SPECIFICATION NO. MP.0.42.00.

01 (Rev 01)

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

SPECIFICATION OF ROOF MOUNTED AC UNITS TO BE

USED IN CABS OF DIESEL-ELECTRIC LOCOMOTIVES

SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

SEPTEMBER, 2005

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RESEARCH DESIGN & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226 011
 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

SPECIF ICATION OF ROOF MOUNTED AC UNITS TO BE

USED IN CABS OF DIESEL-ELECTRIC LOCOMOTIVES

1.0 INTRODUCTION

1.1 Loco cab air conditioning was discussed in the 38th DMG meeting. Some of the
sheds have modified the cabs with locally available materials. It was decided that
RDSO should standardize the air conditioning equipment including the inverter to be
used in diesel loco cabs.

1.2 This specification covers cab air conditioning system to be employed in diesel electric
locomotives. Cab air conditioning system includes one roof mounted AC unit in the
driver’s cab with input power supplied by an inverter.

1.3 Motors used in the cab air conditioning system are alternating current machines
whereas auxiliary supply available in diesel-electric locomotives is 72V DC from
auxiliary generator. An inverter is therefore required to convert 72V DC to 230V, 50
Hz, single-phase supply suitable for input to these motors.

1.4 The specification no. MP.0.42.00.01(Rev-0.00), January 2004 was issued which
covers the requirements of design, manufacture, testing and supply of complete AC
system including inverter unit complete with all associated controls, protection and
indication equipment. In view to increase the reliability of inverter & make it more
compact, it is felt necessary to modify some operational requirements and make
some changes. The specification has been revised to incorporate these changes.

2.0 GENERAL REQUIREMENT

2.1 The locomotive cab air conditioner assembly shall be used to provide interior cab
temperatures in a comfortable range during high as well as low temperature weather
conditions encountered during locomotive operation throughout the year.

2.2 Single, self-contained air conditioner module shall be used for cooling, filtering, and
distributing re-circulated air within the cab with condensate drain connection,
mounting and support structures.

2.3 The air conditioning system shall have sufficient capacity to meet following
performance requirements:

Cooling capacity : (a) 6600 kcal/hr (2.2 TR) at 35 deg C ambient

: (b) 5100 kcal/hr (1.7 TR) at 50 deg C ambient
: (c) AC unit shall be able to operate continuously
at 55 deg C ambient without tripping of any
control and without any damage.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

Heating Capacity : 2 kw

Humidity : 60% maximum inside the driver’s cab.

Fresh air : 30 cubic mtr/hr

2.4 AC unit shall re-circulate the cab interior air volume through the evaporator core at a
rate adequate to provide the cooling capacity as specified above. Similarly the
condenser air flow shall be adequate to provide the condenser heat rejection
necessary to obtain the cooling capacity specified above.

2.5 The temperature inside the cab shall be maintained between 24 deg.C to 29 deg.C in
cooling mode. In heating mode it shall be between 19 deg.C to 21 deg.C.
Temperature indication shall be provided on AC unit to indicate temperature in deg.C.
Thermostats shall be preferably of electronic type.

2.6 The cab AC equipment and inverter location will vary depending upon maximum
moving dimensions allowed for the loco and equipment layout for different class of
locomotives. The firm shall submit detailed layout drawing of AC equipment and
inverter to RDSO for approval.

3.0 GOVERNING SPECIFICATIONS

Assistance has been taken from following specifications:

Sl. No. Publication no. Title

1 IEC –60571 Rules for electronic equipment used on rail
vehicles.

2 IEC-60571-1 (1990) General requirements and tests for electronic

3 IEC-60310 (1991)
4 IEC-60411-1 (1975)
5 IEC-60411-5 (1992)
6 IS: 7788 (1993)
7 IS: 8623 (1993)
8 IS: 4237 (1982)
9 IS: 13947 (Pt.1) – 1993
10 IS: 4691 (1985)
equipment
Rules for traction transformer and reactors.
Rules for traction converters
Rules for traction converters
Specification for single phase traction converter
Specification for factory built assemblies of
switch-gear and control gear for voltage up to
and including 1000 VDC
General requirements for switch gear and control
gear for voltage not exceeding 1000V or 1200
VDC.
Degree of protection provided on enclosure for
low voltage switch gear and control gear.
Degree of protection provided by enclosures for
rotating electrical machinery (First revision).

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

11 IEC-601287-1(1997- Power converters installed on board rolling stock.

07) (Characteristics and test methods)
12 IS: 659 (1964) Safety code for air conditioning (Revised)
Amendment-1.
13 IS: 732 (1989) Code of practice for electrical wiring and
installation (Third revision).
14 IEC: 6077 (1968) Rules for electric traction equipment.

4.0 SCOPE OF SUPPLY

Scope of supply includes complete roof mounted air conditioning system and its
inverter based single-phase power supply arrangement with associated control,
protection and indication equipment.

5.0 ENVIRONMENTAL CONDITIONS

The complete AC unit and inverter shall be required to work under following
atmospheric conditions :

Ambient -5 to 55 deg. C.
temperature
Humidity Up to 100% during rainy season

Altitude Max. 1200 meter above mean sea level

Annual rainfall Between 1750 mm to 6250 mm.

Dust Extremely dusty and desert terrain in
certain areas. The dust content in air may
reach as high a value as 1.6 mg / m³.
Atmospheric (a) Maximum PH value : 8.5
conditions in
coastal areas in (b) Sulphate : 7 mg / liter.
humidity salt
laden and (c) Max. concentration of chlorine : 6 mg / liter
corrosive
atmosphere (d) Maximum conductivity : 130 micro semen / CM.

The AC unit shall be suitable for rugged service normally experienced for rolling stock
where locomotives are expected to run up to a maximum speed of 160 kmph in
varying climatic conditions existing throughout India.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

6.0 REQUIREMENTS OF INVERTER

6.1 Input DC power supply to the inverter will be taken from the auxiliary generator.
Output of the inverter will be used to supply AC unit as well as hot & cold water
dispenser fitted in the driver’s cab. The inverter shall be suitable for following
operating requirements :

(1) Input supply to inverter : 72 VDC (Range 60 VDC to 90 VDC

with ripple of 20%.)

(2) Rated output capacity of inverter : 5 KVA (at 0.8 P.F.)

(3) Connected load : As per clause 9.0

(4) Inverter output supply : (a) 230 VAC + 5% , 50 Hz + 3%, single

phase PWM sine wave for DOL system
of compressor and condenser motors.

OR

(b)VVVF control for compressor and

condenser motors for soft starting
system

WITH

(c) DOL starting of evaporator motor either

from the main output of DOL inverter in
case of (a) above or separate DOL
converter in case of (b) above.

(5) Starting of motors : As per clause 10.0 .

(6) Current harmonics at full load : Total harmonic distortion not more than 5% up
to 20th harmonics (up to 1000 Hz).

(7) Duty cycle : The unit shall be capable to withstand 20

cycles/hrs. of 1.5 min. 'OFF' for actual
connected compressor and condenser load
with continuous load of evaporator motor to
meet 5 KVA load.

(8) Cooling : Natural cooling (preferable) or force cooled

(9) Efficiency (at full load) 90%

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

(0.8 pf, 50 Hz.)

(10) Construction : Modular (Rack / box type)

(11) Protections : As per clause 6.10

(12) Indications : As per clause 6.11

(13) Meters As per clause 6.13

(14) Vibrations & shocks As per IEC-60571 clause 6.3

6.2 For ease of maintenance, rack type / modular construction shall be adopted.

6.3 The envelope size of the inverter assembly shall not exceed : 400 mm (Width, i.e.
across the loco) * 300 mm (Depth, i.e. along the loco) * 850 mm (Height) including
mounting arrangements. Inverter shall be housed in the control panel of the
locomotive. Inverter location and dimensions may vary for different class of
locomotives. Inverter dimensions shall be finalized in consultation with RDSO.

6.4 The inverter shall use IGBT power semi-conductor devices.

6.5 The cooling fan, if provided, shall preferably be of low speed. The bearing shall be
double sealed type with minimum life of three years. The cooling fan shall be suitable
for working at continuous temperature of 60 degree C.

6.6 The inverter with all electronic and power devices shall be designed to meet the
abnormal conditions under minimum/maximum current / voltage limits and
current/voltage surges that may be expected during fault conditions.

6.7 Inverter should have sufficient overload capacity to supply high starting current
required for different motors of air conditioning unit.

6.8 AC unit will be fitted in one cab of the loco. However, design of inverter system
should be sufficiently flexible to incorporate two AC units per loco (one AC unit with
it’s controls in each cab of the twin cab loco), if required. In this case, inverter
provided should be able to feed any of the AC units, one at a time.

6.9 Power required for hot & cold-water dispenser will be 600 Watts. Inverter should have
sufficient capacity to meet this requirement in addition to power required for AC unit.

6.10 PROTECTIONS

The inverter unit shall be provided with following protections :

DC MCCB semi conductor fuses on input side

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

Low input voltage (less than 60 VDC) cut off

High input voltage (more than 90 VDC) cut off

Input fuses with fuse blown indications.

Filter circuit on input side to reduce input ripple

Reverse polarity protection on input side.

Earth fault on AC side.

Inverter overload cut off.

Voltage surge suppressor at input and output side.

Thermal protection of power semiconductor devices and transformer.

Output short circuit protection (preferably with IGBT trigger pulse block).

Input DC current exceeding 65 amps for more than two seconds cut off.

Output AC current exceeding 22 amps (230 volt AC, single phase) cut off.

Capability to withstand input of 120 VDC for two minutes.

Protection against ingress of dust, water, oil fumes etc. as per IP 25.

6.11 INDICATIONS

Following indications shall be available on the outside panel of inverter :

a) Inverter ON
b) IGBT overheating
c) Transformer overheating.
d) Input DC ON
e) Booster fault
f) Inverter fault
g) Fuse Failure (For input fuses)
h) Inverter cooling fan failure (in case of forced cooling)
i) Earth fault
j) Reverse polarity
k) Input voltage less than 65V DC
l) Input voltage more than 90V DC

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

6.12 FAULT DIAGONOSTICS

The inverter shall have preferably either of the following features for fault diagnostics,
if increase in cost and complexity of the inverter due to provision of fault diagnostics
is within reasonable limits :

(a) Display board

The inverter shall be provided with display board indicating fault number with brief
description for voltage/current, temperature parameters etc. Transparent Perspex
window shall be provided in front of indications and display board and it should be
capable to log at least latest ten faults.

(b) Port for down loading of faults

Inverter shall be provided with self-checking feature and facilities to download to

PC through RS-232 or other suitable port. Offered diagnostic system shall be
capable of recording preferably at least 10 latest faults.

6.13 METERS

Inverter shall be provided with the following analogue / digital meters of not less than
72 mm size :

- Input ammeter
- Input voltmeter
- Output ammeter
- Output voltmeter

However, in lieu of analogue / digital meters, LCD/LED display of above parameters

through push button is also acceptable.

6.14 CABLES

The use of wires/cables shall be reduced to minimum. The use of insulated copper
bus bar is preferable. The wires/cables below 10 sq. mm. shall be PTFE and higher
than 10 sq.mm. cables shall be Elastomeric. The use of PVC cables/wires is not
acceptable.

6.15 INVERTER PANELS

6.15.1The enclosure with its control shall be with IP-25 degree of protection. The
manufacturer shall ensure that entry of dust , carbon particles and oil fumes does not

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

affect the performance of inverter. The front panel door shall have suitable locking
arrangement with key.

6.15.2 All the indications / meters shall be visible from front panel and it should be possible
to operate MCCB/other switches without opening the front panel. Removal / fitment
and maintenance of all equipment and connections should be very easy preferably
by opening the front panel.

7.0 GENERAL POINTS FOR GUIDANCE OF INVERTER DESIGN

7.1 Suitable rigid angle frame shall be provided. All the fasteners used should be
cadmium plated or zinc passivated conforming to IS: 1572 and IS: 1364. Hexagonal
headed bolts shall preferably be suitable for both spanner as well as screw driver
tightening. The metallic cold rolled steel sheet min. 1.6 mm thick and conforming to
IS: 513-1963 shall be used for panel construction.

7.2 Aluminium extruded type potential free heat sinks shall be so located as to reject heat
outside the cubicle and should be enclosed in a separate duct. The electronic box
shall be designed to prevent entry of smoke, oil or dust particles into the electronic
control chambers. Modular construction shall be adopted for easy maintenance and
replacement. Anti vibration pads shall be provided for equipment assembly/electronic
control rack in case of rack assembly.

7.3 All the cables and wires used for wiring/cabling shall be of copper multi-strands and
neatly secured in position. The use of PTFE insulated wires is recommended. The
thicker cables shall be with elastomeric insulation. Use of PVC wires/cables is not
accepted. All the cable and wire terminals shall be made through crimped
sockets/lugs. Each cable/wire shall be numbered at both ends for easy maintenance.
The use of pre-insulated lugs suitable for double crimp for insulation and conductor is
recommended. Current collection through threads must be avoided. Size of the
terminals shall be adequate.

7.4 Anti-corrosive protection coating on PCB shall be applied to avoid corrosion in

service. The protective coating shall be transparent so that type/ratings of component
are readable. The protective coating on track side of PCB shall be of solderable type.

7.5 Hylam PCBs are not acceptable since the insulation level reduces drastically in rainy
season. The use of silicon coated wire wound resistors and metal film resistors are
recommended for high reliability. Heat dissipating high wattage resistor or
components shall not be mounted close to control PCB.

7.6 The compressor motors some time may start with some amount of gas back pressure
resulting in requirement of higher starting torque. This shall be taken into account
while deciding the maximum current limit.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

7.7 Each module shall be complete with its power devices, control cards, protections and
card indications etc. for easy replacement in service. Each card shall be numbered
for easy identification and replacement. The wires/cables shall be away from the heat
dissipating resistors or heat sinks and properly supported with the help of insulated
supporting member or in a insulated duct.

7.8 All inverter transformers shall have insulation of “H” class. The temperature rise at full
load out put voltage shall not exceed 90 degree C. Chokes used in filter circuit can
be with “F” class insulation.

7.9 The out put AC voltmeter shall be suitable for PWM application, alternatively it shall
measure output voltage through suitable filter.

8.0 REQUIREMENTS OF THE AC UNIT

8.1 The complete AC unit shall be housed in a compact housing to be located in the
space available within constraints of maximum moving dimensions of the locomotive
permissible on Indian Railways. For WDG3A locomotive, the maximum available
dimensions and location of the pocket in the cab roof which shall house the AC unit
and its mounting arrangement is shown in annexure – G.

8.2 The construction of the AC unit will be preferably with condenser section recessed
and projected inside the driver's cab and evaporator section remaining above the
roof of the cab so as to ensure that condensate water does not enter the driver's cab.
Air Conditioning System shall be designed to avoid sharp corners or edges inside the
cab.

8.3 A trough for mounting the AC unit to be welded on the roof of the loco driver's cabin
shall be supplied along with the air conditioner. The trough shall be at least 3 mm
thick stainless steel type ready for integration with the roof structure of the loco cab.
The trough should be of standard design to ensure interchangeability of AC units of
different makes and supplier shall take approval of RDSO and DLW regarding
proposed trough design. Trough shall have the necessary drain pipes for rain water
as well as condensate water.

8.4 Refrigeration system of the air conditioning system shall be a basic vapour
compression cycle system and shall use R22 as the refrigerant.

8.5 Air Conditioning Systems shall be designed with a pressure relief feature in the
refrigerant circuit so that in conditions of extreme over pressure, it will cause the
refrigerant to vent on the condenser side of the air conditioner and eliminate any
possibility of discharging refrigerant into the cab during said conditions of over
pressure.

8.6 All wiring should have sufficient insulation quality and secured properly so as to
withstand handling during maintenance.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

8.7 All motors used in this Air Conditioning System shall be totally enclosed and
environmentally sealed unless tenderer can supply evidence acceptable to RDSO
that deviation will not be detrimental to either performance, reliability or operation.

8.8 The AC Unit shall be provided with suitable lifting arrangement for easy maintenance.
The maintenance / inspection of the complete system and replacement of any sub-
component should be easy. The equipment / components needing periodic service
attention shall be easily accessible from inside of the cab.

8.9 AC unit should be made from corrosion resistant grade 304 of stainless steel
including housing sheet and structural materials.

8.10 The Air Conditioner shall not have a noise output in excess of 78 dbA when operating
under any specified condition of load or supply voltage. Noise measurement shall be
24 inches to each side of the Air conditioner and 30 inches below the center point of
each evaporator air discharge grill. Main noise generating equipment shall have anti-
vibration resilient mountings.

8.11 The insulating material used shall be of fire retardant type preferably resin bonded
fibreglass or fire retardant polyethylene or any other suitable material.

8.12 All driven equipment, such as refrigeration compressors and blowers, shall be directly
coupled to the driving motor using appropriate flexible couplings where necessary.
Belt drives are not acceptable.

9.0 CONNECTED LOAD

The output of the inverter will be fed to roof mounted AC unit and also for hot & cold-
water dispenser fitted in the cab. The load of the AC unit shall mainly consist of
evaporator fan motor, condenser motor, compressor motor and heating elements.
Power required for hot & cold water dispenser will be 600 Watts. The total power
consumption of the complete system including AC unit and hot & cold water
dispenser will be approximately 3.6 kW at peak operating conditions. The
compressor motor, condenser motor and evaporator fan motor will be working at
input supply of 230 VAC, 50 Hz, single phase with p.f. of the motors around 0.8.
The AC unit shall be working in cooling mode during summer and heating mode
during winter as detailed below :

9.1 COOLING MODE

In this mode, the heating elements will remain ‘OFF’ and evaporator fan motor,
condenser motor and compressor motor will be in operation. The evaporator fan
motor will be continuously ‘ON’ in this mode whereas the condenser motor and
compressor motor will work intermittently depending on temperature requirement in

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

the cab. The total connected load of AC unit during cooling mode may be
approximately 3.6 kW.

9.2 HEATING MODE

In this mode, the compressor motor and condenser motor are switched ‘OFF’
whereas heating elements and evaporator fan motor will be switched ‘ON’ to
circulate hot air inside the cab during winter season. The heating elements will be
working intermittently depending on temperature requirement in the cab whereas the
evaporator fan motor will operate continuously. The total connected load of AC unit
during heating mode may be approximately 2.6 kW.

10.0 STARTING SCHEMES

Inverter may be provided with either “SOFT START” or “DIRECT ON LINE” starting
of connected loads as detailed below :

10.1 SOFT START

To avoid high starting current, compressor motor and condenser motor may be
provided with soft start features. In this case, both the compressor motor and
condenser motors may start/stop simultaneously and time delay relays provided for
these motors will be by - passed. The auxiliary DOL power must be suitable for
starting evaporator motor direct on line. The unit with VVVF control feeding
compressor and condenser motors will be used for supply to heating elements during
heating mode.

10.2 DIRECT ON LINE STARTING

In this case, the motors will be started in sequence to avoid heavy in – rush current
from input source. First the evaporator motor will be switched “ON” with DOL
starting and once it has picked up full speed, the condenser motor and compressor
motor will be switched “ON” with suitable time lag between them. This time lag will be
provided by the time delay relays. The evaporator motor load shall remain “ON” in all
modes i.e. cooling as well as heating. The inverter output supply of 230 VAC, 50 Hz,
single phase will remain ON in direct on line system. The contactors of condenser
and compressor motors or heaters will be closed or opened depending upon the
cooling or heating requirements.

11.0 SAFETY CONSIDERATIONS

11.1 Appropriate warning labels and safety provisions shall be made in the AC unit and
Inverter system to prevent direct human contact to any electrical live part or rotating
shaft during AC operation.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

12.0 WARRANTY

The complete Air Conditioning System (including AC unit, inverter and controls) shall
be warranted for satisfactory and trouble free operation for a period of two years from
the date of commissioning or three years from the date of supply whichever is earlier.
All aspects of workmanship and design shall be covered by this warranty excluding
all wearing parts which require recurring replacements. A list of such wearing parts
shall be furnished in the offer.

13.0 SPARES AND MAINTENANCE MANUAL

13.1 A list of spares for the complete Air Conditioning System required for a period of 2
years maintenance shall be submitted with the offer in printed form and neatly
compiled in a booklet form.

13.2 The manufacturer shall supply 3 copies of the approved operating and maintenance
manual for the complete Air Conditioning System for overhaul/test purposes.
Complete details of installation, maintenance, circuit diagram with voltages at salient
points to locate faults, list of components with brief specifications and suppliers,
trouble shooting and test procedure after repair shall be supplied. In addition,
component handling and precautions to be taken for preventive maintenance shall
also be included in the maintenance manual. A lubrication chart shall also be
enclosed containing the manufacturer's recommendations on indigenously available
lubricants, quantity and periodicity of lubricants etc.

14.0 INFORMATION TO BE FURNISHED BY THE SUPPLIER

The tenderer shall submit the technical information with the offer as detailed below :

a) Technical specifications, test results, ratings, performance data and

characteristic curves of IGBT devices, transformer, motors, input fuses, input
MCCB etc. used.

b) Circuit diagrams along with bill of material and complete circuit description.

c) Drawings and details of mounting arrangement of various equipment used.

d) Declared output voltage waveform of inverter, harmonics, power factor and

regulation.

e) Details of protections provided and safety margins in voltage, current and

thermal (junction temperature) along with limit values for IGBT devices,
inductors, transformer etc.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

f) Duty cycle considered for inverter design for continuous and short time ratings.

g) Details of cooling arrangement used (if any).

h) Details of operating panel and function of each switch, indications and fault
diagnostic features.

i) Data sheet of AC unit duly filled as per annexure – C.

j) Data sheet of inverter duly filled as per annexure – D.

Plant and machinery infrastructure facilities desirable for the manufacture of quality &
reliable AC unit and inverter system are attached at annexure - E and annexure – F
respectively. These shall generally form a criteria for evaluating/grading of the firms
at the tender evaluation stage. Use of all the facilities mentioned in these annexures
are considered necessary during the bulk production and requires verification by
RDSO before placing the firm as a regular source.

15.0 APPROVAL OF DESIGN/DRAWINGS

15.1 After placement of order, the approval of detailed design, drawings will be advised by
RDSO for which detailed design calculations, specification of components and
drawings are to be submitted by the tenderer. The comments received from
purchaser railways shall also be studied and discussed with RDSO.

15.2 Based on provisional approval of design/drawings, prototype unit shall be

manufactured after incorporating all the modifications found necessary during
inspection / testing without any additional charges.

16.0 INSPECTION AND TESTING

The prototype AC unit and inverter with controls shall be type tested by RDSO at
manufacturer’s works or at a reputed test facility (to be accepted by RDSO). The
complete cab AC system shall also be tested by RDSO. The routine tests are to be
carried out by the manufacturer and record kept in proper format. Nominated
representative of railways may ask and see the routine test results conducted.

16.1 Test programs of AC unit and inverter are attached at annexure A and B
respectively. The tenderer shall submit a type and routine test plan for acceptance by
RDSO.

16.2 Subject to agreement between RDSO and manufacturer some or all the type tests
shall be repeated once in two years on sample basis, so as to conform the quality of
product to meet the specified requirements. In addition, the manufacturer shall repeat
the type test either totally or in part in the following cases without any additional cost :

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

Modification of equipment likely to affect its function.

Failure or variations established during type or routine tests.

Resumption of production after an interruption of more than two years.

At the time of indigenisation, if the firm is having TOT with foreign

collaboration in consultation with purchaser.

16.3 In general, the equipment used in the AC unit and inverter shall conform to relevant
IEC/IEEE (latest revisions) specifications and the same shall be indicated by the
tenderer for each equipment. However, the maximum temperature rise limits
specified in these standards shall be reduced by 20 deg C for the equipment used in
AC unit to account for the higher ambient temperatures observed in India. In case
any deviation is proposed from the said standards or from this specification, the
standards followed shall be clearly indicated by the tenderer.

17.0 FAILURES DURING WARRANTY PERIOD UNDER MAINTENANCE CONTRACT

17.1 The details of failures, action taken to arrest re-occurrence of similar failure in future,
failure analysis report etc. are to be submitted to RDSO and purchaser railways.

17.2 In case of repeated failures, necessary changes in design on the units put in service
or in production line are to be made by the manufacturer. Investigation tests, if
considered necessary, are to be arranged/conducted by the manufacturer.

18.0 MARKING AND PACKING

18.1 All surfaces of the Air Conditioning System shall be painted with a good grade of
exterior paint to prevent corrosion. The external surface of the AC system shall be
paintable without necessitating the application of primer.

18.2 Air Conditioning Unit shall bear for identification a serial number and manufacturer’s
name as well as the ratings.

18.3 The inverter rating plate shall be marked with the following information.

i) Type/Make.
ii) Contract number.
iii) Month and Year of manufacturer/Batch No./S.No.
iv) Rating
KVA.
Input voltage range.
Output voltage, frequency and wave shape.
Over-load capacity in KVA and duration in sec.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

v) Connection diagram with terminal marking.

vi) Starting system - Direct On Line/Soft start.

18.4 All units of the complete AC system shall be suitably packed in strong water proof
boxes to prevent any damage during transit and handling.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE - A

TESTS FOR AC UNIT

1.0 Following table lists the summary of type and routine tests to be conducted on the
AC unit :

SN Test Name Type Routine Remarks

1 Dimensional & visual inspection yes yes

2 Test for water tightness yes yes
(a) Rain test
(b) Test for drainage of
condensate water
3 Electrical test yes yes
(a) Insulation resistance test
(b) high voltage test
(c) Voltage change test
(d) Frequency change test
(e) High temperature startup test

4 Fresh air quantity test yes yes

5 Conditioned air delivery test yes
6 Cooling capacity test yes yes
7 Measurement of power yes yes
8 Heating capacity test yes
9 Vibration test yes
10 Shunting shocks test yes
11 Noise test yes
12 Degree of protection for motors yes

Routine tests shall be conducted on each AC unit at the manufacturers work. The
manufacturer shall submit a copy of routine test results for each AC unit to the
inspecting authority.

1.1 DIMENSIONAL & VISUAL INSPECTION

It shall be done for checking the overall dimensions, location of lifting hooks, material
of filters, accessibility of different types of motors, filters, thermostats & protective
devices, quality of welding etc.

1.2 TEST FOR WATER TIGHTNESS

The AC unit shall be tested for water tightness as per details given below :

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

1.2.1 RAIN TEST

The water tightness of the body and electrical equipment shall be inspected at all
openings which might allow penetration of water. A distinction shall be made between
the water tightness of openings (air inlet etc.) which depends primarily on erection
and the condition of joints.

(1) A check on the water tightness of the openings shall be carried out for a period
of 30 minutes with all fans running under artificial rain of an intensity not less
than 60 mm per minute. The angle of rain shall be 45 degree towards
evaporator compartment from condenser side.

(2) A check on the water tightness of covers shall be conducted. It shall be carried
out by means of a jet of 6 to 10 mm internal diameter, at a distance of 2
meters and a pressure of 1 bar with all fans running and then at a pressure of
3 bars with the fans stopped. The water shall be sprayed on each cover side
minimum for 15 minutes.

(3) In each case the penetration of water shall be slight and shall not be of such
nature as to have an adverse effect on cabling and electrical equipment.

1.2.2 TEST FOR DRAINAGE OF CONDENSATE WATER

This test will be conducted to see the efficacy of condensate water drain out system
from the AC package unit with blower motor in working condition.

1.3 ELECTRICAL TESTS

1.3.1 INSULATION RESISTANCE

Insulation resistance of motors (compressor motor, condenser motor etc.) shall be

more than 50 mega-ohms with 1000V DC megger in all the weather conditions.

1.3.2 HIGH VOLTAGE TEST

The Air Conditioner system with all sub-components shall be capable of

withstanding a high voltage test for one minute duration using an applied voltage of
1000 volts AC RMS at 50 hertz frequency applied to appropriate terminals of the Air
Conditioner or it’s sub-components.

1.3.3 VOLTAGE CHANGE TEST

During the normal operation of the AC unit under cooling capacity test condition and
high temperature condition, the power source voltage will be changed from 210 V AC

Page 17 of 37
 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

to 250 V AC. The AC unit shall operate without significant change of discharge and
suction pressure.

1.3.4 FREQUENCY CHANGE TEST

During the normal operation of the AC unit under cooling capacity test condition and
high temperature condition, the power source frequency will be changed from 47.5
Hz to 52.5 Hz. The AC unit shall operate without significant change of discharge and
suction pressure.

3.3.5 HIGH TEMPERATURE STARTUP TEST

The condenser room temperature shall be maintained at 55 deg. C. The AC unit shall
be made to run for one hour as per clause 3.6 (dry summer conditions). The unit
should work satisfactorily without tripping of any of the protective devices.

3.4 FRESH AIR QUANTITY TEST

Measurement of fresh air quantity shall be made when fresh air openings are fully
open and fresh air should be measured at 230 – 5% volts i.e. at 220 V AC (approx.).

3.5 CONDITIONED AIR DELIVERY TEST

Manufacturer shall submit test certificate from a reputed test laboratory for the
suitability of filters.

3.6 COOLING CAPACITY TEST

(a) This test shall be made in the following conditions keeping static head of
supply air at 20 mm WG :

Test condition Condition created in hot Condition created in

chamber cold chamber
Dry summer condition 50 deg.C (DB) 25 deg.C (DB)
25 deg.C (WB) 16 deg.C (WB)

(b) Cooling capacity from evaporator side shall be calculated as under:

C = (60 x Q x (E1-E2)) / S

Where C = Cooling capacity (K. cal/h) evaporator side.

Q = Conditioned air quantity (m3 /min.) of evaporator blower fan.
E1 = Enthalpy of supply air (K. cal/kg)
E2 = Enthalpy of returned air (K. cal/kg)
S = Specific volume of supply air (m3/kg.)

(c) Cooling capacity from condenser side shall also be determined as under :

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

Cc = (60 x Qc x (E3-E4)) / Sc – (Et x 0.86)

Where

Cc = Condenser side total cooling capacity (K. cal / hr.)

Qc = Air flow rate over condenser per minute.
E3 = Enthalpy of air entering condenser (K. cal / kg.)
E4 = Enthalpy of air leaving the condenser (K. cal / kg.)
Sc = Specific volume of air flowing over the condenser (m3 / kg.)
Et = Total power input to module in watts.

3.7 MEASUREMENT OF POWER

Total power input to whole AC unit as well as to each of the motors shall be recorded.
Above measurements shall also be recorded while doing air delivery test under
routine test.

3.8 HEATING CAPACITY TEST

Measure KW rating of heater provided.

3.9 VIBRATION TEST

Air Conditioning System with all sub-components shall be capable of withstanding

vibration levels as per IEC 77 while operating at its rated points without any effects
detrimental to the performance, operation, or reliability.

3.10 SHUNTING SHOCKS TEST

Air Conditioning System with all sub-components shall be capable of withstanding

shock loads as per IEC 77 while operating at its rated points without any effects
detrimental to the performance, operation, or reliability.

3.11 NOISE TEST

Maximum permissible noise level of the air conditioner is 78 db

under any operating conditions, when measured 24 inches to each side of the air
conditioner and 30 inches below the center point of each evaporator air discharge
grill.

3.12 DEGREE OF PROTECTION FOR MOTORS

Test certificate from motor manufacturers shall be furnished for IP55 (TEFC) degree
of protection as per IS : 4691.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE - B

TESTS FOR INVERTER

1.0 Separate type, routine and commissioning tests for inverter assembly and complete
inverter unit installed on the locomotive shall be conducted.

2.0 Following table lists the summary of type and routine tests to be conducted on the
inverter unit :

SN Test Name Type Routine Remarks

1 Vibration and shock test yes

2 Determination of resonance yes
frequency
3 Test with forced vibration yes
4 Shunting shocks yes
5 Test for enclosure yes
6 Test on protection and measuring yes yes
meters
7 Trigger equipment test yes
8 Insulation resistance & Dielectric test yes yes
9 Light load test yes yes
10 Rated current load test yes yes
11 Temperature rise test yes Also after every
50th inverter
12 Power loss determination yes Also on 5% of lot
size
13 Short circuit test yes Also on 5% of lot
size
14 Load break test yes
15 Input under voltage and over voltage yes
test
16 Acoustic noise measurement yes Also on 5% of lot
size
17 Visual inspection yes yes
18 Performance test yes yes
19 Earth fault yes yes
20 Measurement of input RMS current yes
ripple
21 Dry heat and Damp heat test yes
22 Harmonics test yes
23 Transient voltage test yes
24 Endurance test yes

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

2.1 VIBRATION AND SHOCK TEST

The complete inverter cubicle together with its mounting arrangement (including
shock absorbing devices if provided) shall be subjected to the following tests:

The inverter under test shall be secured in a suitable position to a vibration machine
producing vibration of sinusoidal form with adjustable amplitude and frequency. The
test frequency lower than 5 Hz may be omitted. The equipment will be in energized
condition at no load.

2.1.1 DETERMINATION OF RESONANCE FREQUENCY

In order to determine the possibility of critical frequencies producing resonance the
frequency shall be varied progressively over the whole range of 5 Hz to 100 Hz within
a time of not less than 4 min., the amplitude of the oscillation being “a” expressed in
mm is given as a function of “f” by the equation :

25
a = ------------- for 1 Hz to 10 Hz
f

250
a = ------------- for 10 Hz to 100 Hz
f²

2.1.2 TEST WITH FORCED VIBRATION

The inverter under test shall be subject to a set with forced vibrations for a period not
less than 15 min. at the critical frequency if such a well defined frequency
(Resonance frequency) has been detected in course of test at clause 2.1.1 above.

Apart from this, test is also required to be carried out at a frequency of 10 Hz or

around 10 Hz in case resonance frequency is 10 Hz for a period of 4 hrs. in each
direction.

In both the cases, the amplitude of vibrating table is adjusted to the value
corresponding to frequency given above. The inverter shall be tested under
energized condition at no load.

In case failure during service is attributed to vibration, as an investigative test,

vibration test for 25 to 50 hours as decided by the purchaser will be required to be
carried out.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

2.1.3 SHUNTING SHOCKS

The inverter shall be subjected to a series of the three successive shocks (one cycle)
each corresponding to a maximum acceleration of 3g in all the three directions.

The equipment shall be subjected to 4 cycles i.e. 12 shocks in each direction. The
tests are considered to be satisfactory in case there is no resulting damage,
loosening of connections/components/sub-assemblies or abnormality in operation.
The inverter shall be able to pass electrical performance tests after this test.

3.0 TEST FOR ENCLOSURE

The purpose of this test is to verify the effectiveness of the means provided to reduce
ingress of dust and water as per IP25 class of protection for inverter cubicle. The test
shall be conducted as per IS: 13947.

The test is considered satisfactory in case of no ingress of water in the cubicle and
dust deposit on electric cards surface, where tracking can take place, is detected.
The filter shall be clearable and easy to replace.

4.0 TEST ON PROTECTION AND MEASURING METERS

The purpose of this test is to verify that protections provided are functional and
operative at set values.

The tests shall be conducted by simulating the corresponding conditions.

5.0 TRIGGER EQUIPMENT TEST

The object of this test is to verify that the triggering pulses comply with the
specification. The details shall be furnished by the manufacturer.

6.0 INSULATION RESISTANCE & DIELECTRIC TEST

The insulation resistance with 1000 V megger shall not be less than 10 M ohms for
all the circuits.

The dielectric test shall be carried out after shorting power semiconductor devices,
primaries of trigger equipment, pulse transformers earthed and disconnecting special
card if necessary before applying dielectric voltage corresponding to the voltage
given below :

I. For 230V single phase ac circuits, at 80% of isolation voltage (Visol.) r.m.s.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

of IGBTs, 50 Hz for 1 min.

II. For 72 VDC circuits, at 1000V rms sine wave 50 Hz for 1 minute.

III. For 24V circuits (if any), at 500V (rms) sine wave 50 Hz for 1 minute.

Test is considered satisfactory if there is no flash over or tripping of dielectric test

equipment set at 50 mA leakage current is experienced.

7.0 LIGHT LOAD

This test is carried out to verify that the inverter is correctly connected and is capable
of withstanding voltage likely to occur in service. Suitable load is connected and the
supply voltage is maintained at its normal value. Output quantities i.e. trigger, control
signals, output voltage, frequency etc. are to be checked and recorded and
compared with declared values.

8.0 RATED CURRENT LOAD TEST

The purpose of the test is to verify the rated current load capacity of the inverter at
0.8 PF (50 Hz). In case the declared rating is more than rated load, the test shall be
conducted corresponding to higher value claimed by the manufacturer.

The short time rating specified in the offer shall also be verified during the type test
only for the specified time duration or duty cycle.

The test may be conducted during heat-run/Temperature rise test.

9.0 TEMPERATURE RISE TEST

The inverter shall be loaded to full load current corresponding to 5 KVA rating of
inverter with input voltage of 72V DC at 0.8 PF. The temperature rise shall be
recorded by temperature detectors mounted at the specified reference points on the
body of semiconductors, inductors, filter capacitors and other components as agreed
between RDSO and manufacturer. The maximum recorded temperature under worst
loading conditions shall be corrected for 55° C ambient temperature 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. Under loading conditions as specified above, the corrected
temperature of the power devices shall have a margin of minimum 10° C.

Temperature of Inductors/Transformers shall not exceed 155° C when corrected to

55° C ambient. The inverter shall also be subjected for short time rating after
continuous loading to ensure the temperature rise is within the permissible limit. The
maximum temperature rise of the electronics devices on the PCBs should not exceed
approximately 20° C for industrial grade components suitable for 85° C environment,

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

when measured at half inch away from identified critical components. In case, it is
exceeding this limit, use of mil-grade components can be considered keeping RDSO
informed.

10.0 POWER LOSS DETERMINATION

The losses at full load and light load shall be recorded at nominal voltage. The
efficiency when calculated shall not be less than 85% at full load (at 0.8 pf, 50Hz).

11.0 SHORT CIRCUIT TEST

A short-circuiting contactor shall be connected in parallel with the load. The short
circuiting contactor shall be closed after the normal current has been detected and it
shall be cleared by the protective-clearing equipment within total time specified for
the equipment to function. Neither any fuse shall blow nor any semiconductor device
shall fail. The inverter shall remain “OFF” after clearing the fault and shall function
normal on removal of fault and reset operation.

12.0 LOAD BREAK TEST

A contactor is connected in series with the load. After the rated current has been
flowing in load for 1 min., the contactor switches “OFF” the current. The test shall be
repeated three times.

13.0 INPUT UNDER VOLTAGE AND OVER VOLTAGE TEST

The input voltage shall be reduced below 72 VDC and check the alarm sound when
it reduces below 65 V. On further lowering voltage below 60 V, check that inverter
switches “OFF” prior to 57 V and automatically switches “ON” after the input voltage
exceeds 65V.

The input voltage shall be increased beyond 90 VDC and check that inverter
switches “OFF” before it reaches 93 VDC. The input voltage is further raised to 120
VDC and maintained for two minutes. There shall be no damage of any nature to any
of the components of the inverter. The inverter shall automatically switch “ON” after
the voltage is decreased below the set value.

Inverter load current is continuously increased. Check that inverter switches “OFF” if
input current exceeds 65 A for two seconds.

The design will incorporate necessary feature of suitable time delay / hysteresis to
avoid hunting for both under voltage and over voltage trippings.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

14.0 ACOUSTIC NOISE MEASUREMENT

The sound pressure level shall be measured in order to ensure that it is not
exceeding the limit value of 75 dB (A) with cooling blower “ON” (if any) at a distance
of 1 meter away from the equipment in all the directions. Tests will be performed at
No-load and Full load. However the manufacturer shall endeavor to reduce the noise
level below 70 dB.

15.0 VISUAL INSPECTION

The object of this visual inspection is to check that the inverter is free from defects,
surface treatment and the main components are as per approved type and rating.

The dimensions, mounting arrangement, bus-bar terminations and other parameters

considered necessary shall also be verified and checked from approved drawings.

16.0 PERFORMANCE TEST

Inverter unit shall be connected to AC package unit at rated full load and the input
voltage shall be varied from 60V to 90V DC. Output phase voltage and frequency
observed at 60V, 72V and 90V DC inputs shall be recorded. The readings shall be
well within the prescribed limits at no-load, light load and full load at 0.8 PF (50Hz).

Set the input voltage at 72V DC and switch “ON” full load and record parameters i.e.
voltage, current, frequency and regulation from no-load to full load. Reduce the input
voltage below 65 VDC, say 64 VDC and hold for some time at this point. Check for
the alarm sound and visual indication. Reduce the input voltage further and check
that inverter trips below 60V DC. Record the input voltage at which the inverter trips.
This shall not be lower than 57 VDC.

Now increase the input DC voltage and check the inverter is “ON” at 65 VDC and it
trips when input voltage is beyond 90 VDC but less than 93 VDC. Increase the input
voltage further to 120 VDC and maintain for two minutes and check that no damage
occurs in any part of the inverter. The inverter shall function normally after this test.

Check the functioning of the MCCB by operating it at least five times. Verification of
indications shall be done by simulation method.

17.0 EARTH FAULT

Simulate the earth fault by connecting suitable resistor between cubicle frame and
output phase. See that inverter does not trip and earth fault indication is in “OFF”
state till the leakage current is less than 30 mA. However inverter shall trip and earth
fault indication appears when the leakage current exceeds 30 mA.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

Earth fault condition shall also be created by direct short between phase and inverter
frame to ensure that the unit can withstand this condition also.

18.0 MEASUREMENT OF INPUT RMS CURRENT RIPPLE

The additional generated RMS current ripple by the inverter to the battery / DC
supply when measured as mutually agreed test program, is less than max. specified
value under worst conditions from no-load to full-load.

19.0 DRY HEAT AND DAMP HEAT TEST

The dry heat and damp heat test shall be conducted on all PCB’s as per latest IEC-
60571. However the temperature for Dry Heat Test shall be 80° C against 70° C.

20.0 HARMONICS TEST

Inverter will be tested at the manufacturer’s works or at a reputed laboratory for total
harmonics content using the wave analyzer and RMS distortion meter. Total
harmonics content shall be less than 5% up to 20th harmonic.

21.0 TRANSIENT VOLTAGE TEST

The transient voltage test shall be done by applying surge voltage waveform as
shown in para 22 of IEC-60571 corresponding to the test voltage of 4 kV and the time
“D” of 1 micro second.

22.0 ENDURANCE TEST

The inverter will be run with full connected load as specified in para 9.0 of this
specification with an input voltage of 72 VDC for 20 hours duration continuously.

23.0 COMMISSIONING TESTS

Unpack the inverter unit and check that it is not damaged. Energize the unit and
check for performance tests by simulation method before fitment on the loco. Mount
the assemblies of the unit on the loco and conduct the tests as per following table :

1. Proper mounting of cubicle and its rigidity.

2. Insulation and dielectric test.
3. Performance test.
4. Proper functioning of protections, indications & meters by simulation method and
operating switches.
5. Ensure operation of earth fault unit as explained above in clause 15.17
6. Check starting of compressors at 60 V DC input on first two locomotives and on
every 20th locomotive provided with same make of inverter.

Page 26 of 37
 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

Apart from this, after clearing the prototype test, the equipment shall be installed on
loco and on-line monitoring shall be conducted by RDSO in association with the
supplier to monitor the following :

1. Temperature rise of critical components as identified.

2. Harmonic analysis at the output of inverter.
3. Acoustic noise measurement.
4. Input over voltage when the load is thrown off.

All the necessary arrangement for the on line testing and instrumentation involved
shall be arranged and installed by the manufacturer. This monitoring is to be done
only once as a type test and need not to be repeated if already carried out, in case
no any significant change is involved in the inverter design.

Page 27 of 37
 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE - C

DATA SHEET FOR AC UNIT

(TO BE FURNISHED BY THE SUPPLIER)

A/C package unit model/type

Make of the AC unit
Cooling capacity of the unit
Over all dimensions (length x width x height)
Weight of the complete AC unit
Refrigerant used
Conditioning air output and static head in water gauge
Fresh air quantity
Total power input for the AC unit under conditions of cooling and heating
Starting current with duration
Rated voltage, frequency and phase of power supply input
Full load current at rated voltage and at minimum voltage

COMPRESSOR UNIT

Type/Model No.
Maker’s name
Power required to drive compressor for specified cooling capacity
Detail of spares
Rated speed
Type of cooling
Insulation class
Enclosure type
Efficiency
Peak current with duration at starting
Details of anti vibration mounting provided
Drawing/Sketch No.

REFRIGERANT CONDENSER UNIT

Maker’s name
Type/Model No.
Heat rejection capacity (Kcal/hr.) at condensing temperature 60 deg.C
Cooling air temperature for inlet and outlet
Corrosion treatment
Method of cleaning
Over all dimensions
Face area in sq. mm
Drawing/Sketch including mounting details

Page 28 of 37
 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

CONDENSER FAN

Manufacturer’s name
Type of mountings
Air displacement ( m³/hr )
Face velocity of air blown over the condenser
Drawing/Sketch No.

CONDENSER FAN MOTORS

Manufacturer’s name
Type of model and make
Nominal voltage
Rated speed
Continuous rating ( HP/KW )
Rated current at rated voltage
Type of cooling
Type of insulation
Type of enclosures
Degree of protection provided for enclosures
Details of anti vibration mounting provided

ACCUMULATOR

Storage capacity
Material
Protection against corrosion

DEHYDRATOR-CUM-FILTER

Manufacturer’s name
Type/Model No.
Frequency of replacement

EVAPORATOR

Maker’s name
Type/Model No.
Refrigeration effects ( Cal/hr ) at evaporation temperature of 5 deg. C
Heater type
Rated heater capacity
Details of condensate water drip tray
Details of distributor type and size

Page 29 of 37
 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

BLOWER

Manufacturer’s name
Type/Model No.
Face velocity of air blown over the cooling coil
Static head (WG)
Pressure drop across the coil (WG)

BLOWER FAN MOTOR

Manufacturer’s name
Type/Model
Nominal voltage
Rated speed
Continuous rating (HP/KW)
Rated current
Class of insulation
Type of enclosure

CONTROL

Type of thermostat
Location of thermostat
Temperature setting for cooling and heating
Differential in deg. C for cut-in & cut-out of thermostat
Details of HP cutout
Details of LP cutout
Details of over heat protector

FILTERS

Type of filters (Dry/Wet)

Overall dimensions
Filteration area
Filteration medium
Filteration efficiency
Air flow rate capacity
Method and frequency of cleaning

MOUNTING AND OTHER DETAILS

Mounting details of the package unit offered, design and structural frame details.
Protection required on the cab roof for safety of roof mounted AC Unit against rain.
Draining arrangement for the condensate water.
Details of opening arrangement for maintenance/attention.
Details of lifting arrangement for mounting and dismantling the AC unit from the cab.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE - D

DATA SHEET OF INVERTER

(TO BE FURNISHED BY THE SUPPLIER)

1.0 RATINGS

Continuous rating. …….kVA. …….PF. …….V. …….Hz.

Short time rating. …….kVA. …….for ……..seconds.

2.0 CUBICLE

2.1 Cubicle sizes (inclusive of all projections)

Height………..mm
Width………...mm
Depth………...mm

2.2 Weight ……………..Kg

2.3 Type of mounting …………… ON Board

Degree of protection

On-Board inverter IP……..

3.0 SWITCHING DEVICE USED

3.1 Type IGBT/MOSFET/GTO

3.2 Make ……………….

3.3 Ratings

Continuous Current ………….. Voltage ……………

Short time Current……………..Voltage ……… Seconds ……
Maximum switching frequency …………………
dv/dt rating ………………....
di/dt rating ………………....

3.4 Characteristic curve ……………........

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

3.5 Total no. of power devices used in the cubicle ………………..

Details of snubber circuit components ........................

Maximum permissible junction temperature for the device and dental-rated

value considered in design. ……….Degree C

Power devices connection arrangement …………

4.0 TRANSFORMER/CHOKE

4.1 Numbers ………….

4.2 Whether used at intermediate

stage or output stage ………………..

4.3 Operating frequency. ………………Hz

4.4 Rating of Inductor/Transformer ……. ………..KVA.

4.5 Type of insulation ……..Class.

4.6 Temperature rise at full load ……….Degree C.

4.7 Degree of protection IP………

4.8 Air cored/Iron cored (for Inductor) ……….

5.0 DETAILS OF CONTROL, PROTECTION AND INDICATION CIRCUITS

6.0 COOLING ARRANGEMENT DETAILS

i) No. of cooling fans …………

ii) Winding insulation of cooling fan …………
iii) Operating voltage of each fan …………
iv) Current …………
v) Watts ………....
vi) Efficiency …………
vii) Type of Bearing …………
viii) Protections for fan …………

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

7.0 EFFICIENCY AND LOSSES

- No load losses ……….. Watt.

- Full load efficiency with

specified input voltage ……….%

- Light load efficiency at

10% of full load at specified
input voltage ………...%

8.0 OUTPUT WAVE SHAPE AND % HARMONICS AT FULL LOAD

……………

9.0 MCCB

Make
Rating
Data sheet
Type test certificate.

10.0 MAIN FUSE

Make
Rating
Data sheet
Type test certificate

11.0 FILTER ELEMENTS (IF PROVIDED)

Nos.
Size.
Type.
Cleaning Method.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE - E

PLANTS AND MACHINERY REQUIRED FOR AC UNIT

1.0 Machineries & Plants Capable for processing stainless steel used during
manufacturing :

1.1 Stainless Steel Processing machines

a) Shearing machine
b) Hydraulic/Pneumatic/Power press
c) Drill machine
d) Punching machine
e) Bending machine
f) Lathe machine
g) Dynamic balancing machine
h) Grinding machine & portable grinder
i) Jig & fixture suitable for welding, leveling and mounting

1.2 Welding / Brazing Machines

a. TIG & MIG welding machine

b. Spot welding machine
c. Brazing machines

2.0 Tools and Plants

a) Vacuum pump
b) Leak testing tank
c) Air compressor with reservoir
d) Refrigerant charging arrangement
e) Tool and dies suitable for stainless steel processing
f) Measuring tapes
g) Vernier calliper
h) Standard measuring gauge
i) Screw gauge
j) Hand lamp
k) Other hand tools like spanner, pipe bending machine etc.

3.0 Testing Facilities

a) Rain test arrangement.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

b) 1000 V DC Megger / Insulator tester.

c) DA set for frequency change test.
d) Power supply arrangement for obtaining variable voltage ( 230 ±
5% ) and variable frequency ( 50 Hz ± 3% ).
e) Electronic leak detector.
f) Capacity test arrangement :

• Test room comprising of hot and cold chambers of size 5 m x 5 m

(approx) each with arrangement to maintain 50 deg.C (DB), 25 deg.C
(WB) and 25 deg.C (DB), 16 deg.C (WB) respectively.
• Raised platform for keeping AC unit for capacity test.
• Dry and wet bulb thermometers.
• Pressure gauge.
• Micrometer.
• Watt meter.
• Power factor meter.
• Voltmeter.
• Ampere Meter.
• Tongue tester.
• Frequency meter.
• Manometer.

4.0 OTHER REQUIREMENTS

a) Firm shall produce their proposed quality assurance plan (QAP) in respect
of procurement of raw material, manufacturing and in house inspection and
testing of complete AC unit.

b) The firm should have R&D facilities to investigate into various types of
failures and suggest necessary preventive measures.

c) Full fledged coil manufacturing facilities, if firm intends to manufacture coils

themselves (desirable).

d) The firm shall be ISO approved.

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 SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE - F

PLANTS AND MACHINERY REQUIRED FOR INVERTER

a) Dust free environment for the assembly of PCBs.

b) Component lead forming machines/fixture.
c) Temperature controlled wave soldering machine with auto-fluxing facilities.
d) Dry heat test chamber.
e) Power analyzer.
f) Multi-channel temperature scanner.
g) Suitable test equipment for measurement of PWM supply.
h) Functional testing of PCBs preferably with computer.
i) Electro static discharge protection in line with IS : 10087-1981. Work
procedure for following ESD practices needs to be submitted :
(i) Automatic / light beam guided component insertion machine for
PCBs.
(ii) In circuit testing machine for checking the correctness of component
inserted in PCBs.
j) ISO 9001 Certificate.

Facilities from serial No. (a) to (g) are considered essential at developmental stage.

The firm will give details of the facilities as existing on date along with the proposed
plan for augmentation of the shortfall with expected duration while submitting the
offer. The duration should be within one year from the date of the first order.

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SPECIFICATION NO. MP.0.42.00.01 (Rev 01)

ANNEXURE – G

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