RESEARCH DESIGNS & STANDARDS ORGANISATION · PDF file(vi) Regulated Battery charger (vii)...

of 21 File No. EL/7.1.108 Effective from 7.10.2003 K2-B-01 Pt.II (Electrical)

Prepared By Checked By

RESEARCH DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAY

POWER SUPPLY & EMU DIRECTORATE

TITLE

PARTICULAR SPECIFICATION FOR LHB VARIANT AC 2 TIER EOG TYPE COACHES FITTED WITH RMPUs

S.N. Date of amendment

Revision No. Page No. Reasons for amendment

APPROVED EDPS



SPECIFICATION NO.K2-B-01 PART-II (ELECTRICAL)

PARTICULAR SPECIFICATION FOR LHB VARIANT AC 2 TIER EOG COACHES FITTED WITH RMPUs

0.1 FOREWARD 0.2 This particular specification for LHB variant AC 2 Tier EOG type coaches has

been prepared for manufacture of these coaches as per the technology received from M/s. LHB, Germany for the same incorporating essentials of Indian Electricity Act and UIC norms. The design and standards for various equipments and sub assemblies have been incorporated as per the specification for the same prepared by RCF based on transfer of technology received by them from M/s LHB. The specification and design for equipments will be standardised by RDSO in future after incorporating the technology offered by M/s. LHB as well as field experience of these equipments. Till such time the RCF specifications for various equipments as mentioned in this particular specification shall be followed.

0.3 This particular specification applies to B.G. L.H.B. variant AC 2 Tier EOG type

coaches to RCF layout No. LW90006. 0.4 The coach shall be suitable to work on End On Generation (EOG) system for

supply of power from the power cars provided at either end of the rake. 0.5 The coach is supplied with 750V 3-phase supply, which is defined as high

voltage as per definitions given in rule 2 of Indian Electricity Rules. This particular specification incorporates the provision of Indian Electricity Rules 2, 29, 30, 31, 32, 33, 34, 35, 37, 41, 42, 43, 44, 45, 48, 50, 51, 52, 54, 58, 61, 64, 64 (A), 67 & 70 for design and manufacture of coaches to ensure electrical safety of passengers. However, in case Electrical Inspector to the Government of India during his inspection considers the relevance of additional clause of IE rules, the same shall also be complied by the owner seeking sanction.

0.6 The UIC codes 550, 550-1,533 shall generally be applicable for the purpose of

electrical design and its standardisation towards public safety and amenities wherever not specified in this specification.

0.7 The provisions of IE rules are statutory in nature and shall be overriding UIC

stipulations wherever applicable.



0.8 The electrical equipments mainly consist of the following:-

(i) Roof Mounted AC Package Unit with micro controller (RMPU). (ii) Switch Board Cabinet (iii) Electrical light fittings (iv) Electrical wiring (v) 60 KVA, 750/415V, 3Ph 50Hz step down transformer (vi) Regulated Battery charger (vii) Battery (viii) Pump equipment with PLC controller and pump box (Water raising

apparatus) (ix) Pantry appliances (x) ZS couplers (Inter vehicle Coupler) (xi) Protection system (xii) Mobile and Laptop charging facility (xiii) Power supply to public address system, anti skid device etc. (xiv) Fan for electrical cubical and toilets

1.0 SCOPE 1.1 This specification lays down the technical requirements of equipments for

electrical lighting, ventilation and air conditioning, water supply, various controls etc. of LHB variant of AC 2 Tier coaches working on EOG system.

2.0 COMFORT CONDITION

2.1 The AC package unit shall have adequate capacity to air condition the coach

under the following conditions:

Summer conditions Dry bulb Wet bulb % RH Outside (dry summer) 50 deg C 25 deg C - Outside (wet summer) 40 deg C 28 deg C - Inside (dry & wet) 22-25 deg C - 60 – 40%

2.2 The design of RMPU shall be such as to restrict relative humidity to 60% maximum inside the air-conditioned compartment under any circumstances.



3.0 GENERAL: 3.1 The 750V three phase, 50 Hz AC power supply will be received in the coach

through two ZS couplers provided on each end wall of the coach. 3.2 Each coach shall be provided with two Roof Mounted A.C. Package units with

a cooling capacity of approx. 21000 K cal/hr. (Not less than 7.0 TR) for each RMPU.

3.3 The Roof Mounted A.C. Package Unit shall work from 415V, 3Ph, 50Hz,

supply obtained from 750/415V, 3Ph, 50Hz, 60KVA transformer provided on underframe of the coach.

3.4 The coach interior lighting will be provided with fluorescent tube lights of

2x18Watt working at 110V AC. The lavatory, doorway, & kitchen will be provided with 1x18 watt fluorescent tube lights working at 110 V AC.

3.5 The coach will have provision of 10 Watt, incandescent emergency lights

working on 110V DC battery. Apart from these, all the lavatories, doorway and few passenger compartment lights of 18 W each will work on 110 V DC also during emergency. The emergency lights switch ‘on’ automatically when power supply from power car fails.

3.6 Each seat will have berth reading light of halogen lamps of 10 Watt each. 3.7 The coach will have two pump equipment with PLC controller for meeting the

water supply requirement of the coach by pumping the water from two under frame mounted 685 liters capacity tanks to the over head tanks.

3.8 The coach will have hot case, bottle cooler and refrigerator working at 240V

AC for the sub-pantry of the coach. 3.9 All the electrical equipments will be provided with suitable protection

arrangements for timely clearance of faulty equipments/circuits. 3.10 The control for anti skid device, light control, emergency lights, reading lights,

telephones, night lights, air condition control, berth indication lights, power contactors etc are working on 110 V DC supply.



3.11 The following equipments shall be provided in the coach.

(a) Equipment mounted on the coach under frame:-

(i) Transformer 60 KVA, 750/415V, 3Ph, 50Hz - 1 No. (ii) Pump equipment with PLC controller - 2 Nos. (iii) Emergency Battery-110V, 70 Ah - 1No (iv) ZS Couplers - 750V, 3Ph, 4 wire - 2 Sets

(b) Equipment mounted on the coach/coach roof.

(i) Roof Mounted AC Package Unit (RMPU) - 2 No. (ii) Switch board cabinet - 1No. (iii) Battery charger - 1 No. (iv) Disconnecting and earthing device - 1 No.

3.12 Roof Mounted Package Unit (RMPU) shall be mounted on both ends of the

coach between roof and false ceiling as shown in RCF layout No. LW-90006. 3.13 The RMPU shall conform to RCF specification No. EDTS-075, Rev.A, corr.1

type I (with two RMPUs and one microprocessor controller). 4.0 DESIGNS FOR ELECTRICAL EQUIPMENT

The design for various electrical equipments will be such that all electric supply-lines and apparatus shall be of sufficient ratings for power, insulation and estimated fault current and of sufficient mechanical strength, for the duty which they may be required to perform under the environmental conditions of installation and shall be constructed and installed to ensure safety of human beings and property.

4.1 Power Supply Arrangement

The power system for the coach has been designed to feed the various electrical loads in the system operating at different voltages. There will be following voltage systems for feeding the various electrical loads. i) 750 V, 3 phase, 50 Hz AC ii) 415 V, 3 phase, 50 Hz, AC



iii) 240 V, single phase, AC iv) 110 V, single phase, AC v) 110 V, DC

4.2 The input supply of the coach is at 750V, 3 phase four wire AC supply from the power cars provided at both the ends of the coach through two feeders running in parallel along the length of the coach.

4.3 The 750V, AC and 415 V, AC supplies are categorized as high and medium

voltage respectively in terms of definitions given in rule 2 of IE rules and therefore its all relevant clauses pertaining to generation, transmission, conversion & distribution should be applicable. As UIC provisions have also been incorporated in the particular specification, the provision of Indian Electricity Rules will be overriding to the UIC stipulations wherever applicable.

4.4 As per rule 29 of IE rules, all electric supply lines and apparatus shall be of

sufficient ratings for power, insulation and estimated fault current and of sufficient mechanical strength, for the duties which they may be required to perform under the environmental conditions of installation, and shall be constructed, installed, protected, worked and maintained in such a manner to ensure safety of human beings, animals and property.

4.5 As per rule 42 of IE rules, all circuits and apparatus shall be so arranged that

there shall be no danger of any part thereof becoming accidentally charged to any voltage beyond the limits of voltage for which they are intended. Where AC and DC circuits are installed on the same support they shall be so arranged and protected that they shall not come into contact with each other when live.

4.6 In compliance to IE rule 35, danger notice should be provided at all electrical

installations. Instructions (in English or Hindi and local language) for restoration of person suffering from electrical shock in English and Hindi shall be provided in compliance to clause no. 44 of IE rule.

4.7 As per rule 41 of IE rules, the power car, switch board cabinet and junction

boxes in which there are any circuits or apparatus (whether intended for operation at different voltages or at the same voltage) shall ensure by means of indication of a permanent nature that the respective circuits are readily distinguishable from one another.



4.8 The switch board cabinet receiving the supply from two feeders should have indication of a permanent nature for clear distinction of the supply from these feeders. Similarly the supply coming from pre cooling socket also needs to be provided with an identification mark on the cabinet.

4.9 The control circuit as well as feeder contactor provided for receiving the supply

from the feeders should have necessary interlocking to prevent simultaneous charging of the coach from two feeders, as per approved scheme for the same.

4.10 As per rule 51 of IE rules, all conductors shall be completely enclosed in

mechanically strong metal casing or metallic covering which is electrically and mechanically continuous and adequately protected against mechanical damage unless the said conductors are accessible only to an authorised person or are installed and protected to the satisfaction of the inspectors so as to prevent danger. Non metallic conduits confirming to the relevant Indian Standard Specification may be used for medium voltage installations, subject such conditions as the inspector or officer appointed to assist the inspector may think fit to impose. All metal works, enclosing, supporting or associated with the installation, other than that designed to serve as a conductor shall be connected with an earthing system as per standards in this regard laid down in Indian Standards and also in accordance with rule 61 (4).

4.11 Every switch board shall have a clear space of not less than one meter in

width in front of the switch board. If there are any attachment or bare connection at the back of the switch board, the space behind the switch board shall be either less than 20 cm or more than 75 cm in width measured from the farthest outstanding part of any attachment or conductor. If the space behind the switch board exceeds 75 cm in width there shall be a passageway from either side of the switch board, clear to the height of 1.8 meter.

4.12 As per rule 30 of IE rules, supply lines will be so laid to be protected against

mechanical, electrical and chemical damage to insulation and with due precaution to avoid danger arising on such premises from such supply lines, fittings and apparatus.

4.13 Appliances to be installed in safe condition so that no danger can arise out

from them. 4.14 As per rule 43 of IE rules, fire buckets filled with clean dry sand and ready for

immediate use for extinguishing fire, in addition to fire extinguishers suitable



for dealing with electric fires, shall be conspicuously marked and kept in all generating stations, enclosed sub stations in convenient situations.

4.15 As per rule 44 of IE, instructions in English or Hindi and the local language for

restoration of persons suffering from electric shocks shall be affixed in power cars and switch board cabinet of coaches in a conspicuous place. All authorised person employed for operation and maintenance shall be acquainted with and are competent to apply the instructions referred to above. In manned coach with high voltage an artificial respirator shall be provided and kept in good working condition.

4.16 While getting any work of electrical installation, commissioning, modification

etc through out side agencies, IE rule 45 should be followed. 4.17 In compliance to the IE rule 54, the incoming supply voltage at coach shall not

vary by more than 6 percent on higher side and 9 percent on the lower side. 4.18 As per rule 50 of IE rules, the control of requisite capacity to carry and break

the current will be placed after point of commencement of supply as per rule 58 so as to be readily accessible and capable of being easily operated to completely isolate the supply of installation, such equipment being in addition to any equipment installed for controlling individual circuits or apparatus. There should be linked switch with fuses or a circuit breaker for low, medium and high voltage.

4.19 As per rule 50 of IE rules, except incase of composite control gear designed

as a unit every distinct circuit protected against excess energy by means of suitable cut out or a circuit breaker of adequate breaking capacity suitably located and so constructed as to prevent danger from overheating, arching and scattering of hot metal when it comes into operation and to permit for ready renewal of fusible metal of the cut out without danger.

4.20 All the insulating material are chosen with special regard to the circumstances

of its proposed use and their mechanical strength is sufficient for its purpose and so far as is practicable of such character or so protected as to maintain its insulating property under all working conditions in respect of temperature and moisture.

4.21 As per rule 64 of IE rules, for supplies at high voltage all the conductor or

apparatus will be so placed so as to be inaccessible except to an authorised



person and all operations in connection with the said conductors and an authorised person carries out apparatus.

4.22 In compliance to the IE rule 64(A), the protection system should automatically

disconnect the supply when rated current of the equipment, cable or supply line is exceeded for a time for which the equipment, cable or supply line is not designed to withstand.

4.23 In compliance to IE rule 31, a suitable cut out should be provided in incoming

supply line of the coach in each conductor of every supply line other than earthed or earthed neutral conductor in an accessible position. Such cut out shall be contained within an adequately enclosed fireproof receptacle.

4.24 The coach will connect the input supply from either of the two feeders

available on the coach at 750V three-phase supply through disconnecting and earthing device provided in switch board cabinet.

4.25 The 750V 3-phase supply is stepped down to 415V, 3-phase supply with the

help of one 60 KVA epoxy cast and encapsulated transformer, which is provided on the under frame of the coach.

4.26 The electrical equipments of Roof Mounted Package Units, exhaust fans &

pump equipment are supplied with 415V, 3-phase supply received from 60 KVA transformer.

4.27 Loads of electrical appliances provided in sub pantry such as hot case, bottle

cooler, and refrigerator shall be fed with single phase at 240V, 50Hz by using one out of the three phases and neutral connection of 3 phase 415 V AC supply.

4.28 The lights, electric razor socket etc. shall be supplied at 110V, single-phase

AC supply received from regulated battery charger. 4.29 The 110 V DC is used for supplying control for Roof Mounted Package Unit,

anti-skid device, light control, emergency lights, telephones, night lights, berth reading lights, power contactors etc.

4.30 A DC-DC converter shall be used to obtain 24 V DC for supplying control

systems for pump, sanitary and public address system, UIC remote control, return air flap unit & servo motor of air conditioning system etc.



4.31 The power & control supply arrangement to various electrical loads in the coaches shall generally be similar to originally imported LHB AC coaches. The 415/240V AC network is designed as unearthed IT-4 conductor system as per IEC-364-4-41.

4.32 Roof coach wiring shall be routed in PVC rigid conduit/trenches conduits.

Under frame wiring shall be with IP 68 protection and shall be covered with perforated cable trays as a primary safe guard against ballasts hitting.

4.33 The design of electrical accessories, connections, terminations of layout etc. of

cables and the sub-assemblies will be in general similar to originally imported LHB coaches.

4.34 The cables used for power and control wiring shall be thin walled Electron

beam irradiated flexible elastomeric cables as per RCF specification No. EDTS 132, Rev. A. Cable marker shall be used for cable identification. The cable markers should not come out during service life.

4.35 All the equipment above 250 V shall be earthed at two places and below 250 V

at one place. Voltage segregation shall be ensured during wiring. 4.36 The system will have earth fault/earth leakage protection to disconnect the

supply automatically, if the earth fault current exceeds the limit of current for keeping the contact potential within reasonable limits.

4.37 General provision of power supply installation in the coach must comply with

the following provision of as indicated in UIC 550. a) Even as per requirement of rule 37 of IE, each vehicle shall be fitted with an

isolating and earthing switch that allows all equipments connected to the train line to be disconnected on load in one action. The position of the device must be marked as given in Annexure A.

b) Suitable rating of the fuses shall be provided to protect against absolute short

circuit that is to say when the short circuit current is more than 5 IN. c) The vehicle axle box shall be fitted with electric insulation in order to allow the

current from loads, connected to the rail line to flow to the rail without damage to the bearing.



d) In order to short circuit the insulation of the axle box following should be fitted on each bogie at least - One axle box with an earth contact through which the return current can

flow and - On the each of the other boxes not fitted with an earthing contact a

shunt of protective resistance of 100 m ohm. - The basic diagram is enclosed as Annexure B

e) All the distribution and control panel of the coach and the equipment cases under the body, in which the voltage is greater than 150V AC or 110V DC shall be marked by a danger sign of skill and bones as per rule 35 of IE rules of a design as per relevant ISS: 2551 on every motor, generator, transformer and other electrical plants and equipments together with apparatus used for controlling or regulating the same, provided that where it is not possible to affix such notices on any generator, motor, transformer or other apparatus they shall be affixed as near as possible thereto (or the word ‘danger’ and the voltage of the apparatus concerned shall be painted on it. Where the generator, motor, transformer or other apparatus is within an enclosure, one notice on the said enclosure shall be sufficient for the purpose of this rule.

f) Sockets that are accessible to passengers and are live during operation can

be fitted with shutters (child protection) as specified in IEC: 884. g) Each coach shall be provided with atleast one spare fuse for high voltage

circuits and two fuses for low voltage circuit, for each size used. h) The spare fuses shall when possible be located in the cupboard equipment,

accessible by means of square socket key. If they are placed elsewhere, their location shall be specified on a notice displaced on the cupboard.

i) The rakes containing the spare fuses shall be marked with the nominal rating

of the fuses. 4.38 All material used in wiring, switch board, connection, clamps/cleats,

assemblies/sub-assemblies will have fire retardant property as per UL 94. 5.0 AIR CONDITIONING AND AIR CIRCULATING SYSTEM 5.1 The coach will be provided with two Roof Mounted Package Unit as per RCF’s

specification No. EDTS-075 Rev.A, cor. 1 type –I (two RMPUs with one microprocessor controller).



5.2 Air conditioning system shall be adjusted for intake of fresh air at the rate of

minimum 0.35 cubic meter per minute per person. 5.3 The air distribution system should be so designed to ensure that maximum air

velocity at 150 mm below duct/ diffuser is 30 m/min and maximum air velocity at the height of 1200 mm above floor level does not exceed 15 m/ min.

5.4 The microprocessor controller shall be mounted in the switch board cabinet of

the coach. 6.0 SWITCH BOARD CABINET 6.1 The switch board cabinet will centrally contain all operating elements for

switching, controlling, adjusting and monitoring of electrical installations. It comprises of all necessary equipments/components for controlling and protection of following coach systems. i) Pantry appliances ii) Heating, ventilation and air conditioning system iii) Public address system iv) Sanitary system v) Coach lighting system vi) Anti skid device vii) Water supply system viii) Cable insulation monitoring system

6.2 The switch board cabinet also contains regulated battery charger and

disconnecting and earthing device. Switch board cabinet shall be as per RCF specification No. EDTS 073 Rev. B.

6.3 The following measuring instruments, luminous signals, switches and keys for

diagnosis and operating function shall be mounted on the door of the switch board cabinet: i) Amp. Meter for battery charging /discharging ii) Volt meter for battery voltage iii) Volt Meter for 3 phase supply , mains 1 iv) Volt Meter for 3 phase supply , mains 2 v) Amp. Meter for 3 phase current



vi) Luminous signals for operation/failure vii) Volume control for public address system viii) Operating and display element for air conditioning system ix) Display of water raising system x) Insulation test etc.

6.4 The coach shall be provided with a power control, distribution, feeder changeover, disconnecting and earthing device, regulated battery charger, microprocessor controller for RMPUs in a Electrical Cubicle. The cubicle shall be provided with five different supply voltage systems isolated from each other i.e. 750V, 415V, 240V, 110V and 24V-supply system.

6.5 A switch shall be provided on switch board cabinet in easily accessible

location for switching off the incoming supply to the coach. 6.6 The disconnecting and earthing device shall be capable to connect/disconnect

“ON” load but it is used after the load is “switched off”. This device is provided for safety of the maintenance staff. The switch should earth the supply system in disconnected position.

6.7 An IGBT based constant voltage constant current (CVCI) regulated battery

charger shall be provided in the switch board cubicle, conforming to RCF specification No. EDTS-074 (Rev.A) for charging the 110V battery.

6.8 The cubicle will have all the protective systems for all the electrical equipment of the coach as provided in the imported coaches from M/s. ALSTOM LHB. 6.9 Precautions shall be taken to prevent the access of passengers to any portion

of electric circuits where there is danger from electric shock and any metal, handrail or metallic substance liable to be handled by passenger, becoming charged.

6.10 All the support members and metallic structure of cabinet shall be properly

earthed to the coach body. 6.11 The general design of the switch board cabinet should meet the following

requirement of UIC 550-1. The switch board cabinet must be provided with one or several doors so as

not to be accessible to passengers.



(a) It must be possible to open the outer doors by means of socket key.

(b) The switch board cabinet must be arranged in two sections one for train staff and one for maintenance staff. The assembly unit, which is subjected to the voltage higher than the permissible contact voltage, must receive special protection against accidental contact.

(c) In the section for maintenance staff, it is recommended that particularly important component which must undergo circumstances be touched should be consequently protected.

(d) Equipments accessible only to maintenance staff must only be accessible by opening all doors of cabinet.

(e) Green push buttons will be used for switching ON and red push buttons for switching OFF.

(f) The operating and control switches grouped on the control panels must carry clear inscription.

(g) All electrical and electronic equipments in the switch board cabinet must have a marking. The marking may be numerical or alphanumeric provided that it confirms to wiring diagram and should allow the function of the equipment together with the fault locating instructions, to be easily understood and maintenance staff to be informed of malfunction as precisely as small.

(h) All locations of fuses must bear an inscription indicating the normal current density, their references in the wiring diagram and also the power intake circuit protected. This inscription must be provided even if fuse concern is not in place.

(j) The door of the switch board cabinet must be so designed that when open during use of the equipment and control panel, they do not interfere with the operation of the automatic door situated in the area and do not hamper passenger’s movement more than a minimum.

6.12 The cubicle should be made from fire proof material with provision of lock to

prevent unauthorised entry. It should be weather proof for working conditions of the coach.

7.0 REGULATED BATTERY CHARGER 7.1 The battery charger is provided for charging 110V, 70 Amp. Hour battery and

feeding the various control supplies and electrical loads working at 110V, DC



supply. The charger is supplied with 415V, 3 phase supply. The charger will be as per RCF specification No. EDTS-074 (Rev.A). It also gives 110V AC for lavoratory and switch board cabinet fans, lights and electric razor sockets etc.

8.0 PUMP EQUIPMENT WITH PLC CONTROLLER AND PUMP BOX 8.1 The requirement of water supply in the coach will be met with the help of two-

pump equipment with PLC controller, which will continuously pump the water from two 685 liters capacity water tank mounted in under frame to the overhead tanks. The pump equipments will work with 415V 3-phase supply and a programmable logic controller will control their functioning. The pump equipment with PLC controller will confirm to RCF specification No. EDTS-094 (Rev. A). The sensor will be provided for dry run protection. Both pump will be working alternatively.

9.0 BATTERY

9.1 The coach will be provided with a battery of 110V, 70 Amp. Hour for supplying the emergency loads of the coach during failures of normal supply of the coach. The battery tank will contain the temperature sensor for monitoring electrolyte temperature that is used to control the charging of the battery for reducing gassing and loss of water. The battery will be as per RCF specification No. EDTS-129.

10.0 TRANSFORMER 60 KVA, 750/415V, 3PH, 50HZ

10.1 3-phase 750V distribution supply voltage for the coach is stepped down to 415V, three phase supply by using a 60 KVA transformer. The transformer will have stainless steel housing with IP 21 protection. The insulation and terminal box will have IP 65 protection. Transformer will confirm to RCF specification No. EDTS-076.

11.0 ZS COUPLER

Each coach will have two set of ZS coupler (inter vehicle coupler) provided on either end of the coach. The couplers with five poles, three phase four wires supply of 750V and two control cables shall be provided at the end walls of the coach at the same location as provided in imported coaches from M/s. Alstom LHB, Germany. The terminal box will have IP-65 protection. The ZS couplers shall confirm to RCF specification No. EDTS-105 (Rev.C).



12.0 EARTHING 12.1 The electrical supply system of the coach will follow the concept of earthing

and protection against shock to the user. As per Para 61 of IE rules the star connected system with earthed neutral or delta connected system with earthed artificial neutral point, the neutral point of every generator and transformer shall be earthed by connecting it to the earthing system as defined in rule 61 (4) and herein above by not less than 2 separate connections.

12.2 The generator will have earthed neutral providing a TN-net. The electrical

couplers of external power cars and passenger’s coaches are fitted with four mains power contactors so that TN-net is continued to each car and coach transformer.

12.3 The 60 KVA transformer will operate, as isolation transformer and secondary

side is not earthed neutral thus providing IT-net according to IEC 364-4-41. 12.4 As no active net conductor is directly earthed, incase of insulation failure only

a low fault current caused by capacitance to earth can flow. The series fuses and circuit breaker do not response to this fault current and supply is maintained even in case of single line earth fault. In case of second fault in another device, one of the faulty devices with fuse or MCB having the lower current capability should be isolated before the permissible contact voltage of 50 V is reached.

12.5 For earthing of metal parts of the coach to ensure safety of passengers the

various aspect of earthing should be followed as per UIC 533. 12.6 All the metal parts of the vehicle liable to be touched by persons and also by

animals and in which excessive contact voltage are likely to be persist, for e.g. due to defect in the electrical installation of the vehicle or from the suspended parts of the category must be at the same potential as the rail, using connections, offering the lowest possible resistance for this purpose.

12.7 The electrical resistance between metal parts and the rail must not exceed 0.05 ohm when measured with a current maintained constantly at 50 Amps with a voltage of 50V or less.

12.8 In compliance to the IE rule 64(A) earth protection system should diconnect

the system automatically in case the earth fault current exceeds the limit of current for keeping the contact potential within reasonable limits.



12.9 When the use of the materials which are poor conductors of electricity, for e.g.

in pivot bearings or axle boxes, do not allow the value specified above to be obtained the following protective earthing must be provided.

- The body to be connected to frame at two different points at least. - The frame to be connected to each bogie at least at one point. - Each bogie must be earthed through atleast one wheel set through the

casing of an axle box or by means of an earthing brush. 12.9 The earth connections, which can be bare or insulated must be flexible and

corrosion resistant. They must be easy to repair and positioned so that they can not suf fer mechanical damage.

12.10 Metal parts fitted to the roof and connected to conducting components inside

the vehicle from where they are accessible must be earthed reliably to the vehicle body.

12.11 The metal parts of current consuming apparatus of an installation must be

earthed to vehicle in a reliable manner. 12.12 As per rule 70 of IE rules, suitable provision shall be made for immediate and

automatic discharge of every static condenser on disconnection of supply. 12.13 The section of the earthing cables depends on that of the conductor through

which the current passes. It must be dimensioned to guarantee reliable functioning of circuit breakers in the event of the failure.

12.14 As per rule 32 of IE rules, an indication of permanent nature shall be provided

by the owner of the earthed or earthed neutral conductor or the conductor which is to be connected thereto, to enable such conductor to be distinguished from any live conductor. No cut out link or switch other than link switch arranged to operate simultaneously on the earthed or earthed neutral conductor and live conductors shall be inserted or remain inserted in any earthed or earthed neutral conductor of a multi wire system or in any conductor connected their to with the exception of a link switch for testing or a switch for use in controlling a generator or transformer.

12.15 As per IE rule 33, an earthed terminal should be provided at the point of

commencement of supply in the coach. All the earthed wires should be provided to have protection against mechanical damages.



12.16 For compliance to IE rule 34, no bare conductor should be used and if at all used, they should not be accessible.

12.17. In compliance to rule 61(3) of I.E rule, all matel casing of metallic covering

containing or protecting any electric supply line or apparatus shall be connected with earth and shall be so joined and connected across all junctions, boxes and other openings to make good mechanical and electrical connections through out the whole length for earthing.

12.18 As per rule 48 of IE rules, for all the equipments working at low and medium

voltage, insulation between each live conductor and earth should be more than one mega ohm with 500V DC applied for a period of one minute. For high voltage equipments, the insulation resistance should be above 5 Mega ohms when 2.5 KV is applied for more than 1 min.

12.19 As per rule 67 of IE rules , all non current carrying metal parts associated with

high voltage installations shall be effectively earthed to grounding system which will limit the touch and step potential to tolerable values. It will also limit ground potential rise to tolerable values so as to prevent danger due to transfer of potential through ground, earth wires, cable sheath, pipe lines etc. It will maintain the resistance of earth connection to such a value as to make operation of the protective device.

13.0 INSULATION MONITORING DEVICE 13.1 Insulation Monitoring Device shall be provided as in the imported LHB

Coaches, which gives indication in case the insulation of the system is less than the preset value of the device.

13.2 Insulation measuring device monitors the insulation resistance of unearthed

AC and 3 phase mains (IT-NETs). 13.3 A measuring DC voltage is created in the device. The positive pole of

measuring device is applied to the mains, which is to be monitored, and the negative pole is applied to earth through an electronic measuring circuits.

13.4 These terminals are permanently monitored and in case of failure (when ohmic

insulation between mains and earth falls below the preset value and closes the measuring circuits) a signal LED flashes and a luminous display on the switch cabinet door is activated.



14.0 ELECTRICAL WIRING 14.1 Superstructure wiring shall be routed in PVC rigid conduit/trenches. Under

frame wiring and 750V, 3 phase supply feeder shall be routed in metallic conduits with IP 68 protection and shall be covered with perforated aluminum cable trays as a primary safe guard against ballast hitting. Junction boards and distribution boards should be provided with suitable inspection covers and shall be easily approachable for maintenance purpose. The coaches shall be wired similar to the imported LHB coaches.

14.2 The wiring on the superstructure as well as on the under frame of the coaches

shall be done with thin walled electron beam irradiated cables conforming to RCF specification No. EDTS-132 Rev A.

15.0 EXTERNAL LOCAL SUPPLY 15.1 External Local supply at 415V, 3Ph shall be provided through the sockets

provided in the coach. The interlocking of external supply with D.A. set supply shall be provided as per design of imported LHB coaches. A 5-pole plug and socket of 125A rating with pilot contact shall be provided for external supply. The necessary protective mechanism will be provided to prevent short-circuiting of two supplies and danger to the operating/maintenance staff, which may be similar to imported LHB coaches.

16.0 LIGHTING 16.1 Fluorescent light fittings with 2X18W shall be provided with electronic ballast

to work on 110V ac supply as shown in the RCF coach layout LW90006. 16.2 Fluorescent lamp with electronic ballast shall be as per RDSO specification

No. RDSO/PE/SPEC/TL0011 (Rev.I). 16.3 Reading lights shall be provided with 12V, 10W halogen lamps similar to

provided in imported LHB coaches. 16.4 An inverter for reading light shall be provided as per RCF specification No.

EDTS-108. 16.5 Night-lights shall be provided as shown in RCF layout No. LW90006.



17.0 FANS 17.1. Exhaust fans shall be provided in the lavatory and switch board cabinet at the

locations similar to original imported LHB coaches. 18.0 APPROVAL OF DRAWINGS 18.1 The schematic coach wiring diagram and detailed assembly drawing for

equipments shall be submitted by production unit to RDSO for approval. One copy of useful information containing details of various equipments shall also be submitted to RDSO.

19.0 USEFUL INFORMATION AND INSTRUCTION MANUAL 19.1 One copy of useful information containing details of various equipments with

layout provided on the coach, commissioning test results, alongwith maintenance and operation details shall be supplied with each coach by coach manufacturer to user railways.

20.0 TEST AND INSPECTION 20.1 The air conditioning system of the coach shall be in general inspected and

tested as per RDSO test programme No. ELPS/TP/AC/01 for AC coaches. However the production unit should submit the test schedule for these coaches offered by M/s LHB along with their comments so that the test programme may be approved by RDSO.



DISTRIBUTION: 1 CEE / Eastern Railway, Fairlie Place, Kolkata 2 CEE / Northern Railway, Baroda House, New Delhi 3 CEE / Central Railway, Mumbai CST 4 CEE / Northeast Frontier Railway, Maligaon, Guwahati 5 CEE / North Eastern Railway, Gorakhpur 6 CEE / South Central Railway, Secunderabad 7 CEE / Southern Railway, Park Town, Chennai 8 CEE / South Eastern Railway, Kolkata 9 CEE / Western Railway, Churchgate, Mumbai 10 CEE / North Central Railway, Hasting Road, Allahabad 11 CEE / Western Central Railway, Jabalpur 12 CEE / Integral Coach Factory, Chennai. 13 CEE / East Coast Railway, Bhuvneshwar 14 CEE / East Central Railway, Hajipur 15 CEE/ Rail Coach Factory, Kapurthala 16 CEE ./ North Western Railway, Jaipur 17 Director / IRIEEN, Nasik Road 18 Director / CAMTECH, Gwalior 19 Secy.(Elec.) Railway Board, New Delhi 20 DDSE/DOC. 21 ADE-9 22 Unit Supervisor

RESEARCH DESIGNS & STANDARDS ORGANISATION · PDF file(vi) Regulated Battery charger (vii)...

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