Spec Hotel Load Conv P4 - Rev 0 - Aug 12

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
DRAFT
SPECIFICATION FOR DEVELOPMENT
OF SINGLE PHASE TO THREE PHASE
HOTEL LOAD CONVERTER
FOR WAP4 LOCOMOTIVE
Specification No: RDSO/2011/EL/SPEC/0109_Ver’1’, Rev. ‘0’
Issued on: Oct’11Aug’12
Issued by:
ELECTRICAL DIRECTORATE
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAK NAGAR LUCKNOW-226011
Prepared by Checked by
JE/DESIGN/RDSO DSE/TPL/RDSO
Draft for internal use of RDSO
From Ver’0’Ver’1’_clear_31.05.11Oct’11
Page 2 of 35 Issued on - RDSO/2011/EL/SPEC/0109, Rev.
Oct’11Aug’12 ‘0’_Ver’1’
S.N. Date of Revision Page No. Revision Reasons for Revision

1.
2.
3.
4.
Oct’11Aug’12 ‘0’_Ver’1’
Contents
Abbreviations PAGE -
Definitions and Interpretations PAGE -
CHAPTER 1 General Description PAGE -
CHAPTER 2 Operating and Environmental Conditions PAGE -
CHAPTER 3 Technical Requirements PAGE -
CHAPTER 4 Scope of Supply PAGE -
CHAPTER 5 Tests PAGE -
Annex-1 Transformer details PAGE -
Annex-2 Hotel load details PAGE -
Annex-3 Loco circuit PAGE -
Annex-4 Space envelops PAGE -
Annex-5 Burn-in test
Oct’11Aug’12 ‘0’_Ver’1’
Abbreviations
The following abbreviations are used in this Specification:
Abbreviation Full Name
AC Alternating Current
BOM Bill Of Material
CFD Computational Fluid Dynamics
CLW Chittranjan Locomotive Works

DA Diesel Alternator
DC Direct Current
ELS Electric Loco Shed
EOG End On Generation
HOG Head On Generation
IR Indian Railways
OHE Over Head Equipment
OEM Original Equipment Manufacturer
RDSO Research Design and Standards Organisation
Oct’11Aug’12 ‘0’_Ver’1’
Definitions and Interpretations

Terms or words not defined in this Specification shall be governed by the definitions contained in the
standards applicable.
In this Specification, the following words and expressions shall, unless repugnant to the context or
meaning thereof, have the meaning hereinafter respectively assigned to them:
Term Definition
BLHO Shall mean switch at driver’s desk to operate hotel load converter;
Hotel Load shall mean electrical loads of coaches of a train such as lights, fans
and air conditioning, pantry etc. as detailed in Annex-2;
Design Concept shall have the meaning set forth in Clause 1.5.1;
Design Package shall have the meaning set forth in Clause 1.5.2;
shall mean the person, firm or department nominated to inspect the

Inspecting Officer
hotel load converters or the representative of the inspecting officer
so nominated;
LHB shall mean coaches manufactured in accordance with design of

Linke Hossman Busch.
Purchaser shall mean the President of the Republic of India as represented by

the IR organisation entering into the contract;
Supplier shall mean the firm or company with whom the order for supply of
the hotel load converter(s) WAP4 locomotive has been placed; and
Tenderer shall mean firm or company participating in the tender for supply
of hotel load converter for WAP4 locomotive.
Oct’11Aug’12 ‘0’_Ver’1’
Chapter 1
General Description
1.1 Introduction
1.1.1 IR is manufacturing tap changer based WAP4 locomotives which are utilized for passenger train
operations. These locomotives take power from OHE through pantograph to traction transformer.
This traction transformer is provided with a hotel load winding to cater for the power supply to
coaches (also referred to as Hotel Load). The capacity of this winding is 1000 kVA, which gives
750 volt single phase at 50 Hz at 22.5 kV supply voltage with rated maximum current of 1333 A.
The details of transformer are provided in Annex-1.
With the technological up-gradation and continuous advancements in the field of power
electronics, control system and power supply systems, IR has decided to adopt an energy
efficient power supply system for feeding to the coaches referred to as HOG for
Rajdhani/Shatabdi trains, presently having EOG system. LHB type of coaches are best suited for
adoption of HOG scheme as the rake integrity with these coaches is expected to be maintained
due to the specific design of their inter vehicle mechanical coupling.
In EOG system the Hotel Load in the coaches of Rajdhani and Shatabdi express trains are fed
from the power cars placed at either ends of the rake. Each power car is installed with 2 DA sets
generating 3-phase power supply at 750 Volts 50 Hz and the same is transmitted to entire rake
through two cable feeders, running through the whole length of the train. This electric power
supply is tapped at each coach through a 50 kVA transformer in Conventional Coaches and 60
kVA transformers in LHB coaches and is converted to 415 Volts for feeding the equipment
working at this voltage and further transformed down to 110 Volts AC single phase for feeding
the equipment working at that voltage. Since the power cars are placed at either end of the rake,
the system is termed as EOG.
1.1.2 In HOG scheme power is fed from the electric locomotive to the train to cater for the Hotel Load
of the train. In WAP4 locomotives, power is taken from the OHE through pantograph to traction
transformer of the locomotive which is provided with a hotel load winding of 1000 kVA, at
nominal voltage of 750 V single-phase, which varies with the OHE voltage variations. This 750
Volts single-phase supply will be fed to hotel load converter, which shall give 750 Volts 3-phase
50 Hz supply as output, for feeding the Hotel Load of the train. Converter output will further be
stepped downed to 415 V, 3-phase AC by existing transformers provided in every coach. This
electrical power will be used to operate the lights, fans, air conditioning, water raising apparatus
of the coaches and the pantry car equipment.
1.2 Scope and Object
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This Specification covers the technical aspect of the IR’s requirement for the IGBT based hotel
load converters for the WAP4 locomotives, to cater for the Hotel Load. It explains the interface
requirement of the converter with the locomotive, and lays down the desired performance and
testing methodology.
1.3 Supplier’s Responsibility
The Supplier’s responsibility shall be extended to the following:
1.3.1 The Supplier shall supply the hotel load converter conforming to the various operational and
functional requirements specified in this Specification.
1.3.2 The Supplier shall be responsible for commissioning, testing and field trials of first set of hotel
load converter in the locomotive and depute team of engineers for this purpose. The Supplier
shall arrange to carry out detailed tests and field trials jointly with CLW/ELS. For commissioning
of remaining sets of hotel load converters at CLW/ELS the Supplier shall depute engineer(s) for
supervision purpose. The special tools, machines, instruments and other facilities, which are
required for installation and commissioning of the hotel load converter and are not available with
IR, shall be supported by the Supplier.
1.3.3 The Supplier shall also be responsible for interfacing the hotel load converter with power car as it
is a developmental item.
1.3.4 The Supplier shall suggest the modifications/re-organizing of the equipment required for
providing the hotel load converter on the WAP4 locomotive and CLW/ELS shall carry out all the
modifications in association with suppliers for the first set of hotel load converter which shall be
subsequently done by CLW in regular production. The Supplier shall submit the drawings for all
the changes required to be carried out as part of Design Package.
1.3.5 The Supplier shall be responsible for supply of special tools, testing jigs, portable
diagnostic/troubleshooting tools preloaded with suitable latest operating system and application
software and instruments, which may be required for troubleshooting and maintenance of the
hotel load converter.
1.3.6 The Supplier shall be responsible for supply of a suitable software “if applicable” for off-line
analysis of diagnostic data downloaded from the hotel load converter.
1.4 Training
The Supplier shall arrange for training of IR personnel on the following subjects at OEM’s work
place under the guidance of OEM’s engineers:
 Assemble, testing, commissioning of hotel load converter;
 maintenance, repair and troubleshooting of the hotel load converter; and
 fault diagnostic analysis.
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Five days training for six persons at CLW and in any ELS shall be organised by the Supplier.
1.5 Documentation and Design Approval
1.5.1 The Tenderer shall submit, including but not limited to following along with the offer for
evaluation, as part of Design Concept:
a) Schematic Circuit;
b) functional description;
c) system design concept;
d) protection concepts;
e) cooling design;
f) mechanical interface diagram and compliance to existing mechanics;
g) clause by clause compliance;
h) calculation of power devices e.g. IGBTs;
i) credentials with details of supply made of such items;
j) data sheets for devices and other equipment proposed along with detailed description of
supply proposed;
k) salient features and advantages of the offered system;
l) details of technical support and training offered;
m) recommended list of spares for 5-year maintenance after warranty along with part no.,
datasheet and details of OEM;
n) list of special tools, jigs and fixtures needed for assembly, testing, commissioning,
maintenance and repair along with full technical specifications and probable suppliers;
o) logistics proposed for warranty support within India;
p) declaration for long-term support by the Tenderer;
q) details of short time rating of the converter;
r) expected efficiency with respect to load; and
s) IRIS/ISO 9000 certification.
1.5.2 The Supplier shall submit, including but not limited to the following, as part of Design Package to
RDSO for approval, before commencing manufacturing. Only on getting the approval from
RDSO in writing shall the production begin.
a) Technical documentation explaining the complete scheme, characteristics, diagnostics,
protection and control etc. including electric schematic circuits;
b) Interfacing and control scheme of hotel load converter with power car;
c) detailed drawings of each system/sub-system with interface details;
d) design calculations for selection of devices, cooling systems and various subsystems,
establishing the adequacy of the components selected;
Oct’11Aug’12 ‘0’_Ver’1’
e) details of output contactor and output filter;

f) complete BOM / technical specification of components with source of supply;
g) cooling system design description, data and cooling fluid data;
h) mechanical drawings, mounting arrangement, weight, details of mounting accessories;
i) procedure for software downloading, diagnostic uploading, analysis etc.;
j) schedule maintenance activities with periodicity;
k) maintenance, trouble shooting and repair manual in English language only in soft form
and hard copy;
l) details of tools and plants with design/drawings and name of probable suppliers; and
m) detail instructions for proper installation of the converter in the WAP4 locomotives.
Approval of design means approval of general design features. Notwithstanding the approval, the
Supplier shall wholly and completely be responsible for the performance of the hotel load
converter.
For the purpose of technical decisions on improvement / modifications etc. on the hotel load
converter, RDSO shall be the final authority from Purchaser’s side.
1.6 IR’s Responsibility
IR shall be responsible for followings:
a) The cabling required in the WAP4 locomotive;
b) the cable for connecting volt free contacts to control and diagnostic system of the WAP4
locomotive;
c) any equipment re-layout and mounting platform on the locomotive necessary for
installation of hotel load converter shall be done by IR in association with the Supplier;
d) consumables and electricity required for erection, testing and commissioning of hotel load
converter; and
e) the wages and allowances as well as the cost of the travel to and from the place of training
for IR personnel.
1.7 Infringement of Patent Rights
The Supplier shall submit a signed undertaking to IR in the following format as part of Design
Concept and while entering the contract:
“Indian Railways shall not be responsible for infringement of patent rights arising due to
similarity in design, manufacturing process, use of similar components in the design and
development of hotel load converter and any other factor not mentioned herein which may cause
such a dispute. The entire responsibility to settle any such disputes/matters lies with the
Supplier”.
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1.8 Reference to various Standards
1.8.1 This Specification is based on the following normative references:
Standards Title
IEC 60077-1 Railway applications – Rolling Stock General Rules
IEC 61287-1 Railway applications – Power converters installed on rolling stock
IEC 60571 Specific rules concerning the electronic control part of converters.
IEC 61373 Railway applications – Rolling stock equipment – shock and vibration test
IEC 60310 Traction transformers and inductors on board rolling stock
EN 50121-3-2 Railway applications – Electromagnetic compatibility
(CENELEC) Part 3-2: Rolling stock - Apparatus
EN 50121-2 Railway applications – Electromagnetic compatibility
(CENELEC) Part 2 : Emission of the whole railway system to the outside world.
EN 50153 Railway applications – Rolling stock – Protective actions against electrical
hazards
EN 60529 Protection classes of cases (IP-Code)

EN 50126/ IEC RAMS
62278
EN 50238
EN 50264
Table 1 - Standards
1.8.2 The latest version of the aforesaid standards, which have been published at least 60 (sixty) days
before the last date of bid submission shall be considered applicable.
1.8.3 Where the aforesaid standards are based on ambient and environmental conditions which are less
onerous than those stated in this Specification, the conditions stated in this Specification shall be
applied in the design and testing of the hotel load converter and sub-systems; and the
requirements of the aforesaid standards shall be adjusted accordingly.
1.8.4 Alternative Standards
The requirements listed in this Specification are the minimum. The Supplier may adopt
alternative internationally recognised codes, standards and specifications if it can demonstrate to
the Purchaser that such alternative is superior or more pertinent to the hotel load converter than
the standards specified in this Specification. The Supplier shall seek the prior approval of the
RDSO for any alternate standards proposed to be used.
1.9 Reliability, Availability, Maintainability and Safety (RAMS)
1.9.1 General
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The Supplier shall design the hotel load converter to ensure high degree of reliability, availability
and high degree of safety in order to provide a dependable service. The optimization of the
system with respect to reliability, availability, maintainability and safety shall form an integral
element of this Specification.
The plan for reliability, availability, maintainability and safety shall conform to EN 50126/ IEC
62278. Reliability of electronic components shall conform to IEC 61709.
1.9.2 The Supplier shall develop RAMS targets both for the hotel load converter and for the major sub-
systems such as rectifier module, DC link, inverter module, contactors, control electronics etc.,
such that it shall provide a high level of dependability. The RAMS targets shall be defined in
Design Package.
1.9.3 The Company shall establish and operate a detailed reliability, availability, maintainability and
safety (RAMS) assessment system in support of the design, manufacture and subsequent testing,
commissioning, operation and maintenance of the hotel load converter.
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Chapter 2
Operating and Environmental Conditions

2.1 Power supply system
The power supply system adopted is 25 kV, 50 Hz single phase AC with following features:
Nominal supply voltage 22.5 kV (rms), 50 Hz, single phase, AC
Normal variation in supply voltage 19 kV to 27.5 kV (rms)
Occasional maximum voltage 31 kV (rms)
Occasional minimum voltage 16.5 kV (rms)
Normal variation in frequency ± 8% (46 to 54 Hz)
Types of Neutral sections (i) 41 m in length having insulated over lap

on both end and neutral wire in between
which is not earthed; and
(ii) Short neutral sections of approximately

4.61 m and 9.6 m length having an insulated
portion (of PTFE) on both sides and middle
portion of neutral section which is solidly
earthed.
There shall be power interruptions at neutral

sections varying from 12 seconds to 30
seconds.
Pantograph bounce Up to 45 ms
Table 2 – Power supply system
Note: The occasional maximum and occasional minimum voltage may persist for 15 minutes.
2.2 Climatic and Environmental Conditions
The climatic and environmental conditions prevailing in India are the following:
 Atmospheric Maximum temperature (outside the locomotive): 50

temperature degree Celsius
Maximum touch temperature of metallic surface of the

locomotive under the Sun: 75 degree Celsius and in
shade: 55 degree celsius
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Minimum temperature: - 10 degree celsius ( Also snow

fall in certain areas during winter season)
 Solar radiation 1 kW/m2
 Humidity 100% saturation during rainy season
 Altitude 160 m above mean sea level
 Rain fall Very heavy in certain areas.
 Atmospheric conditions Extremely dusty and desert terrain in certain areas. The
dust concentration in air may reach a high value of 1.6
mg/m3. In many iron ore and coal mine areas, the dust
concentration is very high affecting the filter and air
ventilation system
 Coastal area humid and salt laden atmosphere with maximum pH

value of 8.5, sulphate of 7 mg per liter, maximum
concentration of chlorine 6 mg per liters and maximum
conductivity of 130 micro siemens / cm
 Vibration The vibration and shock levels recorded on various

sub-systems in existing locomotives of IR are generally
more than the limits given in IEC 61373.
 Electromagnetic High degree of electromagnetic pollution is anticipated

pollution in WAP4 locomotive machine room, where the hotel
load converter shall be mounted.
Table 3 – Climatic and environmental conditions
2.3 EMC
2.3.1 The hotel load converter shall comply with the EN 50121 series of Railway Electromagnetic
Compatibility standards and EN 50238.
2.3.2 The Supplier shall prepare, implement and maintain an EMC management plan in accordance
with the standards referenced in Clause 2.3.1 of this Specification. The EMC management plan
shall be defined in Design Package.
Oct’11Aug’12 ‘0’_Ver’1’
Chapter 3
Technical Requirements
3.1 The hotel load converter shall be completely IGBT based. The control shall be
microprocessor/microcontroller based having diagnostic features.
3.2 Power quality of the hotel load converter output at any load from 0% to 100% shall be as under:
 Output Voltage phase to phase :750V ± 5%, 3Ø sine wave AC

 Output voltage between phase to earth of feeder : less than 1.0 kV (peak)
 Rated output power :375 kVA at 0.9 power factor for all
supply voltage variations in accordance
with clause 2.1 of this Specification
 Output Frequency : 50Hz ± 2%
 Total harmonic distortion (THD) : Less than 10% in output voltage
 Voltage unbalance : Less than 3 %
 Expected current unbalance in load current : Up to 15% of rated output current
 Current harmonics at full load : Less than 5% up to 20th harmonic up
to 1000 kHz
 Input displacement power factor : Shall be close to unity at full load with
nominal input parameters
 Efficiency at full load : Not less than 93% at rated input
voltage
 Direct on load starting of converter : 750A for 3 seconds
3.3 Two such hotel load converters shall be provided in one WAP4 locomotive.
3.4 It shall not be possible to regulate the duty cycle of the loads.
3.5 The variation of hotel load power from the transformer with supply voltage is given in Annex-1.
3.6 Approximate total Hotel Load to be attached with the converter is given in Annex-2.
3.7 The operation of the hotel load converter shall be done by the loco pilot (driver) by pressing
spring loaded BLHO switch provided on the driver’s desk. The circuit from transformer winding
to the input of hotel load converter is shown in Annex-3. The BLHO switch, current sensor and
earth fault protection system shall be interfaced with input contactor.
3.8 If any information is required to be shared with the power car for better operation of the hotel
load converter the complete arrangement like supply of cables, connectors, jumper cables, control
panel or any other item required for the same shall be within the scope of supply of the Supplier.
Oct’11Aug’12 ‘0’_Ver’1’
3.9 Suitable three pole output contactor for the hotel load converter shall be provided at the output of
the hotel load converter.
3.10 Suitable filter circuit shall be provided at the output of the hotel load converter.
3.11 Protection
The devices used in the hotel load converter shall be protected against high rate of rise of voltage
and current, line transient surge, switching surges etc.
The converter shall be protected against following:

 Open circuit in hotel load winding;
 earth fault in AC input circuit;
 earth fault in 3-phase output, limits for earth fault detection shall be around 1Amp
(settable by software and to be fine tuned during field trials);
 converter phase fault, line to line short circuit due to dead short at load terminal;
 thermal over loading;
 high / low voltage in DC link;
 failures of power supply to control electronics;
 DC link short circuit;
 input over voltage / under voltage;
 input over current;
 single phasing in load;
 output over voltage and under voltage; and
 output over current.
The details of such protection shall be submitted by the Supplier for approval as part of Design
Package.
3.12 Indications
3.12.1 At driver’s desk a simple indication ‘LSHO’ shall be provided which will indicate the health of
the hotel load converter.
3.12.2 The following indications shall be provided on the hotel load converter:
 Main contactor stuck ON/OFF;

 input over current;
 input earth fault.
 input available;
Oct’11Aug’12 ‘0’_Ver’1’
 output available;
 converter healthy;
 converter faulty; and
 output earth fault.
3.13 Fault Diagnostic
The following messages shall be recorded in the memory of hotel load converter for the purpose
of fault diagnostic:
SN Fault Remarks
1. Input Fuse Failure In case the input fuse is blown due to high current drawn
2. Input Voltage High Input voltage exceeding upper limit
3. Input Voltage Low Input voltage drops below limit
4. DC Link / Input Current Excess current following in the DC Bus or input High
High current conditions persisting
5. DC Link Voltage High DC Link voltage exceeds upper limit
6. DC Link Low Voltage DC Link voltage drops below lower limit
7. Output Current High In case of output high current conditions persisting
8. Output Voltage High Output voltage exceeding upper limit
9. Output Voltage Low Output voltage drops below lower limit
10. Input Earth Fault In event of earth fault at input of the converter
11. Output Earth Fault In event of earth fault at output of the converter
12. Single Phase Fault Unbalance / single phasing at the output
13. Fault in cooling system Failure of blower/pump/radiator for cooling
14. Rectifier Fault In event of fault in Rectifier section
15. Inverter Fault In event of fault in Inverter section
16. Chopper Fault Chopper section faulty (if design includes chopper)
17. Over Temperature Any temperature sensing device operated in the
Rectifier and Inverter sections
18. Power Supply Fault In event of failure of any of the electronic/ control
power supply
19. Chopper Current High Chopper section current exceeds upper limit
(if design includes chopper)
20. No synchronization/ Communication fault in software
Communication Error
21 XXXXXXXX Any other faults to be specified in Design Package
3.14 Mechanical Dimensions and Weight
3.14.1 There is space constraint inside WAP4 locomotive. On board air compressors have been shifted
to under slung to create space inside machine room. There is some space available on roof and
some space in under frame, which shall be utilized for fitment of the hotel load converter. The
details of space envelops available are given in Annex-4. The Supplier shall ensure that the hotel
load converter along with all accessories shall fit in the space envelops specified in Annex-4. For
this purpose the Supplier shall verify these spaces in the locomotives before finalizing the design.
Oct’11Aug’12 ‘0’_Ver’1’
The weight of the hotel load converter and its accessories shall be specified separately in Design
Package.
3.14.2 A gap of at least 50 to 100 mm shall be maintained between roof and the converter in the machine
room of the locomotive and cooling system design shall be done accordingly. Similarly there
shall be sufficient gap to be maintained between cab wall and the hotel load converter for
maintainability purpose.
3.14.3 The enclosure for electronics shall be free from dust and moisture and shall be protected against
dust and water in accordance with IP54. The panel sheets used for fabrication should be of SST
grade 321 as per ASTM-A240 of minimum 3 mm thickness.
3.15 Cooling
Suitable and efficient cooling system shall be adopted keeping in view the location of hotel load
converter and space constraint inside the locomotive. CFD analysis indicating effectiveness of
cooling system shall be submitted as part of Design Package.
3.16 Safety
Indication of presence of high voltage ( voltage indicator ) shall be provided in each hotel load
converter cubicle for human safety.
3.17 Safety Factors
3.17.1 In the circuit configuration, 25% safety margin in the rating of both voltage and current under
worst conditions shall be ensured. This shall be established in the Design Package with
calculation.
3.17.2 A minimum thermal margin of 10ºC for junction temperature under worst operating condition for
the power devices shall be required. Over load margins and duration shall be furnished as part of
Design Package.
3.17.3 Current density of the bus bars shall be 4A / sq. mm.
3.17.4 Acoustic noise generated by circuits and components shall be less than 80 dB (A) at a distance of
1m from the equipment. The measurements shall be conducted in accordance with ISO 3381.
3.17.5 The electronic cards shall be provided with LED indication to show the health of cards, to assist
maintenance and operating personnel in trouble shooting.
3.17.6 The power portion of the hotel load converter shall be suitably protected to prevent accidental
contact. The shields and screens shall be properly earthed.
3.18 Marking
3.18.1 The major equipments/subassemblies shall bear marking and serial number. The
equipments/subassemblies shall contain serial number and make of manufacturer.
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3.18.2 All equipments / cubicles shall contain name plates of anodized aluminum with engraved /
punched letters.
3.18.3 The inverter rating plate shall be marked with the following information:
(i) Type / Make
(ii) Contract/purchase order number
(iii) Month and year of manufacture / batch no. / Serial no.
(iv) Rating
-- KVA
-- Input voltage range
-- Output voltage, frequency and wave shape
3.18.4 Cable
The use of wires / cables shall be reduced to minimum. Bus bars shall be of high grade copper,
insulated bus bar shall be preferable. The wires / cables shall be of high grade copper with
halogen free thin walled insulations. The insulation/sheathing material shall be fire survival
type according to EN 50264.All the cable terminations shall be made through crimped sockets
/ lugs. The circuit diagram shall be furnished in Design Package. Each cable / wire shall be
numbered at both ends for easy identification. The use of pre-insulated lugs suitable for double
crimp for insulation and conductor is recommended. Current collection through threads shall be
avoided and terminals of adequate size shall be provided.
Oct’11Aug’12 ‘0’_Ver’1’
Chapter 4
Scope of Supply
The following shall be scope of supply:
SL Item Description Quantity

No.
1. IGBT based hotel1load converter with its control system. 2 nos. per locomotive
2. Circuit in accordance
2 with Annex-3 and indication to driver in 01 set per locomotive
. accordance with Clause 3.11.1 of this Specification.
3. Interfacing of hotel load converter with power car as per RDSO Full ordered quantity
modification sheet No. RDSO/PE/MS/AC/0051-2011(Rev.0)
4. Portable data logging
3 and processing unit pre-loaded with Windows XP 01 no. per 5 locomotive
or later for downloading the software, viewing and changing the sets of converter or part
parameters, trouble shooting, in hotel load converter along with user thereof
license.
5. Testing and commissioning
8 of the above equipment 01 locomotive
6. Installation drawings
9 and installation manual (hard copy in A4 size 3 sets for full ordered
paper and soft copy both) in English language only Quantity.
7. Training 1 60 man days
1
8. Special tools and jigs
1 for maintenance. 01 set per 5 loco sets of
2 converter or part thereof.
9. Inter Vehicular 1Couplers (IVC) in accordance with specification 04 numbers per
4 number EDTS105-Rev.’E’ locomotive
10. UIC coupler 04 numbers per
locomotive
11. 3 Pole Output contactor
1 for Hotel Load converter (refer Clause 3.9 of 2 numbers per
5 this Specification) locomotive
12. Maintenance and 1operation manual in hard copy in A4 size paper and 1 set per 5 loco sets of
6 in English language only converter or part thereof.
13. Maintenance and 1operation manual (in English language only) in soft 1 set per 5 loco sets of
7 copy with suitable software to read and edit it converter or part thereof.
Lump sum
14. Any other additional items required for commissioning of the hotel Lump sum
load converters in the locomotives
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Chapter 5
Tests and Trials

Type Test
5.1 Prototype tests shall be performed on one unit (manufactured as per design) to verify that product to meet
the requirements specified and agreed upon between the Purchaser and the Supplier. Series manufacture
shall commence only after successful completion of prototype tests.
Type test shall be repeated in following cases.

 First time supply to IR;
 modification of equipment, which is likely to affect its function;
 failure or variations established during type or routine test; and
 at the time of indigenisation, if the Supplier has supplied the product with foreign collaboration
originally.
5.2 The hotel load converter shall be tested in accordance with IEC 61287 (including all optional tests) and
the control electronics shall be tested as per IEC 60571 [including the following optional test –
performance test (clause 10.2.2), dry heat test (clause 10.2.4 to be done at 80 C), damp heat cyclic test
(clause 10.2.5) , salt mist test ( clause 10.2.10)].
5.3 The list of tests (as per IEC 61287) to be carried out is as follows:
Sl. Clause no. Remarks

No Description
1. 4.5.3.2 Verification of Dimensions and Tolerances
2. 4.5.3.3 Weighing
3. 4.5.3.5 Cooling system performance tests
4. 4.5.3.5.3 Check of effectiveness of air filers Xa
5. 4.5.3.6 Tests of mechanical and electrical protection and
measuring equipment
6. 4.5.3.8 Test of the degree of protection Xa
7. 4.5.3.9 Commutation Test
8. 4.5.3.10 Acoustic Noise Measurement
9. 4.5.3.11 Temperature Rise Test
10. 4.5.3.12 Power loss determination
11. 4.5.3.13 Supply over voltage and transient energy
12. 4.5.3.14 Sudden variation of load Xa
13. 4.5.3.17 Partial Discharge Test Xa
14. 4.5.3.18 Safety Requirements
15. 4.5.3.19 Vibration and Shock
16. 4.5.3.20 Electromagnetic compatibility
17. 4.5.3.21 Step change of line voltage test
18. 4.5.3.22 Short-time supply interruption test
19. 4.5.3.23 Current-sharing Test Xa
a
X = The execution of the test is subject to agreement between the Supplier and the Purchaser.
Oct’11Aug’12 ‘0’_Ver’1’
5.4 The prototype units shall be inspected and tested jointly by the representative of CLW/ RDSO at the
manufacturer’s premises or at mutually decided venue where all the facilities shall be made available for
carrying out the prototype test. The first set of hotel load converter shall be kept in field trials for 50,000
Kms. The RDSO/ CLW engineers shall associate and witness the tests in the locomotive also till they are
successfully completed. Any defects noticed / design improvement found necessary as a result of the test /
trial shall be carried out by the Supplier in the least possible time. Serial production shall only start after
successful trial run on locomotive and clearance to this effect given by RDSO.
ROUTINE TEST
5.5 Routine tests shall be carried out to verify that properties of the product corresponding to those measured
during type tests. Routine test shall be carried out by the Supplier on each equipment.
5.6 The converter shall be routine tested in accordance with IEC 61287 (including all optional tests) and the
control electronics shall be tested as per IEC 60571 [including the following optional test –dry heat test
(Cl. 10.2.4 to be done at 80  C), damp heat cyclic test (Clause 10.2.5)].
5.7 The list of tests (as per IEC 61287) to be carried out is as follows:
Sl. Clause Description Remarks

No no.
1. 4.5.3.1 Visual Inspection
2. 4.5.3.4 Marking Inspection
3. 4.5.3.5.4 Leakage Test
4. 4.5.3.6 Tests of mechanical and electrical protection
and measuring equipment
4. 4.5.3.7 Light Load Test
5. 4.5.3.15 Insulation Resistance Test Xa
6. 4.5.3.16 Dielectric Test
Xa = The execution of the test is subject to agreement between the Supplier and the Purchaser.
Other points to be followed
5.8 The suppliers shall submit complete test programme for type and routine test to RDSO as part of Design
Package. The Supplier shall carry out the test as per mutually agreed test programme at his own cost.
5.9 Investigation tests are intended to obtain additional information regarding the performance of the product.
They shall be specially requested either by the Purchaser or the Supplier.
5.10 Authorised representative of IR may conduct surprise check on manufacturing process and quality control
along with any of the test to ensure quality of product and its conformance to specification.
5.11 Instrumentation
(a) All the instruments used for testing shall be duly calibrated. The calibration certificates shall be
shown to Inspecting Officer on demand.
Oct’11Aug’12 ‘0’_Ver’1’
(b) Value of the fundamental component and total Harmonic Distortion (THD) of hotel load converter
output shall be measured by power analyser during the prototype test at various mutually decided
preset points. True value of output voltage shall also be measured for record.
(c) Input power factor and the efficiency shall be measured using power analyzer at rated load.
5.12 Clarifications with respect to certain tests are given below
(a) Visual inspection –The objective of visual inspection is to check that the equipment is free from
defects and the equipment is as per approved drawing. Bill of materials shall be submitted as part of
Design Package. The make, rating of equipments, subassemblies shall be checked with the details as
per approved Design Package. If a change is needed in make or rating of important equipments, sub-
assemblies, it shall be intimated and shall have approval of RDSO. All the important dimensions shall
be measured and shall be in permissible tolerance.
(b) Power loss determination test – This test shall be done at voltage corresponding to 22 .5 kV in OHE.
The efficiency shall be measured at full and 80 % of load.
(c) Earth fault – Simulate the earth fault by connecting a suitable resistor between cubicle frame and
output phases. The hotel load converter shall not trip and earth fault indication shall be in “OFF” state
till the leakage current is less than limit approved as part of Design Package submitted by the
Supplier.
(d) Burn in test -- The electronic cards used on the equipment shall be subjected to burn-in 80 hours as
per the temperature cycle in Annex-5. The cards shall be kept energized during the test. Functional
test of each card shall be carried out after the burn in test. (please refer clause 10.2.13 of IEC 60571).
This shall be part of internal test by manufacturer, whose results shall be submitted during routine
test.
(e) Cooling test – The purpose of this test is to verify the cooling of various components / assemblies.
The parameters for measurement to check efficacy of cooling system shall be decided based on
scheme proposed as part of design proposal.
(f) Insulation resistance and dielectric test – The insulation resistance with 1000 V megger shall not be
less than 100 M ohms at 70 % RH for all the circuits. The dielectric test shall be carried out after
shorting semiconductor device, pulse transformer earthed, earthed special cards if necessary before
applying dielectric voltage. The level of dielectric voltage shall be as per IEC 61287.
(g) Temperature rise test –The hotel load converter shall be loaded to full load for 6 hours with input
voltage corresponding to cooling. The temperature rise shall be recorded by temperature detectors
mounted at the specified reference points on the body of semiconductors, capacitors, and other
components as agreed between the Purchaser and the Supplier. The maximum recorded temperature
under worst condition shall be corrected for 55 degree C and compared with maximum permissible
temperature (for power devices at junction). The thermal margin available shall be compared with the
safety margin declared by the manufacturer of the devices. The temperature of the power devices
shall have a margin of minimum 10 degree C.
h) Damp heat test – Functional test of each electronic card shall be carried out after the damp heat test.
Oct’11Aug’12 ‘0’_Ver’1’
Annex-1
Important Data of Transformer
SN Details Ratings
1.0 Rating of the transformer-
1.1 Primary 6670 KVA
296 A
22.5 kV
1.2 Secondary 5400 KVA
2 x2700 A
2x1000 V
1.3 Auxiliary 270 KVA
760 V or 830V
1.4 Hotel load 1000 kVA
1333.33 A
750 V, 50 Hz ± 3%
2.0 Percentage impedance
2.1 Main circuit 10%
2.2 Auxiliary circuit 3 % to 5%
2.3 Hotel load circuit 3 % to 5%
3.0 Magnetizing current 2.5 A
At 22.5 KV
Oct’11Aug’12 ‘0’_Ver’1’
Annex-2/1
Power Requirement With Different
Coach Combinations with HOG System
POWER
REQUIREM
EXISTING
COACH ENT AT 0.8
TYPE CONNECTED
COMBINATION DIVERSITY
LOAD(IN KW)*
FACTOR(IN
KW)
24 COACH AC-20, POWER CAR-
932 745.6
RAJDHANI 2, PANTRY-2
19 COACH AC-15,POWER CAR-2,
742 593.6
RAJDHANI PANTRY-2
12 COACH AC-9,POWER CAR-
440 352
SHATABADI 2,PANTRY-1
* Considered power factor for inductive load is 0.7.
The types of load in detail for each and every type of coaches are given below:
CONNECTED LOAD CALCULATION FOR LHB TYPE COACHES 1-AC

TOTAL
COMPONENT POWER
S.NO. QUANTITY CONNECTED LOAD
IN (WATTS) IN (WATTS)
1. ANTI-SKIDDEVICE 48 1 48
2. FAN
2.1 EXHAUST FAN 132 2 264
3. PANTRY EQUIPMENT
3.1 HOT CASE 1200 1 1200
3.2 BOTTLE COOLER/ 800 1 800
3.3 REFRIGERATION
4. SWITCH BD CABINET 500 1 500
5. COACH LIGHTING
5.1 LIGHTINGS 40 WATTS 40 9 360
5.2 LIGHINGS 20 WATTS
Oct’11Aug’12 ‘0’_Ver’1’
SINGLE COMT.+
VASTIBULE 20 17 340
+DOORWAY
5.3 READING LIGHT 10 24 240
TOILET OCCUPIED
5.4 16 4 64
LIGHT
5.5 LAV. LIGHT 16 4 64
6. AC SYSTEM
6.1 AC UNIT 13600 2 27200
6.2 CONTROL PANEL 140 1 140
7. SANITARY SYSTEM
WC CONTROL
7.1 40 4 160
SYSTEM (24 V)
7.2 WATER PUMP 220 1 220
7.3 MAGNETIC VALVES 8 6 48
ELECTRIC SHAVER
7.4 20 4 80
SOCKET
8. PA SYSTEM
LOUDSPEAKER
8.1 60 1 60
EQUIPMENTS
ELECTRIC CAR
9.
EQUIPMENTS
9.1 BATTERY CHARGER 6160 1 6160
37948
TOTAL LOAD 37.95 KW

S.NO. TOTAL
POWER CONNECTED LOAD
COMPONENT QUANTITY
(WATTS)
(WATTS)
1. ANTI-SKID DEVICE 48 1 48
2. FAN
Oct’11Aug’12 ‘0’_Ver’1’
3. PANTRY EQUIPMENT
3.1 HOT CASE 1200 1 1200
BOTTLE COOLER/
3.2 800 1 800
REFRIGERATION
4. SWITCH BD CABINET 500 1 500
5. COACH LIGHTING
SINGLE COMT.+
20 15 300
VASTIBULE +
5.3 READING LIGHT 10 52 520
TOILET OCCUPIED
5.4 16 4 64
LIGHT
5.5 LAV. LIGHT 16 4 64
6 AC SYSTEM
6.1 AC UNIT 13600 2 27200
7 SANITARY SYSTEM
WC CONTROL
7.1 40 4 160
SYSTEM(24 V)
7.2 WATER PUMP 220 1 220
ELECTRIC SHAVER
7.4 20 4 80
SOCKET
8 PA SYSTEM
LOUDSPEAKER
8.1 60 1 60
EQUIPMENTS
ELECTRIC CAR
9
EQUIPMENTS
TOTAL 38188
TOTAL 38.2 KW
Oct’11Aug’12 ‘0’_Ver’1’
TOTAL CONNECTED
POWER IN LOAD
S.NO. COMPONENT QTY
WATTS
IN (WATTS)
1 ANTI-SKID DEVICE 48 1 48
2 FAN
3 PANTRY EQUIPMENT
3.1 HOT CASE 1200 1 1200
3.2 BOTTLE COOLER/ 800 1 800
4 SWITCH BD CABINET 500 1 500
5 COACH LIGHTING
SINGLE COMT.+ VASTIBULE
5.3 20 10 200
+DOORWAY
5.4 TOILET OCCUPIED LIGHT 16 4 64
5.5 LAV. LIGHT 16 4 64
6 AC SYSTEM
6.1 AC UNIT 13600 2 27200
7 SANITARY SYSTEM
7.1 WC CONTROL SYSTEM(24 V) 40 4 160
7.2 WATER PUMP 220 1 220
7.4 ELECTRIC SHAVER SOCKET 20 4 80
8 PA SYSTEM
8.1 LOUDSPEAKER EQUIPMENTS 60 1 60
9 ELECTRIC CAR EQUIPMENTS
TOTAL IN WATTS 37568
TOTAL KW 37.57
Oct’11Aug’12 ‘0’_Ver’1’
CONNECTED LOAD CALCULATION FOR LHB TYPE PANTRY CAR (HOT

BUFFET)
3-PH 1-PH 1-PH DC/110
S.NO. COMPONENT POWER
AC/415 V AC/240V AC/110V V
IN QUANTITY
(WATTS) WATTS WATTS WATTS WATTS
ANTI-
1 48 1 0 0 0 48
SKIDDEVICE
2 FAN
2.1 EXHAUST FAN 132 2 264 0 0

PANTRY
3
EQUIPMENT
HOT CASE,FOR
3.1 1500 1 0 1500 0 0
140MEAL
BOTTLE
3.2 COOLER 90 200 1 0 200 0 0
LTRS
REFRIGERATOR
3.3 300 1 300
, 310LTRS
DEEP FREEZER,
3.4 400 1 400
230 LTRS
OVEN TOSTER
3.5 1200 2 2400
GRILL
WATER
3.6 3000 3 9000
BOILER-1,2 &3
ELECTRIC
3.7 2000 2 4000
BURNER-1
ELECTRIC
3.8 2000 2 4000
BURNER-2 & 3
ELECTRIC
3.9 5100 1 5100
BURNER-4
ELECTRICAL
3.10 CHIMNEY-1,2 & 300 3 900
3
3.11 INSECT KILLER 20 2 40
3.12 WATER FILTER 200 1 200

SUB TOTAL OF PANTRY
28040
EQUIPMENTS
SWITCH
4 BOARD 500 1 0 0 0 500
CABINET
COACH
5 0
LIGHTING
Oct’11Aug’12 ‘0’_Ver’1’
LIGHTINGS 40
5.1 40 9 0 0 360 360
WATTS
LIGHINGS 20
5.2 0
WATTS
SINGLE COMT.+
5.3 20 15 0 0 300
VASTIBULE +
5.4 DOORWAY 0
5.5 LAV. LIGHT 16 2 0 0 32 0

TOILET
5.6 OCCUPIED 16 2 0 0 0 32
LIGHT
6 AC SYSTEM
6.1 AC UNIT 13600 2 27200 0 0 0

CONTROL
6.2 140 1 0 0 0 140
PANEL
SANITARY
7
SYSTEM
WC CONTROL
7.1 40 2 0 0 0 80
SYSTEM(24 V)
7.2 WATER PUMP 220 1 220 0 0 0
MAGNETIC
7.3 8 6 0 0 0 48
VALVES
ELECTRIC
7.4 SHAVER 20 2 0 0 0 40
SOCKET
8 PA SYSTEM
LOUDSPEAKER
8.1 60 1 0 0 0 60
EQUIPMENTS
ELECTRIC CAR
9 0
EQUIPMENTS
BATTERY
9.1 6160 1 6160 0 0 0
CHARGER
SUB
33844 28040 392 1608
TOTAL
TOTAL Watts 62276
TOTAL (KW) 62.276
Oct’11Aug’12 ‘0’_Ver’1’
CONNECTED LOAD CALCULATION FOR LHB TYPE WORKING POWER CAR
S.NO. COMPONENT POWER TOTAL CONNECTED LOAD

QTY
(WATTS)
(WATTS)
1 ANTI-SKID DEVICE 48 1 48
2 FAN
3 SWITCH BOARD CABINET 800 1 800
4 COACH LIGHTING
4.1 LIGHINGS 20 WATTS 20 20 400
5 AC SYSTEM
5.1 AC UNIT 13600 1 13600
6 SANITARY SYSTEM
6.1 WC CONTROL SYSTEM(24 V) 40 2 80
6.2 WATER PUMP 220 1 220
6.4 ELECTRIC SHAVER SOCKET 20 3 60
7 PA SYSTEM
7.1 LOUDSPEAKER EQUIPMENTS 80 1 80
8 ELECTRIC CAR EQUIPMENTS
8.1 BATTERY CHARGER 110 V 6160 1 6160

8.2 BATTERY CHARGER 24 V 1987 1 1987
9 GENERATOR SET WITH
9.1 DIESEL ENGINE
9.2 ELECTRIC MOTOR DRIVEN 30000 2 60000
9.3 FAN FOR ENGINE RADIATOR
BLOWER FOR VENTILATION OF

9.4 3900 4 15600
GENERATOR ROOM
99463
TOTAL KW 99.46
Oct’11Aug’12 ‘0’_Ver’1’
Annex-3
Oct’11Aug’12 ‘0’_Ver’1’
Annex-4/1
A B C
Oct’11Aug’12 ‘0’_Ver’1’
Annex-4/2
A. Free Space after removing Compressor-1 and Compressor-2 in machine room.
1750 mm
1340 1560 mm (with non

650 600 mm Approximate height = modular loco duct)
1300 mm
1150 1100 mm
600 650 mm
B. Free Space for Contactor Panel between RSI panel and ATFEX transformer.
3680
ATFEX
RSI Panel 600 630 Approx.
height= 1450 Transformer
1650 mm
Oct’11Aug’12 ‘0’_Ver’1’
Annex-4/3
C. Free space on roof near pantograph
2055
Approx.
height= 650
350 (w)
350
Space in under slung
After shifting control reservoir (between TM3 and transformer), available free space is:
1350 mm
480 mm
Approx. Height = 700 mm
Oct’11Aug’12 ‘0’_Ver’1’
Annex-5
BURN-IN TEST
Tem perature
in Degrees Temperature Cycle
0
+70 C
+250C
00C
-250C
1.4 2.1 5.2 5.5 9.1 9.4 12.5 13.2 15
Time (Hrs)
0.1=10 Min
1.55 5.27 5.42 9,17 9.32 12.57 13.12 14.41
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Spec Hotel Load Conv P4 - Rev 0 - Aug 12

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GOVERNMENT OF INDIA

Specification No: RDSO/2011/EL/SPEC/0109_Ver’1’, Rev. ‘0’

Issued on: Oct’11Aug’12

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR LUCKNOW-226011

S.N. Date of Revision Page No. Revision Reasons for Revision

Definitions and Interpretations PAGE -

CHAPTER 1 General Description PAGE -

CHAPTER 2 Operating and Environmental Conditions PAGE -

CHAPTER 3 Technical Requirements PAGE -

CHAPTER 4 Scope of Supply PAGE -

CHAPTER 5 Tests PAGE -

Annex-1 Transformer details PAGE -

Annex-2 Hotel load details PAGE -

Annex-3 Loco circuit PAGE -

Annex-4 Space envelops PAGE -

Annex-5 Burn-in test

Abbreviation Full Name

BOM Bill Of Material

CFD Computational Fluid Dynamics

CLW Chittranjan Locomotive Works

Definitions and Interpretations

shall mean the person, firm or department nominated to inspect the

LHB shall mean coaches manufactured in accordance with design of

Purchaser shall mean the President of the Republic of India as represented by

1.2 Scope and Object

1.3 Supplier’s Responsibility

The Supplier’s responsibility shall be extended to the following:

1.5 Documentation and Design Approval

e) details of output contactor and output filter;

IR shall be responsible for followings:

a) The cabling required in the WAP4 locomotive;

1.7 Infringement of Patent Rights

1.8 Reference to various Standards

1.8.1 This Specification is based on the following normative references:

EN 60529 Protection classes of cases (IP-Code)

1.8.4 Alternative Standards

1.9 Reliability, Availability, Maintainability and Safety (RAMS)

Operating and Environmental Conditions

Nominal supply voltage 22.5 kV (rms), 50 Hz, single phase, AC

Normal variation in supply voltage 19 kV to 27.5 kV (rms)

Occasional maximum voltage 31 kV (rms)

Occasional minimum voltage 16.5 kV (rms)

Normal variation in frequency ± 8% (46 to 54 Hz)

Types of Neutral sections (i) 41 m in length having insulated over lap

(ii) Short neutral sections of approximately

There shall be power interruptions at neutral

Table 2 – Power supply system

2.2 Climatic and Environmental Conditions

 Atmospheric Maximum temperature (outside the locomotive): 50

Maximum touch temperature of metallic surface of the

Minimum temperature: - 10 degree celsius ( Also snow

 Solar radiation 1 kW/m2

 Humidity 100% saturation during rainy season

 Altitude 160 m above mean sea level

 Rain fall Very heavy in certain areas.

 Coastal area humid and salt laden atmosphere with maximum pH

 Vibration The vibration and shock levels recorded on various

 Electromagnetic High degree of electromagnetic pollution is anticipated

Table 3 – Climatic and environmental conditions

 Output Voltage phase to phase :750V ± 5%, 3Ø sine wave AC

 Direct on load starting of converter : 750A for 3 seconds

The converter shall be protected against following: