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DRAFT SPECIFICATION

OF

SMPS BASED TELECOM INTEGRATED POWER SUPPLY SYSTEM

FOR

STATION

VERSION 0.0

Number of Pages :32

SPECIFICATION NO. RDSO/SPN/TC/102-2013

TELECOM DIRECTORATE

RESEARCH, DESIGNS & STANDARDS ORGANISATION

LUCKNOW - 226011


DOCUMENT DATA SHEET

Specification Number

RDSO/SPN/TC/ 102 -2013

Version

0.0

Title of Document

SMPS based Telecom Integrated Power Supply System for

Station(TIPSS)

Prepared by:

Shri Rakesh Sahariya

Designation: ADE/Tele-I

Shri Rajesh kumar Pandey

Designation: Director / Telecom-IV

Approved by:

Name: Shri S.K.Vyas

Designation: Executive Director/Telecom, RDSO

Abstract

This document defines specification of SMPS based Telecom Integrated Power Supply System

(TIPSS) for Station


DOCUMENT CONTROL SHEET

Designation

Organization Function Level

ADE/Telecom-I RDSO Member Prepare

Director/Telecom

RDSO

Member

Prepare

ED/Telecom

RDSO

-

Approval


TABLE OF CONTENTS

Para No. Item Page No.

Abbreviations used 5

1.0 Foreword 6

2.0 General Requirements 7-11

3.0 Electrical & mechanical Requirements 11-18

4.0 Requirements of DSCA 18-19

5.0 Requirements of DC-DC Converter 19-20

6.0 Requirements of MPPT Charger 20-21

7.0 Source Priortisation 21

8.0 Packing 21

- Schematic of TIPSS 22-23

9.0 Test and Requirements 24-25

10.0 Test Procedure 25-29

11.0 Information to be given by purchaser 29

Annexure-I General Requirements for RFIS 30-31

Annexure-II Schematic diagram of Surge and lightening protection 32


ABBREVIATIONS USED

Abbreviation Detail

AMF Panel Auto Mains Failure Panel

ASM Assistant Station Master

DSA Distribution Switching & Alarm Unit

DG Set Diesel Generator Set

DOD Depth of Discharge

EMI Electromagnetic Interference

FRBC Float Rectifier Cum Boost Charger

IPS Integrated Power Supply

IS/IEC Indian Standard/ International Electrotechnical Commission

LCD Liquid Crystal Diode

LED Light Emitting Diode

MTBF Mean Time Between Failure

MOV Metal Oxide Varistors

OEM Original Equipment Manufacturer

PF Power Factor

PWM Pulse Width Modulation

RE Railway Electrification

RFI Radio Frequency Interference

SMPS Switched Mode Power Supply

SPD Surge Protection Devices

VRLA Valve Regulated Lead Acid

MPPT Maximum Power Point Trecking


GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

RESEARCH, DESIGNS & STANDARDS ORGANISATION (RDSO)

DRAFT SPECIFICATION

OF

"SMPS BASED TELECOM INTEGRATED POWER SUPPLY SYSTEM (TIPSS) FOR STATION"

1.0 FOREWORD

1.1 This Specification Requirement of Switched Mode Power Supply (SMPS) Based "Telecom

Integrated Power Supply System (TIPSS) for Station" has been prepared for the use of various

Telecom equipment provided at station on Indian Railways. This System will consists of 48Volts (V)

SMPS based Power Plant to provide 48V for Control Communication equipments , OFC equipment,

Radio equipments, GSM-R equipment etc provided at station. The System will also provide

galvanically isolated 24V, 12V, and 3-6V DC for other telecom applications with the help of DC-DC

Converter.

1.2 SMPS Based Telecom Integrated Power Supply is intended to be used in Auto Float Rectifier-cum

Float-charger (FR-FC) and/or Float Rectifier cum Boost Charger (FR-BC) mode as a regulated DC

power source, DC-DC Converters are for various DC power supply requirements of Telecom

equipment at Railway Stations. Some of the typical requirements of telecom equipment at the station

are as under:

1.3 This specification requires reference to following specifications:

IRS: S 88/2004 Low Maintenance Lead Acid Battery

IRS:S 93/96(A) Valve Regulated Lead Acid Sealed Maintenance Free

Stationary Battery

IRS: S 63/07 PVC insulated underground unscreened cables for Railway

signalling

RDSO/SPN/144/2006 Safety & reliability requirements of electronic signalling

equipment.

IS:9000 Basic environmental testing procedure for electronic and

electrical item

IEC-61643 Surge Protective Devices connected to low-voltage power

SN Name of Equipment Working Voltage Required Current

1. 25W VHF Set 12V DC 2-3 Amp

2. VF Repeater 12V DC 0.5 Amp

3. Gate Telephone 12V DC 100mA- 500mA

4. Gate Telephone 24 V DC 200 mA-1Amp

5. Way Station Control Telephone 12V DC 100mA

6. Magneto Telephone 3-6 V DC 50mA

7. STM1/4 OFC Equipment 40-60V DC 3 Amp

8. PD MUX 36-72V DC 2 Amp

9. Router 12V DC 3 Amp

10. Switch 12V DC 2 Amp


distribution systems

EN 55022 European Standard for Information Technology Equipment

MIL HBDK 217F Military hand book "Reliability Prediction of Electronic

Equipment"

IEC 61312 Protection against Lightning Electromagnetic Impulse

1.4 Wherever, in this specification, any of the above mentioned specifications is referred by number only

without mentioning the year of issue, the latest issue of that specification is implied

2.0 GENERAL REQUIREMENT

2.1 Telecom Integrated Power Supply System shall consist of a Distribution-Switching-Control- Alarm

Arrangement (DSCA) and Float Rectifier-Cum-chargers (FR-FCs) or Float Rectifier cum Boost

Chargers (FR-BCs) (in N+1 configuration in hot-standby and one module in cold standby), DC-DC

converter (in N+1 configuration in hot-standby) for 24V, 12V, 3-6V, 48V MPPT Battery Charger

(optional) , 48V battery set of adequate capacity.

2.2 The Telecom Integrated Power Supply System shall be capable of meeting the load requirement

(equipment and battery bank) for various telecom equipments. The system shall be expandable at

rack level itself, using the basic modules of the same rating.

2.3 To cater for higher load requirements, (for modules with more than 50 watts) same type of modules

mounted in the same rack shall be capable of working in parallel load sharing arrangement.

2.4 The Telecom Integrated Power Supply System shall be suitable for operation from AC Mains, solar

power supply or from a DG Set.

2.5 The Telecom Integrated Power Supply System shall work satisfactorily either with VRLA

maintenance free Battery as per IRS;S93/96(A) or Low Maintenance Lead Acid Battery as per

IRS;S88/2004 with latest amendment. Battery as per purchaser requirement will be integral part of

system.

2.6 In case purchaser decides to provide solar power as additional source of power supply as indicated in

clause 11.0, Solar Panel Modules of adequate capacity along with suitable Bracket & Bracing Plate as

per IRS:S 84/92 with Latest Amendments shall be supplied alongwith TIPSS. Actual requirement of

number of Solar Panels & its capacity etc. shall be indicated by purchaser based on site requirement.

2.7 One panel consisting of status indications and critical alarms of TIPSS is to be provided in ASM‟s

room. The monitoring panel shall be of wall mounting type. OEM shall supply 12 core, 1.5 sq.mm

signalling cable as per IRS:S 63/2007 for connecting TIPSS to Status Monitoring Panel in Station

Master‟s room (distance to be given by Railways at the time of indenting).

2.8 There shall be an automatic arrangement for disconnecting the mains within 500 ms to the rack

whenever the input voltage is beyond the specified operating limits with suitable alarm indication.

The TIPSS shall resume normal working automatically when the input is restored within the working

limits. A self storing type static switch should be provided at the input. It shall be capable to

with-stand 400 volts input continuously without any damage.

2.9 Components

I. Semiconductor and other components used in the equipment shall be of industrial grade with

operating temperature range -25oC to + 85

oC.

II. Semi-conductor power devices and other Solid state components used in TIPSS shall not be operated

at more than 50% of the rated maximum peak voltage and at not more than 50% of the rated

maximum average current under any prevailing conditions. Manufacturer shall submit design details,

components datasheet at the time of type approval.

III. The manufacturer shall declare the peak reverse voltage, current rating and working temperature of

the rectifier element under ambient conditions, the number of elements used and the manner of their

connection. The peak reverse voltage rating should not be less than two times the expected reverse

voltage across the devices.


IV. The recommended list of major components and their makes given in Annexure VI of RDSO/SPN/

165/2012 shall be applicable for this specification also.

V. Printed Circuit Board

Printed Circuit Board shall generally conform to relevant provisions of latest RDSO/SPN/144/2006

for safety & reliability requirement of Electronic signalling equipment.

2.10 Cables & Wiring

a) All the cables and wires used for wiring and inter connections of modules shall conform to

specification No. IRS: S 76-89/IS 694 of grading 1100V. Aluminium wires shall not be used. The

gauge of wiring shall be such that the current density does not exceed 3 amperes/mm square.

b) The colour scheme employed for the rack wiring shall be as below:

I) AC line : Yellow

II) AC neutral : Blue

III) Earthing : Green

IV) DC positive : Red

V) DC negative : Black

VI) Control wiring : Grey

c) All connections shall be made through crimped eyelets and shall be numbered with PVC cable

marker rings/ inkjet printing on cables corresponding to the numbers/letters shown in the schematic

wiring diagram. Soldering shall be used only where use of crimped eyelets is not possible.

d) All non-current carrying metal parts shall be bonded together and adequately earthed.

e) All wiring shall be neatly secured in position by bunching /strapping & adequately supported.

Where wires pass through any part of metal panel or cover, the hole through which they pass shall be

provided with rubber grommets.

f) There shall not be any exposed wiring outside the cabinet.

2.11 Transformers and chokes

Transformers and inductors/ chokes used shall be vacuum impregnated and shall be of natural

air-cooled type conforming IS: 6297 (Category 3 & Grade 2). Class F or higher grade insulating

material as per IS:1271 and polyester enameled copper winding wire conforming to IS 13730(Pt. 3)

shall be used for winding transformers and inductors/chokes. The gauge of winding wires shall be

such that the current density shall not exceed 3A/sq.mm. All exposed metal parts of the transformer

including laminations shall be protected against corrosion.

2.12 Fuses & Connectors

a) All plug- in connectors shall be non-interchangeable. Connectors as per IEC 947 shall be

provided.

b) Fuse holder identification shall include details of fuse rating and type.

c) All power fuses shall confirm to specification IS 13703 / IS 9224.

2.13 Earthing

2.13.1 All non-current carrying metal parts and +ve of 48 V shall be bonded together and earthed. An earth

terminal suitable for taking minimum 4 mm dia wire and with suitable marking shall be provided.

2.13.2 The TIPSS and its individual modules shall have earth terminals and shall be properly earthed to the

cabinet. User shall provide earthing arrangement having earth resistance less than 5 Ohm. The

manufacturer of TIPSS shall clearly provide earthing guidelines/ arrangement required for

satisfactory working of the system. It shall be jointly ensured by Zonal Railways and manufacturer of

TIPSS that earthing has been provided as per system requirement at the time of installation and

commissioning and pre-commissioning check-list in this regard shall be signed jointly.


2.14 Terminations

a. The AC input connection to the FRBC/FRFC module shall be by means of plug and socket

arrangement as per specification No. UL 248 & DIN 41576.

b. The DC output connection should be taken through irreversible plug and socket having power

pins with locking arrangement.

c. The output of each FRBC/FRFC in the Negative lead shall be taken through the HRC fuse of 1.5

times of rated capacity of FRBC/FRFC.

d. In all cases, the male connector shall be mounted in the FRBC/FRFC module and the female

connector shall terminate the cable.

e. To prevent hazards or damaging conditions, all plug-in components shall be

non-interchangeable.

f. All the connections between DSA unit and FRBC/FRFC shall be through proper rated cables

only.

g. Circuit breakers at the input of each FRBC/FRFC shall be easily accessible and rated to 16A for

FRBC/FRFC module.

h. Proper termination for AC at the input of the circuit breakers and its output to the FRBC.

2.15 Labelling And Marking

a. Each electrical/solid state component should be possible to be located by the layout/circuit

drawing. The wiring shall be clearly and permanently identified with a designation or a colour

code, which corresponds to the equipment circuit diagram. Where non-standard colours are

used, cable functions shall be clearly and permanently labelled at both ends.

b. A screen printed cabling / wiring diagram shall be placed on the inside of the front door or any

other convenient place for ready reference of maintenance staff.

c. Screen-printed Do‟s & Don‟ts, adjustment procedures and operating instructions shall be

provided at convenient place on front panel of the TIPSS cabinet. One laminated block diagram

shall also be provided at convenient place inside the cabinet.

d. The layout of the components and wiring shall be such that all parts are easily accessible for

inspection, repairs and replacement.

e. All markings shall be legible and durable. Where the marking is by use of labels, they shall be

metallic or screen-printed. These shall be firmly struck and shall not be capable of being

removed by hand easily. They shall be placed in the vicinity of the components to which they

refer.

f. All cubicles belonging to one TIPSS shall be identified with a common serial number.

g. Each FRBC, DC-DC converter shall be marked with its name & rating on its front panel. The

placement for particular module in respective rack shall be clearly marked with its application

for the purpose of appropriate replacement.

h. Every SMPS based TIPSS shall be provided with a rating plate fixed outside at a conspicuous

place in TIPSS cubicle. It shall be clearly and indelibly etched, engraved or screen printed and

shall show the following minimum information:

I) Name and trade mark of the manufacturer

II) Specification No.

III) Nominal AC input voltage and frequency

IV) Serial number and year of manufacturing.

V) Version number as per RDSO/SPN/144/2006.


i. All input and output terminals shall be clearly identified by using proper name tags/labels.

2.16 Battery Bank

2.16.1 TIPSS shall be suitable for charging 48V battery bank of 200 AH in case of RE area /300AH in case of

non-RE area Low Maintenance cells as per IRS:S 88/2004 or VRLA Maintenance free cells as per

IRS:S 93/96(A). Battery bank is part of this specification and the same shall be supplied and

commissioned along with TIPSS. If Railway requires higher capacity batteries it should be mentioned

specifically in the Purchase Order.

2.16.2 Battery racks of MS for VRLA batteries or wooden/ FRP rack for low maintenance batteries, along

with its accessories, shall also be supplied with battery bank.

2.16.3 OEM shall supply copper cable of suitable dia as per IS: 694 and grade 1100V for connecting TIPSS to

Battery bank (distance to be given by Railways at the time of indenting) as given below –

a) For 200AH battery – 16 Sq.mm

b) For 300AH battery – 25 sq.mm

2.17 Module replacement time and MTBF

2.17.1 The mean time to replace a faulty module of IPS shall be less than 30 minutes.

2.17.2 The DC fan. provided at rack /module level should have MTBF better than 70,000 hours at 40o C. The

fan shall be covered with grill to prevent dust ingress.

2.18 Installation & Commissioning

Installation & commissioning of TIPSS shall be as per guidelines issued by railway board/Zonal

railway.

3.0 ELECTRICAL AND MECHANICAL REQUIREMENT OF FR-FC & FR-BC MODULES

3.1 Mechanical Requirement

3.1.1 The FRBC/FRFC Modules shall be provided with natural/forced cooling. The capacity of

FRBC/FRFC module will be 25 Amp .

3.1.2 The FRBC/FRFC module shall be removable from the front of the rack only. All AC input, DC output

and alarm/control /monitoring cables inter connecting the modules and racks shall be easily

removable/replaceable.

3.1.3 All the modules shall be housed in 19” rack. Cable entries will be from the top of the rack. In the rack

Control panel, FRBC /FRFC Module , DC-DC Converter should be placed from top to bottom

respectively. It shall be also possible to place all the DC-DC Converters in a separate wall mountable

rack of suitable/9U size which may be installed in the ASM Room situated at a maximum distance of

200 Mtr. 48 V supply with class-C SPD Protection (as per Cl. 3.2.12.3 Of this specification) will be

extended to this unit in case this unit is kept in ASM Room. Two core signaling cable of 16 mm2 as

per IRS:63-07 with latest ammendement is to be supplied by manufacturer and railway/purchaser has

to specify the distance of the ASM Room from TIPSS.

I. Rack Configuration-The cabinet shall be within the overall dimensions of 2000-mm max. Height

750 mm. max. Depth and 750 mm max. Width. Cabinet will have min 10-mm thick

anti-vibrating pad and 75 mm x 5-mm bottom channel .The rack structure and the module frame

shall be made up of rigid framework of steel profiles. The front door, if used, shall be of hinged

type. The rear panel shall be provided with proper ventilation arrangement. Fan shall be

provided at rack level for forced cooling. The operation of such fan shall be continuous.

II. The size of DC-DC Converter/ alarms rack to be provided in the ASM room shall be of 9 U size.

The mounting arrangement of installation in the ASM room shall be approved by In-charge at

the time of installation.


III. The racks and module cabinets shall be of robust construction. They shall be housed in

self-supporting cubicles made of cold rolled closed annealed mild steel sheet of thickness not

less than 1.6mm. The rack shall be adequately ventilated. The ventilating opening shall be less

than 3mm size for protection against entry of lizard‟s etc. The rack shall conform to IP31 type of

protection as specified in table 1 of specification no. IS 2147-1962.

IV. The racks and the modules shall be treated with zinc chromate primer followed by electrostatic

epoxy powder coating paint finished, passivation shall be done through seven stage process/sand

blasting. Small metal parts such as nuts, bolts and washers shall be chrome plated. All other

metal parts of the rack shall be plated for protection against corrosion.

V. The racks and the module cabinets shall be free from sharp edges & sharp corners.

VI. Provision of doors are optional, the cabinet sides shall have 3mm louvers covered with wire

mesh. However, if the doors are not provided, the sub system shall have proper enclosures so

that any reptile/ insect shall not enter in the TIPSS cabinet. The magnetic latches/handle shall be

provided on the doors.

VII. The racks and the modules shall be designed for easy maintenance and installation.

VIII. Facility shall be provided at the top of the rack to connect external AC power and lightning

arrestors (if provided inside the rack). Where cables pass through metal panels, suitable rubber

grommets shall be provided to protect cable from damage.

IX. The modules shall be of modular type. The module shall be easily mounted or removed from the

front side of the rack. The module shall be designed to slide into the rack on a suitable

mechanical arrangement. Suitable arrangement shall be made for pulling out each module

separately. The associated AC input, DC output connection, control/alarm & interface cable

connecting the module shall be disconnected/installed easily without causing any

interruption/damage to supply & working module.

X. The input and output terminals shall be accessible only when the cover of the cubicle is removed.

All the terminals shall be clearly, neatly and indelibly marked to correspond with the wiring

diagram for easy identification.

XI. Input and output connections of SMR, DC-DC converter, MPPT Charger shall be made using

plug & socket of adequate rating having power pins with locking arrangement. The male

connector shall be mounted on the device and the female connector shall be terminated on the

cable. Use of terminal blocks for input and output connections is not accepted.

XII. The finish of steel and panels shall conform to relevant IS specification. The colour scheme shall

be as follows:

a) Rack & doors Pebble Grey RAL 7032

b) All TIPSS modules shall harmoniously match with rack colour

3.2 Electrical Requirement

FR-FC & FR-BC MODULES shall be based on High Frequency Switch Mode Techniques using

switching frequencies of 20Khz and above.

3.2.1 AC Input supply

The Telecom Integrated Power Supply system using FR-FC or FR-BC shall operate from single

phase AC input supply range from 150-275 V with nominal input frequency of 50Hz which may vary

from 48-52Hz.

3.2.2 DC output Characteristics

DC output Characteristics

(I) Auto Float Mode

a) The Float voltage of each rectifier module shall be continuously adjustable & pre- settable at any

value in the range of 48V to 56V. The prescribed float voltage setting is 54V for VRLA battery.


b) The DC output voltage shall be maintained within ±1% of the half load preset voltage in the range

25% load to full load when measured at the output terminals over the full specified input range.

(II) Auto Charge Mode:

In Auto Charge Mode FR-FC shall supply battery & equipment current till terminal voltage reaches

set value, which is normally 2.3V/Cell (55.2V) & shall change over to Auto Float mode after a

defined delay of 0, 1, 2, 4 hours adjustable, to be set as per battery manufacturer‟s specification. If

battery voltage falls upto 48 V it will change to Auto Charge mode.

3.2.3 Efficiency

The efficiency of the unit shall be as given below:-

a) At nominal input, output and full rated load better than 90 %

b) For other specified input, output conditions better than 85 % and load between 25% to 100%

3.2.4 Input Power Factor

The input power factor at nominal input, output voltage and load 75% to 100% shall be between 0.95

lagging and 0.98 leading but it shall remain between 0.90 lag and 0.90 lead in any other working

condition and load between 25% to 100%

3.2.5 Total voltage Harmonic Distortion

The total line harmonic voltage distortion shall not be more than 10%.

3.2.6 Total current Harmonic Distortion

The total current harmonic distortion contributed by the unit at the input shall not exceed 10% for

input voltage range 150-275 V for load 50% to 100% of the rated capacity. While input voltage

harmonic Distortion is less than 5%.

3.2.7 Current limiting (Voltage Droop)

(i) The current limiting (Voltage Droop) shall be provided for Float Charge operation. The

Float/Charge current limiting shall be continuously adjustable between 50 to 100% of rated

output current for output voltage range of 44.4V to 56Volts. For test purposes upper limit of

100% + 5% and lower limit of 50% -5% shall be acceptable.

(ii) The float and charge current limit adjustment shall be provided on the front panel of the rectifier

module or through the DSCA controller.

(iii) The FR-FC modules shall be fully protected against short-circuits. It shall be ensured that short

circuit does not lead to any fire hazard.

3.2.8 Soft Start Feature:

(I) Slow start circuitry shall be employed such that FR-FC module input current and output

voltage shall reach their nominal value within 10seconds.

(II) The maximum instantaneous current during start up shall not exceed the peak value of the

rectifier input current at full load at the lowest input voltage.

3.2.9 Voltage overshoot/undershoot

Following requirements shall be achieved without a battery connected to the output of FR- FC

module.

(a) The FRBC/FRFC modules shall be designed to minimize output voltage overshoot/undershoot

such that when they are switched on the DC output voltage shall be limited to ±5% of the set

voltage & return to their steady state within 20ms for any load of 25% to 100%.

(b) DC output voltage overshoot for a step change in AC mains shall not cause shut down of FR-FC

module and the voltage overshoot shall be limited to ±5% of its set voltage and return to steady

state within 20ms.


(c) The modules shall be designed such that a step load change of 25 to 100% shall not result in DC

output voltage overshoot/undershoot of not more than 5% return to steady state value within

10ms without resulting the unit to trip.

3.2.10 Electrical Noise

(I) The rectifier (FRBC/FRFC) modules shall be provided with suitable filter on the output side.

A resistor shall be provided to discharge the capacitors after the rectifier modules have

stopped operation and the output is isolated.

(II) The Psophometric Noise (e.m.f. weighted at 800Hz) with a battery of appropriate capacity

connected across the output should be within 2mV while delivering the full rated load at

nominal input of 230V. For test purposes, this shall be taken as equivalent to 4mV when the

battery is not connected and other conditions remaining the same as per ITU-T Rec P53.

(III) The Peak to Peak Ripple: voltage at the output of the rectifier module on full load without

battery connected shall not exceed 300mV at the switching Frequency measured by an

Oscilloscope of 50/60 MHz band-width (typical)

3.2.11 Parallel Operation

FRBC/FRFC operating in parallel with one or more modules of similar type, make and rating, other

output conditions remaining within specified limits. The current sharing shall be within ±10% of the

average current per rectifier module and within individual capacity of each rectifier module in the

system when loaded between 50 to 100% of its rated capacity for all other working conditions.

3.2.12 Protection

3.2.12.1DC over voltage protection

Each rectifier module shall be fitted with an internal over-voltage protection circuit. In case output

DC voltage exceeds-57V the over voltage protection circuit shall operate & shut off the faulty

module. A tolerance of ±0.25V is permitted in this case. Restoration of the module shall be through a

reset switch/push button. Shutting-Off of faulty FRBC/FRFC module shall not affect the operation of

other FR-FCs operating in the rack. Operation of over- voltage shut down shall be suitably indicated

on the module and also extended to monitoring/control unit.

The circuit design shall ensure protection against the discharge of the battery through the FR- FC

module in any case. The over voltage protection circuit failure shall not cause any safety hazard.

3.2.12.2 Fuse/circuit Breakers

Fuses or circuit breakers shall be provided for each FRBC/FRFC module as follows:

a) Live AC Input line

b) Negative DC output

c) Against failure of Control sensing circuit.

All fuses/circuit breaker used shall be suitably fault rated.

3.2.12.3 Lightning Protection

System shall have modular type I/class. B and Type II/Class C type surge protection in TT

configuration of wiring. Both type I/Class B and Type II/Class C arrestors should be from the same

manufacture and shall be mounted as per the specific installation recommendations of the

manufacturer to achieve perfect coordination.

a)Stage 1 Protection (at the entry point of input 230V AC supply in the power/ equipment room)

The Stage 1 protection shall consist of coordinated Class I/ B & II/ C type SPDs at the entry point of

input 230V AC supply in Power /Equipment room in TT configuration in a separate wall mountable

box. The Class I/B SPD shall be provided between Line to Neutral & Neutral to Earth. They shall be

spark gap type voltage switching device and tested as per IEC 61643 with the following

characteristics and features-

SN Parameters Limits

Between Line & Between


Neutral Neutral & Earth

1 Nominal Voltage (U0) 230V 230V

2 Maximum continuous operating voltage

(Uc) 255V 255V

3 Lightning Impulse current 10/350s

(Imp)

25KA 50KA

4 Response time (Tr) 100 ñs 100 ñs

5 Voltage protection level (Up) 2.5KV 2.5KV

6 Short circuit withstand and follow up

current extinguishing capacity without

back up fuse (Isc & Ifi)

3KA 100A

7 Temporary Over Voltage (UT) 334V min. for 05

secs.

1200V min. for

200ms

8 Operating temperature / RH - 25oC to +80

oC/

95%

- 25oC to +80

oC/

95%

9 Mounted on din rail din rail

10 Indication Mandatory Optional

11 Pluggability Optional Optional

12 Potential free contact for remote

monitoring

Optional Optional

13 Encapsulation Encapsulated Encapsulated

14 Degree of protection IP20 IP20

15 Housing Fire retardant as

per UL 94

Fire retardant as

per UL 94

(b) The Class I/ B SPD will be followed by Class II/ C SPD adjacent to it and connected between

Line & Neutral. The device shall be a single compact varistor of proper rating and in no case

a number of varistors shall be provided in parallel. It shall be voltage clamping device,

thermal disconnecting type and shall be tested as per IEC 61643 with the following

characteristics and features-

SN Parameters Limits (between Line &

neutral)

1 Nominal Voltage (U0) 230V

2 Maximum continuous operating voltage (Uc) 300V

3 Nominal discharge current 8/20s (In) 10KA

4 Maximum discharge current 8/20s (Imax) 40KA

5 Response time (Tr) 25 ñs

6 Voltage protection level (Up) 1.5 KV


oC/ 95%

8 Mounted on Din rail

10 Indication Mandatory

11 Pluggability Mandatory

12 Potential free contact for remote monitoring Mandatory


13 Degree of protection IP20

14 Housing Fire retardant as per UL

94

(c) Class I/B and class II/C SPDs of Stage I shall be so coordinated that the voltage protection

level of the coordinated devices is 1.5 KV. As such, these devices shall be from the same

manufacturer and necessary test certificate in this regard shall be submitted by the

manufacturer/ supplier.

(d) Stage 2 protection (at the output side of 48 V)

The Stage 2 protection shall consist of Class II/ C type SPDs for ≥ 24V-60V DC supplies at

the output side inside the rack of IPS. These shall be provided for External circuits. The Class

II/C type SPD shall be a single compact varistor of proper rating and in no case a number of

varistors shall be provided in parallel. It shall be voltage clamping device and thermal

disconnecting type. They shall be tested as per IEC 61643 with the following characteristics

and features-

SN Parameters Limits (between L1 & L2, L1 & E

, L2 & E)

1 Nominal Voltage (U0) 24V-60V DC

2 Maximum continuous operating voltage (Uc) 100 (DC)

3 Nominal discharge current 8/20s (In) 10KA

4 Maximum discharge current 8/20s (Imax) 40KA

5 Response time (Tr) 25 ñs

6 Voltage protection level (Up) 0.5 KV


oC/ 95%

8 Mounted on Din rail

10 Indication Mandatory

11 Pluggability Mandatory

12 Potential free contact for remote monitoring Mandatory

13 Degree of protection IP20

14 Housing Fire retardant as per UL 94

3.2.12.4 Length of all cable connection from SPDs to earth/ equi-potential busbar shall be kept less

than 0.5mtrs. For this, a sub earth equi-potential busbar shall be installed at approx. 20cm

from the SPD box. The details of connection of SPDs for Stage 1, & 2 of a typical installation

with TIPSS is enclosed as Annexure-II.

3.2.12.5 Batch test report of OEM should be submitted by the manufacturer /supplier of Lightning &

Surge protection devices to the IPS manufacturer at the time of supply of these devices. Copy

of the same shall be submitted by IPS manufacturer to RDSO at the time of acceptance test of

IPS system.


3.2.13 Alarms and Indicating Lamps

Visual indications/display such as LEDs, LCDs or a combination of both shall be provided on each

FR-FC module to indicate.

Functional Indications:

A. Mains available

B. FRBC/FRFC on Auto Float

C. FRBC/FRFC on Auto charge

Alarm Indications

A. AC/DC Rectifier module Over Voltage, Under Voltage or Output Fail

B. FRBC/FRFC over Load (Voltage Droop)

C. Fan fail (due to any reason)

Functional indications shall be extended as status and alarm indications as “ FRBC/FRFC” Fail to

Distribution-Switching-control and Alarm Arrangement.

3.2.14 Radio Frequency Interference Suppression: The module shall be designed to minimize the level

of electromagnetic interference (EMI), both conducted and radiated, detected in its vicinity and

generated by Switch Mode Power conversion Equipment operating within the rack. The radiated &

conducted noise shall be within the limits specified in International specification no. IEC CISPR 22

„A‟. The firm shall submit certificate to this effect from accredited national/international test house

at the time of type test. Limits and test methods are given in Annexure-I.

3.2.15 Noise & Vibration: The Fully equipped rack at full load shall not contribute more than 15dB

(weighted) to the ambient noise level taken as 45dBA. It shall be measured at a distance of 1 meter

from the unit and 1.25m above the floor level in the Acoustic range. The correction factor for Total

Noise when the ambient noise level is more than 45dBA shall be as given below:

Note: The correction factor shall be added to the limit of 60dBA to arrive at the limit when

the ambient is greater than 45dBA.

3.2.16 Rack Configuration:

Rack shall be composed of following units accommodated in sub racks

a) Float Rectifier cum Float Charger (FR-FC) Modules or Float Rectifier Cum Boost Charger

(FR-BC) Modules, and DC-DC Converters.

b) MPPT Charger modules in N+1 configuration with its Master Control.

c) Distribution-Switching-control-Alarm Arrangement (DSCA).

AMBIENT

NOISE

CORRECTION

FACTOR

AMBIEN

T NOISE

CORRECTION

FACTOR

AMBIEN

T NOISE

CORRECTION

FACTOR

45dBA 0dB 51dBA 1.41dB 57dBA 3.69dB

47dBA 0.18dB 52dBA 1.73dB 58dB 4.17dB

48dBA 0.39dB 53dBA 2.07dB 59dBA 4.68dB

49dBA 0.86dB 55dBA 2.82dB

50dBA 1.12dB 56dBA 3.25dB


d) The number and rating of FR-FC, FR-BC and DC-DC Converters Modules shall be provided as

per purchaser‟s requirement. The Distribution-Switching-Control- Alarm Arrangement (DSCA)

shall be provided for the Ultimate Expandable Capacity. All factory wirings for the rack shall be

for the Ultimate Expandable Capacity so that only plugging-in of FR-FC or FR-BC module,

DC-DC Converter shall in trance ultimate capacity of Telecom Integrated Power Supply

System.

3.2.17 ADDITIONAL REQUIREMENTS FOR LMLA BATTERIES:

Low Maintenance Lead Acid batteries have special requirement of periodic boost charging @ 2.7V

per cell. To meet this requirement, the Telecom Integrated Power Supply shall be so configured that

in addition to the specification requirements, detailed above, shall also have a provision of a group of

FR-BC (as per battery capacity) for charging the batteries @ 2.7V/cell.From 2.4 volt to 2.55 volts the

current capacity will be half of the rated capacity

Float Rectifier-Float-Charger-Boost Charger (FR-FC): In addition to requirement of FR- FC

Modules, the FR-FC Modules shall meet the following additional requirement.

a) The FR-FC module shall be programmable to work as FR-FC or FR-BC. When programmed as

FR-FC, it shall be capable of working as FR-FC with other FR-FCs and shall comply with all the

requirements of FR-FC.

b) It shall also be programmable as a Boost Charger (BC) under manual control after isolating it from

the float bus.

c) As a Boost Charger, its output voltage shall be continuously adjustable and pre-settable at constant

current up to 100% for voltage range 44.4 to 56V and up to 50% to 70% rated capacity at any value in

the range of 56V to 64.8V as per design of the FR-BC. The firm has to specify the percentage of rated

capacity of FR-BC module when it is working in the boost charging mode (56 to 64.8V)

d) The Boost Voltage shall be maintained with ±1% of the set value over the full boost current range as

specified.

e) When programmed in Boost Charging Mode, FR-BC modules shall work in parallel load sharing

arrangement with other FR-BC modules in the same mode, keeping other output conditions within

specified limits.

(I) The current sharing shall be within ±10% of the average current per FR-BC module (in Boost

charging Mode) in the system (mounted in the same or different racks) when loaded between

50 to 100% of its rated capacity (as BC) for all other working conditions.

(II) In addition to the Visual indications/display specified for FR-FC the following shall also be

provided in FR-BC Module.

a. Functional Indications : FR-BC on Boost Mode

b. Alarm Indications : Following Alarms shall actuate in BC mode:

FR-BC Over Voltage.

FR-BC Over Load (Voltage Droop)

f) Protection: The module shall also be protected against DC over voltage in BC mode. Shutting-off of

faulty FR-BC module in FR-BC mode shall not affect the operations of other FR-BC & FR-BC in

FR-FC mode.

4.0 REQUIREMENT OF DISTRIBUTION-SWITCHING-CONTROL AND ALARM

ARRANGEMENT (DSCA)General:

Depending on the system requirements system shall be provided with a Distribution-

Switching-control-alarm Arrangement (DSCA) for the Ultimate Expandable Capacity.

The unit shall comprise of the following:

a) Termination for the batteries


b) Termination for the load

c) Interconnecting arrangement for power equipment

d) Battery Switching Arrangement (connection to/Isolation from system)

e) Termination for AC input to the rack

f) Termination for AC and DC to FR-FC modules

g) Circuit Breakers/Fuses etc.

h) Termination for Solar power

i) Termination for DG power

Two numbers of potential free contacts for connecting to network monitoring system for monitoring

DC output fail, DC output over voltage, DC output under voltage and mains fail shall be provided.

4.1 Battery Monitoring

a) Battery Under Voltage Isolation:

Cut-off: 1.85V/cell (44.4V+0.25V) Reconnect: 2V /Cell (48 V)

However on resumption of AC mains this contactor should get reconnected automatically.

b) Battery health Monitoring in Auto Mode:

The system shall change over to Auto charge mode to charge the battery at higher voltage of 55.2V till

the battery is fully recouped.

c) It should also be possible to monitor individual cell (for 24 Cells of 2 V each) of battery bank and

status of all cells shall be made available in a graphical form / Table and strength of week cell can be

detected and alarm should be generated which can be displayed in a Alpha-Numeric display provided

in DSCA.

d) Battery Current Limiting Circuit: In auto mode, to ensure the availability of required load and safety

of the battery, battery path current limit shall be settable as per the battery bank requirements so that

the battery path current is kept to 10% of battery Ah capacity.

e) Temperature Compensation for Battery: There shall be provision for monitoring the temperature of

battery and consequent arrangement for automatic temperature compensation of the FR-FC, FR-BC

output voltage to meet the battery temperature dependent charge characteristics.

f) Battery Reverse Polarity Protection: Protection for battery reverse polarity shall be provided in the

system.

g) DC Contactor: High quality DC contactors, UL approved should be used for battery path

disconnection circuit.

4.2 Requirement of ASM Panel:

Status monitoring panel shall be installed in the room of ASM on duty. The panel shall have

following LED indications and alarms with resetting switch:

Instruction Condition LED

Ind.

Remark

A Run Gen set 50% DOD

RED Audio / visual alarm. Alarm can be

acknowledged for audio cut off.

B Emergency

start generator

60% DOD RED -do-

C System shut

down

70% DOD RED

All DC-DC converters to work.

Audio alarm will continue till

Generator is started.


D Call S & T

staff

Equipment fault RED Failure of any module or in case

battery gets disconnected from

circuit will give the alarm in panel.

Alarm can be acknowledged for

audio cut-off.

E Stop Gen Set FRBC change

over to float

mode

GREEN Audio /Visual alarm

Audio alarm in case of A, B & C shall be of one type of tone and there shall be different tone

for the case of D & E cases.

4.2.1 In A, B & C conditions, the visual LED indication will remain lit until fault is cleared or the

DG set is started and battery is charged upto 110V i.e. 2V/cell as the case may be until reset

push button is pressed. In case of D condition, if fault is not cleared, the LED will continue to

glow, even if reset push button is pressed.

5.0 REQUIREMENTS OF DC-DC CONVERTER

5.1 The DC/DC converter covered under this specification shall work satisfactorily meeting all the

prescribed parameters as long as the DC input voltage is within 44V to 58V ( 66V in case of FRBC).

The output regulation shall be ±1% of set value from 10% load to full load for the entire input range.

Typical voltage ratings are 24V, 12V, and 3-6V DC and typical current ratings are 1 Amp and 5 Amp

depending upon load requirement.

5.2 Each converter shall be provided with a proper plug in arrangement for DC input & output. A switch

shall be provided for switching ON/OFF the unit.

5.3 The converter shall be provided with means for protection and visual indication on front panel for the

following:

5.4 The unit shall be provided with over-load protection, over-voltage protection and output short circuit

protection with fold back characteristics. The over-load protection shall be effective at 105% and

output short circuit protection shall be effective at 110% of the rated current.

5.5 The DC over voltage protection shall be auto tracking type. Over voltage trip shall be set at

approximately 110% of the set output voltage.

5.6 Output voltage settability of the converter shall be within the -2% of the minimum rated voltage

and +2% of the maximum rated voltage of the converter.

5.7 Output shall be free from overshoot because of “Turn on /Turn off” or power failure or when the

battery charger is switched ON/OFF.

5.8 In case of failure of DC-DC converter the output voltage shall not exceed beyond pre-set value. For

this a Fail Safe Feature for the module be explained and demonstrated so as to , a) protect the Load

under all circumstances , b) maintain continuity of the DC circuit even if one of the module has failed

(i.e.to isolate one module only and not the entire group ).

5.9 No load input current shall not be more than 10% of the rated input current at maximum full load for

all setting of output voltage and input voltage variation from 44V to 58V ( 66V ) of nominal input

voltage for DC-DC Converters of 50 VA and above.

Description Nomenclature Indication

i) Input Power ON indication INPUT Amber

ii) DC-DC Converter output OK OUTPUT Green

iii) DC-DC Converter fail FAIL Red


5.10 Overall efficiency of the converter at full load shall not be less than 75% for converters rating from

50VA to less than 150VA at rated load and 80% for converters of 150VA or more rated output at 44V

to 58V ( 66V ) of nominal input voltage. . For converters of rating 10VA - 50VA, overall efficiency

shall be greater than 50%. The efficiency shall be measured at the maximum output voltage of the

specified range.

5.11 Each DC-DC converters shall be of modular type which shall be fitted in main rack. The input and

output connections shall be made using irreversible plug in connectors of appropriate rating.

5.12 Output must be isolated from input. Each DC-DC converter shall have blocking diodes at the output.

The test points shall be provided before the blocking diode.

5.13 Radio Frequency Interference Suppression: The DC-DC Converter shall be designed to minimise the

level of Electromagnetic interference (EMI/RFI), both conducted & radiated in the vicinity of

DC-DC Converter. The radiated & conducted noise shall be within the limits specified in

International Specification No.EN-55022. The firm shall submit certificate to this effect.

5.14 The converter shall have self-resetting type protection from over load/ short circuit of DC output. The

converters shall be adequately protected against surges/ lightning at the input.

5.15 The output ripple (peak to peak) of the converter shall not be more than 50mV at full load.

5.16 Provision shall be made for measuring voltage of DC-DC Converter modules with the help of

common meter.

5.17 Parallel Operation:

DC-DC Converter ( more than 50 Watts) operating in parallel with one or more modules of similar

type, make and rating, other output conditions remaining within specified limits. The current sharing

shall be within ±10% of the average current per converter module and within individual capacity of

each converter module in the system when loaded between 50 to 100% of its rated capacity for all

other working conditions.

6.0 REQUIREMENTS OF MPPT CHARGER (OPTIONAL)

MPPT( Maximum Power Point Trecking)Charger Module : The MPPT charger module shall be

designed to take DC power form the SPV panels and convert it into suitable DC power so as to

supply 48V DC bus demand. It should be used in N+1 configuration and should have following

features:

(a) It should be using MPPT Algorithm.Giving algorithm efficiency of 98% or higher. Efficiency

at rated output voltage and full load should not be less than 93%. Even at less than full load,

efficiency should not drop to less than 90% at 30% full load.

(b) It should work over higher DC ( SPV ) voltage and should cover 70V to 200V DC

(c) Suitable DC filter with protection be provided at its output.

(d) It should have protection against Lightening and Surges at its input.

(e) It should have facility to be connected with the Mains ( AC ) based SMPS charger modules and

should also work in stand-alone mode when AC mains is not available.

(f) It should work as priority over SMPS charger module so as to save the mains consumptions

when PV is available

(g) It should have protection against DC overvoltage and should isolate itself in case of any such

eventuality . It is Fail Safe feature of the module.

(h) It should have Auto Float/Boost Changeover , Battery path current limiting features.

(i) The module ratings should be 25A/Module.

(j) Compliant to IEC 62509 with the exception of self consumption and set point accuracy (±3%

will be allowed).

(k) Protection against moisture and dust shall be of at least IP 31 level.

(l) Capable of handling 120% of module‟s rated current.


(m) Temperature compensated charging.

(n) Provision of blocking diode, preferably a Schottky diode, to prevent the battery from

discharging itself through the SPV system/ charge controller. The current capacity of the

blocking diode shall be 50% higher than the short circuit current at STC. The peak inverse

voltage (PIV) of the diode shall be at least equal to the open circuit battery voltage. In case any

alternative to Schottky diode is proposed, then technical literature and evidence in support of

successful working of the same should be submitted for the consideration of RDSO/ purchaser.

(o) On the SPV power source side, the charge controller shall be protected against lightning and

surges with the help of SPDs if the distance between charge controller and AJB is more than 10

m. The SPDs used shall be rated for at least 10KA at 8/20 μSec for protection against lightning

induced surges Class II as per IEC 61643-1. The voltage rating of the SPDs shall be at least

10V higher than the specified value of the SPV array.

(p) Protection shall also be provided against the following: battery overload, battery overcharge,

short circuit and reverse polarity. Auto resettable reverse polarity protection should be

provided.

(q) Cables of appropriate size shall be used to reduce the voltage drop between SPV and battery;

and battery and the output of the charge controller.

(r) The charge controller shall incorporate the auto, bulk and float charging methods. Though not

mandatory, manufacturers are however encouraged to provide equalization charging facility

also. Battery charging modes shall be selectable as per battery type.

7.0 Source Prioritization:

If all power sources are available and option of Solar Power has been used first priority will be given

to solar energy i.e.. Power supply to DCDC converters, telecom loads and Battery will be supplied

through solar modules and if it is not upto the requirement the available current from Solar will be

used and balance requirement will be taken from AC Power Supply. While solar energy is sufficient

enough to support the load all other sources will be disconnected.

Second priority is AC 220V 50 Hz Power supply.

Third priority is given to battery. When grid supply is not available, the main controller checks the

health of battery. If battery is in charged condition and state of charge is greater that 70%, battery

power will be used to support DCDC converters, and telecom loads. If battery is also discharged and

no other source is available, it will give an indication as well as potential free contact should be

provided which may be utilized for starting the DG.

8.0 Packing

8.1 Complete TIPSS shall be packed in suitable wooden boxes/crate, strong enough, without additional

packing to prevent damage or loss to the unit during transit. Loose space inside the box/crate shall be

filled up with suitable packing material.

8.2 FRBC module, DC-DC converters, shall be separately packed. These shall be wrapped in bubble

sheet and then packed in thermocole boxes and empty space shall be filled with suitable filling

material. All modules shall be finally packed in wooden case of sufficient strength so that it can

withstand bumps and jerks encountered in a road / rail journey.

8.3 Each box shall be legibly marked at one end with code numbers, contents, quantity and name of

manufacturer/ supplier. The upside shall be indicated with an arrow. Boxes should have standard

signages to indicate the correct position and precaution "Handle with Care" with necessary

instructions.


9.0 TEST AND REQUIREMENTS

Inspection & tests shall be carried out to ensure that requirements of this specification are complied.

All tests, unless otherwise specified, shall be carried out at ambient atmospheric conditions on all the

modules. For inspection of material, relevant clauses of IRS: S 23 and RDSO/SPN/144/2006 shall

apply unless otherwise specified. Manufacturer shall provide necessary machinery and plants /

/assistance for testing of the TIPSS.

9.1 Initial type approval

Initial type Approval shall be given with solar option and without solar option. Manufacturer shall

furnish following information at the time of initial type approval of TIPSS system.

I) Details of protection provided and their effectiveness / proposed set values and range and

working principle.

II) Bill of material for racks and modules. Details of semi conductors devices used and its

specification and data sheets.

III) Safety margins in voltage, current, thermal (for junction temperature) along with the limit

value for power devices, inductors and transformer etc.

IV) Installation & commissioning manual, Quality Assurance Plan and Service manual

(consisting of indications and fault diagnostics, Do's & Dont's etc.)

V) Design approach for the TIPSS system and salient features through which required MTBF has

been achieved.

While granting initial type approval, it shall be ensured that the system conforms to all the clauses and

passes all type tests as mentioned in clause 9.3.1and other relevant guidelines of RDSO.

9.2 Maintenance type approval

Before expiry of validity period, manufacturer shall submit prototype samples as per guidelines of

RDSO. The TIPSS must pass all type tests as per Clause 9.3.In case of design changes, RDSO may

call for fresh sample in the intermediate stage. ( Manufacturer shall not carry out any changes in

designe till it is approved by RDSO)In such cases, manufacturers shall submit all the information as

per clause 9.2.

9.3 The following shall comprise the Type Tests:

i. Visual Inspection (Cl. 10.1)

ii. Insulation Resistance (Cl. 10.2)

iii. Applied high voltage test (Cl. 10.3)

iv. Temperature rise test (Cl. 10.4)

v. Performance test (Cl. 10.5)

vi. Test for protective devices (Cl. 10.6)

vii. Environmental & Climatic Test (Cl.10.7)

viii. Functional test (Cl. 10.8)

ix. Vibration test on modules as per RDSO/SPN/144/2006.

x. Static discharge test as per RDSO/SPN/144/2006. Electrostatic discharge test shall be carried

out as per international standard IEC 61000-4-2 or its equivalent with 150 Pico Farad

charged capacitor of 7KV and should be discharged through 330 ohm resistor.

Note:

(i) Test for protective devices and performance test shall be carried out before and after

climatic test. There shall not be any significant deviations in the observations recorded.

(ii) Vibration & Static discharge test shall be conducted on one module of FRBC along with DSA unit,

DC-DC Converter.


9.4 The following shall comprise the Acceptance test:

The acceptance test shall be carried out as per the sampling plan given in Clause in 9.4.1.

a) Visual Inspection (Cl. 10.1)

b) Insulation Resistance (Cl.10.2)

c) Applied high voltage test (Cl. 10.3)

d) Temperature rise test (Cl. 10.4)

e) Performance test (Cl. 10.5)

f) Test for protective devices (Cl. 10.6)

g) Functional test (Cl. 10.8)

9.4.1 Visual inspection shall be carried out on one of the TIPSS unit of each type. The functional

test shall be carried on each TIPSS.The modules shall be tested for insulation resistance, high

voltage test, temperature rise test, performance and protection tests as per the sampling plan

given below:

Test Description Ins.

Res.

HV

test

Temp

rise

Performance

test

Protection

test

SMPS (FRBC) N/2 N/2 N/2 N N

DC-DC Converter (of each

type/ rating)

N/2 N/2 - N N

Battery Bank -10 hrs discharge test for capacity: Sample shall be taken as per Clause 11.1

of IS: 8320-1982. Cells shall be taken from all banks of TIPSS.

N = Denotes the no. of modules offered for inspection. N/2 shall be rounded off to the next

number. In case of any failure during acceptance test, the lot shall be rejected.

For acceptance of the lot there shall be no failure in any of the test as mentioned under clause

9.4 above.

9.5 The following shall comprise the Routine test:

The routine test shall be carried out on every module of the TIPSS system and the results will

be submitted by the manufacturer to the inspecting authority at the time of inspection.

a) Visual Inspection (Cl. 10.1)

b) Insulation Resistance (Cl.10.2)

c) Applied high voltage test (Cl.10.3)

d) Performance test (Cl. 10.5)

e) Test for protective devices (Cl. 10.6)

f) Functional test (Cl. 10.8)

10.0 TEST PROCEDURE

10.1 Visual Inspection

Test for visual inspection shall be carried out as per relevant clauses of this specification and

RDSO/SPN/144/2006.

10.2 Insulation Resistance

Insulation resistance (I.R) test shall be carried out:

1) before the high voltage test

2) after the high voltage test

3) after climatic test


The measurement shall be made at a potential of not less than 500 V DC. The insulation resistance

shall be measured at module level / rack as follows:

i) Input line terminals and the body of the equipment

ii) Output line terminals and the body of the equipment

iii) Input line terminals and output line terminals

iv) Between rack and earth

Value of the insulation resistance shall not be less than 10 M.ohm for the rack / equipment when

measured at a temperature of 40ºC and relative humidity of 60%. There shall not be appreciable

change in the values measured before and after high voltage test and after the temperature rise test.

After completion of climatic test, the values shall not be less than 5 M.ohm for the equipment when

measured at a temperature of 40ºC and relative humidity of 60%.

Note: - In case, temperature and humidity prevalent at the time of the above measurements of

insulation resistance are different from those specified above, the values of I.R. shall be obtained from

the table given below –

R.H

25ºC 30ºC 35ºC 40ºC

60% 10 M.ohms 10 M.ohms 10 M.ohms 10 M.ohms

65% 10 M.ohms 9.0 M.ohms 8.5 M.ohms 8.0 M.ohms

70% 8 M.Ohms 7.0 M.ohms 6.5 M.ohms 6.0 M.ohms

75% 6 M.ohms 5.3 M.ohms 4.7 M.ohms 4.3 M.ohms

80% 4.2 M.ohms 3.6 M.ohms 3.3 M.ohms 3.0 M.ohms




100% 1.0M.ohms 0.6 M.ohms 0.3 M.ohms 0.1 M.ohms

10.3 Applied High Voltage test

The module shall withstand the application of 2000 V AC rms for one minute without puncture and

arching. The test voltage shall be approximately sine wave and of any frequency between 50 and 100

Hz. The high voltage shall be applied between the following:

(i) Input and earth

(ii) Output and earth

(iii) Input and output

Note:

For FRBC, item(ii) above shall be tested at 1000V AC rms

DC-DC Converter shall be tested for 1, 2 & 3 at 1000V AC rms.

The test shall be carried out after removing surge arrestors /MOVs or any other surge absorbing

components.

In routine test, only one module of each type shall be tested.

10.4 Temperature rise test

Temperature rise test should be logged during functional test of TIPSS after 8 hours, either with the

help of thermo-couple or with resistance method on one module of each type.


While conducting the test with the help of thermo-couple, the temperature of MOSFET/IGBT, diode,

Transformer/ Ferrite Transformer, choke, Internal ambient, Inside cabinet and outside cabinet shall be

recorded at every one hour for first four hours and every half hour for next four hours. During this test,

the temperature compensation probe shall be disconnected.

The temperature rise of heat dissipating components above the ambient measured directly and at heat

sink shall not be more than

(i) Transformer and chokes : 90ºC

(ii) Thyristor & diodes : 40°C

(iii) IGBT/MOSFET : 30ºC

10.5 Performance test

10.5.1 Performance test for FRBC/FRFC shall include following and other relevant clauses of this

specification.

i) The FRBC shall be tested for its output performance (efficiency, power factor, harmonic distortion,

psophometric noise and ripple voltage) at the AC input voltages 150V, 230V and 275V at different

load currents by connecting a variable resistance load across the output terminals for the auto float

mode and auto boost mode respectively.

ii) In auto float mode, readings shall be taken for float voltage setting of 2.15 V/cell & 2.25V/cell for low

maintenance lead acid batteries & VRLA batteries, respectively at load current in the ranges 25% load

to full load.

iii) In auto boost charger mode, readings shall be taken for boost voltage setting of 2.42V/cell & 2.3

V/cell for conventional lead acid batteries & VRLA batteries respectively at load current in the ranges

25% load to full load.

iv) During the performance test, the system shall fulfil the requirements of efficiency, power factor,

psophometric noise, harmonic distortion, ripple voltage etc. as given under clauses 3.2 of this

specification.

The test report from National /International test house of RFI/EMI shall be submitted by the

manufacturer as per clause 3.2.14.

v) The current sharing of the module working in parallel shall be tested as per clause 3.2.11& 5.17.

10.5.2 Performance test on DSCA unit, DC-DC Converter shall be carried out as per clause no. 4 & 5

respectively.

10.6 Test for protective devices:

10.6.1 Test for protective devices for FRBC shall include following: and other relevant clauses of this

specification.

i) Short circuit: During this test, system shall be connected to AC input voltage of 275V. Output

terminals shall be short-circuited through a suitable arrangement. Steady short circuit current shall be

measured. It should not exceed rated current + 5%. There shall not be any damage to charger.

Working of over load/ short circuit indications/ alarms will also be checked on the FRBC. This shall

be achieved by controlling output current and voltage under short circuit condition and not by

switching off the input/ output voltage under short circuit condition.

ii) Reverse battery connection: A fully charged battery shall be connected in reverse polarity to output

terminals of charger. There shall be no emission of smoke of undue temperature rise of any

component of charger. Working of corresponding indication/ alarm shall also be checked.

iii) Other protection such as over voltage, battery under voltage, battery temperature compensation,

battery current limit, input high & low voltage protection test shall be carried out as detailed as per

clause 4.1.


10.6.2 Test for protective devices for DSA unit, DC-DC Converter shall be carried out as per relevant clause

of the specification.

10.7 Environmental & Climatic test

10.7.1 i) The Environmental & climatic tests shall be conducted on complete TIPSS system in

integrated manner. Not more than 2 chambers shall be used for conducting the tests.

SN Test Reference Severity

1 Change in temperature

test

IS: 9000 Part XIV

Section II

-10 ºC to

+70 ºC (as per indoor application of

RDSO/SPN/ 144/2006)

2 Dry Heat Test IS:9000 Part III

Section III

Temp as per indoor application

specification no. RDSO/SPN/

144/2006.

3 Cold test IS: 9000 Part II Section

III

-10 ºC (as per indoor application of

RDSO/SPN/ 144/2006)

4 Damp Heat test

(Cyclic)

IS: 9000 Part V

Section 1 & 2

Temperature 55ºC and other

conditions as per

RDSO/SPN/144/2006 for indoor

application.

5 Damp Heat (Storage) IS:9000 Part IV As per Indoor applications of

RDSO/SPN/144/2006

ii) The climatic tests shall be carried out by setting the system in boost charge mode of operation.

During the period of exposure in each test, the system shall be connected to supply mains of

nominal input voltage and shall deliver the rated output voltage of 2.3V/ Cell or 2.4V/cell for

VRLA/LM batteries respectively to a resistive load.

iii) During the exposure, the system shall be loaded and output of the DC-DC Converter shall be

monitored at the end of every cycle.

10.7.2 Following tests shall be conducted on one module of FRBC/FRFC, DSCA unit, DC-DC

Converter,MPPT Charger & ASM unit.

SN Test Reference Severity

1 Salt Mist test IS:9000 Part XI

Procedure 3

As per Indoor applications of

RDSO/SPN/144/2006

2 Dust test IS: 9000 Part XII As per Indoor applications of

RDSO/SPN/144/2006

The performance of modules subjected to above tests shall be observed in TIPSS system.

10.7.3 Vibration test shall be conducted on FRBC, DSA unit, DC-DC Converter,MPPT Charger & ASM unit

as per RDSO/SPN/144/2006. The working of modules subjected for vibration test shall be observed

with the TIPSS.

10.8 OVERALL FUNCTIONING OF TIPSS

After above tests, overall functioning of TIPSS shall be checked as follows:

10.8.1 All sub systems shall be put on full load and with battery bank connected to the TIPSS. The overall

functioning of TIPSS shall be observed for 72 hours during type test, 8 hours during acceptance test &

4 hours during routine test with frequent ON and OFF condition of AC Mains alternately, after every

30 minutes.


10.8.2 All the sub systems of TIPSS shall be connected. The output of all sub systems shall be checked. The

switching over from mains to standby and vice versa of FRBC, and DC-DC converters shall be

checked. Indication of working and faulty condition of FRBC& DC-DC converters shall be checked.

10.8.3 All alarms and indications of ASM status monitoring panel shall be checked for its proper

functioning.

11.0 Information to be given by Purchaser:

1. Type of Battery:LMLA/VRLA and AH capacity.

2. Type of Stand in case LMLA is utilized: Wooden/FRP.

3. Solar (MPTT Charger )(optional) required /Not required.

4. No. of DC-DC Converter, voltage and rating. (1 Amp/5 Amp)

5. Distance of ASM Room from location of TIPSS. (In meters)

6. Distance of Battery Bank from TIPSS. (In meters)

***************************************************************************************


ANNEXURE-I

General Requirements : Radio Frequency Interference Suppression: The system (FR-FC, FR-BC

& DSCA modules) shall be designed to minimize the level of electromagnetic interference (EMI),

both conducted and radiated, detected in its vicinity and generated by the module and shall comply the

following clause.

1. Radiated Emission from power equipment.

Requirement: Any network of conductors and apparatus connected thereto shall not exceed the

level of field strength specified in IEC-CISPR 22 'A' as given below:

Frequency (F) (MHz) Distance (Meters)

Quasi peak limits dB(VV/m)

30-230

230-1000

10M

10 M

40 dB (µV /m)

47 dB (µV /m)

1. The lower limit shall apply at the transition frequency.

2. Additional provisions may be required for cases where interference occur.

Test Procedure: Test setup, Test procedure & Measurements shall be conducted as per IEC –

CISOPR 22.

2. Conducted Emission Limits: All conducted emissions from power equipment or accessories

connected thereto, intended to be connected to the power lines of a public utility shall not

exceed. the limits specified in IEC-CISPR 22'A' as given below :

Frequency (MHz) (F) (MHz) Quasi peak limits dB (µV) Average limit dB(µV)

0.15 – 0.5

0.5 – 30.0

79 dB (µV)

73 dB (µV)

66 dB (µV)

60 dB (µV /m)

The lower limit shall apply at the transition frequency.

Test Procedure: Test set up, Test procedure & Measurements shall be conducted as per IECCISPR

22.

3. Conducted Susceptibility Limits : Power equipment used in Telecom Network shall not

malfunction when high voltage surge as specified below is superimposed at the input power

mains to the power equipment, for more than two seconds as per IEC 61000 – 4-12 9(b). The

equipment shall also not fail or degrade in performance after the surge is withdrawn.

Test levels:

Voltage Rise time (First peak ): 75 nano sec ±20%

Oscillation Frequencies : 100 KHz & 1 MHz ±10%

Repetition rate : at least 40/s for 100KHz and 400/s for 1 MHz

Decaying : 50% of the peak value between the 3rd & 6th periods.

Burst duration : not less 2 S

Surge amplitude : 250V (-10%) to 2.5 KV (+ 10%)

Wave shape : Damped.

Test Procedure: Test set up, Test procedure & Measurements shall be as per IEC 61000-4-

12. EMI surge of specified levels injected on power leads of test sample shall not cause

degradation of performance or malfunction

4. Electrostatic discharge (ESD) immunity limits: the limits shall be as per IEC 61000 -4-2,

9(1) (Both contact discharge method and Air discharge method) as given below :

Test level:

Contact discharge Air discharge

Level Test voltage KV Level Test voltage KV

4 8 4 15

Test Procedure: This test shall be conducted as per IEC 61000-4-2 for both requirements &

unit shall comply of clause 9(1) of IEC 61000-4-2.

5. Electrical fast transient/Burst immunity limits : The limits shall be as specified in IEC

61000-4-4.

Test level:

Open-circuit output test voltage (±20%)


Level On power supply port, Protection Earth

Voltage peak KV4 Repetition rate KHz

4 4 2.5

Rise time of one Pulse -5 ns ±30%

Impulse duration - 50 ns ±30%

Test Procedure: This test shall be conducted as per IEC 61000-4-4. Test results shall be in

compliance of clause 9(1) of IEC 61000-4-4.

6. Radiated radio-frequency Electromagnetic field immunity limits: The limits as per IEC

610004-3.

Test level:

Frequency range: 80MHz to 1000 MHz

Level Test field strength V/m

3 10

Test Procedure: This test shall be conducted as per IEC 61000-4-3. Test results shall be in

compliance of clause 9(a) of IEC 61000-4-3.

7. Surge Immunity limits: The limits as per IEC 61000-4-5.

Test level:

Level Open circuit test voltage (± 10%) KV

1

2

3

4

0.5

1.0

2.0

4.0

Voltage surge – 1.2/50Vs

Amplitude - 2KV (DM)

- 4KV (CM)

- After testing for 4KV, the amplitude shall also be increased to 6KV (1.2/50 Vs Combined

wave form as per EEE C62 41 – 1991 to cover lightening/Surge protection test also.

Test results shall be in compliance of clause 9(b) of IEC 61000-4-5.

Test Procedure: This test shall be conducted as per IEC 61000-4-5. After testing for 4KV, the

amplitude shall also be increased to 6KV (1.2/50 Vs). Combined wave form as per EEE

C62.41-1991 (to cover Lightening/Surge protection test also.).

Note: The rated voltage of the MOVs issued for the above shall not be less than 320V.

8. Radio Frequency Conducted Susceptibility immunity limits: The limits as per IEC 61000-

4-6.

Test level:

Frequency range: 150 KHz – 80 MHz

Level Voltage level ( e.m.f.)

3 10

Test Procedure: This test shall be conducted as per IEC 61000-4-6. Test results shall be

compliance of clause 9(a) of IEC 61000-4-6


ANNEXURE-II

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