequency) Semikron/ Mitsubishi /

Infineon

-

4 Gate driver card It shall be from IGBT

vendors or from the

reputed sources

Type test report shall be

submitted along with

internal test result which

shall be examined by

RDSO

5 Input/ Output Connectors (All type)

Hypertac, Harting,

Amphenol & Allied

For input - Allied make

cat. No MG02R24-10P

and MG08F24-10S or

equivalent.

For output - Allied make

cat. No MG08F28-10P and

MG02F28-10S or

equivalent

6 Electronic Components - Industrial Grade suitable

for 85ºC minimum or

higher

7 PCBs - FR-4 or better

8 Contactor GE/ABB/C&S -

9 MCB/MCCB GE/Siemens/L&T/ MDS -

10 DC filter choke EPI/ ARYA/Bhurji or

from the reputed sources

11 Thermal switch Mikron/Honywell -

12 DC/DC converter card/Booster card Type test report shall be submitted along with internal

test result which shall be examined by RDSO . 13 Battery charger card

14 Power wires As per RDSO Specification No. ELRS/SPEC/ELC/

0019

Note: i) For other items (not mentioned above), Type test report/data sheet of the components shall be submitted along with design details for examination.

ii) Items components for which RDSO approved sources makes are available, only approved sources / makes shall be used.

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ANNEXURE-2

Hkkjr ljdkj jsy ea=ky; - rdso. · PDF fileREGULATED BATTERY CHARGER FOR LHB COACHES 0.0 FOREWORD: At present, 6.5kW „ON Board‟ type Regulated Battery Chargers (RBC) are being provided

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