DIRECTORATE/SECTION CARRIAGE DIRECTORAT COMPUTER WING ETI Psi fr (08 fonds Bist Eibienies 13 Peg COVERING LETTER Ce (S daatat 12 fags SUBJECT. ScAMMINGDIGITISATININDEXNG OF Grigaibocinenr: oF ican OE O80. sane —_* "eo © fay NAME OF THE DIRECTORATE NAME OF THE SUB- _ NAME & DESIGi CORDINATION OFFICERISTAFE so le % NAME OF THE RECORD/FILE “| DOCUMENTISPECIFICATION etc. AND ITS VOLUME/VERSION = TOTAL NO OF PAGESINAGES NAME, SIGNATURE AND DESIGNATION OF "THE HANDING OVER RDSO OFFICIAL NAME, SIGNATURE AND DESIGNATION OF ‘THE TAKING OVER CMC OFFICIAL DATE OF HANDING OVER FILE(DOCUMENT ete. eG wera 14 [tr FIELOS FOR INDEXING Type of Document (File? DRAWINGITECHNICAL CIRCULAR/MODIFICATION SHEE T/SPECIFICATIONINP) 2 | Documient No. _ { 3 | SUBJECT 4 [SUB-SUBJECT ‘DATE OF CREATION OF Fil ( Dealer™ DATE OF RECEIVING BACK THE DOCUMENT! a | NAME, SIGNATURE AND DESIGNATIONOF ‘THE ROSO OFFICAL RECEIVING BACK ‘THE DOCUMENT AFTER SCANNING (No of papers'to be chacked by department) t REMARKS/FEEDBACK IF ANY ‘A) COMPUTER GENERATED GOOD QUALITY B) COMPUTER GENERATED (00T MATRIX) C) TYPE WRITTEN D)_ HAND WRITTEN ae oo CLeS DGGE WSO SPECI FI C*TION ‘oR ELECTRIC TRACTION INS? ALL ATION “ PUCIFT CATION NO. STIyPsi/1(6/ 81)1.6 11 Service con “GOVERNMENT OF INDI ay MINISTRY OF RAILWAYS RESEARCH DESIGNS & STANDARDS CRGANI SATION . ~ Maviake: Nagar ,Lucknow-2601L Speci fication No. BII/PSI/1(6/81). R_FOR 110 VOLT BATTSAY, 40. an The specification arplies to battery: chargers for charging . 119V, 40 th lead actd batteries installed: st unattended 25.k¥ traction switching stations. The battery chargers‘ shall be: complete with all parts. and accessories necéssary for their efficient operation. all such parts and accessories shall te deemed. to be’ within. tte scope of this specification whether specifically mentioned or not, ee od : ¢ it thons: The hattery “chargers are intended for use in moLst tropical climate jh India, where the maximwn ambient temperature may Teach 45°C jn ‘shade, the daily maximum average” .mbient reaching 35°C, with a relative humidity reaching upto 109%. The battery. chargers are reouired for installation in control. cubicles of. attended 25 kV switching stations. to-keep the batteries on float charge wnder normal . emditions, .The charger shall also be suitabdle: for. . The 93@ V ac supply ts, ‘therefore, Ps effocting quick oherge of a discharged battery, when set to the boost charge position. The steady super-imposed Toad on the charger will be about 100 "ma = 006 The battery charger, shall be ‘suitable for’ operation of f= 20 volt single phase, 50°Hz supply obtained from a, OV 26 kil 200 volts," 10 kia LT surply transformer, the || “4 primary of whichis comected to the 25 kV switching -statiod bus bars at one end and to earth’ at the other, ject to fluctuations ’ of voliage between 199 Vand 250 Governing spect Meation: ls ‘the battery chet ger “and-1ts main components shall comply with-tie following -specifiestions walch shall be arriied : in the.manner; al€éred, amended or supplemented by this vspecification ard the Indian Blectricisy Rules, whére srpitesbies=| : ee : 1) Keko-crystilline “semi- * ase IS: 4540-1968, , censimetoriectifier sssemblies Is: 6619-1972. and equipment.» ao : t Jo3.2 4.0 4.1 11) Redtifier transformer ee IS: 2096-1977, 411) Monocrystalline semi- a» IS: 3895-1966, conductor rectifier cells and stacks, iv) lectrical indtcating «» 13: 1946-1968, instruments. IS: 2419-1979. v) Miniature cireult ee IS: 8828-1978. breaker. : my ‘deviation from this specification calcuiated to improve the performance, utility and efficiency of the equipment, proposed by the Tenderer, will be, given due consideration, provided, full partiqulars with justification thereof, are furnished. In ‘such a case the tenderer Shall quote accord~ ing to this specification and the deviat ons proposed by him shakl be quoted as an alternative proposmb 7 Rating and other particulars: : The battery charger shall be designed for the following rating and other particulars: 1) Type* Two-rate, monocrystalline semt- conductor siliccn rectifier type, suitable for floor mounting. 41) Nominal primary 230 V SC Hz ac, subject to variation VoLisges , from 190 to 250 V. 4144) Nominal output 11€ V de. voltage. iv) Charging characteristics: a) Trickie charge: Adjustable between 50.m4 & 500 mA in suitable steps at any voltage in the range 115 V to 135 Vv. b) Boost charge: Adjustable between 0.5 4 and 5 Ain ° suitable steps at any voltage in - the range 100 V to 150 V. The battery cherger shall be equipped with ‘suitable filter circults on the output side to reduce the ripple factor of outputs voltage to less than five per cent at full load, when meqsured across a resistance load, OTE? Rs 2 Serine AC. wms voltage NOTES Rijeblu factor = Ne = PaBe4.3 The battery charger shall bé provided with'a suitable i ballast on primary side of the rectifier transformer such , that 10% inoresse in primary voltage wider boost. charge ‘condition shall not result in a increase by more thn 26% _ of the maximum boost charge current to the battery, Under ttrickle charge condition, similar requirements shall also be met with by provision of a suitable resi stor in-the ‘elreuit, 1f considered necessary, : 5.0 Construction: | * ¥ aad cos 5.1. The equipment shall be housed in a suitable cubicle —. fabricsted as angle tr framework fitted with mild steel “ “sneet panels of thickness not less than 1.6 mit, The side aid Tear panels shall be provided with louvres to provide aiequate ventilation, ‘ire mesh with opening not more than Snm shall be provided on the inner side of the louvres for protection against entry of li zards, vermin etc. a 5.2- te battery charger cubicle shall be treated with a suitable ) - Tust resisting primer paint applied on the interior and . exterior surfaces followed by an ‘application of two coats ~ of enamel paint evenly sprayed to presomt a fine appearance, ~The colour ‘or enamel paint spplied on exterior’ sur faces . Giall be "Dark Adniralty Grey", shade 602 of IS: 5-1961, and erkor sunface shall be finished with white enamél - ponents of the. battery chergers shall be appropriately nted and identified with identification labels. the cat of major components shall permit easy access for pincenancé. ‘the charger shall be of robust construction, ® assembly shall be such that 1% will not be affected fdrorcely by the vibrations induced from nearby rallway ‘racks, The clearances and creepage distances shall be in * ‘aceordence with clause 4 of IS: 6619-1972 ‘The nol se level shall te kent ‘to:the minimums my ie 700 5.4 he vactifier transfémer shall be double-wound, vacuum Oy {apremoted, natural air-cooled and liberally.rated. The™ re “shali be maje of low loss silicon steel laminations. @ windings shall be of copper with class 4 insulation, « Sue prinasy winding of the transformer shall te provided th soitable tapy in stens of 39v- Panging from 129V to 26OVta caver for local adjustment, .43 =n alternative to: provisien of tapping on primary side, voltage stabilization » by farvo resonance method shall also be acceptable. toe 5.5 Chokds nd ballast. shall, be. of coppar winding with. Class 4 OX and shali-be vacuum impregnated: -Using Sli CON DL0GES Win sie ae eee ee -shall be suitably protected against overloading due to short time heavy currents @rawn during closing of the efreuit breakers, short circuits, over voltages and against dnrush currents when charging fully discharged batteries. 8.7 The switches meters and fuses shall be flush mounted on the * front panel and shall te purchased from reputed manufacturers These shall conform to relevant Indian Standards specl fica~ tions. 5.8 The volt meters and ammeters shall _be of flush mounted tyne of accuracy class 25 as per IS: 1243-1968 and shall have . scale length of not less ‘than 60 mm. 5.9 ‘The witing inside the ch-rger shall be with 1100 V grade PYC insulated copper cable having a minimum cross-section of 2.5 sqomm. & conforming to 1S: 694-1977. ‘he cables shall be suitably supported and provided with identification ferrules at the connecting points, 5.10 ‘he ac input nd the de outrut terminals shall be of robust design and shall be suitable for PVC copper cable connections. The polarity of output de terminals shall be clearly marked. 6.0 Fittings end accessories: The following fittings and accessories shall be provided am the battery charger: 1) A low wattage red pilot lamp on the ac side. 41) A doubte pole miniature circult breaker along with a back up slide lock type rewirable fuse on ac side. 442) Two numbers -slidelock type re-yirable fuses on de sides 4v) ‘One moving ccil voltmeter 0-150V, on de sides v) -One meving coll ammeter 0-1M/0-10A dial range along | with shantse vi) One moving iron voltmeter 0-300 Von ac side. vii) ‘Irickie/boost charge changeover switch along with provision for automatic range selection for ammeter. vill) Coarse and fine rotary control matches for trickle ané boost charge. ix)’ Potary control switch for regulating current-in trickle charge.»ROO SC tL ee ee thee on eee er ate md 7.0 1 lel 212 wires, - . 4) PVC insulated PVC sheathed 100V grade 3 core cable © with conver conductors having a min, cross-section of: 2.5 sqemm. and conforming to IS: 694~1977 of 2 meters length fitted with a suitable‘3 pin plug for connection’ to 230 Vasc. supply. a oo ee ago. ‘Tye tests: Following type..tests’ shall he carried out on the prototype complete charger. .~ ~ aac ees a Tests on complete shareer: Visual inspection: st The proper layout, momting, identification, connection and construction shall be checked.:' . 8 No load test? the test. shall be carried out at all the four primary tap positions by applying ‘appropriate rated primary voltage ‘corresporiding to the selected tap -position. . ‘The de output voltage at-no load shall be-recorded for +" 72143 poth boost and trickle charge positions by keeping coarse and fine control -switches at different stepse” “* Load tests with resistance load: he tect shall be carried out at all the-four primary tap positions ty applying appropriate rated primary voltage: --. @ corresponding to the selected tap position; m adjustable © ‘resistance load shall te connected across the output . 2: terminals and the output voltage witr. coarse and fine 2 ow control switches at different.steps shall pe-recorded by wy ‘maintaining the load current to the set value as nearly as * Taled possible. Change in the set value of load current on _ “aecount of change in output voltage .at different steps: shall te teadjusted by simuitaneously changing the load Teslstance. The tests stiall be carried ‘out individually. for winimum and maximum currént values specified under . trickle and boost charge conditions. vs Measurement of Ripple Faetor: S| Ripple voltage on de’ side shall also, be measured during the load test (cl. 7.1.3). and the peteentage ripple content -shall, be colculated. s ent7.1.5 Efficiency test: This test can be combined with no load’ test and load test for which details have been indicated in cl.7.1.2 and 7.1.3 respectively. ‘For this test, input current, voltage and power on the ac side shall also be recorded at the minimum and maximum output voltages. ‘he efficiency and the power factor shall then be computed from the test results. . 7.1.6. Stability test: The test shall be carried out to ascertain that the battery charger satisfies the requirements indi cated in cl. 4.3 of this snecification, It shall be sufficient to carry out the fost at any of the primary tap positions however, the 230V‘primary tap position shall te preferred k for the test, The incoming supply voltage shall be voted voles adjusted to/236% and coarse and fine control switches set -: "to the maximum position in order to. get maximum output voltage. tm adjustable resistance load shall be connected across the output terminals and the load current shall te adjusted to the maximum rated value, the incoming supply voltage shall then be increased by +10% my increase in ousnut voltage shall be offset by increasing the load current by readjusting the load resistance thereby keeping the output voltage unchanged.e This increase in load current shall represent the increase in the charging current to the battery, if ‘it was comected, om account of inerease in primary voltage. The test shall be separately carried out for trickle and boost charge condition and percentage increase in charging current on account of 10% increase in supply voltage calculated: -7.1.7 Tonperature rise test: The test shall be carried out with charger in boost charge position and outrut voltage set to maximum. A suitable resistance load shall be connected across the outrut aad load current shall be adjusted to the maximum rated current under boost sharge. e ambient temrerature, gurface tonperaiure ot transformer, choi s, ballast and Giode base ete. shali be recorded every half an hour. till such © the temperature is,stabiil sed (4.e. the temp. Pise will not be more than 1°C between consecutive hourly readings). ‘he.temp. rise of transformer winding, choke and bailagt measured by the resistance method shall not exceed BOC. The diode base temp. rise shall be within the prescribed value recommended by the manufacturer. ~ 7.1.8 Insulation_resistance test: Insulation resi stance shall be measured by using 500V de megeer between -7.3 e)" | between at line 10 a0 GaN eee These values shall be.measured before and after the high. voltage test and there shall not be any aprreciable change in the measured values. The value‘of insulation resistance shall not be less than 50 meg. ohms in any case. ' High voltage test: ° ; : . The charger shall successfully withstand the test voltage of 2000V-ac rms 50 Hz for one. minute applied between ~ a) de output terminels and earth: b) .ac leads and earth. Test on rectifier transformer : Following tests shall be carried out on the Fectificr transformer : ~ : Pee Measurement of resi stance t / Rest'ctance ‘of primary and Secondary. windings shall be measured, preferably with a bridge instrument, st ambient. temps and recorded. - 7 Open’ clrouit test “Rated primary voltage shall be applied to the primary. of the transformer and the primary and secondary volteges and-no load losses shall be recorded keeping coarse and fine control swltches in differmt positions, « Short cirouit test: ie “ith the control switches corresponding: to. the max. current setting in boost charge position and the ay seooiiary shorted, suitable voltage shali be applied to". primary to pass the maximum rated current in the primary: and the primary voltsge, current and power shall he . recorded and the full load losses ca:culated, This shall no% exceed the guarantéed value by more than 10% 27009 If prototype ofa battery diarger conforming to this. om has already been approved in connection” @ previous supplies to, the Indian Ratlways, fresh - prototype testing may be waived, if it had passed the prototype t earlier and no cianges in. the design or. materiel used, have boon made. e “ Routine test: aaa shefollowing -youtine tests shali be eerrisd out’on the ee WN te ge ro . ~82 8.3 8.4 8.5 9.9 9.1 wt The proper layout, mounting, identification, connections and construction: shall be checked, No load test: ‘the test shall te ‘earried out in accordance with the el. 7.1.2 except that the tests shall be carried out only at the rated input voltage of 220V ac. Load test with resistance load: the tests shall te carried out in accordance with cl, 7.1.3 except that the tests shali te carried out only at the rated input voltage of 230V ac. Insulation resi stance_tests: The tests shall be carried out in accordance with cl. 76108. High voltage test: The tests shall te carried out in accordance with Clo 701.95 ° Technical data and drawings? the Tenderer shall furnish guaranteed performance datay technicel and other particulars for the equipment offered in the proforma attached as ‘nexure ‘ate The Tenderer shall indicate their compliance or otherwise against each clause and sub-clause of the Technical Speci- fication, ‘The Tenderer shall for this nurpose enclose a separate statement, if necessary, indiesting the annexure and clause reference and complisnve or otherwise. Wherever the Tenderer deviates from the provisions of the claust, he shall furnish his detailed remarks. ‘my elsuse or sub-vinuse of the specification not included in the . statement shall be deemed to have been accep ted by the tenderer. oO succeszfl tenderer shall be required to submit the following detailed dimensioned drawings for the equinment -ofiered as per Railways standard size cof 210 mm x 297 mm ot any integral multiple thereof for approval by the purchaser? 1) Outline general arrangement drawing (in three views) along with mounting dimensions. 44) Schematic dtagrem of connections along with components. cr444)" Cross-sectional ews ( showing” ‘Locstion of, major , * components). ' : .iv) Table of guaranteed ana other technical parti outa after approval, six ‘copies’ of approved drawings along with 2 sets of reproducible cepdes shall be ee te : the purchaser. Successful tenderer shall also be required. to furnish ‘the design calculations for the rectifier: transformer rating, rectifier ratings and ag circuits for, - approval, by the purchaser. : (Tht's / supersedes the Specification No, BTI/P S1/1(2/72). Fnel: 1 Annexure 'A', 4n-5.0—Country of Origin. ; 3 .Stndard Governing 4, Manufacturer's ‘type. 5, Rated primary voltage. 6 Nominal’ output’ voltage. visu 2. Dest gned capacity for charging. B. ” Rated output. voltages ; 2) ‘at trickle charge for: current varying ’Prom: 9, Delated. value 1 ‘a) ieee resist ‘Sane ander 1 totes, 1) Boost. 4), trhekle,.. G1) Boo “4. Yard ation! in max. oe current, to hattary’ with 16 crease Ans;. ey goltage a » Deonnected unde 4) Trieneté. _ At) Boost. “10s Size nd type nu, 1 claese of ‘sheet steel’ r ghareet’ eagtales*12, 13. Mw 15. 16. 7. 18. cee ore Regtifier transformer particulars: a) b) e) Cverall dimensions: ~ a). height mm b)- width mm ¢) depth . mm Total welght... kg. Name of manufacturer, Governing specification, 1) Rated inrut voltage, 41) Taps provided for variation,in input voltage, 111) Rated kVA, eo Type of winding. “Type of impregnation. of the winding conductor s. Type of. cooling, Class of insulation. 58 Iron Loss at .100%-rated input voltage. . Vv Co; é pr Loss at full load W Mexiutum ‘tenp. rise on boost charge ©, (SW over ambient, Cc Becti fier partloulars: a) Nane of manufacturer, 3 Govemzing speel fication, ¢) Menufacturer's tyne de si gnetion, a) Total No, of rectifier cells uscd, €) Method of ccnnactions, : f) Repetitive peak inverse. voltages. _ v £) Rated aver: forward current 4 h) Yamperature Ti se over ambient on °. boo st charges Cc Devi ces i 4) Type of szooth: a for protection of rectifier over Agee ing filter.— énme ter particulars: Neme of manufacturer, - Governing -speol fication, Diel size and rane, 4couracy classe Type of mounting,or BAT te 18. Veltmoter poftioulars: 5) Wane of sianufacturer, bp) Goveming specification e) Pal size and Tange = » 4) for ace 44) for des 4) “Accuracy class? 4 4) for’ ac. 44) for dew + e) type of momting. %. . Eittings ond Acce ssories: a) Mindatura clreult breaker? ° i) Make. + Ai) Ratinge Aii)-No, of polese .iv})-Governing | oS. suriestiom b) dude lock type fuses: 1) Make.. switches: = 44, Ratiag . 44a) Type E tgnstion. : 127012