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of 29 File No. EL/1.7.6 w.e.f.

Specification No. RDSO/PE/SPEC/AC/0139 – (Rev.1)-2009

Prepared by Checked by

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

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RESEARCH DESIGNS AND STANDARDS ORGANISATION MINISTRY OF RAILWAYS

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SPECIFICATION OF MICROPROCESSOR CONTROLLER OF ROOF MOUNTED AC PACKAGE UNIT FOR LHB DESIGN

RDSO/PE/SPEC/AC/0139 – 2009 - (REV. 1)

S. No. Date of amendment Revision Reason

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SCOPE

This specification lays down the technical requirements of design, manufacture,

supply & testing of microprocessor controller for Roof Mounted A/C Package unit for Indian Railways. The control and regulation of air-conditioning unit to be provided in these coaches shall be performed by the microprocessor based controller. The logic for control & regulation are specified in this specification for guidance of manufacturer.

1.0 SCOPE OF SUPPLY

1.1 The scope of supply will include the following items.

(a) Microprocessor based controller unit with display to be mounted in switch board cabinet.

(b) Control cables from all the sensors and indicating/display units. (c) All the sensors for voltage, current, humidity, NTC temperature &

pressure. (d) Mounting arrangement for all the above equipments as per

specification. (e) Software for downloading the information from controller unit and it‟s

analysis (f) Maintenance & troubleshooting shooting manual giving the complete

description of its design and operation. 1.2 There shall be following two types of microprocessor controller:

Type – I : Microprocessor controller for RMPU having one blower motor Type – II : Microprocessor controller for RMPU having two blower motors. Purchaser can purchase the controller as per their requirement.

2.0 SERVICE CONDITIONS

2.1 The equipment shall be sturdy and suitable for the following service conditions

normally to be met in service. Environmental conditions:

Maximum ambient air temp. under sun:

70 deg.C.

Average ambient air temp. 35 Deg. C.

Maximum relative humidity 100%

Annual rainfall Ranging Between 1750 to 6250 mm




Altitudes Not exceeding 1200 m

Atmosphere Extremely dusty and desert weather and desert terrain in certain areas. The dust contents in the air may reach as high value as 1.6 mg/cubic meter. Very dusty atmosphere with fog, cast iron dust of brake block shoe, flying ballast etc.

Annual rain fall Very heavy in certain areas: between 1750 to 6250 mm.

Coastal area The equipment shall be designed to work in humid salt laden and corrosive atmosphere. The maximum values of the condition shall be as under : Maximum pH value 8.5 Sulphate 7 mg/liter Max. concentration 6 mg/liter of chlorine Max. conductivity 130 micro Siemens/CM

Shocks and Vibration The RMPU shall withstand satisfactorily vibrations and shocks normally encountered in service as indicated below: a) Max. vertical acceleration - 3.0 g b) Max. lateral acceleration - 3.0 g c) Max. longitudinal acceleration - 3.0 g („g‟ being the value of acceleration due to gravity)

3.0 GOVERNING SPECIFICATIONS

Specification No. Description

IEC 60571 Electronic equipment used on rail vehicles.

IS:513 Specification for cold rolled low carbon steel sheets & strips.

RDSO spec. No. ELRS/SPEC/SI/0015

Reliability of assurance specification for electronic components for use in rolling stocks

IEC 61373 Railway application-Rolling stock equipment-Shock and vibration test

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

and should be available with the manufacturer/supplier.

4.0 POWER SUPPLY




4.1 The microprocessor controller shall work at 110V DC/AC + 30%.

4.2 The Roof Mounted A/C package Unit shall be suitable to work from 415V +

15%, AC, 3 phase, 50 Hz + 3%, sinusoidal/PWM power supply obtained from DG Sets installed in generator car on EOG type AC coaches or 25 KVA inverter (with ripple contents up to 15%) on SG type AC coaches.

5.0 SUPPLIER’S RESPONSIBILITY

5.1 The controller shall be suitable for rugged service conditions normally to be met

within Railway Rolling Stock, where coaches are expected to run upto a maximum speed of 160 kmph in varying climatic conditions existing throughout India.

5.2 The supplier shall be fully responsible for ensuring that all components forming

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

The supplier shall provide “In the field” service support during the guarantee period.

5.3 The supplier shall supply special tools or equipment that may be necessary for

the correct operation, servicing, testing or installation of the controller.

5.4 The supplier will provide assistance, both material and technical, in the

development of the controller as a whole to ensure that when this controller is installed as part of the integrated vehicle system, the performance of the system meets or exceeds the requirements specified.

5.5 If the controller fail to achieve these requirements, the controller shall be

modified at the supplier‟s expense and within a time scale to be agreed with purchaser/consignee/RDSO. The controller already supplied to Indian railways shall than be modified/replaced free of cost.

5.6 The firm should have facilities for in-house testing facilities/simulation kit for

checking/routine test of the controller, so that in any circumstance, the defective controller could not enter into the service of Indian railways. Firm shall keep all the record of internal/routine test carried out by the firm.

5.7 Design requirements




5.7.1 The microprocessor controller unit shall perform the functions, concerning control and regulation of the air conditioning system. Control logic is described in Annexure-C

5.7.2 The over all dimension and interface connections of micro controller unit shall

generally be as per RDSO drawing No. RDSO/PE/SK/AC/075 (Rev.0)-2004, so that the same may be accommodated/mounted on the space available in switch board cabinet. Connections for power & control to the microprocessor unit shall be made through WAGO make connectors‟ type 231/232.

5.7.3 There shall be a display unit in the scope of supply with microprocessor

controller. The display unit of the controller shall be mounted on switch panel and connection to display unit shall be through serial port.

5.7.4 The system software shall record the digital and the analogue inputs of the

system and deliver it processed to the application software. Similarly it shall select the system output according to the logic of the application software. The system software shall also perform the functions for control of the servicing interface, control of the logged faults and a detailed self testing process of the MPC during starting and functioning of the system.

5.7.5 The defined start of the system shall be guaranteed by means of special

monitoring circuits and logic. 5.7.6 During operation, the supply voltage shall be constantly monitored. If the voltage

declines below 400 V the “watchdogs” will stop the system but the system will be re started as soon as it reaches the set value and all the break and make of contacts are made. Restart of the system stopped in the above-mentioned manner shall be performed automatically.

5.7.7 The controller shall actuate the cooling circuit if the passenger compartment

temperature exceeds the set value i.e. 23-25°C and shall actuate the heating circuit if the temperature decreases below the set value i.e. 19-21°C.

5.7.8 The controller shall provide an ON-OFF differential of 2°C for heating as well as

cooling system of the coach. 5.7.9 The operation of compressor will be controlled with suitable logical function to

ensure maximum requirement of switching on and off of compressors does not exceeding 8 cycles per hour, under conditions of normal operation. If the controller counts 8 ON/OFF cycle before completing one hour, the compressor should not start from 8th ON/OFF cycle until one hour is completed. After completion of this one hour, the compressor shall be started as per the requirement of coach condition and controller will start counting further from zero hour to further one hour.

5.7.10 The controller shall ensure that there should be a delay of at least 30 sec.

between the starting of two compressors.




5.7.11 The controller will monitor and record all the performance parameters and faults. The firm will also supply the necessary software for down loading the logged faults from the micro controller on a PC/laptop or a hand held unit for their analysis through USB port.

5.7.12 The controller should able to count the number of times, equipment/motor has

been tripped in a given time period. It shall also be displayed for ease of maintenance staff.

5.7.13 The firm will submit the complete write up on logic for control of air conditioning

unit for various functions under varying operating conditions, however a general guidelines for the same is given in enclosed annexure A.

5.7.14 The micro controller shall have following indications by means of LED for

guidance of maintenance staff.

System functioning: - Following indications shall be provided for system functioning and guidance.

a) Controller O.K. Glows when controller is OK

b) Controller failure Glows when controller fails

c)

Blower 1/1 & 2/1 ON and Blower 2/1 & 2/2 ON

Glows when blowers are active (4 separate LEDs shall be provided for all the 4 blower fans in one coach)

d) Condenser fan 1/1 & 2/1 ON and 2/1 & 2/2 ON

Glows when condenser fans are working (4 separate LEDs shall be provided for all the 4 condenser fans in one coach)

e) Compressor ON Glows when compressors are working (4 separate LEDs shall be provided for all the 4 compressors in one coach)

f) Heaters ON Glows when heaters are working (2 separate LEDs shall be provided for all the 2 heaters in one coach)

g) AC ON Glows when AC supply is ON

h) Power supply ON i.e. 400 V OK

Glows when supply is available

i) Temp. Cond. Fan Glows if winding temp. is in admissible range (4 separate LEDs shall be provided for all the 4 condenser fans in one coach.)

System faults: - Following indications shall be provided for various faults

a) Blower motor 1/1, 1/2 & 2/1, 2/2

Glows when winding temp. is in the admissible range (4 separate LED shall be provided).

b) LP Glows if the pressure switch in the refrigeration circuit has not fallen below the




switching threshold (4 separate LEDs shall be provided for each of the refrigeration circuit.

c) HP Glows when high pressure switch is activated (4 separate LED shall be provided).

5.7.15 Power supply

Operating voltage 110 DC/AC ±30% Power consumption (Max) 30 watts Ripple (Maximum) 48%

5.7.16 Analogue inputs (temp. sensors)

Nos. of inputs 6 (Minimum) Measuring sensor NTC sensor 5.0 KΩ at 25°C

Linearization of the characteristic curve for NTC shall be performed in the arithmetic manner by means of CPU. Offset faults and drift errors of any analogue component shall be compensated on CPU in cyclic manner by means of cyclic reference measurements. The system shall detect faults such as short circuit in the sensor leads. If any of the sensors fails, evaluating of temperature shall be done by the sensor of other system or controller shall read the constant value of 25°C. (Sensors: Four nos. for return air and two nos. for supply air temperature)

5.7.17 Analogue inputs (current loop)

Number of inputs 2 Measuring signal 4--- 20 mA Type of switching Current loop Output voltage 16 to 26 volts DC Output current 24 to 30 mA Resolution 0.01 mA Isolation voltage to the CPU 500V/1s (One for HP and other one for LP switches.)

5.7.18 Binary inputs Number of inputs 22 in 3 galvanic isolated groups Input voltage U low = 0-24 VDC U high=10-150 VDC Input current 3 mA per input at 24 volts Switching capacity Max. 50 watts per output Type of switching Opto-isolated




The condition of the individual input shall be made visible by means of LED each per input. The description is indicated in RDSO drawing No. RDSO/PE/SPEC/AC/0127-2009 (Rev.0)

5.7.19 Binary outputs Number of outputs 20 in 4 galvanic isolated groups

Switching voltage Max. 250 volts AC Switching current Max 1A Type of switching Relay contacts (normally open contacts) Isolation voltage 1500 v/1s The switching condition of the relay contacts shall be indicated via the LED‟s, within the cover of the MPC. The description of LED indication shall generally be as per RDSO drawing No. RDSO/PE/SPEC/AC/0127 – 2009 (Rev.0).

5.7.20 Analogue outputs (optional)

Number of outputs 1 Output voltage 0 to 10 volts DC Resolution 2.5 mV Min. ext. resistor 5.0 K Ohms Isolation voltage to the CPU 1500 v/1s

6.0 TEMPERATURE CONTROL & LCD DISPLAY UNIT

6.1 The system will maintain an identification number of coach and make of

controller, it is going to control. 6.2 Both the temperature sensor shall be mounted in coach just behind return air

grill to ensure accurate measurements, where as the hygrostat shall be mounted at supply air grill.

6.3 NTC sensor shall only be used for temperature sensing and capacitive

hygrostat for relative humidity sensing. 6.4 RMPU testing parameters during starting of plant and during

service/maintenance shall be incorporated in the microprocessor controller.

7.0 FAULT STORAGE/SELF DIAGNOSTIC SYSTEM

7.1 A fault storage system will record at least 2000 faults to be stored on FIFO

basis (First in first out) of various tripping and faults of the RMPU along with the instant status of various parameters like temperature setting. LP & HP pressure and relative humidity etc.

Format for the downloading failure data shall be as follow:




Date Time Nature of Fault

Brief Description (Image of complete event recorded)

7.2 There should be provision of event recording with details on time, date,

coach no, temperature, humidity, voltage, current, HP & LP etc. Past data of 200 hrs. of working of RMPU should be stored on FIFO basis. Event recording data shall be sampled in every two minutes.

7.3 Power up diagnostic: 7.3.1 While the system is being switched on it shall ensure that all functional units

are working and all back up data are still valid i.e. no important data has been corrupted during the period when power had been turned off.

7.4 Indications and display unit 7.4.1 There will be separate display unit to be mounted on switch panel as shown

in enclosed drawing No. RDSO/PE/SK/AC/0125 (Rev.0)-2009. The indication format shall be as mentioned in clause No. 5.7.14.

7.4.2 The following functions shall be possible to view with the help of the

laptop/PC/hand held device through USB port

(i) Setting of time and date, coach no. (ii) Clearing of the fault on display (iv) Viewing of the stored faults (v) Display of digital inputs and outputs (vi) Display of status of the system (HP/LP, temperature of supply & return

air & humidity etc.) 7.4.3 The screen structure of the display unit is given in Annexure –III which shall

be finalised during prototype testing offered by first manufacturer.

8.0 SOFTWARE REQUIREMENT:

8.1 Control and regulation function of the air conditioning system (two nos.

RMPU) shall be performed by microprocessor controller unit (with software installed in it), together with the Electrical components of the air conditioning system. All the information necessary for control and regulation, such as switching condition and temperatures etc. shall be processed and evaluated, taking into account the prevailing operating condition and necessary safety precautions.




8.1.1 Software

Setup files of computer software on a CD. Control flow chart and algorithm for the control logic Operating manual of the software.. Facility to modify the display program through Laptop External facility to change parameters, if required in future, through Laptop

9.0 GENERAL CONSTRUCTION AND DESIGN REQUIREMENTS

9.1 The microprocessor control unit should be compact, robust and light in

weight. 9.1.1 The controller shall have the provision to change the temperature setting

inside the coach through software. The method to change the temperature setting shall clearly be described in the description of the system, which shall be supplied by the manufacturer of microprocessor controller.

9.2 The unit should not require any regular maintenance. Any maintenance

requirement for unit, if recommended by the firm should be submitted to RDSO along with design details of the unit while offering the prototype.

9.3 Electronic components used shall be as under:-

(i) IC (Integrated Circuits) shall be of Industrial Grade. (ii) Electrolytic capacitors shall be rated for max. temperature of 105

deg.C. (iii) Paper/polyester capacitors shall be rated for max. temperature of 85

deg. C. (iv) The resistance shall be preferably made of metal film of adequate

rating. (v) Switching devices such as transistors, MOSFETs and IGBTs shall

have junction temperature 150 deg.C. (vi) Devices shall have the adequate thermal margin at the ambient of 55

deg.C. 9.4 The unit shall have protection against open circuit and short circuit of the

sensor as well as cable. 9.6 The controller unit shall meet the requirement of RDSO Specification no

ELRS/SPEC/SI/0015 “Reliability of Assurance specification for Electronic components for use in rolling stocks.”

9.7 All the cards should be suitably protected and mounted in a robust metallic

housing so that entire assembly is capable of withstanding shocks, vibrations, electromagnetic induction and electrical surges etc. The equipment should withstand surge and spikes as specified in IEC 60571-1.




9.8 System shall have real time clock for recording date and time. 9.9 The enclosure shall be fabricated from the cold rolled annealed sheet to

Specification No. IS 513-1963 of minimum thickness 1.0 mm. Processes like machining, bending, spot welding etc., shall be adopted to ensure geometry of the enclosure and the aesthetic look. The enclosure shall be given suitable anticorrosive paint.

9.10 All mild steel hardware shall be cadmium plated and passivated to IS 1572-

68 “Specification for electroplated coatings of cadmium on iron and steel”. To the extent practicable the screws shall work on tapped hole i.e. provision of loose nuts to be avoided. The screw heads shall be preferably accessible from the front. The depth of the tapped hole shall be more than the diameter of the screw.

10.0 TESTS

10.1 Only after the drawings and the design have been approved and the

clearance given to this effect, the manufacturer shall take up the manufacture of the prototype. It is to be clearly understood that any changes, required to be done in the prototype or any additional tests other than specified herein are required to be conducted on the prototype unit or its components, they shall be done expeditiously.

The type tests may be carried out by RDSO representative on prototype unit

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

A manufacturer undertakes to manufacture for the first time. An important change in design details of machine has been

introduced. Specification is modified necessitating the re-designing of

equipment. Unsatisfactory performance reported from user Railways. Resumption of production after an interruption of more than two

years.

RDSO may conduct surprise check on manufacturing process and quality control along with any of the tests to ensure quality of product and its conformance to RDSO specification.

10.2 The suitability of the controller shall be ascertained by inspection, bench test

at the firm‟s works, in the stationary coach and during service trial of the unit on the coach.

Tests for microprocessor controller unit:




The following tests shall be carried out in the for microprocessor controller unit.

S. No Description of test Clause No. Type test

Routine test Acceptance test

(i) Visual Inspection 10.2.1

(ii) Performance test 10.2.2

(iii) Cooling test 10.2.3 -- --

(iv) Temperature rise test

Dry heat test

Damp heat test

10.2.4 -- --

(v) Surge and transient sient susceptibility test

Direct transient

Indirect transient

10.2.5 -- --

(vi) Transient burst susceptibility test 10.2.6 -- --

(vii) Radio Interface test 10.2.7 -- --

(viii) Insulation test 10.2.8

(ix) Dielectric test 10.2.9

(x) Vibration, shock and bump test 10.2.10 -- --

(xi) Working of RMPU in conjunction with microprocessor controller in respect of logic & control as per Annex-C

10.2.11

10.2.1 Visual inspection: It shall be done for checking overall dimensions, mounting dimensions,

conformity to design and manufacturing standards. 10.2.2 Performance test The microprocessor controller unit shall be subjected to complete examination

of its performance in order to determine whether the unit corresponds to the specification. For this purpose, firm shall develop a simulation kit. The record of internal test shall be kept available with the firm and the same will be produced before inspecting authority, if demanded.

10.2.2.1 Nominal supply voltage Measurements shall be carried out at an ambient temperature of 25±10°C at a

nominal supply voltage of 110V DC.

Check the power on reset

Check the CPU function

Check the data link via RS232 interface and request system status (stat)

Down load test software

Check switching of digital outputs

Check reading of the digital inputs




Check reading of analog data using precision resistor instead of NTCs

Check the fault detection of the analog inputs ie open and short circuit

Check reading of analog data

Check the fault detection of analog data inputs, open and short circuit.

Check the correct analog output voltage with 5K ohm load.

Check the real time clock

Check the data retention of the error memory

Check the charge-and discharge function of the backup capacitor, if provided

Check the down loading system performance parameters and fault data.

Check the analysis software for fault data.

Check the display unit

10.2.2.2 Lower supply voltage: Check that microprocessor controller unit performance is in accordance with

the functional requirements as stated above at lower supply voltage of 77 VDC.

10.2.2.3 Upper supply voltage: Check the microprocessor controller unit performance is in accordance with

the functional requirements as stated above at upper supply voltage of 138 VDC.

10.2.3 Cooling test: The microprocessor controller unit shall be placed without any power supply

in a room where the temperature is progressively lowered from ambient temperature 25°C to -25°C to the lowest agreed temperature over a period of time equal to or greater than ½ hr.

The assembly is kept for two hrs. at the low temperature with a tolerance of

±3°C, starting from the time when thermal enclosure temperature is uniform. At the end of this performance test as per clause 9.2.2 is carried out, keeping the equipment at low temperature.

After recovery, a complete performance check as stated under clause 9.2.2 is

carried out. 10.2.4 Temperature rise test A: Dry heat test: The tests shall be carried out as per clause 10.2.4 of IEC-60571-1998. (Or

latest) for TX class of ambient conditions on the complete microprocessor controller unit in closed condition as during normal operation. At the end of this test the performance test as per clause 9.2.2 is repeated.




B: Damp heat test: The temperature rise test (Damp heat test) to be conducted as per clause

10.2.5 of IEC-60571-1998 (Or latest). At the end of this test the performance (clause 9.2.2), visual (clause 9.2.1) and insulation test (9.2.8) is repeated.

10.2.5 Surge and transient susceptibility test: Direct Transient: - All connections of microprocessor controller unit capable of being connected

to the supply voltage shall withstand the application of the Direct Transient Waveform D as described in para 10.2.6.2 of EN50155. The source impedance shall be 12 ohm (Series Resistor 10 ohm).

a) Positive and negative between the positive power supply and return

potential of the microprocessor controller unit. b) Positive and negative between one binary input of each group and its

return potential. c) Positive and negative between one binary output of each group and its

return potential. d) Positive and negative between the microprocessor controller unit voltage

return and earth terminal. If no earth terminal exist, the waveform shall be generated with respect to a metallic mounting plate under the Digital Controller with a minimum four times size of the Digital Controller.

The waveform shall be applied five times with the voltage supply both present and

absent. Pass/Fail Criteria No irreversible damage shall occur. During the test microprocessor controller unit shall be monitored to detect any

failure or malfunction. If a failure occurs, the Digital Controller shall recover to normal operation automatically within the normal startup time. At the end of the test sequence checks shall be made to verify, that no degradation of the transient absorbers has occurred.

Indirect Transient:- All connections of the microprocessor controller unit connected to the supply

voltage and liable to be affected by electromagnetic coupling shall withstand the application of the indirect transient Waveform H as described in para 10.2.6.3 of EN50155. The source impedance shall be 100 ohm

For each test the waveform shall be generated.




a) Positive and negative between the positive and the negative CAN connections of the microprocessor controller unit.

b) Positive and negative between two of the ten NTC inputs and analog return potential.

c) Positive and negative between one of the two 4…20 mA inputs and its return potential.

d) Positive and negative between all high side connections of the I/Os mentioned above and the Digital Controller supply voltage return.

The waveform shall be applied five times with the voltage supply both present and

absent. Pass/Fail Criteria No irreversible damage, no loss of function or deviation from specified values

shall occur. During the test microprocessor controller unit shall be monitored to detect any

failure or malfunction. If a failure occurs, the Digital Controller shall recover to normal operation automatically within the normal startup time. At the end of the test sequence checks shall be made to verify, that no degradation of the transient absorbers has occurred.

10.2.6 Transient burst susceptibility test

Power supply lines shall be tested with 2 kV according to level 3 as defined in

IEC 1000-4-4. All unscreened I/O lines shall be tested with 2 kV according to level 4 as specified in IEC-1000-4-4. The method of coupling for unscreened lines shall meet the requirement as detailed in figure 9.

Pass /Fail Criteria The microprocessor controller unit shall not experience any failure in the

presence of these transient burst test.

10.2.7 Radio Interface Test

10.2.7.1 Radio Frequency Interface (RFI) Susceptibility test: The microprocessor controller unit shall be in its housing with all covers and

access panels in place. Unshielded wiring shall be used for the connection of a typical load to one I/O line of each group and left exposed to the field for a length of one meter from the point of connection to the microprocessor controller unit. The applied field strength shall be maintained at 10V/meter, as measured by field monitors placed closed to the Digital Controller. The applied frequency is swept from 80 MHz to 1000 MHz. The sweep rate shall not exceed 1.5X10 -³ decades/s. The carrier amplitude shall be 80%




modulated with a 1 KHz sine wave. The test shall be performed with a generating antenna facing all three rectangular coordinates of the Digital Controller. The polarization of the field generated by each antenna necessitates testing each side twice, once with antenna positioned vertically and again the antenna positioned horizontally.

Pass/Fail Criteria The microprocessor controller unit shall not become dangerous or unsafe in

the presence of these radio frequency fields. If a loss of function occurs during the test it shall be verified, that the microprocessor controller unit is able to recover its operative capabilities by itself within the normal startup time after the end of the test.

10.2.7.2 Radio Frequency Interface (RFI) Emission test

The microprocessor controller unit shall be in its housing with all covers and

access panels in place. Unshielded wiring shall be used for the connection of a typical load to one I/O line of each group and left exposed to the field for a length of one meter from the point of connection of the microprocessor controller unit. The microprocessor controller unit shall be tested using the method of measurement as described in EN55011.

Pass/Fail Criteria The measured levels in the frequency range of 30 MHz to 230 MHz shall be

less than 40 dBV/m & in a frequency range of 230 MHz to 1GHz less than

47 dBV/m measured at distance equivalent to 10m from the front surface of the Digital Controller.

10.2.7.3 Conducted disturbance induced by radio-frequency fields

The test shall be performed with a test generator connected to each group of

binary inputs and outputs, one NTC input, one 4…20 mA input, the analog output and the power supply. The frequency range is swept from 150 kHz to 80 MHz, using a single level of 3 Vrms which is 80% amplitude modulated with a 1kHz sine wave. The rate of sweep shall not exceed 1.5X10-³ decades/s the test set-up shall be in accordance with the requirements of the ENV50141.

Pass/Fail Criteria

The microprocessor controller unit shall not become dangerous or unsafe as

result of the application of the test. If a loss of functions occurs during the test it shall be verified, that the Digital Controller is able to recover its operative capabilities by itself within the normal startup time after the end of the test.

10.2.8 Insulation test




The insulation measurement test shall be carried out with 500 VDC between:

a) 110V power supply and the internal 5 VDC supply voltage. b) Each group of relay outputs and the internal 5 VDC supply voltage. c) Each group of binary inputs and internal 5 VDC supply voltage. d) One NTC input and the internal 5 VDC supply voltage.

10.2.9 Dielectric test

After the insulation measurement test the voltage withstand test shall be

carried out. The test voltage shall be applied between the two sides of the isolation barrier for 1 minute. The test voltage shall be 1500 VAC for :

a) 110V power supply and the internal 5 VDC supply voltage. b) Each group of binary inputs and internal 5 VDC supply voltage.

The test voltage shall be 500 VAC for

a) One NTC input and the internal 5 VDC supply voltage. b) CAN-interface and the internal 5 VDC supply voltage.

After the voltage withstand test the insulation measurement test shall be

repeated. Pass/Fail Criteria The test shall be considered as satisfactory if neither disruptive discharge nor

a flashover occurs. There shall be no fundamental deterioration from the initial insulation measurement.

10.2.10 Vibration, shock and bump test

Vibration and shock test to be conducted as per clause 10.2.11 to IEC-60571-

1998 (Or latest) at 3g in all the three directions. “The resonant frequency will be searched between 0-50 Hz at the critical

locations of the unit. The vibration test shall be conducted in energized condition for two hours each in all three directions i.e. lateral, Longitudinal and vertical direction, at critical frequencies. In case critical frequency is not observed, vibration test shall be conducted at 10 Hz.”

“Shunting shocks test shall be conducted by giving 12 shocks of 3 g level in

energized condition of unit in all the three direction each.” Pass/Fail Criteria After the test the microprocessor controller unit shall be examined for cracks,

breakouts, deformations and other mechanical damages. Afterwards a




complete performance test shall be carried out as stated under 9.4.2. The tests are considered satisfactory if no damage or malfunctioning is detected.

10.2.11 Working of RMPU in conjunction with microprocessor controller in respect of logic & control

Each microprocessor controller shall be checked for it proper function as per logic and control specified in annexure – D enclosed with the specification. The checking shall be done in conjunction with RMPU. A check format for the same shall be made available with the firm containing microprocessor serial number, make & the functions verified.

11.0 TECHNICAL DATA

11.1 The manufacturer shall indicate their compliance or other wise against each

clause and sub-clause of the technical specification. The manufacturer shall enclose a separate statement for this purpose, if necessary, indicating the Annexure and clause reference and compliance or otherwise. The same shall also be furnished at the time of prototype testing.

11.2 The manufacturer shall submit complete design details including Bill of

Material to the purchaser & RDSO before offering the prototype of controller for clearance.

11.3 The manufacturer shall also supply following drawings in CAD software:

1. Operating Instructions 2. One set of the followings will be supplied with each controller. a) Operating and troubleshooting manual bilangual. b) Parts illustrated catalogue-indicating sources. 8. Power & control electrical diagrams showing various connections to

microprocessor controller & RMPU, indicating ferrules/cable numbers

12.0 MAINTENANCE MANNUAL

The general maintenance requirement for controller, which should contain periodicity, work content and justification for each maintenance requirement, if any.

13.0 GUARANTEE/ WARRANTY

Guarantee/warranty obligation of the equipments shall be as per IRS condition

of contract. 14.0 INFRINGEMENT OF PATENT RIGHT




14.1 Indian Railways shall not be responsible for infringement of Patent rights arising due to similarity in design, manufacturing process, use of components in design & development of this item any other factor not mentioned herein which may cause such a dispute. The entire responsibility to settle any such dispute/matters lies with the manufacturer/supplier. Details/Design/documents given by them are not infringing any IPR and they are responsible in absolute and full measure instead of Railways for any such violations data. Specification 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 IPs acceptable to them. Firm has to sign an undertaking in this regard at the time of vendor approval.

15.0 SCHEDULE OF TECHNICAL REQUIREMENT

15.1 STR of this item shall be RDSO/PE/STR/AC/0023 (REV-0) - 2008

16.0 TRAINING

16.1 The contractor shall undertake to train, free of cost, the supervisors & staff of

the Indian Railways for operation, maintenance, fault finding, repair of offered controller under guidance of skilled engineers, during the warranty period of the controller.

17.0 SERVICE ENGINEERS

17.1 The successful tenderer shall be required to make available the services of

his engineer/engineers free of cost to watch performance of the equipment in service periodically and also carry necessary repairs or replacement under warranty obligations. The necessary spares needed for replacement during service should be available with the service engineers at all possible places where these coaches are maintained.

18.0 CARTEL FORMATION

19.1 The firms will not engage cartel formation with other firms and will also submit

a declaration in this regard as per annexure III attached.

19.0 ENCLOSURES

19.1 Proforma for undertaking against cartel formation Annexure A to be furnished by the manufacturer

19.2 Screen display & Screen structure Annexure B




19.3 Logics and control Annexure C

19.4 RDSO drawing No. RDSO/PE/SK/AC/0127.-(Rev.0)-2009 : “Dimensional

requirement & LEDs description of microprocessor controller unit for RMPU (LHB variant AC coaches)




ANNEXURE - A

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 Railways/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

(Authorised signatory of the firm)

Date: Place: Seal:




ANNEXURE - B

SCREEN STRUCTURE (FORMAT FOR DISPLAY OF INFORMATION)

Default display

DATE TIME COACH NO. RH 25/09/08 22:06 ACCW 04065 67%

Status

BLR1.1/1.2, CD1.1/1.2, CD2.1/2.2 CP1.1/1.2, CP2.1/2.2, HTR1.1/2.2

DISPLAY SCREEN

4 LINES X 40 CHARACTERS

MENU ENTER ACK

UP

DOWN




ANNEXURE - C

THE LOGIC AND CONTROL TO BE PERFORMED BY MICROPROCESSOR CONTROLLER

The controller shall perform the following functions concerning control and regulation of air-conditioning system to maintained the desired comfort condition inside the coach: 1. The controller will activate immediately after getting 110±20% V dc

supply. 2. The controller shall perform diagnostic checks such as Watch dog &

Real time clock, Memory OK & RAM OK. If they are OK, it shall be indicated by glowing LED for Controller OK. An additional LED shall also be provided on controller for controller not OK, if fails to recover in twice. Message for the same shall be displayed on display unit regarding failure of probable components of the controller in addition to the storage in controller error memory.

3. The controller shall also monitor the power supply voltage and give

indication by LED for 400 V OK. If it is not OK, massage for the same shall be displayed on display unit regarding failure of probable components in addition to the fault storage in controller memory.

4. If controller is OK, the controller shall monitor the out side ambient,

return air temperature & Relative humidity at supply air and perform the following:

a) Dehumidification mode

b) Normal cooling & heating c) Emergency Operation

d) Safety devices operation under various operation of mode,

such as HP/LP/control pressure switch, TOP, OHP & fusible link

After appearing 400 V OK signal on controller unit, the controller shall

be ready to perform the control, regulation & smooth operation of RMPU.




A) DEHUMIDIFICATION

Dehumidification process shall be started, if the relative humidity of return air is more than 60% and the temperature is below 23°C. During the process one compressor and heater shall be ON, while another compressor and one condenser fan will be in OFF position. The heater will be switched OFF after 3 minutes and remain be OFF for further 5 minutes. After 5 minutes the relative humidity shall again be monitored by hygrostat, if still it is more than 60%, the cycle shall be repeated till the RH is reached down upto 40%. During process it shall be ensured that the return air temperature should not fall below 23°C.

ON/OFF status of each equipment shall be indicated on controller unit by means of glowing respective LEDs. Total power consumption of the unit during dehumidification shall not exceed the total power consumption of the unit arrived under cooling capacity test.

Dehumidification should not be started under the following conditions and checks for which shall be appeared on display unit:

1. There is no power supply to condenser, blower fan motor, heater and

compressor. 2. TOP of blower motors are defective. 3. Compressors are tripped from LP/HP or permanently blocked after three

successive tripping within one hour. 4. All temperature sensors are defective. 5. Hygrostat is defective

(NOTE: Before switching of various equipments, the safety checks of devices such as TOP, HP/LP, pressure control switch OHP, temperature sensors, hygrostat & fusible link for its healthiness shall be ensured by the microprocessor by means of glowing respective LEDs on controller unit).

B) NORMAL COOLING In normal cooling, the controller shall perform control & regulation of the air-

conditioning system (RMPU) as stated in this chapter as well as specified in under various clauses the specification.

It shall be ensured that the compressors shall work only when the temperature of return air is between 23°C and above.

Cooling should not be started under the following conditions and checks for which shall be appeared on display unit:

1. AIR-CO switch is turned OFF. 2. There is no power supply to condenser, blower fan motor and

compressor.




3. TOP of motors are defective. 4. Compressors are tripped from LP/HP or permanently blocked after three

successive tripping within one hour. 5. All temperature sensors are defective.

(NOTE: Before switching on various equipments, the safety checks of devices such as TOP, HP/LP, pressure control switch OHP, temperature sensors, hygrostat & fusible link for its healthiness shall be ensured by the microprocessor by means of glowing respective LEDs on controller unit).

C) EMERGENCY OPERATION OF RMPU

1. The working of blower fans shall be ensured during emergency, if the refrigeration circuit is totally failed for any reason and fault cannot be rectified during run of the coach.

2. There shall a provision to change over the inverter supply to blower

motor for emergency operation of RMPU automatically. 3. If microprocessor fails to perform control & regulation of RMPU, than

massage for failure of microprocessor shall appear on display unit. In case of microprocessor controller failure, it shall be possible to run RMPUs in manual mode, keeping all safety devices & interlocking remain in functional.

D) SAFETY DEVICES OPERATION

1) Starting of compressors: Both the compressors shall not be started at a time. First compressor of each unit should be started after 2 minutes from switching ON of AIR-CO switch. Second compressors of the units shall be started after a delay of 30 seconds from start of first compressors.

2) High Pressure switches: The compressor should be switched

OFF/tripped, if discharge pressure of compressor rises beyond limit of 430 psig. Once the compressor has been switched OFF, it shall not be started before 30 second even it is required.

If the compressor tripped three times in one hour, the fault shall be stored/displayed by means of glowing fault indication lamp provided on switch panel and message shall appear on display unit, in addition to LED indication.

In case both the compressors of any unit are switched OFF at a time, first

compressor shall be started after 2 minutes and other one after 30 seconds from start of first compressor.




The provision shall be there to restart the unit in case both the

compressors have been tripped three times in one hour. This facility shall be available only for two time exercise by escorting staff of air-conditioning coach by re-switch ON of AIR-CO switch. This event shall be recorded/stored in controller memory. After two time exercise, only blower motor shall be run upto destination of the train.

3) Low Pressure switches: The compressor should be switched

OFF/tripped, if suction pressure of compressor goes down beyond limit of 30 psig. Once the compressor has been switched OFF, it shall not be started before 30 second even it is required.

If the compressor tripped three times in one hour, the fault shall be stored/displayed by means of glowing fault indication lamp provided on switch panel and informative massage shall be appeared on display unit, in addition to LED indication.

In case both the compressors of any unit are switched OFF at a time, first

compressor shall be started after 2 minutes and other one after 30 seconds from start of first compressor.

The provision shall be there to restart the unit in case both the

compressors have been tripped three times in one hour. This facility shall be available only for two time exercise by escorting staff of air-conditioning coach by re-switch ON of AIR-CO switch. This event shall be recorded/stored in controller memory. After two time exercise, only blower motor shall be run upto destination of the train.

4) Control Pressure switch: Control pressure switches are provided in

each circuit to monitor the discharge pressure of compressor. If the discharge pressure is below 275 psig, only one condenser fan will be in working. If the discharge pressure rises above 275 psig, the second compressor shall be started.

5) Thermal over load protection: Thermal over load protection devices are

embedded in the winding of each motors, which allow to disconnect motor supply through contactor, if the winding temperature of the motor rises 130ºC and shall be automatically re-started when the temperature of the winding comes down. The message shall be displayed on display unit in addition to LED indication on controller unit.

If it happens three times in one hour, the fault shall be indicated by means of fault indication lamp provided on switch panel in addition to LED indication on controller unit.

(NOTE: The fault indication light provided on switch panel should be reset

by turning of AIR-CO switch. The OFF time of motors under this condition shall also be recorded/stored in memory of the controller.)




6) Over heat protection (OHP) for heater: During heating mode in winter,

the overheat protection switch shall take care for excessive heating of supply air. If the supply air temperature is reaches beyond the set value i.e. 65ºC due to any reason, the OHP will react immediately to disconnect the power supply to the heater through controller and will block the heater working further. The blinking message shall be displayed for the same on display unit. The heating facility shall be available only by re-switch ON of AIR-CO switch. This event shall be recorded/stored in controller memory with the time and at which temperature it has acted.

6) Fusible link (ESTI): In case OHP fails to perform to disconnect the power

supply at 65ºC supply air temperature, an another Fusible link (ESTI) having setting to operate at 130ºC shall be operated by way of bursting the bulb to disconnect the power supply permanently. The action of the fusible link shall be recorded/stored in memory and shall be indicated by means of LED provided on controller unit. In addition to LED indication, blinking message shall also be displayed on the display unit for 5 minutes to alert escorting staff to note down the position in log book.

IMPORTANT:

1. The microprocessor controller shall be compatible with NTC sensors

& capacitive hygrostat. 2. The return air temperature shall be the average of both side return

air temperature being sensed by temperature sensor. In case, any sensor is defective the reading shall be taken from healthy sensor.

3. The ambient temperature shall be the average of both side fresh air temperatures being sensed by temperature sensor. In case, any sensor is defective the reading shall be taken from healthy sensor.

4. In case both sensors are defective, message shall appear on display unit with blinking.

5. Heater should not work under the following conditions and checks for which shall be appeared on display unit:

a. AIR-CO switch is turned OFF. b. If power supply to heater is absent. c. Return air temperature sensors are not working or defective. d. Blower fan motors are in tripped condition or not in working. e. OHP switches are in tripped condition f. Fusible link (ESTI cartridge) is defective or already burst. g. The software should be window based and user friendly in

common syntax language and should be able to import/export the fault failure report reports or data logging reports for further analysis.

*******




DISTRIBUTION

CHIEF ELECTRICAL ENGINEER:

1 Northern Railway, Baroda House, New Delhi – 110 001.

2 Central Railway, II Floor, Parcel office, CST Mumbai – 400 001.

3 Eastern Railway, Fairlie Place, Kolkata – 700 001.

4 South Eastern Railway, Garden Reach, Kolkata – 700 043

5 Southern Railway, Park Town, Chennai – 600 003.

6 Western Railway, Churchgate, Mumbai – 400 020.

7 South Central Railway, Rail Nilayam, Secunderabad – 500 371.

8 East Central Railway, Dighi Distt- Vaishali, Hajipur Bihar- 844 101.

9 North Central Railway, Balmiki Crossing, Nawab Yusuf Road, Civil Lines, Allahabad- 211 001.

10 South Western Railway, 1st Floor, DRM Office, Hubli 580 020

11 South East Central Railway, Bilaspur.495004

12 North East Frontier Railway, Maligaon, Guwahati - 781001

13 North Eastern Railway, Gorakhpur – 273001

14 North Western Railway, Jaipur – 302006

15 West Central Railway, Jabalpur - 482001

16 East Coast Railway, Bhuvneshwar, Orrisa – 751016

17 Konkan Railway, Belapur Bhavan, Sector-11, Belapur, Mumbai - 400614

18 Metro Railway, 33 /1 J.L. Nehru road, Kolkata- 700071

19 Integral coach factory, Perambur, Chennai - 600038

20 Rail Coach Factory, Kapurthala (Punjab) – 144 602

CHIEF WORKS MANAGER:

1 Matunga Workshop, Central Railway, Mumbai 400 019.

2 Liluah Workshop, Eastern Railway, Howrah

3 C&W Workshop , Northern Railway, Alambagh, Lucknow-226 05

4 C & W Workshop,N. Rly., Jagdhari – 135 002

5 Mechanical Workshop, NER, Gorakhpur – 273 012

6 Carraige Workshop, Southern Railway, Perambur, Ayanavaram, Chennai–600023.

7 SCR, Lallagudda Workshop, Lallaguda, Secunderabad - 500017

8 Carriage Workshop, Western Railway, Lower Parel, Mumbai-400013

9 CRWS, W. C. Railway, Nishatpura, Bhopal-462010

10 Carriage Workshop, NW Rly,. Ajmer - 305001

11 Carriage Repair Workshop, Gadag Road, SWR, Hubli – 580 020

12 Carriage Workshop, S.W. Railway, Mysore Vishwanath.




13 Carriage Workshop, SE Rly., Kharagpur - 721301

14 New Bongaigaon , Railway Workshop, Dangtal, Distt. Bongaigaon, Assam-783380

15 Carriage and Wagon Workshop, N. C. Rly., Jhansi – 248003

16 Carriage and Wagon Workshop, WC Rly., Kota - 324002

17 Carriage and Wagon Workshop, Eeastern Rly., Liluha - 711204

18 Carriage and Wagon Workshop, W. Rly., Pratap Nagar, Vadodara - 390004

19 Carriage and Wagon Workshop, N Rly., Amritsar - 143001

20 Central Workshop, Goldenrock, S. Rly., Trichi - 620004

OTHERS:

1 Director, IRIEEN, Nasik Road (Maharashtra). - 422101

2 Senior Professor (Elect.), Railway Staff College, Lalbaug, Vadodara. - 390004

3 Director, IRCAMTECH, Maharajpur, Gwalior – 474 020.

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