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of 14 Issued on 25.04.2014 Specification No. IRS:S 9112014 Version l.0Document Title: Specification for Transformer-Rectifier Set

SPECIFICATION

OF

TRANSFORMER RECTIFIER SET

FOR

S&T INSTALLATIONS

Version 1.0

Number of pages 14

SPECIFICATION NO. IRS:S: 91/2014

Issued by

SIGNAL DIRECTORATERESEARCH DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYSMANAK NAGAR

LUCKNOW-226011

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of 14 Issued on 25.04.2014 Specification No. IRS:S 9112014 Version 1.0Document Title: Specification for Transformer-Rectifier Set

DOCUMENT DATA SHEET

Designation - IRS:S 91/2014 Version 1.0

Title of Document

Specification for Transformer - Rectifier Set

Authors:

S.N.RamDesignation: Jt. Director/Signal, RDSO

Approved by

Name: Shri Mahesh MangalDesignation: Sr. Executive Director/Signal,RDSO

Abstract

This document defines specification for Transformer-Rectifier Set

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I of 14 I Issued on 25.04I Document Title: Specification for Tr

DOCUMENT CONTROL SHEETNAME ORGANI

Vijay Kumar, DDSIG-1 RD

S. N. Ram, JDSIG-1 RD

Sh. Mahesh Mangal, RDSr.EDSIG

.

.

I Prepared by: ~ I Chec

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.2014 Specification No. IRS:S 9112014ansformer-Rectifier Set

SATION

so

so

so

Version 1.0

FUNCTION LEVEL

Member Prepare

Member Prepare

ApprovingAuthority

Approve

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of 14 Issued on 25.04.2014 Specification No. IRS:S 91/2014 Version l.0Document Title: Specification for Transformer-Rectifier Set

Specification Version Amendment Amendment Issued OnNo. Details

IRS:S 91/93 --- --- --- 1993IRS:S 91/93 --- 1 CI. 2.7 modified, CI. 2.9 (vii) 01.10.1999

modified, CI. 2.11 modified,CI. 3.7 modified, CI. 3.8modified, CI. 3.1° added, CI.4.1 modified, CI. 4.4 modified,CI. 4.8, CI. 4.11.1 modified

IRS:S 1.0 --- Causes modified-91/2014

CI. 1.3,2.2,2.3,2.4,2.6,2.7,2.9(i), 2.9(iii), 2.9(v), 2.9(viii),2.11,2.12,2.13,3.4,3.5,3.7,3.10,4.1,4.2,4.3,4.5,4.6,4.8,4.10,4.11.1.

New clause added- CI. 2.9(ix)

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of 14 . Issued on 25.04.2014 Specification No. IRS:S 91/2014 Version 1.0Document Title: Specification for Transformer-Rectifier Set

INDIAN RAILWAYSTANDARD SPECIFICATION

FOR

Transformer - Rectifier Set, IRS:S: 91/2014 Ver. 1.0

1. SCOPE

1.1 This specification covers the technical requirements of Transformer-Rectifier set for use in Railways signalling installations, where reliable ACsupply is available.

1.2 The performance of the Transformer-Rectifier set is guaranteed for avariation of ± 10% around the rated nominal input voltage of 230/11 OV. Incase the input voltage varies by more than 10%, use of a separate ACvoltage stabilizer in conjunction with the transformer-rectifier set isrecommended. Additional input tappings of 200, 210 & 220V shall beprovided to cater for cable voltage drop for remote locations. In case of110V input unit, additional input tappings shall be 90, 95 & 100 V.

1.3 The nominal output voltage and current shall be specified by the purchaser.Recommended voltage ratings are 12, 24, 60 & 110V and current ratingsare 5, 10, 20 and 50/80 Amps.

2. GENERAL REQUIREMENTS

2.1 The Transformer-Rectifier set shall be air-cooled type having sufficientslots/holes provided for ventilation in such a way that dripping water doesnot enter inside easily.

2.2 The outer casing of the transformer - rectifier set shall be fabricated of coldrolled closed annealed mild steel sheet of at least 2 mm ± 0.12 thickness asper IS: 513.

2.3 The unit shall be of robust construction and withstand bumps and shocks asencountered in transportation by rail or road in Packed/unpacked condition.

2.4 The cabinet sides shall be provided with less than 3 mm louvers coveredwith wire mesh to prevent entry of rodents, lizards, etc for ventilation.

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2.5 A circuit diagram on an anodized aluminum plate of minimum thickness of 1mm shall be fixed conspicuously inside. All components shall be indeliblymarked and their values/ratings indicated on the diagram.

2.6 The cubicles of transformer rectifier unit shall be treated with zinc; chromateprimer followed by electrostatic epoxy powder coating paint finish;passivation shall be done through seven stage process. Small metal partssuch as nuts, bolts and washers shall be either galvanized or chromeplated. All other metal parts of the transformer rectifier unit shall be platedfor protection against corrosion.

2.7 All cables and wire used for wiring shall conform to Specification No. IRS:S76-89/1S 694 (1100V grade) and shall be procured from ROSa approvedsources. The cables and wires used shall be neatly secured in position bybunching and strapping. The gauge of wiring shall be such that the currentdensity does not exceed 3A/mm2

.

2.8 All connections shall be made though crimped eyelets and shaU benumbered with PVC cable marker rings.

2.9 Following components shall be provided on the front panel.

i) A double pole ON/OFF switch conforming to IS: 60947 (Pt. 3) forswitching ON/OFF of the AC mains.

ii) Power 'ON LED' indication.iii) HRC fuses of suitable rating conforming to IS: 13703 (Part-1) along

with fuse carriers on the output side and input side. Fuse links up to6.3A rating shall confirm to IEC 60127-2.

iv) One set of insulating output terminals for connection of load. Thenegative terminal shall be of black colour while positive terminal shallbe of red colour. These shall be of sufficient size to facilitateconnection of wires of size commensurate with rating.

v) A common Digital meter of 3% digit with accuracy ± 1%, ± 3D orbatter shall be provided to display output voltage/current with pushbutton type selector switch.

vi) A green terminal marked 'Earth' for earthing.vii) .Input taps shall be provided for 200V, 210, 220 and 230V (for unit of

230V nominal input) and 90,95 & 100 V (for unit of 110V nominalinput)

viii) Additional output taps shall be provided at 15V, 28V, 65V and 130Vfor 12, 24,60 and 11OV rating units respectively.

ix) Input taps and output tap shall be provided inside the cubicle on theTransformer and shall be accessible only when the cover isremoved.

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2.10 Provision shall be made to terminate the AC input leads on terminalsprovided on the equipment.

2.11 The transformer used shall be double wound and shall be vacuumimpregnated. It shall be air-cooled type and shall conform to IS:6297 as faras applicable. Class '8' or some higher grade of insulating material shall beused.

The temperature rise of the core and winding shall not be more than 65deg. C over the ambient temperature under worst operating conditions. Thegauge of the winding wire shall be such that the current density does notexceed 2.0 A/Sq.mm.

2.12 When tested in accordance with CI. 8.2.1.6 or IS: 6297 (Pt. I) thetransformer shall not show insulation resistance of lower than 1000 M.ohms when measured at an ambient temperature of 40 deg. C and RH of60%. Also the insulation resistance value shall not fall below 500 M/ohms atan ambient temperature of 40 deg. C and RH of 60% at the end of climatictests.

2.13 Semiconductor diodes in bridge configuration for full wave rectification shallbe used. The peak inverse voltage of the diodes shall be more than doublethe expected voltage across them. Maximum temperature of semiconductordevices shall not rise by more than 40 deg.C above the ambienttemperature. The current rating of the diodes used shall be more than twicethe value of current through them. The manufacturer shall declare the peakinverse voltage, current rating and working temperature of thesemiconductor diodes under ambient conditions.

Diodes shall be mounted on heat sinks of adequate capacity and RC surgesuppression network shall be used for protection of diodes. All electricalcomponents shall be suitably derated to improve reliability.

2.14 Solid state industrial grade components of high reliability shall only be used.These shall conform to relevant IS specification.

2.15 All non-current carrying metal parts shall be bonded together and earthed.An earth terminal capable of accommodating a 4 mm dia Wire, shall beprovided.

3. PERFORMANCE REQUIREMENTS

3.1 The transformer rectifier unit shall be designed and manufactured forcontinuous operation at rated load in the ambient temperature range of 0 to55 deg.C with RH reaching up to 95%.

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3.2 The unit shall be rated for 230/11 OV AC single phase input voltage at afrequency of 50Hz ±2Hz.

3.3 The nominal output voltage and current shall be as specified by thepurchaser.

3.4 The DC output of the unit shall be smoothened by use of a suitable filtersuch that the RMS ripple content of the output voltage when delivering therated output current through a resistive load, measured by an oscilloscope/true r.m.s. multimeter shall not be more than 5%.

3.5 The overall watt efficiency shall not be less than-

i) 75% for rectifiers above 500VA capacity.ii) 65% for rectifiers of 500VA to 250VA capacity.iii) 55% for rectifier less than 250VA capacity.

3.6 The no load input current of the transformer-rectifier unit shall be less than10% of the rated input current.

3.7 No load to full load voltage regulation of the transformer when measuredwith the highest voltage tapping on secondary side loaded to the ratedcurrent shall be < 10% for < 100VA, < 5% for 100VA & above.

3.8 The 'ON LOAD' output tap voltages shall be within 2.5% of the nominalvoltages.

3.9 Each transformer-rectifier unit shall be provided with an anodisedaluminium weather proof plate having following information.

a) Name or trade mark of the manufacturerb) IRS specification No.c) Rated input voltage and frequencyd) Rated output voltage and currente) 'Serial No. and year of the manufacture.

3.10 The output voltage regulation of transformer rectifier unit at no load to fullload shall be less than-

i. 30% for 12V.ii. 20% for 24V.iii. 10% for 60V & above ratings.

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of 14 Issued on 25.04.2014 Specification No. IRS:S 9112014 Version 1.0

4. TESTS

Document Title: Specification for Transformer-Rectifier Set

4.1 Type tests

The following tests in under noted sequence shall be carried out as typetests

a)b)c)d)e)f)g)h)

Visual inspectionInsulation resistance testApplied high voltage testInduced High voltage testTests for continuous operationPerformance testTemperature rise testClimatic tests

(CI4.4)(CI. 4.5)(CI. 4.6)(CI. 4.7)(CI. 4.8)(CI. 4.9)(CI. 4.10)(CI.4.11)

Type test shall be carried out on one sample.Firm shall submit the sample of the following rating:-

i. 24V, 20A rating for covering the approval of all voltage & currentfrom 0-20A and

ii. 24V, 50/80A rating for covering approval of all voltage & current fromgreater than 20A to 50/80A as per rating of the equipment tested.

The sample shall successfully pass all the type tests for proving conformitywith this specification. If the sample fails in any of the type tests, thepurchaser or his nominee at his discretion may call for another sample ofthe same type and output rating and subject it to all tests or the tests inwhich failure (s) occurred. No failure shall be permitted in the repeat tests.

4.2 Acceptance test

a)b)c)d)e)f)

Visual inspectionInsulation resistance testApplied high voltage testInduced High voltage testPerformance testTemperature rise test

4.3 Routine Test

(CI 4.4)(CI. 4.5)(CI. 4.6)(CI. 4.7)(CI. 4.9)(CI4.10)

The following shall constitute routine tests and shall be conducted by themanufacturer on every transformer-rectifier unit and test results shall besubmitted during the inspection.

a) Visual inspection (CI4.4)b) Insulation resistance test (CI. 4.5)c) Induced High voltage test (CI. 4.7)

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Performance testTests for continuous operation

(CI. 4.9)(CI. 4.8)

4.4 Visual Inspection

The Transformer-rectifier unit shall be examined for provision of all facilitiesstipulated in the Clause 2 of specification, correct wiring, proper mounting ofcomponents, workmanship and finish for which no tests have beenspecified.

4.5 Insulation Resistance test

This test shall be carried out

a) Before the high voltage testb) After the high voltage testc) After the climatic test

The measurement shall be made at a potential of 500V, DC. The insulationresistance for transformer - rectifier unit shall be measured between -

a) Input line terminals and the body of the transformer-rectifier unit.b) Output line terminals and the body of the transformer-rectifier unit.c) Input terminals and output terminals of the transformer-rectifier unit.

The insulation resistance for transformer shall be measured between -a) Primary & Secondary of transformerb) Primary and Bodyc) Secondary and Body

When measured at a temperature of 40°C and relative humidity of 60%, thevalue of the insulation resistance shall not be less than 10 Meg ohms forthe complete transformer- rectifier unit and shall not be less than 1000 Megohms for the main transformer. There shall not be any appreciable changein the measured value of insulation resistance before and after highvoltage test. When the test is repeated after the climatic tests, these valuesshall not be less than 5 Meg ohms and 500 Meg ohms respectively, whenmeasured at a temperature of 40°C and relative humidity of 60%.

Note: In case the prevalent values of temp. & R.H. at the time ofmeasurement are different from those specified above the IR valuesshall be obtained from table 'A'

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I ofl4 I Issued on 25.04.2014 I Specification No. IRS:S 9112014 Version 1.0I Document Title: Specification for Transformer-Rectifier Set

Table 'A'Value of Insulation Resistance in M.ohms at different temperature andrelative humidity

95% 15 M 10M.

65% 100 M

R.H>100 M >100 M

90 M.>100 M. -1-------185 M

>100 M.80 M.60 M.

85% 29 M 25 M. 22 M. 18 M.

60%

70% 80 M 70 M. 65 M.75% 60 M 53 M. 47 M. 43 M.80% 42 M 36 M. 33 M. 30 M.

90% 20 M 16 M. 13 M 10 M.7 M. 5 M.

100% 10 M 6 M. 3 M. 1 M.

Note 1. The value of insulation resistance has been taken at 100 M.ohms ata temp. of 40°C and R.H. of 60%. Values of I.R. at different temp.and R.H. may be obtained from the table.

2. To obtain the value of I.R., corresponding to 500 M.ohms or 1000M.Ohms or 50 M.ohms at 40°C and 60% RH, a multiplying factor of5.0, 10 and 0.5 respectively may be used.

3. The value of insulation resistance for extreme conditions oftemperature and humidity shall not be less than 1 M.Ohm even ifthe value at 60% R.H and 40°C temperature is less than 100M.ohms.

4.6 High Voltage Test

The transformer-rectifier unit shall withstand for one minute, a test voltageof 2000V, AC rms applied between-

i. Input terminals and output terminals.ii. Input terminals and Earthiii. Output terminals and Earth

4.7 Induced High Voltage test

The transformer of the unit without load shall be connected to a voltageequal to 2 times the nominal input voltage at double the rated frequency.The voltage shall be raised from 1/3rd of the nominal value to full value. Fulltest voltage shall be maintained for one minute and shall then be rapidlyreduced to 1/3rd of the nominal voltage before being switched off. At the endof this test, the unit shall meet the requirements of IR test (CI.4.5) and noload input current (CI. 3.6)

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4.8 Continuous operation test

The unit shall be subjected to a continuous operation for 1000 hours in typetest (CI. 4.1 (e) ) and for 72 hours in routine test (CI. 4.3 (e) ) at maximumrated input and 125% of the rated output current. After these tests, the unitshall not show any deterioration in its performance.

4.9 Performance test

The unit shall be tested to check the performance requirements specifiedunder clause 3.2 to 3.8.

4.10 Temperature rise test

The cold resistance of transformer windings shall be measured afterconditioning the unit. This temperature shall be taken as referencetemperature T1.

The transformer rectifier unit shall be connected to input voltage of230V/110V and rated maximum load shall be connected across the outputterminals. The unit shall be kept ON till temperature equilibrium is reachedi.e. the temperature variation between three successive readings taken at30 minutes interval is less than 1 deg. C. Now hot resistance of transformerwindings shall be measured within 1 minute of switching off the inputsupply. The ambient temperature T2 shall be measured.The temperature rise of the windings shall be computed by the followingformula

R2- R1T = --------- (234.8 + T1) - (T2- T1)

R1

T is the temperature rise.R1 is resistance of winding at the beginning of the test.R2 is resistance at the end of the test.T1 is the room temperature at the beginning of the testT2 is the room temperature at the end of the test

The temperature of the rectifying diodes, resistors, electric junction(carrying more than 5 amps current) shall be measured by means ofthermometer (thermo couple type) without disconnecting the load. Thethermo couple used for determining the temperature rise of the differentcomponents shall be attached to the back of a small blackened disc ofcopper or brass 15 mm in diameter and 1 mm thick which is flush with thesurface of component.Maximum temperature rise above ambient (T2) of different componentsshall be as per Table-B.

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Table -8

SN Components Max pennissible temperature riseabove ambient temp.

1 Diodes Not more than 40°C2 Electric junctions (terminals, switches 15°C

etc.)3 Resistors 50°C4 Transformer & Choke <65°C for Class B (CI 2.11) & <90

°C for Class F type insulation.

4.11

4.11.1

4.11.2

4.11.3

4.11.4

4.12

Climatic test

Dry heat test

The unit shall be subjected to this test in accordance with IS:9000 (PartIII/Section 5) - 1977 at 70 deg. C for a period of 16 hours. During the test,the unit shall be loaded with its rated capacity and at the end shall bechecked for performance required as per clause 3.0.

Damp heat (Cyclic) test

For variant 1 for 7 cycles as per IS: 9000 (pt. V) Section 2 shall beperformed.

Cold Test

The test shall be done at 0 deg. C in un-energised condition for 2 hoursduration as per IS:9000 (Pt. II).

Immediately after the damp heat test, the IR value of the unit andtransformer shall be measured.

Sampling plan

The following sampling plan shall be adopted for acceptance tests

Lot size Sample size (except for Sample size (for temp.temp. rise test & induced rise test & induced high

high voltage test) voltage test)2-8 2 19-15 3 116-25 5 226-50 8 251-100 13 3101-150 20 3151-200 32 3

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of 14 Issued on 25.04.2014 Specification No. IRS:S 91/2014 Version 1.0Document Title: Specification for Transformer-Rectifier Set

4.13 Packing and Labeling

Transformer-Rectifier units complete shall be packed in suitableboxes/crates, strong enough, to prevent damage to the unit during transitand handling. Loose space inside the box/crate shall be filled up withsuitable packing material.

***********

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