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of 29 File No. EL/ 7.1.108/SBC Effective from Dec. 2019

Spec. No RDSO/PE/SPEC/TL/0185 -2019 (Rev. 0)

Prepared by – SSE/Alternator

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DSE/MRVC

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

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RESEARCH DESIGNS AND STANDARDS ORGANISATION

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SPECIFICATION FOR SET OF PANELS OF INDIAN RAILWAYS FOR LHB EOG/HOG NON AC COACHES

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Spec. No. RDSO/PE/SPEC/TL/0185– 2019 (Rev 0)

S. No. Month of amendment Revision Reason

1. Rev. ‘0’ Conversion of RCF specification into RDSO specification

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APPROVED

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Executive Director/PS&EMU




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DSE/MRVC

INDEX

Clause No.

Description Page No.

1.0 Foreword, Scope of Supply, Operating and service conditions & Governing specifications

3, 4

2.0 Technical and Constructional requirements 5-8 3.0 Tests, Schedule of tests & description of tests 9, 10, 11 4.0 Technical data to be submitted 17 5.0 Commissioning 17 6.0 Manufacturer’s responsibility 17 7.0 Marking and packing 18 8.0 Guarantee and Warranty 19 9.0 Training 19 10.0 Infringement of patent right 19 11.0 Service Engineers 19 12.0 Cartel formation 19 13.0 Enclosures

Annexure A :: List of drawings and wiring diagram 20

Annexure B : Undertaking against Cartel formation 21

Annexure C: Bill of material 22-25

Annexure D: Terminal block fitment position 26-27

Annexure E: Harness chart for LHB type EOG AC coaches 28




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0.0 FOREWORD

0.1 Presently, governing specification for set of panels for LHB EOG/HOG non-ac

coaches is EDTS-355 rev-1 with amendment no. 1 & 2 (RCF number) and which comprises of RCF drawings. It is felt desirable to convert RCF’s in to RDSO drawings and also assign RDSO no. for specification. Opportunity, also awaited to incorporate all acceptable changes based on field experience & technological advancements which have taken place so far.

0.2 This specification is for design, manufacture, testing and supply of set of panels

(Switch Board Cabinet) housing all the power & control switchgear related to feeder selection, distribution & control of coach loads viz. coach lighting, etc. for LHB EOG/HOG NON-AC Coaches suitable for 3 phase, 750 volts, 50 Hz twin train line system.

0.3 SCOPE OF SUPPLY:

S.No Item description Qty/Coach 1 Set of Panels for LHB EOG Non AC coaches consisting of:

i) High Voltage Cubicle(1 no.) as per drawing no.

RDSO/PE/SK/TL/0214-2019 (Rev 0) sheet 1, 2 & 3. ii) Low voltage panel(1 no.) as per drawing no.

RDSO/PE/SK/TL/0215-2019 (Rev 0) sheet 1, 2, 3, 4. iii) Fuse cum Rotary switch panel as per drawing no.

RDSO/PE/SK/TL/0215-2019 (Rev 0) sheet 5 of 5.

1 set

1.0 GOVERNING SPECIFICATIONS

Manufacturers should be under possession of the following standards referred in the specification:

S. No. Standard No. Description 1 IEC 60947-1 : 2004 Low voltage switchgear and control gear Part-I General rules.

2 IEC 60947-3 : 1999 Part-3- Switches, disconnections and fuse combination units. 3 IS:8623-1993 Pt.-1 Low voltage switchgear and control gear assemblies:

Part-I Requirements for the type tested and partially type tested assemblies.

4 IS:10118-1982 Code of practice for selection, installation and maintenance of the switchgear and the control gear.

IEC 61000 Electromagnetic compatibility (EMC/EMI Compatibility test)

5 IS:13703-1993

Low voltage fuses for voltages not exceeding 1000 volts ac or 1500 volts DC.




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IEC 61373 Shock and Vibration test 6 IS:1248 Pt.II-1983 Direct acting indicating analog electrical measuring instruments

and their accessories (ammeter and voltmeters).

7 IEC 60898-1:2002 Electrical accessories, circuit breakers for over current protection for household and similar installations.

8 IS:1573-1986 Electroplated coatings of Zinc on Iron and Steel.

9 IS:1364-1992 Hexagon head bolts, screws and nuts of product grades A & B.

10 UIC 550 IS: 13947 (Pt-I)-93

Power supply installation for Passenger stock. Low-Voltage switch gear and control gear.

MDG 0008 Specification for tolerance

IS 6911 Stainless steel plate, sheet & strip.

EN 45545 European Railway Standard for fire safety’s.

IEC 60529 Degree of protection provided by enclosure (IP 67)

IS 2500 Sampling procedure for inspection.

Any deviation from this specification proposed by the manufacturer, aimed to improve

upon the performance, utility and reliability/efficiency of the component/panel will be given due consideration, provided full particulars of the deviation with justification are furnished. Latest edition/version of above specification shall be applicable and shall be available with firm.

2.0 OPERATING & SERVICE CONDITIONS

The switch board cabinet and its components shall be sturdy and suitable for satisfactorily performance under following environmental & service conditions normally to be met in service on Railway coaches:

Ambient - 10 to 55deg C Temperature under sun inside stable coach

70 deg. C

Train speed 200 Km/h Relative Humidity Maximum Up to 98% Altitude Max 1600 m above sea level Annual rain fall Annual rainfall ranging between 1750 mm to 6250 mm. Atmosphere i) Saline atmosphere in coastal areas having continued exposure

to salt laden airborne contaminants like smoke and chemical vapors and also in industrially polluted zones: Maximum pH value 8.5 Sulphate 7 mg/liter Max. concentration 6 mg/liter




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of chlorine Max. conductivity 130 microsiemens/cm ii) Extremely dusty / foggy and arid climate/desert terrain in certain areas. The dust contents in air may attain values up to 1.6mg/m3

Shocks and Vibration

The equipment, system and their mounting arrangement shall be designed to withstand satisfactorily the shock and vibration encountered in service as indicated below: a) Max. vertical acceleration - 3.0 g b) Max. lateral acceleration - 3.0 g c) Max. longitudinal acceleration - 5.0 g (‘g’being the value of acceleration due to gravity)

Operating Train/Electrical Environment

The equipment should function satisfactorily under 25 kV AC electric traction. It should not be susceptible to malfunction due to interference from overhead traction power supply lines or under abnormal conditions such as overloads and faults in the electrical circuits of the coach.

3.0 Technical and CONSTRUCTIONAL REQUIREMENTS:

3.1 The quality, aesthetics, design and overall workmanship of Switchboard cabinet

as a whole shall be to international standards. Firm shall have adequate experience of design, development and manufacturing of similar complex panels on CNC machines and shall be capable of developing materials to the required quality and standards. Care shall be taken to achieve a neat and symmetrical layout.

3.2 It will be the responsibility of the supplier to ensure and confirm that the equipment/parts purchased from other vendors are as per relevant standard and original manufacturer test certificate are being obtained by the firm and are tested before installation. Firm shall also keep record of in-house inspection.

3.3 The set of panels comprises of the following 02 cubicles housing power and

control switchgear:

S.no. Item Drawing no. Max. dimension (in mm) i H.V.

cubicle(underslung)

RDSO/PE/SK/TL/0214-2019 (Rev 0) sheet 1, 2 & 3.

2000(L)X550(D)X525(H)

ii Low voltage panel(on-board)

RDSO/PE/SK/TL/0215-2019 (Rev 0) sheet 1, 2, 3 & 4.

500(L)X130(D)X1250(H) (mounting angle 125mm)

iii Fuse cum Rotary switch panel (on board)

RDSO/PE/SK/TL/0215-2019 (Rev 0) sheet 5 of 5.

290X(L)X490(D)




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No positive tolerances are allowed. However, negative tolerances shall be governed by MDG0008.

3.4 The cubicle frames shall be of TIG welded stainless steel construction. 3.5 Under slung HV Cubicle shall be fabricated out of 2mm thick SS 304 grade S2

unpainted to IS:6911 (latest revision) SS fasteners as indicated in the respective drawings shall only be used. Cubicle shall not be painted.

3.6 The on-board Low voltage cubicle shall be fabricated out of CRCA sheet of

thickness 2 mm conforming to IS:513 ( Latest Edition ) as indicated in the drawing. The on-board panel shall be powder coated to Siemens Grey shade no 6102/08038, after giving surface treatment.

3.7 The dimensions/mounting/general layout of the cubicles shall be as per drawings

given in clause 3.3. For change in switchgear layout for ease in manufacturing/improving the aesthetics/ease of maintenance, the manufacturer shall take prior approval.

3.8 Most critical safety component in the panels is wide-band contactors. No

deviation shall be given for these contactors. Inspecting agency shall specifically check these contactors regarding make thereof.

3.9 Suitable fire retardant, zero halogen PVC alleys/duct with snap-in element shall

be provided for cable traversing as indicated in the drawings. Whenever the cables cross the door/passage area, the cables shall be covered by self extinguishing and halogen free PMAJACK braiding/nylon jacket (polyamide 6.6) of approved make in BOM (annexure-C).

3.10 Doors and placement/mounting of all the switchgears in the cubicle/panels shall allow easy access for maintenance of all the equipment from the front. For maintenance attention to any switchgear, other switchgears in vicinity should not require shifting/removal.

3.11 The internal wiring shall be done with Halogen free, electron beam irradiated

cables conforming to RDSO specification no ELRS/SPEC/ELC/0019 Rev-4 or latest. The size/type of cables shall be as indicated in drawing no. RDSO/PE/SK/TL/0216-2019 (Rev 0) or latest. All cables/wiring/Sleeves shall be color coded according to phases for easy identification. Control wiring and power cables shall be segregated according to the voltage level and adequately secured with fire retardant cable ties.

3.12 All components provided inside the cubicles or panels shall be identified by

screen/photo printed or computer generated designation labels/legend marking anodized aluminum plates. These should be mounted near the concerned component duly ensuring visibility. Circuits and components shall also be provided with the name plates indicating the operation/function of the




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switches/circuits. Contactors and circuit codification diagram (with fuses details) shall be identified by aluminum anodized legend plates fixed by adhesive of approved make on back side of front doors. Balance indicating/measuring switchgear/devices installed on front door shall be identified by aluminum anodized legend plates by adhesive of approved make on the front doors itself. No rivet/screw is allowed on front door.

3.13 a) The outgoing/incoming terminal connections shall be brought out to a

adequately rated cage clamp type terminal block/MCB. b) The terminal blocks shall be located for easy access as indicated in the drawings. c) Separators/intermediate plates shall be provided between adjacent terminal blocks. d) All cables leading to a terminal block shall be properly secured/ clamped before termination. e) It shall be ensured that not more than two wires are terminated at one point. f) The cubicles/panels shall be complete with all necessary crimping sockets and ferrules for ready connections. Rings type copper crimping sockets shall be used for cable sizes up to 1.5 sqmm otherwise tubular crimping sockets shall be used with suitable palm size to prevent loose connections during vibrations. Only copper crimping sockets of approved make and conforming to the requirements of RCF specification no. EDTS200 and EDTS201 shall be used. Crimping sockets of size smaller than 16 sqmm shall be with metal reinforcement. g) Marking ferrules shall be of computer generated type for easy identification of the cables with the help of heat shrinkable sleeves (self extinguishing) of suitable size horizontally printed or with the help of mintmark carrier/label approved make (as per BOM-Annexure C). h) All cut-outs wherein cables enter/exit the cubicle/panel shall be provided with V-grooved fire retardant rubber grommets/edge protection sleeves of reputed make from protection against sharp edges.

3.14 Two earthing terminals shall be provided on the both panels on diagonally opposite ends. For earthing with coach body two braided copper cable of 25 sq.mm and 300mm in length each duly crimped shall be supplied with the panel. Earthing of the metal parts/sub-assemblies inside the panel shall also be done with suitable wire size as stipulated in clause 7.4.3.1.7 (a) of IS:8623(Pt-I)-1993.

3.15 The Power/Control connections of the switch board cabinet shall be as per

drawing RDSO/PE/SK/TL/0216-2019 (Rev 0).

3.16 Only makes mentioned in the bill of material as per Annexure-C shall be used. For any deviation prior approval from RDSO shall be taken.

3.17 All rotary switches shall conform to IEC 60947-3 : 1999 and shall be suitable for

universal mounting & operation voltage.




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3.18 All fasteners used shall be of stainless steel to IS 1364 Part 2.

3.19 All the components/ equipments/ materials including paint shall be fire retardant

and shall confirm to EN 45545, HL.2 or IEC 60332. Panel manufacturer shall certify this requirement.

3.20 General and safety requirements shall be governed by IS: 13947 (Pt-I)-93 and

IS: 8623-1993.

3.21 All the H.T fuses and 750 V MMRs shall be mounted on minimum 5 mm thick backelite / FRP sheet. Gap of 100 mm shall be maintained between two 750 V, MMR’s.

3.22 Two RC filters shall be provided as per RDSO modification sheet no.

RDSO/PE/MS/AC/0051-2011 (rev. 1) with amendment 2 to make coach Head on Generation (HOG) system compliant.

3.23 The location and size of the hinges shall be as per the respective drawing for the

cubicles. 3.24 Manufacturer’s name plate indicating name and address, Sr. No. of the panel,

Specification no. month and year of manufacturer and weight shall be fixed on the front door of the panel. Size of name plate shall be as per drawing no. RDSO/PE/SK/AC/0205-2019 (Rev 0) sheet 16 of 16.

3.25 Danger Notice plate shall be screen printed or sticker shall be provided on front

of the panel door conforming to IS: 2551-82 for 750V. Size of danger plate shall be 200 mm X 250 MM.

3.26 High Voltage cubicle : 3.26.1 Disconnecting and earthing device and high voltage fuses (Main fuses) shall be

located as indicated in the drawing. The main function of disconnecting and earthing device is to electrically switch ON/OFF two 750V feeders/networks (input supply) and simultaneously earth outgoing 750V AC network of the coaching in “OFF” position. The connection to this unit shall be made/ removed by removing the perforated metal sheet provided on the front of it.

3.26.2 Cubicle shall conform to IP-67 degree of protection as per IEC 60529. 3.26.3 Mounting plate for Main contactors (K1 & K2) and other switchgear shall be

provided on the back of the cubicle with cage clamp connectors on the front as indicated in the drawing.

3.26.4 Contactors for the pump along with controller (not in the scope of supply) shall

be provided inside the cubicle along with cage clamp connectors.




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Note: Wheel slide protection is not in the scope of supply of power panel manufacturer, however, space shall be provided for the same in the panel along with the connectors for connections.

3.28 LV (On-Board) Panel

3.28.1 The on-board LV panel shall house the AC and DC rotary switches, HRC fuses

etc. for distribution of lights, fan etc. as per the schematic/wiring diagram RDSO/PE/SK/TL/0216-2019 (Rev 0).

3.28.2 The rotary switch for feeder selection shall be provided in the on-board panel.

3.30.3 The connectors and fuses for the mobile charging socket shall also be provided

in the panel. 3.30.4 MPCB for exhaust fan shall be provided in the panel. 3.30.5 RCBO for mobile charging shall be provided in the panel.

4.0 TESTS 4.1 The manufacturer shall take up the manufacture of the prototype. Only after the

drawings and the design have been approved and the clearance given to this effect by RDSO. It is to be clearly understood that if 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 at the expenses of manufacturer. The firm manufacturing for the first time shall get the prototype approved from RDSO.

4.2 The required testing facilities for inspection & testing shall be available at firm’s

premises. In house testing shall be done by manufacturer’s qualified person & the test results shall be submitted to RDSO.

4.3 The type testing of prototype unit shall be witnessed by RDSO representative either

totally or in part under the following conditions without any additional cost:

a) Manufacturer undertakes to manufacture the set of panels for the first time as per this specification.

b) An important change in design details of any of the panels has been introduced. c) Specification is modified necessitating the re- designing of the panel (S). d) Unsatisfactory performance reported from user Railways. e) Resumption of production after an interruption of more than two years. f) A new variant of set of panels is introduced by existing manufacturer. g) A fundamental change in design is introduced and modification is likely to affect

its function. h) Failure or variations established during retest/samples test. i) Resumptions of production after an interruption of more than two years. j) Specification gets amended or revised. k) During Quality audit if required.




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l) In any other condition, whenever RDSO/Purchaser feels necessity of the type tests. Manufacturer shall prepare detailed test protocol/plan and get it approved from RDSO.

4.4 RDSO/purchaser may conduct surprise checks on the manufacturing process and

quality control along with any of the tests to ensure quality of product and its conformance to RDSO specification.

4.5 The firm shall maintain date-wise in-house quality control system and in-house quality

control records etc. for in stage process inspection and testing the same along with QAP shall be made available to the inspecting official during type testing.

4.6 Third party inspecting Agency/RITES shall carry out the acceptance & routine tests

specified in tender specification tests at manufacturer premises. Check list consisting of testing details /measurements and acceptability shall be prepared and submitted along with inspection certificate to production units (PUs)/Purchaser.

4.7 TYPE TESTS: All the type tests mentioned in clause 5.0 shall be carried out on a prototype unit.

4.8 ROUTINE TESTS: Routine tests mentioned in clause no. 5.0 shall be carried out on each unit by the

manufacturer at his works to ensure compliance with the specification and the drawings.

4.9 ACCEPTANCE TESTS: Acceptance tests mentioned in clause no. 5.0 shall be carried out at manufactures

cost in the presence of inspecting authority nominated by the purchaser at the works of the manufacturer, on the picked up samples. A copy of the internal tests conducted by the firm shall be made available to inspecting/purchasing authority before hand.

5.0 SCHEDULE OF TESTS :

5.1 Tests as mentioned in table below shall be carried out as per applicable standards

indicated against each.

SN Tests Type Test

Routine Test

Accept- ance Test

Applicable standard

Clause of standard

1. Visual inspection, including inspection of Wiring, dimensional checks and electrical operation test

Yes Yes Yes IS 8623 8.3.1

2. Temperature rise test Yes No No IS 8623 8.2.1

3. Mechanical operation and Yes Yes Yes IS 8623 8.2.6




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sequence test 4. Test for verification of clearance

and creep-age distances Yes Yes Yes IS 8623 8.2.5

5. Test for verification of dielectric properties


6. Test for verification of insulation resistance


7. Checking of electrical continuity


8. Verification for effectiveness of protective circuits


9. Vibration & shock test on both the cubicles/panels.

Yes No No IEC 61373

10. Water ingress protection test for HV cubical /panel.

Yes No No IEC 60529

11. Check for satisfactory operation of rotary switches by rotating 10 times clockwise and 10 times anticlockwise

Yes Yes Yes ---

12. Check for BOM and proof of material as per specification with proof of invoices.

Yes Yes Yes --- Annexure-C

Note: WTC’s (Work Test Certificates) of respective OEM’s of all major items shall be checked & verified by inspecting authoring

5.2 The accuracy of measuring instruments used for tests shall be class 0.5.

6.0 DESCRIPTION OF TESTS: 6.1 Visual inspection including inspection of wiring, dimensional checks and electrical

operation test: The test shall include visual inspection of panels, overall dimensions, marking and

general layout of switchgears, earthing, colour coding as mentioned in the specification& drawings. Electrical operations shall also be checked as per approved drawings and in accordance with test protocol/ plan & Clause 8.3.1 of IS:8623 Pt -I.

6.2 Visual inspection of complete Set of Panels after wiring and electrical operational

test: The test shall include the following checks: -




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i. General workmanship of Set of Pnaels and its accessories such as MPCB, MCB, fuse, relay, contactor, connector, cable etc. shall be checked.

ii. Name plate & danger plate iii. Interface dimensions with coach and overall and mounting dimension of set of

panels. iv. Provision of Earthing cables v. Sticker /Marking plate of components vi. Marking and general layout of housing, vii. Colour coding of cables as mentioned in the specification & drawings. viii. Electrical operations shall also be checked as per applicable drawings and

prepared test protocol. ix. Detailed dimensions

Sr. No (a) to (g) shall be checked during acceptance test/routine test also.

6.3 Temperature rise test: Temperature rise test of the Set of Panels shall be carried out as per clause no. 8.2.1 of

IS 8623 Pt -1. The firm should submit the test protocol for temperature rise test in advance to RDSO.

6.4 Mechanical operation and sequence test: This type test shall not be conducted on such devices components/parts of the

assembly which have already been type-tested according to their relevant specifications provided their mechanical operation is not impaired by their mounting.

For those parts which need a type test, satisfactory mechanical operation shall be

verified after installation in the assembly. The number of the operating cycles shall be 50.

Note: In case of withdrawable functional units, the cycle shall be from the connected to

the disconnected position and back to the connected position. At the same time, the operation of the mechanical interlocks associated with these

movements shall be checked. The test is considered to be satisfactory, if the operating conditions of the apparatus, interlocks etc. have not been impaired and if the effort required for operation is practically the same as before the test.

6.5 Test for verification of clearance and creepage distances: Switchgears shall be mounted in accordance to drawing no. RDSO/PE/SK/TL/0216-

2019 (Rev 0) of latest alteration for maintaining clearance and creepage distance. This test includes the following checks

a) Following clearance shall be checked




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i. 100 mm between two MMRs (K03 & K04) ii. 20 mm between 750 V circuit current transformers on contactor plate

assembly. iii. 20 mm between 125 A fuses on fuse plate assembly. iv. 50 mm neutral terminal on fuse plate assembly.

b) Electrical switchgears/cable alley shall be mounted keeping in mind the clearance

given in drawings mentioned in Annexure A for maintaining clearance and creepage distance.

6.5(a) shall be checked during acceptance/routine test also.

6.6 Test for verification of di-electric properties:

6.6.1 The set of panels shall be tested with 3 kV test set between live parts and earthed body.

Applied voltage Time (Sec.)

Result Condition Leakage current (Max.)

3 kV on 750 Volt & 415 Volt circuit

60 Should withstand the test

Disconnected equipment- DC-DC converter, insulation monitoring relay & SDS type wago relay

30 mA.

1.5 kV on below 415 Volt circuit

60 Should withstand the test

Disconnected equipment DC-DC converter, insulation monitoring relay & SDS type wago relay

30 mA.

6.6.2 The HV test shall be done with AC (50 Hz) which shall be gradually increased (applied

for one minute). The test is considered pass, if no electric breakdown or flashover occurs.

6.7 Test for verification of insulation resistance

During testing, insulation monitoring relays have to be disconnected. All the MPCBs/MCBs shall be kept in the OFF position. Insulation resistance shall be measured with direct current. Measuring voltage and minimum insulation resistance values are given in the single test items.

Insulation resistance test shall be carried out on all the circuits. The meggering voltage

and the value of the insulation for the various circuits shall be given as under-




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SN Rated circuit voltage

Meggering voltage

Insulation resistance value (Minimum)

1 750 volts AC 1000 V DC 5 M ohms 2 415 volts AC 500 V DC 3 M ohms 3 230 volts AC 500 V DC 2 M ohms 4 190 volts AC 500 V DC 2 M ohms 5 110 volts AC/DC 500 V DC 2 M ohms 6 24 volts AC 500 V DC 2 M ohms

6.8 Checking of Electrical continuity:

(i) Continuity of protective circuits shall be ensured by effective interconnections either

directly or by means of protective conductors. In particular, screwed connections shall be checked for adequate contact, possibly by random checks.

(ii) When a part of cubicle/panel is removed from the enclosure, for example for routine

maintenance, the protective circuits for the remaining part of the cubicle/panel shall not be interrupted.

(iii) Means used for assembling the various metal parts of set of panels are considered

sufficient for ensuring continuity of protective circuits, if the precautions taken, guarantee permanent good conductivity and a current carrying capacity is sufficient to withstand the earth fault current that may flow in cubicle/panel.

(iv) For lids, doors cover plates and the like, the usual metal screwed connections and

metal hinges are considered sufficient to ensure continuity provided that no electrical equipment is attached to them. If equipment is provided, flexible copper braided cable need to be provided between lid, door cover plate with cubicle body/enclouser.

(v) All parts of protective circuit within the cubical/panel shall be so designed that they are

capable of withstanding the highest thermal and dynamic stresses that may occur at the place of installation.

(vi) During prototype test continuity of all live components shall be checked as per wiring

diagram attached with specification.

(vii) During acceptance/routine test continuity of any 5 of following circuit shall be checked: -

i. 750 V circuit D&ED, ii. K01, K02 contactors iii. 415 V circuit iv. MMR K03 & K04 circuit v. pump control circuit, vi. Exhaust fan circuit vii. Lighting power circuit viii. Laptop & Mobile charging circuit




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During acceptance test inspecting agency shall examine the testing of pervious lot of the Set of Panels and it shall be ensured that the above 5 tests are not repeated with previous lot.

6.9 Verification for effectiveness of protective circuits:

a) It shall be verified that the different exposed conductive parts of the assembly are effectively connected to the protective circuit in accordance with requirements. A protective circuit in an assembly consists of either a separate protective conductor or the conductive structural parts or both. It provides the following-

(i) Protection against the consequences of faults within the assembly. (ii) Protections against the consequences of faults in external circuits supplied through

the assembly.

b) Following interlocking shall be checked during this test (i) Interlocking between feeder contactors K1& K2 shall be checked. (ii) Interlocking between feeder contactors K1 & K2 and D & ED shall be checked.

c) Following component shall be tested on test bench

i) D & ED. ii) Single phasing, Phase sequence reversal, Unbalancing of phase voltages, Under

voltage, Overvoltage of Phase control relay (MMR). iii) Contactor K1, K2, pick up and drop out voltage. iv) All MPCBs/ and MCBs of each rating for different voltage grades.

These tests shall be carried out during type test and routine test. In acceptance test any 2 of the above shall be tested on test bench.

d) Tripping of relevant MCB/MPCB of different circuit of after creating fault at the output terminal of set of panels shall be carried out during type test and routine/ test. In acceptance test any 3 MPCB/MCB shall be tested for tripping.

6.10 Shock & Vibration test:

Shock & vibration test of high voltage panel and on board panel shall be conducted as per category 1, class B & location D given in Annexure B of IEC 61373 – 2010 from any Government lab/NABL accredited agency as per RDSO ISO document. Firm will submit internal performance test report after shock & vibration test to RDSO.

6.11 Water Ingress protection test:

High voltage (HV) panel shall be tested for IP 67 protection as per IEC 60529 with the

latest amendment. Suitable gasket shall be provided on the lower opening. On board

panel shall be tested for IP-23 protection as per IEC 60529 with the latest amendment




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6.12 Check for satisfactory operation of rotary switch: Rotary switches shall be checked for satisfactory operation by rotating 20 times clockwise

and 20 times anticlockwise. 6.13 Check for BOM:

(i) Bill of Material (BOM) used in set of panels as given in Annexure-C (description, make, part no./Catalog no. of each item ) shall be checked.

(ii) In view of updating of the various catalogue/technical data sheets resulting in discontinuation/Non-availability of a particular make/part no, the firm shall take prior approval from RDSO for alternate part no. of a particular make before effecting supplies.

(iii) Proforma in invoice of all major items shall be supplied along with each supply of set of

panels.

Note: Work Test Certificate (WTC) of OEM for all following major items shall be checked & verified by inspecting authority.

a. MCBs/MPCBs

b. Feeder contactors

c. Rotary switches.

d. Insulation Monitoring Relay & Phase control relay(MMR)

e. RC filter

f. Control transformer

g. Earthing & disconnecting device

h. H.T fuses

i. Cables

j. Cable alley

k. Polycarbonate sheet

l. Door hinges & locks

m. RCBO

n. Auxiliary contactors

6.14 Testing of Control Transformer:

Control transformer used in set of panels shall be tested for 500 ‘ON’ and ‘OFF’ operation of power contactors simultaneous connected with one control transformer at ambient temperature of 70°C. Half operations shall be performed on 110-20% and remaining operation shall be performed on 110+10% rated supply received from PWM inverter.




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During the testing, power contactor shall be remaining in no-load condition. The rating of control transformer shall be adequate to supply control coil of all approved make power contactor as mentioned in BOM.

7.0 Technical Data To Be Submitted; 7.1 The manufacturer shall submit complete design details including supportive

calculations, if any of set of panels and its fittings. . 7.2 The manufacturer shall also supply following:

a) Component drawings in CAD software in line with drawings enclosed with

specification along with the material and specification. b) One set of the following will be supplied with every 10 set of panels.

i) Operating and trouble-shooting manual. ii) Parts illustrated catalogue-indicating sources.

8.0 COMMISSIONING:

Firm shall be responsible for commissioning of prototype unit in one coach & prove out the scheme for proper functioning of all related equipment at Production Unit (PU) / purchaser premises. The provisions in set of panels shall be fully compatible with the coach harness provided for various equipment/circuits. For the commissioning of first set of panels, manufacturer shall depute his staff at production unit (PUs) / purchaser for interface with respect of items falling in PU/purchaser scope of supply.

9.0 Manufacturer’s responsibility

9.1 Set of panel shall be suitable for rugged service conditions normally to be met in Indian Railways throughout India.

9.2 The manufacturer shall be fully responsible for ensuring that all equipment forming part

of the supply are entirely fit for the purpose and no part of this specification shall in any way remove or reduce his obligation in this respect. In addition, it is his responsibility to underwrite the complete switchgear system design and ensure that it is compatible with and will, in no way, compromise the design and performance of supply.

9.3 The manufacturer shall provide “in the field” service support during the warranty period.

9.4 The manufacturer shall supply any purpose built or special tools or equipment that may be necessary for the correct operation, servicing, testing or installation of the equipment of the set of panels.




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9.5 The manufacturer will provide assistance, both in terms of material and technical, in development of the system as a whole to ensure that when set of panels are installed as part of the integrated vehicle system, the performance of the system meets or exceeds the requirements specified.

9.6 If the panels fail to achieve these requirements, panels shall be modified at the

manufacture expense and within a time scale to be agreed with purchaser/RDSO. 10.0 MARKING AND PACKING 10.1 Both the cubicles/panels and its main component/accessories shall be provided with a

name/rating plate on the enclosures. The following information shall be available either by etching process or by engraving or screen- printed at the front door on each panel:

a) Name and Address of the manufacturer. b) Month and year of the manufacture.

c) Serial number of panel. d) Specification number. e) weight of cubicle/panel

The first two digits shall indicate the year of manufacture and next two digits shall indicate month. Further next four digits shall indicate manufacturing serial number.

10.2 Schematic/Connection diagram /fittings arrangement of the equipment shall be

provided on the back side of the door.

10.3 The name/identification plates shall be of bright anodized aluminum with black letters embossed or etched on white background. These plates shall be fitted by riveting on the door.

10.4 All components provided inside the panels shall be identified by screen/photo printed

or computer generated designation labels/legend marking plates. These should be mounted near the concerned component duly ensuring visibility. Circuits and components shall also be provided with the name plates indicating the operation/function of the switches/circuits. Contactors and circuit codification diagram (with fuse details ) shall be identified by aluminium anodized legend plates by adhesive of approved make on back side of left hand front doors. Balance indicating/measuring switchgear /devices installed on front door shall be identified by aluminum anodized legend plates by adhesive of approved make on the front doors itself. No riveting is allowed on front door except number plate and caution plate.

10.5 Danger Notice plate shall be screen printed or sticker shall be provided on front of the

lower panel door conforming to IS:2551-82 for 750V. Size of danger plate shall be 200 mm X 250 MM.

10.6 Both panels and its sub-assemblies shall be packed in thermocol boxes and the empty

spaces shall be filled with suitable filling material. Before keeping in the thermocol box, the panel shall be wrapped with bubble sheet. The panels shall be finally packed in a




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wooden case of sufficient strength, so that it can withstand bumps and jerks encountered in road/rail journey.

11.0 GUARANTEE/WARRANTY Guarantee/Warranty obligation of the equipment shall be as per IRS condition of

contract. 12.0 TRAINING

The contractor shall undertake to train, free of cost, the supervisors & staff of the Indian Railways for operation, maintenance, fault finding, trouble shooting, repair of the offered set of panels under the guidance of the skilled engineers as and when asked for by Railways.

13.0 INFRINGEMENT OF PATENT RIGHT 13.1 Indian Railway shall not be responsible for infringement of patent rights arising due to

similarity in design, manufacturing process, use of similar components in design& development of this item and any other factor not mentioned herein which may cause such a dispute. The entire responsibility to settle any dispute/matters lies with the manufacturer/supplier.

13.2 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 RDSO and right of Railways/RDSO on such IP is acceptable to them.

14.0 SERVICE ENGINEERS

The manufacturer shall be required to make available the services of his

engineer/engineers free of cost to monitor 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 engineers at all the zonal & divisional Railway Head Quarter & Production Units to cover entire Indian Railways network. The service engineers shall be fully conversant with panel & electrical circuitry employed in it.

15.0 CARTEL FORMATION

The firm will not engage in cartel formation with other firms and will also submit a declaration in this regard as per attached Annexure –B.




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16.0 ENCLOSURES: Annexure-A

Sr. No.

Drawing/ Document No.

Description

1. RDSO/PE/SK/TL/0214-2019 (Rev 0) sheet 1, 2 & 3.

HV cubicle/panel

2. RDSO/PE/SK/TL/0215-2019 (Rev 0) sheet 1, 2, 3, 4 & 5.

Low voltage on-board fuse cum Rotary switch Panel.

3. RDSO/PE/SK/TL/0216-2019 (Rev 0).

Schematic wiring diagram for panel for LHB EOG/HOG Non-AC coaches

4. RDSO/PE/SK/TL/0179-2014 (rev. 1)

Schematic single line wiring diagram for LHB type non AC EOG/HOG coaches

5. Annexure-C Bill of Material 6. Annexure-B Performa for undertaking against cartel formation




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Annexure-B

UNDERTAKING AGAINST CARTEL FORMATION 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.

RDSO may de-list 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 (Authorized signatory of the firm)

Date: Place: Seal




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Annexure- C Bill of Material (BOM) for Set of panels

S.N Gr Item code

Description Drawing/Catalogue no.

Make Place of Installation

HIGH VOLTAGE CUBICLE

1 12 F01, F02, F03, F04, F05& F06

High voltage fuse (with holder) for net 1 & net 2 Current Rating: 25 A AC Voltage: 1000 V AC Breaking capacity: 25kA

2038603+2138601 of M/s Siba

Siba S1F50, S1F51, S1F52, S1F53, S1F54 & S1F55

EFEN

Ferraz

ETI

Eaton Bussmann

2 12 F10, F11 & F12

Low voltage fuse (with holder) for transformer (secondary) Current Rating: 25 A, Voltage: 500 V AC Breaking capacity: 25kA

03912, 03760 of M/s Wohner

Siba S1F44, S1S45 & S1F46

EFEN

Ferraz

ETI

Siemens

Bussmann

GE

L&T

Schneider

3 12 F15, F16 & F17

Low voltage fuse (with holder) for transformer (secondary) Current Rating: 16 A, Voltage: 500 V AC Breaking capacity: 25kA

3NH-3030+3NA7-805-0RC of M/s. Siemens & 03912, 03760 of M/s Wohner

Siba S1F47, S1F48 & S1F49

EFEN

Ferraz

ETI

Bussmann

GE

L&T

Siemens

4 12 A1 Disconnecting and earthing device, 8 pole , 2 way, without OFF on load 63A 1000 V AC, with 4 NO contacts with heavy handle and pad locking arrangement in off position, mounted in a stainless steel enclosure suitable for AC 23 duty conforming to IEC 60947

M137.0827407.R2 of M/s Schaltbau and 74168SIB32LOGBSS of M/s Salzer

Schaltbau/ Salzer/L&T

S1A2

5 21 K01 & K02.

Voltage phase control MMR net 1 & net 2 3AC, 1000 V, aux voltage 110 V AC/DC

BD 9080 Dold S1K03 & S1K04 --- Carlo Gavazzi

CM-MPN .72 ABB

6 28 K01 Drop out delay time relay for antiskid time off delay control supply voltage 110-240 V AC/DC

CT-ARS.21S ABB S1K05

3RP25401AW30 SIEMENS

RE22R2KMR Schneider

23GDT0 L&T

MK7873N DOLD

7 31 F03 & F04

Fuse 5x20 mm (fuse clamp at the X1.2) anti skid device T 6.3A

282128/281- 418 (clamp)

Wago S1F63 & S1F65

Wickmann

RS

Ferraz




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Weidmuller

Phoenix

8 32 K01 & K02

Feeder Contactor for Net 1&2 Voltage Rating : 1000 V AC, Current Rating: 100 A, Rated KVA-100 at rated voltage & 70 deg and insulation category 6 a. Main Pole: 4 NO, Aux. contact: 2 NO + 2NC Control Voltage: 110 V AC, With surge suppressor

ABB

S1K01 & S1K02

LC1D1150046F7+LADN2

Schneider

Siemens

MCX-34 L&T

9 33 Q1 MPCB for water pump MBS 25 with 02 nos. of aux. contact (1NO+1NC) and terminal block db, Current rating: 1.6 A Thermal release range: 1-1.6 A Voltage Rating: 415 V Breaking Capacity: 50kA Pole: 3 P

MS116-1.6, HK1-11 ABB S1F21

GV2-ME06+GV-AE11 Schneider

3RV2021-1AA10+3RV29011E

Siemens

ST41894OOOO + ST41945OOOO

L&T

10 12 T01& T02

Control transformer(T1) 100 VA, 750V/110V, 6 KV insulation, Class H, suitable for rolling stock, 02 Nos.

Bhasin Packard

NACEI

AEL

RAMYAA

ABROL

Trinitron

11 F101, F102, F103, F104, F105 & F106

Fuses (with holder), 2A, 1.2 KV AC, Qty - 6 nos

* Siba S1F101, S1F102, S1F103, S1F104, S1F105 & S1F106

EFEN

Ferraz

ETI

Bussmann

GE

Siemens

ABB

L&T

12 F107, F108, F109 & F110

Fuses (with holder), 2A, 500 V AC, Qty - 4 nos

C10G2+BMM6031SQ Eaton S1F107, S1F108, S1F109 & S1F110

184000.2+7103401 Siba

BMM6031SQ+C10G2 Bussmann

1SCA833001R2001 ETI

ST30725 with HD32 Base

L&T

3NWNS2+3NW20NNSF

Siemens

OFAFN000GG2+OFAFN000GG2

ABB

13 33 K06 & K07

Auxiliary Contactor (with diode) for Water Pump: 1 & 2 Contacts: 3 NO + 1 NC Control Voltage: 77-143 V DC Rated voltage 690 V AC Rated current 10A (at rated voltage & AC-3 Utilization category)

AF9ZB-30-01 ABB S1K24 & S1K25

CA4KN31FW3 Schneider

3RH2131-1BF40+3RT29161DG00

Siemens

MO0DC L&T

* C&S




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14 X1 Terminal blocks for high voltage cubicle

Wago/Phoenix/Weidmuller

S1X1.1

15 MCB for RBC cum EBC Rated Current : 25 A, Curve: C, Rated Voltage : 415 V AC, Pole: 3 P, Breaking Capacity: 10 kA

5SL43257RC Siemens S1F111

S203MT-C25 ABB

BB30250C L&T

A9N3P25C Schneider

FAZ-C25/3 Eaton

ON-BOARD LV CUBICLE

1 Fuse cum Rotary switch panel for Non AC Coaches

RDSO/PE/SK/TL/0215-2019 (Rev 0) Sheet-5 of 5

RDSO/PUs approved sources

2 RSW-1 Rotary Switch 16A, 440 VAC, 4 Position. 4 Pole ON-OFF for Mobile Charging Socket & Exhaust Fan ON-OFF

61196SBB03TDYR of M/s Salzer

Siemens

RSW-1

Kaycee

TEKNIC

GE

Salzer

3 RSW-2 Rotary Switch 10A, 440 VAC, 4 Position. 4 Pole ON-OFF for Mobile Charging Socket & Exhaust Fan ON-OFF

61196SBB03TDYR of M/s Salzer

Siemens RSW-2

TEKNIC

GE

Salzer

Kaycee

4 RSW-3 Rotary Switch 10A, 440 VAC, 4-Position, 2 Pole ON/OFF, for power supply ON-OFF

61198SBB03TDYR Siemens S1S01

TEKNIC

GE

Salzer

Kaycee

K10D012QCH Schneider

5 RSW-4 Rotary Switch 10A, 440 VAC, 4-Position, 2 Pole, 2 Way with OFF for Net-1 & Net-2 Selection

3SB5000-2DB01 + 3SB5400-0A

Siemens

S1S02

TEKNIC

GE

61152SBB03TDYR Salzer

Kaycee

K10D012QCH Schneider

6 F01 & F02

Low voltage fuse (with holder), 25 A, Qty - 2 nos.

3NA78100RC+3NH30300RC

Siemens S1F42 & S1F43

03912,03760 Wohner- Italweber

OFAFN00GG25+ 1SCA833001R2001

ABB

25NHG000B+SB00PB

Eaton

SF90152+SK91314 L&T

7 Low voltage fuse (with holder) for fan circuits,6 A, 250 V AC, Qty - 6 nos.

* Siemens

ABB

Wohner-Italweber

Ferraz

Siba

8 RCBO, 16 amps. 30mA, 4 Pole : (H.V Panel), C series

Siemens

MDS

Legrand




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AVFAVFC 401603 L&T

A9N26595+A9N4P16C

Schneider

9 MPCB for exhaust fans, 04 nos. Thermal release range - 0.24 to 0.4 A, Continuos current rating- 0.4A Voltage rating 415 V No. Of pole-03 1 NO+1NC and terminal block

3VU1340-0MD00 Siemens

GV2ME03 Schneider

MS116-.04 ABB

ST41891OOOO L&T

10 Accidental emergency light (AEL), push button

XB5AA42N Schneider

Salzer/L&T

Teknic

3SB50000AC01+3SB54000C

Siemens

11 RC filter consist of 1 ohm, 6W resistor connected in series with parallel connected 1.5 MFD, 850 V capacitor in each arm of 415 V circuit between phase to neutral and phase to earth circuit. Qty 04 nos.

Bhasin Packard RDSO Modification sheet no. RDSO/PE/MS/AC/00051-2011 (Rev.2) or latest to be followed.

AEL

RAMYAA

Trolex

NEC

ISG

Trinitron

ABROL

MISCELLANEOUS

NACEI

1 PVC alleys L&T/AKG

2 Halogen free e-beam irradiated cables of various sizes

RDSO spec. No. ELRS/SPEC/ELC/ 0019 (Rev.4) or latest

RDSO approped sources

3 Multiple accessories like locks, hinges, handles etc. of HV panel.

Own make

4

Multiple accessories like locks, hinges, handles etc. of LV Panel

Dirak

Southco

Hafele

or equivalant imported make

5

Computer generated ferrules class R22/R23 in EN 45545-2 with HL-2 category.

Tyco

Phoenix

MV Electro System

Altronix

6 Cable Jackets class R22/R23 in EN 45545-2 with HL-2 Category

PMA Jack

Federal Mogul

MV Electro System

Tyco

ISG

Werner Hahm

7 Powder coating of Siemens Grey shade no 6102/08038 of M/s Nerolac Paints

M/s Nerolac Paints or 877 of M/s Berger Paints

Note:




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1. * Part number shall be decided at design approval stage before prototype manufacturing. 2. Inspection agency will check all the components and preserve record for future

reference. 3. Inspection agency shall ensure that switchgears shall be used as per description where

catalogue no. is not mentioned. 4. The DIN rail used shall have minimum depth of 15mm. 5. Coloured heat shrinkable sleeves shall be provided as per phase for easy identification. 6. The part numbers mentioned in the above Bill of Material (BOM) are indicative only and

shall be finalized at design stage of prototype. Firm has to obtain prior approval of part no at the design stage before use in prototype Set of Panels.

7. All components / materials provided in Set of Panels shall conform to EN 45545 with hazard level HL-2, shock & vibration to IEC 61373 and suitable for rolling stock application to work in temperature range of -10 Deg C to 70° C & relative humidity up to 98 %.

8. Specified current for all switch gears items shall be at rated voltage and specified utilization category at surrounding air temperature of 70°C.

9. Rated insulation voltage for components used on 750 Volts AC & 415 Volts AC side shall be 1000 volts AC & 690 Volts AC respectively.

10. Manufacture of Set of Panels shall verify the specification of equipment to be installed in Set of Panels at their end and ensure its compliance as per the requirements mentioned in this specification.

11. For any deviation on above prior approval of RDSO shall be obtained.

of 29 File No. EL/ 7.1.108/SBC Spec. No RDSO/PE/SPEC/TL/0185 -2019 (Rev. 0)

Prepared by – SSE/Alt.

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TERMINAL BLOCK FITMENT POSITION FOR NON-AC SET OF PANELS ANNEXURE-D

HIGH VOLTAGE CUBICLE TB FITMENT FOR LV PLATE

For Antiskid Device

TB fitment for K1 / K2 Contactor Plate

TB fitment for F44 / F45 Fuse Plate

Block No. Wago Number




EL 249-117 END LOCK

EL 249-117 END LOCK

EL 249-117 END LOCK

EL 249-117 END LOCK

F63 282-128/481-418

EP 283-325 END PLATE

10 283-671 BLOCK

1 280-901 BLOCK

F65 282-128/481-418

1 283-901 BLOCK

11 283-671 BLOCK

2 280-901 BLOCK


2 283-901 BLOCK

12 283-671 BLOCK

3 280-901 BLOCK

41 280-833 BLOCK

3 283-901 BLOCK

13 283-671 BLOCK

4 280-901 BLOCK

42 280-833 BLOCK

4 283-901 BLOCK

14 283-671 BLOCK

5 280-901 BLOCK

43 280-833 BLOCK

EL 249-117 END LOCK


6 280-901 BLOCK

44 280-833 BLOCK

EL 249-117 END LOCK

EL 249-117 END LOCK


45 280-833 BLOCK

5 280-901 BLOCK

15 284-681 BLOCK

7 282-681 BLOCK

46 280-833 BLOCK

6 280-901 BLOCK

16 284-681 BLOCK

8 282-681 BLOCK

47 280-833 BLOCK

7 280-901 BLOCK

17 284-681 BLOCK

9 282-681 BLOCK

48 280-833 BLOCK

8 280-901 BLOCK

18 284-681 BLOCK

10 282-681 BLOCK

49 280-833 BLOCK

EP 280-308

19 284-681 BLOCK


50 280-833 BLOCK

EL 249-117 END LOCK


11 282-687 EB

51 280-833 BLOCK

EL 249-117 END LOCK

12 282-687 EB

52 280-833 BLOCK

20 284-681 BLOCK


53 280-833 BLOCK

21 284-681 BLOCK

13 280-681 BLOCK

54 280-833 BLOCK

22 284-681 BLOCK

14 280-681 BLOCK

55 280-833 BLOCK

23 284-681 BLOCK

15 280-681 BLOCK

56 280-833 BLOCK

24 284-681 BLOCK

16 280-681 BLOCK

57 280-833 BLOCK


17 280-681 BLOCK

58 280-833 BLOCK

EL 249-117 END LOCK

18 280-681 BLOCK



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59 280-833 BLOCK

25 284-681 BLOCK

ADJ 280-402 Adjacent Jumper

60 280-833 BLOCK

26 284-681 BLOCK

19 280-681 BLOCK

61 280-833 BLOCK

27 284-681 BLOCK

20 280-681 BLOCK

62 280-833 BLOCK


21 280-681 BLOCK

63 280-833 BLOCK

EL 249-117 END LOCK



30 280-833 BOLCK

22 280-681 BLOCK

EL 249-117 END LOCK

31 280-833 BOLCK

23 280-681 BLOCK

32 280-833 BOLCK

24 280-681 BLOCK

33 280-833 BOLCK

25 280-681 BLOCK

34 280-833 BOLCK


35 280-833 BOLCK


36 280-837 EB

EL 249-117 END LOCK


EL 249-117 END LOCK

F58 282-128/481-418

F59 282-128/481-418


298 280-833 BLOCK

299 280-833 BLOCK

300 280-833 BLOCK

301 280-837 EARTH BLOCK

302 280-833 BLOCK

303 280-833 BLOCK

304 280-833 BLOCK

305 280-837 EARTH BLOCK


EL 249-117 END LOCK



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S

WELCOME TO RDSO - Hkkjr ljdkj jsy ea=ky; · 2019. 12. 24. · Spec. No RDSO/PE/SPEC/TL/0185 -2019...

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