Page tof22 ‘| File No. ile | Specification No. RDSO/PE/SPEC — | | OS _|eti7.1.108rtransformer__| TL/0/0203-2020 (Rev.0) _ wena sen FRA ROR Ya Hare GOVERNMENT OF INDIA MINISTRY OFRAILWAYS. saat armed vd We Wst RESEARCH DESIGNS AND STANDARDS ORGANISATION anda ta S vaowaomto var F WM /ar Teh. / TeTASIST gaits alah Sara vd oe OR vd I OR $ Raa as Sfete A ggat eM are apa GRA vd tut decor gramrix a fafertte SPECIFICATION OF CONTROL TRANSFORMER AND MESASURING VOLTAGE TRASNFORMER FOR SWITCH BOARD CABINET OF LHB EOG/HOG TYPE AC /NON AC COACHES, LSLRD COACHES, POWERCAR AND PANTRY CAR OF INDIAN RAILWAYS SSL U.A. /HS. / TA / 0203 2020 (aferer1.0) Spec. No. RDSO/PEISPEC/AC/0203- 2020(Rev.0) S.No. | Date of Revision | : Reason amendment reps fet APPROVED vert onferdfreee /a er ws £ TH PEDIPS &EMU Prepared by Checked by |____ADE TEAC System Design} DSE(TL-AC System Design)| Page 2 of 22 File No. ‘Specification No. RDSO/PE/SPEC/ ] | EL/7.1.108/Transformer__| TL/D/0203-2020 (Rev.0) | x INDEX [Sr ] Clause no | Description | Page | No. No. [140 Forward aaa 3 < 2.0 Scope 3 | 3 | 3.0 ‘Scope of supply ae 3 4 [40 Operating and service conditions 4 5 [50 Relevant specification/Standards 5 6 [60 ‘Supplier's Responsibility S| 7 {70 Terminolog) s 5 8 [80 Technical requirements of Control Transformer 6 9 [9.0 Constructional Features 9 [0110.0 Inspection and testing 9 41 [10.7 Type Tests 410 12 Descriptions of tests ch 40.10 5) . a Marking and packing : 16 11.0 14_| 12.0 Technical Data to.be submitted 16 15 113.0 ‘Operating and Maintenance Manual 17 16 Guarantee/Warrantee, 17 14.0 7 Training and after sales service 7 15.0 Aa [18 | 16.0 Infringement of patent right 17 I 19 Cartel Formation 18 17.0 [20 | 18.0 ‘Annexures 8 21 (Annexure A | Bill of Material 19 | ‘Annexure B [Data sheet, 20 [Annexure C | Undertaking against Cartel Formation. 2 Prepared by ADE TLAC System Design) OS ‘Checked by DSE(TL-AC System Design) |~ [Page 3 of 22 |FileNo. a ] ‘Specification No. RDSOPE/SPEC] | | | EU7.1 108/Transformer _| TLID/O203-2020 (Rev.©) a 4.0 | FOREWORD: ‘This is required for providing Single Phase 418V AC power supply to operate the auxiliary coil of various contactors of Power car and various type ACINon AC anes. phase 3 wires supply is received through HOG compliant Electric Loco Gitte 3 phase 4 wire supply Is received through DA set in EOG system. Power wi or of feeder , Bus coupler and working Power car Non working Power Cot cofactors, LSLRD contactors, Feeder contactors of AC non AC ‘coaches are AC conrattore hence need the Single Phase 416V AC power supply to actuate their Senillary col, Single Phase 415V AC power supply is made by taking Pome supply ae as B phase of Power car/AC/Non AG coaches and this supply 's aIVeh 1 1 phase 750 V/4i5 V Control transformer. Secondary coll of this control transformer gives the desired Single Phase 418V AC power supply whieh is fed to auxiliary coil of above contactors. Measuring Voltage transformer are required at variants of Switch Board Cabinet for feeding 415 V AC supply to measuring instruments and meters of SBC for MSSBC AC coaches LSLRD AC/Non AC coaches and LHB AC Power caf. « 2.0 SCOPE: {Al The specification covers the design, manufacture, testySupPly requirements of following four types of Control transformer: a ia ‘Type | 500 VA, 750V/415V VAC, 1 phase, dry |For the LSLRD AC/Non AC 1 | type and air cooled Contraltransformer _['eoaches.—_— a Typell | 200 VA, 750V/415V VAG, 4 phase. dry |Fonthe SBC of Power cat Set of | type and air cooled Controltransformer.._| panel for Garibrath AC coaches | and MSSBC of Smart HOG AC mel N coaches. _ “i Type ii | 100 VA TSOVIATB'V AC, T phase, dry |For the Switch Board cabinet fo es typevand air cooled Control ransformer__| LHB HOG AC coaches. | ‘Type IV 400 VA, 750V/110 V AC, 1 phase, ‘dry | For the set of panels ‘of Non AC 7S _| type ané air-cooled Control ransformer_| HOG coaches | Type V 200 VA 750V/24 V AC, 1 phase control LHB AC Power Car. transformer for indication | Type VI “KVA 240V/110 V AC, 1 Phase Control__| For LHB Hot Buffet AC Coaches. | transformer J [8] The Specification covers the design, manufacture, test, supply requirements of fol two types of Measuring Voltage transformer: el Pe | Type Vil | 100.VA, 750/415V AC , 3 Phase 3 Wire| For the LSLRD AC/Non AC | | Delta/Delta Voltage +=» Measuring | coaches. and =MSSBC AC : Transformer. coaches Type Vill | 250 VA, 750/415 V AC , 3 Phase, 3 Wire | For LHB AC P =| ; 5 wel Delta/Detta Voltage Measuring ie | __| Transformer. 3,0 SCOPE OF SUPPLY: 3.1 The scope of supply of each transformer shi ll include anyone or combination of above transformers for variant of Switch Board Cabinet as per requirement of Electrical scheme . These shall com iply the specification inch per Annexure A of this specification, ‘ ge ae Prepared by € y = [ Che e ecked by ADE TEAC System Design) : Ds ISE(TL-AC System Design) |[Page 40f22 | File No. ~~} Specification No. RDSO/PE/SPEC/ i 4.0 44 5.0 54 Prepared by AD | e17.1.108/Transformer__| TL/D/0203-2020 (Rev.0) Soe All OPERATING & SERVICE CONDITIONS: ‘The transformer shall be sturdy and suitable for the following service conditions normally encountered on the Railway rolling stock, under climatic conditions existing throughout India. i) Ambient: 5 to +55 deg Celsius ii) Train speed (Max): 200 Kmph iii) Relative Humiity: Up to 98% during rainy season iv) Altitude: Max 1700 meter above sea level vy) Atmosphere: Extremely dusty, foggy, and desert terrain in certain areas. The dust concentration in air may reach at high value of 1.6mg/cubic meter vi) Rainfall Very heavy in certain areas: vil) 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: a. Maximum Ph value :8.5 b. Sulphate 7 mofitre ¢. Max.concentration _: 6imgflitreof chlorine d. Max. conductivity 130 micro Siemens/cm vi) Vibration: The equipment, system and theit mounting arrangement shall be designed to satisfactorily withstand the vibration and shocks encountered in service as specified below: (a) Maximum vertical acceleration 30g) (b) Maximum lateral acceleration 309 (c) Maximum longitudinal acceleration 50g ((g! being the value of acceleration due to gravity) RELEVANT SPECIFICATIONS/STANDARDS Reference shall be made to following standard / specifications control gear for voltages not exceeding 1000 V AC 1s 12021 } Specification for Control transformers for switchgear and | measures in passenger carrying rallway vehicles or assimilated vehicles used on international service TEC-61373 Railway applications-Rolling stock equipment-shock and soph __| vibration tests _ es “1S: 1363-84 (Part il) _| Hex. Hd. Sorews (M5-M36) 1S: 649-1997 Method of testing steel sheets for magnet | power electrical apparatus : Stainless steel plate, sheet and strips. Checked by 1S3156(Part 2) Voltage Transformers-Specification. _| 1S: 12730, Pt 13-93 | “Part 13, Polyester or polyesterimide over coated with ie | polymide enameled round copper wire, Class 200, 1S: 30241997 ‘Specification for electrical steel sheet (oriented). CRGO. | 1S. 1885 (Pt. Electro-technical vocabulary for transformers | ON ee ee ne 1S: 1271-85 Thermal evaluation and classification of electrical | Ss insulation. ess meslegetal UIC 564-2 Regulation relating to fire protection and fire fighting “AC System Design) DSE(TL-AC System Design) || Page 5 of 22 | File No. 7 Specification No. RDSO/PE/SPEC/ —| 52 6.0 61 62 63 64 65 66 7.0 7A 72 |EL/7.1.108/Transformer __| TL/D/0203-2020 (Rev.0) | [is:9676.___—_| Temperature rise Test of transformer ] Not Latest editions/version of the above specification / standards shall be applicable and shall be available with the firm before commencement of the prototype testing. ‘Any deviation from this specification proposed by the firm to improve upon the performance, utility and efficiency of the transformer shall be given due consideration, provided full particulars of the deviations with justification are furnished. In case of any contradiction between the provisions of above standards, the details mentioned in this specification shall prevail SUPPLIER'S RESPONSIBILITY: ‘The transformer shall be suitable for rugged service conditions normally to be met within Railway Rolling Stock, where coaches are expected to run up to a maximum speed of 200 kmph in varying climatic conditions existing throughout India, as mentioned in clause 4.0 of this specification “The supplier shall be fully responsible for ensuring that all equipments 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 respectsIn addition, itis the suppliers responsibilty to underwrite the complete design and ensure that it's compatible with ‘and will, in no way, compromise the design and performance of transformer of his supply. ‘The supplier shall provide “In the field” Service support during the guarantee period. The supplier shall supply any purpose built or special tools or equipment that may be necessary for the correct operation, servicing, testing or installation of the transformer. The supplier shall provide assistance, both material and technical, in the installation of the system as a whole to ensure that when it is installed as part of the integrated vehicle. system, the performance of the transformer meets or exceeds the requirements specified. If the transformer fail to achieve the requirements, then it shall be modified at the suppliers expense and within a time scale to be agreed with purchaser/consignee/RDSO. TERMINOLOGY: For the purpose of this standard, the definition as given in IS: 1885 (Pt. XXXVIIl) (Electro-technical vocabulary for transformers) shall apply. HOG] Head on Generation System of Indian Railways. | End On Generation system of Indian Railways Non Air condi ac LSLRD coach | LHB type Self luggage Rake for Disabled RDSO [_ Research Design Standards Organisation SBC Switch Board Cabinet oes by Gi Checked by aa ADE TEAC System Design) DSE(TL-AC System Design) |[Pageéof22 | File No. Specification No. RDSO/PE/SPEC! : | EU/7-1-1osrTransformer | TLID(0203-2020 (Rev 9) 5 ; e ‘Microprocessor Based Smart Switch Board cabinet oe [indian Standards pee: 8.0 TECHNICAL REQUIREMENTS OF CONTROL TRANSFORMER: 8.1. The technical requirement of the control transformer shall be as under: [sn | eam EL [TYPE [TYPEEM | TYPEIV | TYPE [ate |v wi sod 1 Rating 500 VA 200VA 100 VA. 100 VA | 200 VA 1000 | VA | 2 Number of 1 phase 1 phase 1 phase, | 1 phase 4 1 | phases cs 2 phase _| phase 3 Rated Primary 1Phase, 1Phase, 1Phase, 1Phase, 1Phase | 1Phase voltage 7soVe \750Ve | 750V 25% | 750 Vit. 5% |, 750v |, 240 | 59% (line to | 5% (line tox) (line to line), | (inet line) | + 5% + 5% line), S0HZ | line), SH | 60Hz 23% | SOHz #39 ) (line to (Line to EB%AC, | #3%AC, PAC, THD | AC, THD pine), Neutral | THD THD <10% <10% 50Hz |), 50HZ | <10% <10% : 23% | 23% BG AS, THD THD <10% <10% | 4 Rated 415V AC | 415 VAC. 415 VAC 110 VAC 24V 110 V- | ‘Secondary Ac Ac voltage 5 __| Frequency S0HZ SOHZ a | 50Hz 50H2 SOHZ | 50HZ | Sei eat dena [Less than_| Less than | Less than [Less than [Less | Less of conductor | 26A1 26A/ 268A! 2.6A/ than | than | Primary, soMM | SQMM) | SQMM SQM 2.6A/ | 2.6A/ a __|samm_| Samm | 3 Current density | Less than Less than | Less than Less than Less Less | of conductor | 2.6A/ 2.641 2.641 2.6A! than | than ‘Secondary sQum ‘SQMM sQvM SQMM 2.6A/ 2.6A1 «vay SQMM | SQMM | 3 | Waterial& grade |CRGO& |CRGO& |CRGO& |CRGO& | CRGO | CRGO | M27 M27 M27 27 aor |ama7 | 9 | Thickness of [0.27103 [0.27103 [0.27103 — | 0.271.03 0.2710 [0.2710 core lamination 3 3 10 | Fluxdensity of | 1.47 14T 14T T4T 147 [147 | core maximum | maximum | maximum | maximum | maximu | maximu m m | 1 Clase ot s CLASSH |CLASSH |CLASSH | CLASSH | CLASS [CLASS | # | Winding n iE 12 | Insulation >50 >50 >50 >50 >50 =50igs | Resistance MEGAOH | MEGAOH | MEGAOHM | MEGAOHM | MEGA | MEGA Prepared by Se ‘Checked by S ADE TL-AC System Design) __DSE(TL-AC System Design|| Page 7 of 22 File No. ‘Specification No. RDSO/PE/SPEC/ = EL/7.1.108/Transformer__| TL/D/0203-2020 (Rev.0) | | iM M OHM [OHM | 143} Temperature | <118Deg |=115Deg | <115 Deg C rT rise of Winding | C cS DegC |Degc | by resistance | method 1 4a [Temperature |75DegC | 75DegC | 75 Deg 75 Deg | 75Deg | rise of Terminals | Maximum | Maximum | Maximum c c | by thermometer Maximu | Maximu method ts al m m_ 16 No load loss at | Max 15 Max 11 Max 6 Max 11 | Max 15 rated voltage | Watts Watts Watts Watts | Watts and frequency 16 | Load loss at Max 16 | Max 11 Max 10 Max 17 | Max 16 | rated current at | Watts Watts Watts, Watts: Watts | 75 deg.C | T7 | Efciency atfull |>90% | >90% | 289% 380% | >90% load at 75 deg.C [48 | Efficiency at 389% | >90% 289% 590% |>90% three forth load at 75 deg.C [= * = 49 | Noload current | Less than | Lessithan | Less than Less [Less | at rated voltage | 10% of | 10% of ).10% of than | than & Frequency rated rated rated 10% of | 10% of | current current ‘current rated rated current _| current 20 | Crimping 7.5 SQMM | 1.5 SQMM | 7.5 SQMM 15 15 socket's make & saqmm | SQMM size 21 | Heat shrinkable | 4MIM NM MM avm_— | 4M sleeve. TUBE | TUBE | TUBE TuBE | TUBE 22 | Length Max 160 | Max 130 |Max115 Max Max | mm mm mm 130 170 i mm__| mm 23 | Width Max 150 | Max 130 | Max 110 Max | Max mm mm mm 130 150 tt mm___| mm 24 | Height Max 180 | Max 130 | Max 130 Max 130 Max Max | mm mm. mm 130 | 185 = mm. Weight 10 kg max | 6.5 kg 4.5 kg max 6.5 ke eae [25 me g 9 max _| max _ 8.2 The technical requirement of the Measuring Voltage Transformer shall be as under:- TYPE Vil 100 VA Prepared by Or a Checked by Ll _ADE FERC System Design) | ___—=—=———_—DSE(TL-AC System Design) _|Page 6 of 22 | File No. a Specification No. RDSOIPE/SPEC/ | | | EL/7.1.108/Transformer | TL/D/0203-2020 (Rev.0) ol 2 ‘Accuracy Class 1%, a ee 2 Number of phases ‘3 phase | 3 phase 4 ~~ | Rated Primary voltage 3 Phase, 750 V+ 3 Phase, 750 V = 5% (line to line), 5% (line to line), 5OHz 43% AC, THD | 50Hz 23% AC, <10% ___| THD <10% 5 Rated Secondary voltage | 415V AC 415V AC \6 ____| Frequency _ ‘SOHz ‘50HZ 7 Material & grade of core | CRGO & M27 CRGO & M27 = Thickness of core 0.27/.03 0.27/.03 lamination a= Class of insulation of SS H CLASS H ee Winding __ si - | (10 Insulation Resistance 350 MEGAOHM | >50 MEGAOHM "1 Temperature rise of <115 Deg © 115 Deg C Winding by resistance zi ___| method : sil 12 Temperature rise of 75 Deg C Maximum | 75 DegC Terminals by thermometer Maximum ss ten | Met ode een res eee isl odessa 13 No load loss at rated, Max 6 Watts Max 11 Watts voltage and frequency 4 Load loss at rated current | Max 10 Watts Max 17 Watts at 75 deg.C 15 Efficiency at full load at 75 | >90 % >90 % . deg. S 16 Efficiency at three forth 290 % 790 % | load at 75 deg. C 7 Noload current atrated | Less than 10% of | Less than 10% of voltage & Frequency. rated current rated current 18 Begone ages me? & /1.5SQMM 1.5 SOMM si 19 Heal shrinkable sleeve. | 4MM TUBE 4MM_ TUBE 20 Length Max 115 mm Max 130 mm 24 | Width. [Maxt10mm | Max 730 mm __ 22 __ Height Max 130 mm Max 130 mm 23 | Weight 6 kg max 8.5 kg max _ 9.0 CONSTRUCTIONAL FEATURES: 9.1 Over all dimensions, construction and mounting of the control transformer shall confirm to RDSO drawing no. RDSO/PE/SK/AC/0223-2020 (Rev-0) Sheet 1 to Sheet 6 with latest alteration, 9.2 Over all dimensions, construction and mounting of the Voltage transformer shall confirm to RDSO drawing no. RDSO/PE/SK/AC/0223-2020 (Rev-0) Sheet 7 to Sheet 8 with latest alteration. Prepared by = Checked by ets ystem Design) DSE(TL-AC System Design)93 94 95 96 97 98 99 9.10 944 10.0 10.1 10.2 [Page 9 of 22 | File No. | Specification No. RDSO/PE/SPECT =| | EL/7.1.108/Transformer _| TUDI0203-2020 (Rev.0) _ ‘The manufacturer shall take prior approval of the manufacturing drawing from RDSO before developing prototype of the transformer. Material of the core shall be of CRGO as per |S: 3024 of 0.27/0.3 mm thickness. Firm wii salemit a test certificate complying with 1S: 3024-1997 (latest version) from NABL accredited laboratory. ‘The lamination structure shall be interleaved, Complete primary & secondary windings shall_be done with polyester or polyesterimide over coated with polyamide enameled round copper wie, class 200 as per iS: 13730 pt. 13. Winding wire shall be got tested from.any NABL recognized laboratory in addition to OEM test certificate. Over both primary and secondary winding 'H’ class varnish impregnation shall be routed to protect winding trom effect of moisture, dif and also impact of mechanical Stress. Impregnation shall be done by vacuumypressure impregnation method. ‘H’ class insulating material shall only be used in manufacturing of transformer. Core & winding and primary & secondary winding shall be separated by insulated separator made up of SRBGF material confirming tollS: 10192-1992 withEPS grade The separator provided shall not be loose, so as not te fall during service, The cable ends shall be provided!with suitable sizeof crimping socket. Crimping socketlug shall be duly crimpad and fire-retardant heat, shrinkable sleeve over lug shall be provided. Crimping socket shall only be used Hardware used for clamping of core and mounting arrangement of complete assembly ‘shall be of high tensile steel only. All the matefial used in the equipment shall be fire retardant and shall fulfill the requirement of UIC-864-2 INSPECTION AND TESTING: ‘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 additionaltests other than specified herein are required to be conducted on the prototype unit or its components, they shall be done expeditiously. During the process of manufacture of the equipment, if the purchaser so desires, he may conductirepeat any of the routine or additional tests to satisfy himself that the quality of the product being manufactured is of the required standards. The type tests shall be carried out by RDSO representative on prototyp ithe prototype unit either totally or in part under the following conditions without any additional cost (@) A manufacturer undertakes to manufacture for the first time as per this specification. (b) An important change in design details of machine has been introduced (c) Specification is modified necessitating the re-designing of equipment. (d) Unsatisfactory performance reported from user Railways. (e) Resumption of production after an interruption of more than two years [ Prepared by Th | Checked by l vies * ADE yystem Design) | DSE(TL-AC System Design)10.3 10.4 105 106 10.7 10.7.1 10.8 10.8.1 10.9 10.9.1 @|fileNo. ~—T Specification t No. RDSOIPEISPEC! — F114 108Transformer __| TL/DI0203-2020 (Rev yams 1 (f) All existing Control transformer/Measuring Voltage transformer manufacture appearing in BOM also have to undergone the prototype test. As per this specification. Investigation tests are intended to obtain additional information regarding performance of the production. They shall De specially requested either by the user or by the manufacturer. ROSO may conduct surprise check on manufacturing prone and quality control Tong with any of the tests to ensure quality of product and ts conformance to RDSO specification. ‘The suitability of the transformer shall be ascertained by inspect en bench test at the firm's works, in the stationary coach and during service ‘of the unit on the coach. Because of inevitable difference in basic material and variation manufacture, as eee easurement error, the value obtainedion test may differ fom the calculated we oe ty tolerances on guaranteed value necessary, The table 7 to 1S: 2026 (pt. |) gives tolerances to be applied to certain rated quantiies when they are the subject to Bee etiurer guarantees referring in (Si 2026 (Pt..)),where the tolerance in one rection is omitted, there is no restriction on the value in the direction. ‘The transformer shall be considered as complying with the standard when the quantities subject to tolerances arejnot cut side the folerances given in table 7 to IS: 2026 (Pt. |) ‘Test format for recording of test results during|Foutine & acceptance test shall be available with the firm. Type test: INI the type testsimentioned jmGlause 10.10.1 shall be carried on a protolyee unit he ter, manufacturing for the first time shall get prototype approved from RDSO. poréle offering the prototype for type testing, firm will submit internal test results fdiong with drawings of transformer indicating over all, mounting, thickness of Sheet/channel & other important dimensions to RDSO for approval Acceptance Test: Acceptance tests mentioned in clause 10.10.1 shall be carried out by an inspecting authority nominated by the purchaser at the works of the manufacturer on the ‘sample picked up as per sampling plan by the inspecting authority Routine test: Routine tests mentioned in Clause 10.10.1 shall be carried out on each unit by the manufacturer at his premises to ensure compliance with the specification and canst, ies test results shall be produced before Indian Railway representative, if demande i All the tests shall be carried out at firm's premises at manufact jurer’s cost. Inspectin: officer shall witness the tests on each unit. A copy of these internal tests ceca by the firm shall be supplied to the inspecting/purchasing authority. Not withstanding Checked by ADE-TLAG System Design) DSE(TL-AC System Design)[Page 11 of 22 File No. ~ | Specification No. RDSOPEISPECT | | | EL/7.1.108/Transformer | TLID/0203-2020 (Rev.0) above, RDSO reserves the right to have these equipments also tested as per this specification at any reputed test house in India at firm's cost. 10.10 Tests desc ion: 40.10.1 Test mentioned in table below shall be carried out on Control transformer as per respective clause by RDSO or NABL accredited Lab: - [SN ] Description [Type | Routine | Acceptance | Remarks test__|test__| test al 7, | Visual inspection and Yes | Yes Yes Clause 10.12 dimensional checks. 3 Sees || Verification ofterminal | Yes |Yes | ves Clause 10.13 | markings y Z| Measurement of winding [Yes [Yes @[¥es Clause 10.14 resistance &_| Measurement of Yes |Yes | Yes Clause 10.15 Dielectric properties = = “5, | Measurement of Yes’ | Yes Yes ‘Clause 10. insulation resistance sf a) S|} Measurement ofnoload | Yes | Yes | |'Yes Clause 10.17 |__| current [7 Secondary voltage test_|Ves__| Ves __| Wes Clause 10.18 | 8, | Measurement of Yes Yes | Yes Clause 10.19 impedance voltage aI 9, [Measurementofweight |Yes Yes _}.Yes_ Ciause 8.1(25) 10 | Voltage regulationtest | Yes |Yes | Yes Clause 10.20 |_| max 49% 41 | Temperature rise test. | Yes | - Clause 10.21 72, | Cyclic on/off test 1000 | Yes |= = Clause 10.22 operations = 43, | Vibration and Shock test _| Yes _| ~ = Clause 10.23 [14- | Short circuit test | Yes_ ee Clause 10.24 | * Dliring acceptance test, temperature rise test shall be carried out on 1 sample for @ lot size up to 20 and subsequent sampling shall be done @ 1 for every 20 or part thereof of entire lot offered for inspection for temperature rise test 40.10.2 Test mentioned in table below shall be carried out on Measuring Voltage transformer as per respective clause by RDSO or NABL accredited Lab: - 4,_| Measurement of [Yes [Yes Yes “Clause 10.15 | Prepared by Checked by a = ADI “AC System Design) DSE(TL-AC System Design) SN | Description Type | Routine | Acceptance | Remarks test_|test__| test 4. | Visual inspection and Yes | Yes Yes Clause 10.12 |__| dimensional checks | 2. | Verification of terminal | Yes | Yes | Yes Clause 1073] markings. [ 3, | Measurement of winding | Yes | Yes ‘Yes Clause 10.14 resistance | || File No. [Page 12 of 22 | eL/7.1.108/Transformer | 111010203-2020 (Rev.0) Specification No. RDSO/PE/SPEC/ \ =} ae — 3 Dielectric properties Fa pene ese ee 5 acetone eS Yes “| Clause 10.16 | insulation resistance \ | | Measurement of noload | Yes |Yes | Clause 10.17 sit \ current levies | 7, | Secondary voltage test__| Yes Yes Clause 10.18 | {. [Measurement of Yes Yes | Yes [Clause 10.19 | |__| impedance voltage ___| —__ | SacBee 9 weight_| Yes | Clause 6.223) _ 40 | Voltage regulation test | Yes Cause 10.20 | max 4% \ T1_| Temperature rise test Yes | Clause 10.21 [42, | Gyclie onfoff test 1000 | Yes | - = Clause 10.22 | operations __ oa ais meas [713._| Vibration and Shock test Yes Clause 10.23 44. | Short circuit test Yes |= [= Clause 10.24 15 | Acuuracy Test Yes laves”_| Yes Clause 10.25 | * During acceptance test, temperature rise test shall bélcarried out on 4 Sample for a lot size up to 20 and suk 40.103 Performance tests which has tobe veri _ vibration tests on Control Transformer | Visual inspection sequent sampling shall thereof of entire lot offered for inspection for temperature rise test re as under: ibe done @ 1 for every 20 or pat fied/compared after completion of shock & 1 [2 Meas urementiof winding resistence 3.__| Dielectric Test 3 4. | Measurement of insulation resistance al é 5. ‘Measurement of no load ‘current, 40.10.4 Performance tests whieh has to be ‘Verified/compared after completion ‘of shock & Vibration tests on Measuring Voltage Transformer are as under. __ Visual inspection ff (2. | Accuracy Test 33... | Measurement. of winding resistance 4, | Dielectric Test ss + Measurement of insulation resis Commissioning tests: 40.14 10.11.1 The supplier will associate during commiss 10.12 Visual Examination Test: sioning of their initial few transformers. 40.12.1 Overall dimensions and mounting arrangements shall be verified as per the approved drawings. constructional detail sh during the test: a) Dimension and Weight verification. The dimensions of assem blies and sub-assemblies and all be checked to ensure that these are consistent with sound engineering practices. In addition to the al bove, the following shall also be verified Prepared by Oo 7 ADE-TL-AC System Design) “Checked by DSE(TL-AC System Design)[Page 130f22 | File NO ] Specification No. RDSO/PE/SPEC/ te [EL/7.1.108/Transformer TL/D/0203-2020 (Rev.0) _ b) _Billof material ete. as per approved RDSO design document ¢) Terminal arrangement as per approved drawings. 2) Provision of metric fasteners & its tightens e) Marking plate. f) Size and type of crimping sockets. ) _Earthing terminals. f) Invoice’ Purchase bill and Test certificates of raw materials from approved sources as per annexure-A of RDSO specification 1) Test cerificates for core stampings and winding wire strips from Government approved /NABL accredited laboratory, 10.13. Verification of terminal markings. Terminal marking shall be verified in conformity to clause NO11 of this specification. 10.14 Measurement of winding resistance ‘The resistance of both windings shall be measured at room temperature across their respective terminals with direct current. Care shall be taken during the measurement, temperature of the windings should not be affected Corrected values (at 75 Deg C) of cold winding resistance recorded during acceptance test shall be compared with the corrected values (at 75 Deg C) recorded and approved during prototype testing, Variation in corrected cold winding resistance Shall not exceed 10% in accordancelto, clause 10.82 of IEC 60310 subject to temperature rise not exceeding 115 Deg C. Resistance is to be measured between each terminal and neutral of secondary winding with Micro ohm meter with range 2 milli ohm to 500 milli ohm. Measured Value at ambient temperature shall be corrected at 75 Deg C by using formula given below: - Corrected resistance R28R1 x (235+75)/(235+T 1) milli ohm: Ri = Cold resistance of winding measured in mill ohm at ambient temperature T1 Deg C Ti= Ambient temperature in Deg C. R2= Corrected cold resistance in milli ohm at 75 Deg C. 10.15 Dielectric test The dielectric tests shall be conducted on transformer completely assembled as in service, at ambient temperature. Each winding of the transformer shall be subjected to a high voltage value of 6.2 KV (RMS) at 50 Hz for one minute. This test shall be conducted after the temperature rise test 10.16 Measurement of insulation resistance ‘The insulation resistance of each winding to other winding, core, frame and earth shall be measured at 1000 V DC. It shall not be less than 50 Mega ohms. This test shall be carried out after Di-electric test. 10.17 Measurement of no load current Prepared by yi ~ | Checked by SaETE.|| L AD System Design) | DSE(TL-AC System Design) _[Page 14 of 22 File No. ~~ | Specification No. RDSO/PE/SPEC/ EL/7.1.108/Transformer__| TL/D/0203-2020 (Rev.0) The no load current shall not exceed more than 10 percent at rated voltage. The no load current in the primary winding shall be measured and recorded at the regulated frequency at the rated voltage and 120 percent of the rated voltage. The secondary winding shall be left open. The variation in the current measured at 120 percent of the rated voltage shall not exceed by more than 20 percent of the deciared value at that voltage. 10.18 Secondary voltage test 10.18.1 No Load Secondary Voltage Test The primary winding shall be applied rated primary voltage 750 V AC at the rated frequency §0 Hz. The secondary winding terminal shall be left open-circuited, The value of the secondary voltage reading shall be compared with the rated secondary voltage. The secondary terminal voltage at the.open circuit shall not exceed 105 percent of the rated secondary voltage when the rated primary voltage is applied across the terminals of the primary winding, 10.18.2 Rated Secondary Voltage Test The primary winding shall be-applied rated primary voltage 750 V AC at the rated frequency 50 Hz. The secondary winding shall be connected to the rated burden. The value of the secondary voltage reading shall be measured and recorded. The secondary voltage reading shall be compared with the rated secondary voltage. The variation in the reading shall be within +/- 5 percentof the declared value. 10.18.3 Short Time Secondary Voltage Test The primary winding shall be applied rated primary voltage 750 V AC at the rated frequency 50 Hz, The secondary winding terminal shall be connected to the rated short time burden at a specified power factor 0.7 to 0.8. The value of the secondary voltage reading shall be measured and recorded. The secondary voltage reading shall be compared with the rated secondary voltage. The secondary terminal voltage at the open circuit shall not be less than 95 percent of the rated secondary voltage when the rated primary voltage is applied across the terminals of the primary winding 10.19 Measurement of impedance voltage Impedance voltage shall be measured at rated frequency by applying voltage to one winding, with other winding short circuited. The measurement may be made at any current corresponding to a value between 25 percent and 100 percent of the rated output The measured value of this voltage shall be corrected by increasing it in ratio of rated current to the test current and shall be expressed as percentage of the rated voltage of the corresponding winding For the purpose of routine tests, the corrected values shall not exceed the value obtained for the transformer subjected to the type test. 10.20 Voltage Regulation Test Voltage regulation of control transformer should not be more than 4%. Control transformer should be capable to supply high current during picking of used [reese by oe ig Checked by ADE TL-AC System Design) DSE(TL-AC System Dé[Page 15 of 22 | File No. Specification No. RDSO/PE/SPEC) iS EL/7.1.108/Transformer___ TL/D/0203-2020 (Rev.0)____ felay/contactor. The power rating of control transformer should not be less than 180% of the connected contactors coil burden. 10.21 Temperature rise test Primary winding terminals shall be applied 110 percent of the rated primary voltage at the rated frequency and the rated burden shall be connected across the secondary winding terminals. Final steady temperature shall be measured and recorded subjected to the following: - a) Ambient condition shall not be more severe than 50 Deg C. b) The transformer shall be considered to have attained a steady state temperature when the rate of temperature rise does:not exceed 1 Deg C per hour. ©) The temperature rise of the winding shall beMeasured by the increase in resistance method, The temperature rise of the core, frame and other parts Where accessible may be measured by thermometers or thermocouples. Method of temperature rise are given in IS : 9678, d) The temperature rise shall not exceed 115 Deg C 10.22 Cyclic on/off test Control transformer used in switch board cabinet shall be tested for 500 ‘ON’ and ‘OFF’ operation of power contactors simultaneous connected with one control transformer at ambient temperature of 70°C. Half ‘Operations shall be performed on 415-20% and remaining operation shallbe performed.on 415+10% rated supply received from PWM inverter. During the testing, power contactor shall be remain in no load condition, The rating of control transformer shall be adequate to supply control coil of all approved make power contactor as mentioned in BOM. 10.23 Vibration & Shock tests Vibration & Shock tests shall be got earried out by the manufacturer from NABL approved recognized laboratory a8 per IEC 61373 under the category 1 class B, Location Das given in figure B.1 to above IEC. Test severity and frequency range for functional random vibration tests shall be as per clause 8.1 of above IEC; however, the frequency range from 5 Hz to 70 Hz may be accepted til the facilities for frequency range from § Hz to 150 Hz at NABL accredited lab is developed. Table 1, 2 &3 and figure 2 &6 of IEC-61373 shall be followed for the test conditions. After completion of the test, the performance test as given in clause 10,10.2 to this specification shall be repeated. The value of the test results should fall within the tolerance limit specified in 1S: 2026 (Pt-1) when compared with the test results carried out before shock & vibration tests. 10.24 Short circuit test At the beginning of the short circuit test the average temperature of the winding shall be below 50 Deg C The primary of control transformer shall be applied at the rated primary voltage at the rated frequency. The prospective short circuit current at the point of connection Checked by DSE(TL-AC System Design)Page 10.25 11.0 12.0 12.4 122 123 12.4 16022 |FileNo. Specification No. ROSO/PE/SPECT | EL/7.1.108/Transformer__| TL/D/0203-2020 (Rev.0) | to the supply terminals of the transformer shall be at least ten times the full load current at the rated output A protective device indicated by the RDSO shall be incorporated in the primary winding circuit. The secondary terminal shall be shorted with negligible impedance The duration of test shall be maximum 1 second. The transformer shall be deemed to have withstand the short circuit test if the following conditions are satisfied: - @) No physical deformations shall have occurred: and 5) The transformer shall ass routine test as specified in clause 10. 10.1 Accuracy test To prove compliance of the measuring voltage transformer with limits of voltage error and phase displacement , the test shall be made at80 percent ,100 percent and 120 percent of rated voltage at rated frequency and at 25 percent and 100 percent of rated burden. Primary shall be energized by tated voltage and rated burden of appropriate value shall be connected to the secondary terminals For acceptance and routine test accliracy test may:be carried out atfated voltage and at 25 percent and 100 percent of rated burden’at power factor of 0.8 lagging MARKING: Control transformer shall be marked indelibly with the following data. The marking shall be on the transformer name plate permanently attached to the equipment and shall be located in place where it is visible and legible after the transformer is installed. i) Manufacturers name and trade mark i) Serial number iit) Year and month of manufacture iv) _...Capacity/Rating output in VA and Vector symbol y) Primary & Secondary voltage & current and Frequency vi) Class of Insulation vil) Specification No. TECHNICAL DATA TO BE SUBMITTED: The technical information as per Annexure B “Data sheet” complete in all respect should be furnished before development of prototype. 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 manufacturer shall submit complete design details along with necessary calculation. ‘The manufacturer shall also supply following approved drawings in CAD software and hard copy’ Prepared by Qe Checked by s, ADE TL-AC System Design) ___DSE(TL-AC System Design)Page 17 of 22 File No ______| Specification No. RDSO/PE/SPEC? | | EU/7.1.108/Transformer | TLID/0203-2020 (Rev.0) J 1, Layout drawing/Dimensional drawings showing the important dimensions of transformer showing locations of various components. Structural frame drawing showing size of various sections used & gauge of stainless steel sheet provided, Drawings of mounting details. Operating and Maintenance Instructions One set of Operating and trouble shooting manual will be supplied with each transformer. oAw ON 13.0 OPERATING AND MAINTENANCE MANUAL. 13.1. The general maintenance requirement for the transformer should be of cleaning of parts and blowing of dust etc. from it, Howeverthe firm will submit the recommendations on maintenance requirement of transformer, which should contain Periodicity, work content and justification for each maintenance requirement. 14.0 GUARANTEE/WARRANTY Guarantee/Warranty obligation of the complete Switch Board shall’be as per IRS condition of contract 15.0 TRAINING& AFTER SALES SERVICES 15.1 The contractor shall undertake to/train, free of cost the supervisors & staff of the Indian Railways for operation, maintenance, fault finding, trouble shooting, repair of the offered Control transformer for Switch Board Cabinet under the guidance of the skilled engineers as and when asked for by Railways. 15.2 The manufacturer shall be required to make available the services of his engineers free of cost to watch/monitor the performance of the equipment in service periodically and also carry necessary repairs or replacement under warranty obligations, The necessary spares needed forireplacement during service should be available with the service engineers at all the zonal Railways, Divisions Head Quarter & Production Units, Workshops and Coaching Depot to cover entire indian Railways network. The Service engineers shall be fully conversant with Switch Board Cabinet & its electrical circuitry. 16.0 INFRINGEMENT OF PATENT RIGHT 16.1 Indian Railway shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, use of similar components in design & development of this item and any other factor not mentioned herein which may cause Such a dispute. The entire responsibility to settle any dispute/matters lies with the manufacturer/supplier. 16.2 It shall be responsibility of firm to ensure that details/design/documents given by them. are not infringing any IPR and they are responsible in absolute and full measure instead of Railways for any such violations, Data, specifications and other IP as generated out of interaction with Railways shall not be unilaterally used without the consent of RDSO and right of Railways/RDSO on such IP is acceptable to them. 17.0 CARTEL FORMATION Prepared by Ves Checked by ie ADE TL-AC System Design) DSE(TL-AC System Design)Page 18 of 22. File No. ‘Specification No. RDSO/PE/SPEC/ = ELI7.1.108/Transformer__| TL/D/0203-2020 (Rev.0) = The firm will not engage in cartel formation with other firms and will also submit a declaration in this regard as per attached Annexure —C. 18.0 ANNEXURES i) _| The over all dimensions, construction and RDSO Drawing No. mounting of the transformer RDSO/PE/SK/AC/O225- 2020(Rev-0) ‘ii) | Bill of Material ‘Annexure - A ii) | Data sheet a Annexure - B iv) | Declaration against cartel formation Annexure - C | VA Prepared by Checked by ADE TEAC System Design) | DSE(TL-AC System Design) |Page 19 of 22 File No. ___| EU/7.1.108/Transformer | Specification No. RDSO/PE/SPEC? | | TL10/0203-2020 (Rev.0) ANNEXURE ~ A ACCEPTABLE MAKE AND SPECIFICATION OF THE MATERIAL USED IN CONTROL TRANSFORMER S.N | Description of the | Nos. Make Specification | material E 3 =f 1. | Super enameled | As RDSOICLWICFIRCF 1S: 13730, Pt 13- copper required | approved make 93 roundirectangular winding wire | | s Connecting lead [2 input | E-beam cable as per 1S: 6195 and2 | RDSO specification no. output | RDSO/SPEC/ELC/0019 L (Rev.0)-2002 or latest. 3. | Epoxy As PED 50 VT or any other | Dr resin/Varnish required | make approved byRDSO »,, BECK(ELANTAS i ee | eer BECK INDIA LTD) 4 | CRGO grade M27 | As Mis POSCO(Kérea), M/s | IS: 3024 of 0.27 | required | NIPPON STEEL mmm thickness Corporation (Japan), M/s THYSSCENKRUUP(INDIA) or any other make with pele prior approval of RDSO. 5 ‘SRBGF material As RDSO/CLWIIGF/RCF 18:10192-1982 ae | required | approved make _| with EP3 grade | Crimping 2 Output | Chetna/Ascon/Dowels or | Fire retardant as_| ‘socket/lug and 2 any other make approved per UL-94 V-0 | z Input__| by ROSO. __| grade 7 Connectors/ As Wago/Phoenix/Connectwell | Fire retardant as Terminal Block | required | or any other make per UL-94 V-0 | __| approved by RDSO _| grade 8 | Fuse 2 Output | RDSO/CLWIICFIRCF 4 Amp 1000V AC, and2 | approved make 2 Amp 00 VAC. | Input = 9 | Fiber Sheet for | As RDSO/CLWIICFIRCF Fire retardant as mounting control required. | approved make per UL-94 V-0 transformer | = __| grade Note: 1. Allthe materials should have fire retardant property. 2. Firm should have test records of all raw material used in their transformer. 3. Firm will, submit the purchase bills of raw materials from approved sources as above. ss G Prepared by = Checked by __ADE TLAC System Design) DSE(TL-AC System Design)Page 20 of 22 File No ‘Specification No. RDSO/PE/SPEC/ DATA SHEET EL/I7.1.108/Transformer__| TL/D/0203-2020 (Rev.0) Annexure - 8 Firm shall submit the following data for all type of control transformer:- Name of Manufacture Rating _ Number of phases Rated Primary voltage Rated Secondary voltage [Frequency Vector group Class of insulation of Winding Insulation Resistance Temperature rise of Winding by resistance method ee 2 i Temperature rise of Winding by back to back method Ea 2 Temperature rise of Terminals by thermometer method _ 13 No load loss at rated voltage and frequency _ 14 Load loss at rated current at75 deg.C 15 Efficiency at full load at 75 deg.© 16 Efficiency at three forth load at 75 deg.C [77 Efficiency at half load, at 75 deg.C 18 Efficiency at one forth load at 75 deg.C | 49 No load current at rated voltage & Frequency = 20 Current density of conductor Primary 24 ‘Current density of conductor Secondary (V1) a [22 Material & grade of core 5 = jaa Thickness of core lamination a z 24 Flux density _of core 25 Terminal Biock il 26 ‘Crimping socket's make & size z 27 Heat shrinkable sleeve. = z 28 Length s 29 ‘Wiatih 30 | Height i [at [ Weight ry 2 : Prepared by pe ADE TL-AC System Design) Checked by DSE(TL-AC System Design) || File No. "] Specification No. RDSO/PE/SPEC/ | EU/7.1.108/Transformer TUD/0203-2020 (Rev.0) | Page 21 of: ANNEXURE ~ C UNDERTAKING AGAINST CARTEL FORMATION We, 5 cowuhereby, give an undertaking that as a Registered Vendor for manufacture and supply of 5 be a part of a cartel with other vendors and will be quoting competitive rates in the tenders invited by the Indian Railway/Production Units. will not We 2 cso are aware of the fact that the Registering Authority i.e DSO may devlist the name of our firm from thesMaster List of Approved Vendors, if complaint is received about such cartel formation ffom any of the Railways/Production Units, Seal and Signature (Authorized signatory of the firm) Date: Place: Seal Prepared by eo Checked by __ADE TL-AC System Design) __DSE(TL-AC System Design)Page 22 of CHIEF ELECTRICAL SERVICE ENGINEER: 22 | File No, Specification No, RDSO/PE/SPEC/ LEL/7.1.108Transformer | TL/D/0203-2020 (Rev.0) Dis} IBUTION LIST Northern Railway, Baroda House, New Deihi-770 001. 2 _| Central Railway, I Floor, Parcel office, CST Mumbai ~ 400 001. 3 | Eastern Railway, Fairlie Place, Kolkata — 700 001. af = 4 South Eastern Railway, Garden Reach, Kolkata — 700 043 oat 5 _| Southern Railway, ParkTown, Chennai - 600 003, = me & _| Western Railway, Churchgate, Mumbai - 400 020. _7 | South Gen ‘allway, Rail Nilayam, Secunder 0 37 eee ; 8 __ East Central Railway, DighiDistt- Vaishali, Hajipur Bihar. 844 101. st 8 | North Gentral Railway, North Central Raliway, Block A ,Subedargan], Allahabad: ES 211033. a = Tr gouth Western Raliway, 1" Floor, DRM Office, Hubli680020 | ‘1 __| South East Central Railway, Bilaspur.495004 ae 12 | North East Frontier Railway, Maligaon, Guwal asl ee oe 22. “lana | West Central Railway, Jabalpur - 482001 os | 16 | East Coast Railway, Bhuvneshwar, Orrisa ~ 761016 | 47__| Konkan Railway, BolapurBhavan, Sector, Bélapur, Mumbai 400814 sa |_18 | Metro Railway, 3371 J.L. Nehru road, Kolkata- 700071 19 CHIEF WORKS MANAGE! Integral coach factory, Perambur, Chennai - 600038 F tory, Kapurthala (Punjab) Modern Rail Coach Factory, Lalganj,Rai Workshop, Central Railway, Mumbai 400 07 Liluah Workshop, Eastern Railway, Howrah a C&W Workshop , Northern Railway, Alambagh, Lucknow-226 08 © & WWorkshop.N. Rly., Jagdhari - 435 002 Mechanical Workshop, NER, Gorakhpur - 273 012 Carriage Workshop, Southern Railway, Perambur, Ayanavaram, Chonnal ~ 600023. tees oe ae SCR, Lallagudda Workshop, Lallaguda, Secunderabad - 500017 Carriage Workshop, Western Railway, Lower Parel, Mumbai-400013 CRWS, W. C. Railway, Nishatpura, Bhopal-462010 Carriage Workshop, NW Rly,.Ajmor — 305001 { Prepared by L ~| Carriage Repair Workshop, Gadag Road, W. Carriage and Wagon Workshop, W. Rly., Pratap Nagar, Vadodara - 300004 Carriago Workshop, S. Carriage Workshop, SE Rly., Kharagpur— 721301 New Bongalgaon , Railway Workshop, Dangtal, Distt. Bongaigaon, Assam-783360 Carriage and Wagon Workshop, N. C. Rly., Jhansi - 248003 Garriage and Wagon Workshop, WC Rly., Kota - 324002 me i Carriage and Wagon Workshop, Eeastern Rly., Liluha - 711204 | ilway, MysoreVi Garriage and Wagon Workshop, N Rly., Amritsar — 143001 ral Workshop, Goldenrock, S. Rly., Trichi ~ 620004 Directo Nasik Road (Maharashtra). - 422101 | 1), Railway: [Checkedby __ADE TL-AC System Design) Te DSE(TL-AG System Design)