SPECIFICATION No RDSU:PE/SPEC/PS/0019-2000 (REV-1 JUNE -2003) GOVERNMENT OF INDIA MINISTRY OF RAILWAYS SPECIFICATION FOR XENON BASED FLASHER LIGHT SYSTEM FOR ELECTRIC, DIESEL-ELECTRIC, DIESEL-HYDRAULIC LOCOMOTIVES SPECIFICATION No RDGO/PE/SPEC/PS/0019-2000 (REV-1- JUNE 2003) RESEARCH DESIGNS & STANDARD ORGANISATION MANAK NAGAR, LUCKNOW — 226 O110.2 03 04 os 10 Mw 13 (Page 2 of 13 [issued on 186.2003 | Spec. No.. RDSO/PE/SPEC/PS/0019-2000 (REV-1 June -2003 | TECHNICAL SPECIFICA’ SO/P EK 19-2000 (REY-1 June/2003) XENON BASED LOCOMOTIVE FLASHER LIGHT SYSTEM FOR ELECTRIC, DIESEL-ELECTRIC, DIESEL-HYDRAULIC LOCOMOTIVES FOREWORD: Locomotives were originally provided with flasher lights with incandescent lamp/ halogen lamps. Later with advent of LED, LED based flasher light were developed ani adopted to RDSO spec No ELRSISpec/flasher light0017 (Rev-0). Further for achieving longer visibility, Xenon lamp flasher lights were adopied to RDSO spec. No. RDSO/PE/SPEC/PS/0019-2000 (REV-0). These flasher lights were provided 360 ° Visibility on pattem of equipment received on imported WAGO/WAPS class locomotives. Their visibility was not up to the mark and accordingly Xenon flasher light with front visibility only were developed for longer visibility ‘and this specification issued as Revision -1 of earlier specification. “This specification requires reference to the following standard specifications: 18.616 _ Safety requirements for mains operated electronics 1997 ‘or related apparatus for household and similar general use. (i) 1EC:60571 = Rules for electronic equipments used on rail 1997 Vehicles “The purpose of flasher light system is to attrac the attention of the approaching train driver to stop the train in the event of any unsafe track conditions. “The flasher light systemunit is a safety item and therefore rust have high degree of reliably while working under severe environmental conditions of dust, rains, humidity, high ambient temperature, shocks/ vibrations, variations in supply voltage and electrical switching surges ete In order to ensure high reliability, the guidelines indicated in the RDSO Specification No. ELRS/SPEC/SV/O015 Oct. 2001 Reliability of Electronics used in Rolling Stock Application should be implemented. SCOPE: This specification covers the general features, performance requirements and tests of XENON based flasher light system for its use on Electric, Diesel-Electtic and Diesel Hydraulic locomotives. Flectric locomotive/Diesel Electric/Diesel hydraulic locomotive will be provided with two XENON flasher units, one at each end. ‘The XENON flasher unit shall consist of the following (a) ‘Lamp Unit, XENON lamp assembly covered with toughened heat ‘treated amber | colured lens with parabelic reflector. (b) Gonirol Unit ‘Control unit shall consist of trigger and timing circuit, Current Regulator and Power Supply unit. () ‘Switch Zam] Switeh- cum indication unit will be housed in a case with . ON/OFF indication unit switch, mains/standby switch, audio visual repeater indications, contro! cards, terminals, protections and hardware.Page 3 of 13 | Issued on = 18.6.2003 | Spec. No.. RDSOIPE/SPEC/PS/00 19-2000 (REV-| June =2003 | 1.4 The installation of the units on the locomotives, connections for power supply. lines for lamp re tol units and Switch cum indication units will be carried out by the Railways as per circuit diagram supplied by the manufacturer. 20 24 22 23 30 31 32 33 SERVICE CONDITIONS: General arrangement of Xenon Flasher lamp unit will be as per Drg. No. RDSO/SKEL/4673. It ise shows in mounting arrangement for ‘E’ type flasher unit for Electric locomotive. Mounting for diesel electric “D’ type and diesel hydraulic locomotives “DH type shall be to Drg No. SKDL-3628 & SKDL- 3673 respectively. Copy of drawings are enclosed “The equipment shall operate salisfactorily under the following climatic conditions (i) Ambient temperature (under shade) up to 55°C and under sun temperature at 70°C (ii) Humidity 100% REL. (ii) Heavy and continuous rains (iii) Dusty atmosphere. (iv) Corrosive atmosphere in coastal and industrial areas “The equipment and its mounting arrangement shall be of robust design for traction duty and shall withstand vibrations and shocks encountered in service as per IBC-60571 ‘TYPE OF SYSTEMS: ‘The supply system voltage on Electric, Diesel-Blectric and Diesel-Hydraulic locomotives are different, Therefore, this specification covers three types of systems For electric locomotives | For Diesel-elecitic locomotives sel Hydraulic locomotiv System type DH ‘The voltage variation for different rolling stocks is given below: |The ype Tipe | Maximum 140 V de 88 V de 30 V de ‘Average WoVde | 72 Vdc 24V de Minimum 70 V de 46 V de 16.8 V de “The manufacturer shall furish the information as per Appendix "A" along with the offer/ {Page 4 of 13 [issued on : 18.6.2003 | Spec. No.: RDSO/PE/SPEC/PS/0019-2000 (REV-1 June -2003 | DESIGN FEATURES 4.1 GENERAL: 4.1.1 The Xenon flasher unit should be fully electronic type without use of any electromechanical relays, 4.1.2 The unit shall be designed with switching mode operation to keep the heatsink size to minimum and avoid losses in any resistor in power circuit. The current regulation provided shall be better than 5% variation for the full working range of the unit 4.1.3 Resistors of less than 1.0 W shall not be used even when the loading is very low. Under ‘worst operating conditions, the wattage rating of any resistor shall not be less than twice of load at 70°C, Capacitor shall be of reputed make suitable for 85°C temperature rise. ‘The temperature in transformer/choke shall conform to IEC-4O at an ambient temperature of 35°C 4.1.4 The Xenon flasher unit should be so designed that it is capable to withstand the direct short circuit current at the output terminals without any damage to the equipment. The short circuit current shall be limited to the extent possible value. The equipment shall function normal after the short circuit at output terminals is removed. 4.1.5 Flasher Unit should be capable to withstand 1.8 times of the average voltages defined in clause 3.2 above for two minute 4.1.6 There should not be any damage to the equipment at voltages less than the minimum specified value for an indefinite period 4.17 The Xenon flasher unit shall be capable to withstand the voltage surges as per surge test clause 10.2.6.2 of LEC 60571-1 4.1.8 Design shall incorporate the protection for protecting the unit from output short circuit and reverse polarity. Appropriate indication shall also be provided for these protections. 4.1.9 The components used in the manufacture of the equipment shall be screened and of standard quality meeting requirement as per RDSO reliability assurance spec no. SPEC/E-16/(Rev-A) The supplier shall indicate specification/particulars in this regard. Rating of all the electronic component used shall clearly be visible. 4.1.10 The wires/cables used for internal construction of the unit shall be of PTFE insulation and multistrand copper conductors, covered with fiber glast sleeve. Ail wires/eables shall be provided with ferrules covered with transparent heat shrinkable sleeve for their identification of connections 4.1.11 The sheet steel used for the enclosures shall have thickness of at least 1.6 mm. The fabricated enclosures shall be thoroughly cleaned and given two coats of primer and two coats of paint of approved colour. 4.1.12 The manufacturer shall submit his own drawings fer lamp unit, contol unit and switch unit for approval before manufacture. 42 LAMP UNIT: 4.2.1 The Xenon lamp shall be of ‘U" shape, eight (8) pin type valve connector with suitable holder having pin configuration as under: + Pino. | as Anode * Pin No. 3 as trigger (Triggering peak voltage is ~ 6 KV) + Pin No. 5 as cathode(Page 5 of 13 [Issued on: 18.6 2003 | Spec. No. RDSO/PE/SPEC/PS/0019-2000 (REV-1 June -2003 J ‘The wattage of, the lamp shall be about [5 W. XENON lamp shall preferably be of Xenon part No. 891-1937 from Xenon corporation USA. Any other make shall require the approval of RDSO. In all the cases test certificate of lamp manufacturer shall be furnished 4.2.2 General arrangement of lamp unit is given in drg No. RDSO/SKEL/4673. Lamp of unit will be provided for front visibility with reflector at the back, amber colour lens in front of lamp and hood in the front to give longer visibility \\/ 4.2.3. Current drawn by lamp and audio circuit under specified voltage shall be as follows: E Type (0.25 amp. £ 5% to LAMP circuit. 0.08 amp. max. to audio cireuit DType 0.37 amp. + 5% to LAMP circuit. 0.08 amp max. to audio circuit ‘DH Type 2.1 amp £5%to LAMP circuit 0.25 amps max. to audio circuit Note The current values are for the guidance purpose only, However the manufacturers may submit their designed current values. However the current reguitation shall be limited +/- 5% from the design values as specified herein \424 The Xenon lamp unit and also control unit shall be housed in totally enclosed housing, 43 a It shall be provided with suitable arrangement for heat dissipation, protection against ingress of water under heavy rain and dust under storm. It shall comply to 1P66 protection. However switch cum indication unit shall be of with IP 20 protection for mounting ‘4.2.5 The Xenon lamp unit shall be housed in a suitable enclosures on the right hand side of the cab on roof of electric locomotive. The enclosure shall be waterproof and suitable gasket shall be provided to ensure water tight joints, However for Diesel Blectric/Hydraulic locomotive, it shall be front mounted in existing housing. CONTROL UNIT & SWITCH / INDICATION UNIT: 4.3.1 Switeh/indication unit will consist of (a) Switches: ON/OFF - 1No. MAINSTDBY —- 1 No. FRONT/REAR 1No. (b) Fuses: MAIN - INo. STD BY : 1 No. SPARE : 1 No. (©) Indications: MAIN : 1 No. STD BY - 1 No. Audio/Visual Indication (Buzzer, LED)re (Page oF 5 Tse on 5.0 60 61 62 63 70 a 22 73 74 186.2003 Spec. No= RDSOPERPECPSI05 19-2000 O(REV-1 June “43 ual indication of working of flasher unit shall be provided in the drivers cab, The toggle switch, LED indicator and buzzer shall be Provided in the switch-cum indication unit, “43.4 The conirol unit shalt be housed in lamp unit enclosure. Switch-cum indication unit shall 435° Itis desirable that Xenon crntzol unit shall have the featur, ig with contr Manufacturer's name 1 2 3° Month &¥ear of uit 4 Rated voltage range 5. Rated current 6. 7 Block circuit diagram slearly indicating the wising with different colour & their VISUBLITY REQUIREMENT. Colour of fanp light shall be Amber Yellow, The ON-OFF period of Masher iatsistal! be50 to 65 Atashes per ‘minutes. This frequency of 50. 3.2 will be acceptable. The clear visibility of flasher "ight shall not be less than 3 kas, in clear day tight PRAWINGS DATA AND SAMPLES: The manufacturer The final seis of drawings, bill of materia (BOM), design details and ‘Maintenance/operating ‘manuals are to be supplied to the Purchaser with each order in cise Of random checking ip any deviation is noticed fiom the approved drawings and BOM, the approval granted earlier tothe Supplier is liable to be withdrany[Page 7 of 13 [issued on : 18.6.2003 | Spee. No: RDSO/PE/SPRC/PS/00 19-2000 (REV-1 June -2003 ] 8.0 81 82 ol loa GUARANTEE: “The equipment shall be guaranteed against defects in design, materia, workmanship etc. for a period of 24 months from the date of dispatch or 18 months from the date of commissioning whichever is earlier. During the warranty period, all defective parts shall be replaced promptly and free of cosi to the purchaser. The replaced components sall carry the same guarantee, INSPECTION AND TESTS: ‘The complete equipment shall be subjected to the following type of tests:~ a) ‘Visual inspection on each unit b) Type tests on two units after incorporating all modifications found necessary c) Routine tests on each unit. “The tests to be carried out on complete unit are given in the following table, together with the clause number to which reference should be made. LIST OF TESTS: 7 om Clause ‘S.No. | Type of Tests ‘Type Tests [Routine Tests | ri | Visual Inspection. i — 2 | Insulation o4 3 __| Resistance a [3 ‘Visibility test . = ee 4 Performance test | 9.6 - [5 Dielectrictest [9.7 - 6 ‘Surge test o8 = 7 | Temperature rise | 9.9 e : test (Dry heat) 8 Temperature rise | 9.10 > = |__| (damp neat [9 | Salt mist test__ — s . : 7 10 _| Cooling Test 9.12 = iW ‘Vibration ‘shock | 9.13 - 9.13 and 5 bumptest__|__ 12 __ | Water tightness test | 9.14 a - 13__| Reliability test 9.15 - - e [14 | Over voltage Test_| 9.16 15 Reverse polarity | 917 _—_| test iM ae 16 | Output short circuit [9.18 test ial T7___| Acceptance test 10.0 BrassPage 8 of 13 | Issued on 186 3003 |§ 93 4 98 26 96.1 96.2 963 96.4 965 VISUAL INSPECTION: Check for general workmanship fiting, finish and ‘Mounting arrangement as per approved drawing of purchaser. Check for proper water tight fitting of XENON lamp unit, Check terminals, switches, indications, type number ete. as Per approved drawing. Verify that the electronic cards are coated with CRC Spray with suitable adhesive coating (CRC Spray) and it is in dry condition, INSULATION RESISTANCE: Meeger the electronics and control circuit, lamp unit with Fespect 0 earth and check the insulation level with SOOV megger range and ensure thar he insulation resistances are greater ‘han the following minimum requirements and record the actual values obtained ~ 110 V circuit and earth 20 M ohms. ~ Control and Electronics to earth 10 M ohms ~ Screen to earth 10M ohms. ~ XENON Lamp unit to earth 10M ohms, VISIBILITY TEST: The equipment will be checked to verify that it meets the visibility clause 6.0 PERFORMANCE TEST: ‘The unit shall be operated for one hour continuously at average specified voltage. The number of “ON” and “OFF” cycle of the flasher per minute shall be reccodae During this test the supply voltage should be varied from 70 V to 140 V in type “E”, 46 V 10 88 {it (ype “D” and 16.8 V to 30 V in type “DH equipment ‘The frequency of “ON” and “OFF” lamp voltage, lamp current etc. shall be recorded. The frequency rate shall be 50 to 65 flashes per that the case te manufacturer offers the design wih higher rate of flashes. it shall be verified that the lamp ON/OFF is cleanly distinguishable ftom a ditganee of 3.0 Kms in clear day lightPage 9 of 13 | Issued on : 18.6.2003 | Spec. No. RDSO/PE/SPEC/PS/0019-2000 (REV-1 June -2003 ] 97 98 99 9.10 9.1 WIZ 9.13 DIELECTRIC TES! Control and switch/indication unit of flasher unit type “E” and type “D” should be subjected to 1000V (rms) and type “DH” to 500V(rms) The test voltage should be of sine wave, 30Hz applied for one minute between the terminals of the circuit board, short circuited, and the metallic frame oftthe assembly box The test voliage for the lamp unit shall be $00 V(rms) for | minute, SURGE VOLTAGE TEST: = The test shall be conducted as per LEC-6057, clause 10.2.6.2 TEMPERATURE RISE TEST (DRY HEA‘): ~The testis to be conducted as per IEC-60571, clause 10.2.4 at 70 deg C in energize.condition. At the end of the period, a performance testis to be carried out as per clause 9.6. ‘TRMPERATURE RISE TEST (DAMP HEAT): ~ The (est is to be carried >» a5 per clause 10.2.5 of IEC-60571. After end of the period, a performance test is to bece'rie’ as per clause 9.6. SALT MIST TEST: — The testis to be carried out as per clause 10.2.10 of IEC-60571. COOLING TEST: ‘The test is to be conducted as per IEC-6057! “aus: 10.2.4 VIBRATION SHOCK AND BUMP TEST: — The test is to caiicc! out as per IEC-60571, clause 10.2.11 ‘The complete unit (lamp unit and flasher unit) together with uni arrangements (including shock absorbing devices if provided) shall be subject to th wing tests: ‘The unit under test shall be secured in a suitable position to a vibration machine producing, vibrations of sinusoidal form with adjustable amplitude and frequency. ‘The test frequency lowers than SHz may be omitted. The unit shall be tested in energized condition. 9.13.1 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 1 Hz to 100 Hz within a time of not less than 4 min, the amplitude of the oscillation being that indicated “a” expressed in millimetres, is given as a function of “f” by the eqiation - for |< f< 10 (Hz) for 10 [MS | 4 = 2 i LAMP UNIT BODY Tas [1 TESCRIPTION [Hare] ory REE SCE «NTS & MOUNTING: ELEC, DTE. SKEL-~4673| # ApeROVED UY. TE OF] riast’issucn ELASHER LIGHT | ens: oR 03 |