Reasoned Documents of comments received from the firms on Final draft-1 specification tripping of the RBC at 135±2 V DCwith

tripping of the RBC at 135±2 V DCwith 2 second delay

to avoid false tripping.
Item:- 4.5kW UNDERSLUNG TYPE CONSTANT VOLTAGE REGULATED BATTERY CHARGER 4.5.3 AC over / under voltage protection: RBC M/s Star Electric:- Accepted.
shall deliver 100% load up to 350 V and What would be the output voltage for input AC from Clause modified
FOR LHB COACHES , Specification No. RDSO/PE/SPEC/AC/0183 (Rev’1’)-2018
35% load from 350V to 300V or in the event 300V to 350V. incorporating-RBC shall
Cl. N. Specified in draft specification Comments received RDSO Comments of single phasing. Input AC under and over M/s Electrowaves:- deliver 100% load up to 350
4.1(i) Nominal input voltage-415 V AC, 3-phase, M/s Signotron:- Not accepted. voltage protection shall be at 300±2 V and RBC shall deliver 100% load up to 350 V and 35% V and 35% load from input of
3/4-wire system Please clarify whether the charger shall work with both Since single phase input is 480±2 V. load from 350V to 300V or in the event of single 350V to 300V or in the event
3 wireand 4 wire system or whether it shall work with required for emergency mode, phasing. Input AC under and over voltage protection of single phasing. Input AC
either 3 wire system or 4 wire system. 4-wire input voltage system is shall be at 300±2 V and 480±2 Vand shall be locked under and over voltage
ICF Chennai:- specified. in trip condition after three consecutive restart protection shall be set at
Specification calls for input nominal voltage 3/4wire attempts if low voltage condition is still present. 300±5V and 480±5Vand shall
system; whereas the input voltage from DA set/ HOG M/s Rishab:- be locked in trip condition
is always provided with 3 phase 3 wire only from The window on 300±2 V should be increased. Turning after three consecutive restart
60kVA transformer. Hence this clause may be referred OFF at 298V will suddenly cause input voltage rise attempts at an interval of
to 3 phase 3 wire only. which in turn will cause the battery charger to turn ON 5second. RBC shall again try
4.1(ii) Type & Ah rating of batteries- Lead acid, RCF:- Not accepted. and this may continue to happen till the input voltage to start after a gap of 10
70/120 Ah Type & Ah rating of batteries-VRLA, 70/120 Ah Clause modified reaches safe level of operation minutes by which time input
incorporating- Type & Ah M/s PIGaziabad:- voltage is likely to get
rating of batteries- Lead acid, RBC shall deliver 100% load up to 350 V and 35% normalized. After that RBC
70/120 Ah (both flooded load from 350V to 300V or in the event of single shall be locked in trip
&VRLA). phasing. Input AC under and over voltage protection condition. Above clause
4.4 RIPPLE CONTENTS: Output voltage and M/s Powernetics Not accepted. shall be at 300±2 V and 480±2 Vand shall be locked shifted in clause No.4.5.5
current ripple factors (r.m.s.) shall be less This would be difficult at light load. So, make it Output voltage and current in trip condition after three consecutive restart
than 2% and 3% of the set voltage/current applicable above50% load, not 10% load. ripple factors (r.m.s.) at light attempts if low voltage condition is still present.
respectively, when measured across a load(10%)already achieved by 4.5.4 RBC shall have self-reset feature. M/s Electrowaves:- Accepted.
resistive load. approved sources as per RBC shall have self-reset feature, system shall be Clause modified
existing specification, hence locked in trip condition after three consecutive restart incorporating-
no change in contemplated attempt.To avoid stress on RBC and its power RBC shall have self-reset
4.5.1 Over voltage: Output over voltage M/s Star Electric:- Accepted. electronics components, RBC should attempt only 3 feature. The system shall be
protection shall be provided by tripping of If the set value is 135V, then what would be OVP. Clause modified or 4 time to restart. If fault is still present it should locked in trip condition after
the RBC at 135±2 V DC. M/s ICElectrical:- incorporating-Output over lock in shut down position. three consecutive restart
Output over voltage protection suggests to be keep at voltage protection shall be Let there is a short present in the output side of the attempts at an interval of 5
least 136±2V, beyond the maximum operating voltage provided by tripping of the Batt. Charger and RBC is always trying to restart, seconds. Above clause shifted
limit 135VDC. RBC at 136±2 V DC with 2 every time we are applying stress to power devices, in clause No.4.5.6
M/s PIGhaziabad:- second delay to avoid spurious result in degrading of the performance of power
Output over voltage protection shall be provided by trippings.

5.1 RBC shall be as compact and as lighter in
weight as possible. Overall size of the unit
including terminal box shall not be more than
900 mm (L) X 755mm (D) X500mm (H).
The mounting dimension of underslung
cubicle shall be 850 mm (L) X 300 mm (D)
(Refer RDSO drawing No.
RDSO/PE/SK/AC/200-2018 (Rev’0’) as
Annexure-2). However, RDSO reserve the
right to change the dimensions at the time of
design approval or prototype approval. Total
weight shall not exceed 80 kg.
device. 5.2 Terminal markings input AC (R, Y, B) and M/s Star Electric:- Accepted.
M/s PIGaziabad:- output DC+, DC- & BC+ shall be engraved Required terminal would be 9 connections-3 nos. for 3- Clause modified
RBC shall have self-reset feature, system shall be on terminal board/block. The termination of phase AC input and 6 nos. for DC output ( 2 for each incorporating- Terminal
locked in trip condition/state after three consecutive re- internal connections shall facilitate palm-to- DC+/DC-/BC+). blocks shall be ‘Cage clamp
startattempt with in specified time period i.e. 5-10 palm connections. Not more than one wire ICF Chennai:- type’ with suitable numbers of
minutes which shall be specified during the prototype shall be terminated on one terminal. Terminal Terminal block type is mentioned as clamp type, which terminal blocks of
test. blocks shall be ‘clamp type’. One extra may be modified as Cage clamp type. Wago/Phoenix make. 20 %
ICF Chennai:- Based on the ICF’s referred terminal block shall be provided with each terminal blocks shall be spare.
ICF has prepared Drg. No. ICF/SK3-7-1-100 which is drawing, the RDSO OGA output terminal for paralleling of coach
suitable for all types of LHB coaches(AC and Non drawing has been revised and cables.
AC). This drg. May be studied and incorporated in incorporated with terminal
RDSO specification. box along with 29 mm holes
in the bottom for entry of
cables and door hinge 5.3 Cubicle shall be made of minimum 2.0 mm M/s Hitachi:- Partially accepted.
arrangement as per ICF OGA thick, SS304 grade stainless steel sheet Because of SS weld, steel will change its basic property
Relevant clause modified as
RCF:- drawing. conforming to IS: 10632 Pt-3 and will be at welding place & hence after some time it will start
Cubicle shall be made of
The mounting dimension of underslung cubicle shall be Not accepted.- without exterior/interior painting rusting from welding area. Please suggest that either
minimum 2.0 mm thick,
850 mm X 300 mm X 300 mm instead of 850 mm X The lesser dimension (depth- we pain entire unit or we paint only welding area. SS304 grade stainless steel
300 mm. RDSO/PE/SK/AC/200-2018 (Rev’0’) may be 600mm) as proposed by ICF sheet conforming to IS: 10632
modified accordingly. The mounting holes shall be size is being accepted. Depth of Pt-3 without Exterior/interior
of 13mmx24 mm, elliptical shape, 6 holes. 600mm with mounting painting. However
300mm apart (depth side) as Exterior/interior painting with
per requirement of SLR fire retardant black paint can
M/s Electrowaves:- coaches & for provision of be done for better heat
Total weight shall not exceed 95 kg. Emergency mode. dissipation during regular
M/s Hind:- Accepted.100kg. RCF:- production.
Weight may increase to 85 kg due to additional Due to Emergency mode Grade of stainless steel may be specified as SS-304/S2 Accepted.
components. operation feature Clause or SS-304/L being commercially available grades. Clause modified
M/s PIGaziabad:- modified incorporating Total incorporating-SS-304/S2 or
Total weight shall not exceed 95 kg for better product weight shall not exceed 100 SS-304/L
reliability. kg. 5.4 All the hardware including those used for M/s Powernetics:- Not accepted.
electrical terminals shall be stainless steel Allow pan head star type screws for assembly like Hexagonal head screws is
hexagonal head screws and nuts conforming devices and capacitors. more suitable.
to SS-304. Plain and spring washers shall be
used as per the requirements of fastening
arrangement. Screws used for mounting of
the components shall preferably be on tapped
 holes, wherever necessary.
5.9 All electronic components used shall be of
industrial grade. Only long life dry type
Capacitors having self-healing feature and
suitable for operation up to 1050C shall be
utilized. Capacitors should not require any
replacements during the service life of the
RBC unit.
5.15 Complete windings of transformer/choke
shall be done with polyesterimide over
coated with polymide-imide enameled
copper wire. Impregnation shall be done by
FT 2005/500EK of Dr BECK through
vacuum pressure impregnation method.
5.19 Zero halogen, low smoke, fire retardant
polyamide-6 cable glands (1 for incoming
and 3 for outgoing cables) with IP-68
protection shall be provided on the terminal
box of the unit for the incoming & out going
cables
up to 1050C shall be utilized. Capacitors should not
M/s ICElectrical:- Accepted. require any replacements during the service life of the
We suggest that the design of power module of RBC Clause modified RBC unit.
shall not use Electrolytic Capacitor for long life and incorporating- Only long life 5.11 Entire electronics of the equipment shall be RCF:- Not accepted.
maintenance free operation. Only use of metalized poly dry type Capacitors having reliable and shall comply with RDSO Compliance of electronics to RDSO Specification No. Entire electronics should
film capacitors shall be permitted in the power stage of self-healing feature and Specification No. ELRS/SPEC/SI/0015-Oct- ELRS/SPEC/SI/0015-Oct-2001or industrial grade of comply RDSO Specification.
input and output. suitable for operation up to 2001 or latest for reliability requirement. reputed makes may be added. Industrial Grade is already
M/s Electrowaves:- 1050C shall be utilized in the mentioned in clause No.5.9 of
Only long life dry type Capacitors/ Electrolytic main power circuit DC bus. specification
Capacitors suitable for operation up to 105 ◦ C shall be Electrolytic Capacitors having 5.14 For better thermal management, Choke M/s Electrowaves:- Partially accepted.
utilized.In the first stage input AC is rectified through self-healing feature and (inductor) and transformer may be provided For better thermal management, Choke (inductor) and Choke (inductor) and
bridge rectifier to produce DC. Then this high voltage suitable for operation up to in a separate compartment/cubicle and can transformer may be provided in a separate transformer may be provided
DC is switched at high frequency in DC –DC converter 1050C may be utilized in have IP-65 protection up to 135mm from the compartment/cubicle and can have IP-65 protectionup in a separate
section to produce Galvanically isolated constant control power supply and top. Ingress protection level of main cubicle to 135mm from the top. Ingress protection level of compartment/cubicle (if
voltage low voltage DC at output. control circuit. Capacitors shall however be IP-68 from bottom to 135 main cubicle shall however be IP-68 from bottom to required for better thermal
To reduce ripple in rectified DC, electrolytic should however not require mm from top. Use of sealant of any kind for 135 mm from top. Use of sealant of any kind for management) but shall be
capacitors of higher values to be used for better any replacements during the achieving stipulated IP level is not achieving stipulated IP level is not permissible. provisioned within overall
performance. service life of the RBC unit. permissible. M/s Powernetics:- size as specified in RDSO
M/s Signotron:- . Sealant of high temperature withstand ability to be Drawing
In any electronic product several capacitors are used in allowed heat sink mounting &Perspex cover. No.RDSO/PE/SK/AC/200-
which many are used in low voltage low power M/s PIGaziabad:- 2018 (Rev’0’) with IP-65
supply and control circuit with very less ripple current For better thermal management, Choke (inductor) and protection.
with service life more than 20 years . Replacing them transformer may be provided in a separate
with dry type capacitor is unnecessary and compartment/cubicle and can have IP-65 protection.
difficult.However Electrolytic capacitors in the main Use of sealant of any kind for achieving stipulated IP
power circuit DC bus with high ripple current have level is not permissible.
limited service life if not properly chosen. So, the M/s Rishab:-
requirement may be revised as “Only long life dry type This Box is totally enclosed & there is no ventilation.
capacitors having self healing feature and suitable for So, it should be only either IP67 or IP 65, i.e. one
operation up to 105 ◦ C shall be utilized in the main standard to be followed. Otherwise, it gets difficult to
power circuit DC Bus . In control power supply and test.
control circuit Electrolytic capacitors suitable for RCF:-
operation up to 105 ◦ C may be utilized “. The unit shall be designed as a single unit only to
M/s PIGhaziabad:- reduce interconnection of the wiring between
All electronic components used shall be of industrial transformer and choke and if required only separate
grade. Only long life dry type/ Electrolytic Capacitors compartments in the same cubicle may be
having self-healing feature and suitable for operation permitted.
M/s Rishab:- Not accepted. RDSO/PE/SPEC/AC0138-2009 (latest) instead of
We have noted & Understood the requirement. It is Same is using in 60kVA Cable glands.
also suggested that impregnation by 50VT of Dr. transformer. 5.21 Suitable ON/OFF switch shall be provided M/s Hind:- Accepted.
ELANTAS (Dr. BECK) is better than FT 2005/500EK on input side. MCB will be provided. A 20 Amps three pole MCB
of Dr BECK. A separate sheet is attached which M/s Star:- suitable for rolling stock
describes advantages of 50VT of Dr. Beck (Refer What is the utility of ON/OFF switch, for service application shall be provided
Annexure A). Also, it is our observation that due to purpose? on input side in the terminal
strong & bad odor of FT 2005/500EK, becomes box.
difficult to work with and health hazard for the RCF:- ON/OFF is in terminal board
workmen. Both clause 5.21&5.25 are contradictory, however of unit included for once
M/s AAL:- provision of ON/OFF switch shall be made on the switching ON/OFF the unit.
Complete windings of transformer/choke shall be done underslung equipment as well as on board also for Therefore it should work
with polyesterimide over coated with polymide-imide remote operation. without human intervention.
enameled copper wire. Impregnation shall be done by ON-board ON/OFF switch is
FT 2005/500EK of Dr BECKor equivalent suitable not required. 20 A MCB shall
for traction through vacuum pressure impregnation be provided on input side in
method. the terminal box.
ICF Chennai:- Accepted. 5.22 Two potential free contacts shall be provided M/s Hitachi:- Already there in the
Cable gland with IP68 is called for provision in the Relevant clause modified in the terminal box for using them for HHPE will use two potential free contacts with specification.
terminal box. The cable are normally routed through accordingly. Terminal box indication of RBC ON/OFF in the coach in capacity of 230VAC & 1Amps.
flexible polyamide conduits which are not compatible shall have four 29 mm plain case of AC coaches. RCF:-
for interfacing with cable glands. Hence, it is suggested holes through which PMA Two sets of potential free contacts shall be provided for
that the terminal box shall have plain holes through end fittings with flexible 1) RBC ON/OFF indication- on board
which PMA end fittings with flexible PMA conduits PMA conduits will be 2) RBC unit fault indication- on board
will be provided which will be IP68 protection. The provided in the bottom which
number of holes requirement is covered in ICF Drg. will be IP68 protection. RBC 5.23 On output side HRC fuse of 40 A shall be ICF Chennai:- Not accepted.
No. ICF/SK3-7-1-100 and same may be adopted. unit shall however be supplied provided in +ve load circuit in terminal box 40Amps fuse shall be provided in the main unit instead Replacement of fuse will be
M/s Hitachi :- with these holes in blocked attached to main unit/box. of terminal box, as the present terminal box very difficult from inside the
Please mention the size of cable gland and cable to be condition. arrangement is shown in ICF drg. Is not covering the IP65 protected underslung
used. HHPE suggests if terminal box is in 135mm from . fuse box else the terminal box has to be redesigned to cubicle en-route. Hence
the top then IP68 cable gland is not required. HHPE bigger size. provision of fuse hasbeen
suggests to use threaded M6 stud for connection done in terminal box.
instead of terminal.
RCF:-
The input output cables shall be routed through end
fittings as per RDSO Specification No.
5.25 RBC shall start functioning without any
human intervention with the availability of
input power supply without any need for
switching ‘ON’ and ‘OFF’.
5.29 Two tinned copper earthing pad with tapped
hole and M10 brass bolt with flat surface &
spring and flat washers shall be provided on
left and right sides of the unit for earthing
with coach body.
5.33 Equipment cubicle / body shall not be
connected to any circuit / PCB and shall not
be used for any type of earthling or
shielding.
5.34 Theterminal box shall be located on upper ICF Chennai:-
side of the left face of the unit and cable The cable entry hole shall be provided on the side ways
entry holes shall be provided on its bottom. as shown in ICF Drg.No. ICF/SK3-7-1-100.
5.36 Earth leakage detection for both positive and
negative lines of both battery and load
circuits shall be provided. RBC shall
function normally in case of leakage on any
one of the line (positive or negative) but shall
trip respective circuit in the event of leakage
5.38 New clause added
Door stopper arrangement for holding the door of RBC New
during any maintenance shall be included as shown in incorporated Front door shall
ICF Drg.No. ICF/SK3-7-1-100.
SPECIAL REQUIREMENT(New clause)-
Added
M/s IC Electricals:- Not accepted. on both lines of that circuit. This type of earth leakage detection is generally
A three phase 25Amps MCB will be provided inside ON/OFF of MCB is very continuous insulation resistance monitoring and used
the underslung charger box at input R,Y,B side to difficult from IP65 protected for critical applications like underground cable fault
ON/OFF the charger and normally kept in ON underslung cubicle during detection . This solution also will increase the cost .
condition always. tripping of MCB en-route. So for the charger application trip in case of leakage on
M/s Star:- Hence MCB has been any one of the line may be implemented.
What is the utility of ON/OFF switch, for service provisioned in terminal box. M/s Electrowaves:-
purpose? Earth leakage detection for both positive and negative
lines of both battery and load circuits shall be provided.
RCF:- Not accepted. RBC shall be trip in any above condition to avoid
M10 brass bolt may be replaced with stainless steel Brass bolt is better. human hazardous.
screw. M/s IC Electricals:-
If the earth fault as specified is provided the it violate
the clause of insulation resistance, since for each
M/s Electrowaves:- Not accepted. (DC+,DC-) output line if 30mA is the bench mark of
To reduce the high frequency noise/EMI/EMC of Existing vendors have already leakage current than their has to be a resistive path
system, a noise immunity circuit shall be incorporate in developed such circuit with between DC & Earth points which if mounted will fail
the system, which needs to be earthed.To bypass high EMI/EMC compliant. the IR of the entire equipment.
frequency noise components of control circuit, bypass M/s Star:-
capacitors need to be connected with earth, So that Topology of isolating battery circuit frm other load
noise components can be bypassed to earth, which circuit may be elaborated.
reduces EMI/EMC of system. M/s Hind:-
M/s PI Ghaziabad:- Single earth fault will be provided.
To reduce the high frequency noise/EMI/EMC of M/s Powernetics:-
system, a noise immunity circuit shall be incorporate in Both lines are same after connecting load/battery,
the system, which needs to be earthed. standard earth leakage for both positive and negative.
Not accepted.Entry holes Leakage from either of the line should trigger
shall be on bottom of terminal action(Trip/alarm). The detection shall be comparing
box. outgoing and incoming current, both should be equal in
case of healthy condition.
M/s PI Ghaziabad:- Not accepted. M/s AAL:-
Earth leakage detection for both positive and negative Earth leakage detection for “RBC shall function normally in case of leakage on
lines of both battery and load circuits shall be provided. both positive and negative any one of the line (positive or negative) but shall trip
RBC shall be trip in any above condition to avoid lines of both battery and other respective circuit in the event of leakage on both lines
human hazardous. load circuits are required. of that circuit”.These lines should be removed from
M/s Signotron:- specification because positive and negative terminals
shall have common earth leakage reference as it is
driving load consisting of coils also. activated, wherein separate
ICF Chennai:- Accepted. circuit operating at 230V
clause modified input(any of the phases &
neutral) for feeding 2.5kW
be openable (hinge on top) coach load at 110VDC
and shall have suitable (nominal) shall come into
stopper arrangement for operation (just like EBC).
holding the door for easy Emergency mode will be
maintenance indicated on indication panel
6.1-At odd hour (00.00hr) through an LED. The
every day, RBC shall be emergency mode circuit shall
automatically switched ‘off’ generally conform to RCF
(zero output) and the DC load specification No. EDTS 163
will be transferred to battery Rev ’C’ for Emergency
for one hour (max.). During battery charger.
this period battery voltage 6.1 Protection against ingress of dust and water M/s PI Ghaziabad:- Accepted.
shall be monitored. RBC shall be IP-68 from bottom to 135 mm from Protection against ingress of dust and water shall be Clause modified
should start functioning top and IP-65 up to 135 mm from top. IP65. incorporating-Protection
normal after one hour or M/s Rishab:- against ingress of dust and
before, if battery voltage falls This box is totally enclosed & there is no ventilation. water shall be IP65 complete
below cut off voltage (settable So, it should be only either IP67 or IP65, i.e. one unit.
through Key pad). If battery standard to be followed. Otherwise, it gets difficult to
voltage drops below cut off test.
voltage i.e. 100V (settable M/s Electrowaves:-
through Key pad) in less than Protection against ingress of dust and water shall be
one hour, ‘battery not healthy’ IP65.
indication shall glow on 6.1 Input supply over voltage set at 480±2 V. M/s ICElectrical:- Accepted.
indication panel. We suggest to kept on 480±5V (less than2% of set Clause modified accordingly.
6.2 RBC will have the point 480V) considering three phase input source
following modes:- stiffness, wire length and voltage drop at full load.
6.1 Input supply under voltage set at 300±2 V. M/s PI Ghaziabad:- Accepted.
(i)Normal mode, wherein full Input supply under voltage set at 300±4V @35%load. Clause modified
output for both circuits will M/s ICElectrical:- incorporating- Input supply
be available. We suggest to kept on 300±5V (less than2% of set under voltage set at 300±5V
(ii)In the event of failure of point 300V) considering three phase input source @35%load.
normal mode, Emergency stiffness, wire length and voltage drop at full load
mode will be automatically M/s Electrowaves:-

6.1 Output overvoltage trip at 135 ±2 Volts.
6.1 Reverse polarity protection for both the
output circuits.
6.2 Following indications through 10 mm LEDs
of any colour other than RED visible
through transparent perspex window on front
door of the unit (up to 135 mm from the top)
shall be provided.
 Input AC on (3-Phase) – R, Y, B
 Battery charging “ON”
 Single phasing indication.
 Positive earth leakage (> 30 mA)
independently for both output circuits
 Negative earth leakage (> 30 mA)
independently for both output circuits
7.1 The wires/cables below 10 Sq.mm shall be
copper with PTFE insulation of reputed make
and higher than that e-beam cables as per
RDSO Specification No.
ELRS/SPEC/ELC/0019 (Rev ‘3’) of RDSO
approved make.
9.5(ii) 110V dc circuits- 1500V (r.m.s), sine wave,
50 Hz for 1 minute
9.7 Weight: Overall weight of the unit shall not
exceed 80 kg.
9.15 25% outer surface area of heat sinks shall be
covered with insulating material during this
test.RBC shall be loaded to full load current
corresponding to 35 A DC rating with
minimum input voltage of 350V AC± 5volts.
The temperature rise shall be recorded with
the help of temperature recorder having at
least 12-14 sensors mounted at the specified
reference points on the body of
semiconductors, transformer/inductor, filter
capacitors and other components till
stabilization of the temperature at all the
locations. The maximum-recorded
temperature under worst loading conditions
shall be corrected for 55ºC and compared
with maximum permissible temperature. The
thermal margin available shall be compared
with the safety margin declared by the
manufacturer. Under loading conditions as
specified above, the corrected temperature of
Input supply under voltage set at 300±4V @35%load
M/s ICElectrical:-
Output over voltage protection suggests to be kept at
least 136±2V, beyond the maximum operating voltage
limit 135VDC.
M/s PI Ghaziabad:-
Reverse polarity protection in battery circuit.
M/s Powernetics:-
Only battery reverses polarity protection possible.
There is no reverse polarity of the load, so not required.
Detection not possible as load is not source
M/s Electrowaves:-
Reverse polarity protection in battery circuit.
RCF:-
Unit fault indication may be added to know the health
of the system.
M/s AAL:-
Positive earth leakage (> 30 mA) independently for
both output circuits, Negative earth leakage (> 30 mA)
independently for both output circuits. “lines should be
removed” because positive and negative terminals shall
have common earth leakage reference as it is driving
load consisting of coils also.
M/s Hind:-
Perspex sheet not suitable from IP68.
M/s PI Ghaziabad:-
 Input AC on (3-Phase) – R, Y, B
 Battery charging “ON”
 Single phasing indication.
 Earth leakage trip indication
M/s Powernetics:-
Should be avoided the indication as it is very complex
to provide transparent Perspex window, being it IP68
and underslung. Difficult to get Perspex with required
hardness, like steel. Otherwise will break in no time.
M/s Electrowaves:-
M/s Signotron:- Not Accepted.
The wires/cables below 10 Sq.mm shall be copper with
PTFE insulationor e-beam cable of reputed make and
higher than that e-beam cables as per RDSO
Specification No. ELRS/SPEC/ELC/0019 (Rev ‘3’) of
RDSO approved make.
M/s ABB:-
As per IEC 61287-1, 110V dc circuits- 1200V (r.m.s),
sine wave, 50 Hz for 1 minute
M/s Electrowaves:-
Overall weight of the unit shall not exceed 95 kg.
M/s Hind:-
Weight may increase to 85 kg due to additional
components.
M/s PI Ghaziabad:-
Overall weight of the unit shall not exceed 95 kg.
M/s AAL:-
H-class transformer is recommended to be used in 25% outer surface area of
RBC which is designed for 180 ºC. heat sinks shall be covered
Therefore,maximum temperature can be increased to with
155 ºC (with a good margin with respect to 180 ºC).
M/s Electrowaves:-
25% outer surface area of heat sinks shall be
covered with insulating material during this test.
RBC shall be loaded to full load current corresponding
to 35 A DC rating with minimum input voltage of
350V AC± 5volts. The temperature rise shall be
recorded with the help of temperature recorder having
at least 12-14 sensors mounted at the specified
reference points on the body of semiconductors,
transformer/inductor, filter capacitors and other
components till stabilization of the temperature at all
the locations. The maximum-recorded
temperatureunder worst loading conditions shall be
corrected for 55ºC and compared with maximum
permissible temperature. The thermal margin available
 Input AC on (3-Phase) – R, Y, B
Accepted.  Battery charging “ON”
Clause modified.  Single phasing indication.
 Earth leakage trip indication
6.3 The RBC shall have following features fault M/s AAL:- Partially accepted.
Partially accepted. diagnostics features accessible through key Positive earth leakage (> 30 mA) independently for Clause modified
Clause modified pad/down loading. both output circuits, Negative earth leakage (> 30 mA) incorporating-Reverse
incorporating-reverse polarity independently for both output circuits. “linesshould be polarity for battery circuit.
protection in battery circuit i. Display of following faults with brief removed” because positive and negative terminals shall
description. have common earth leakage reference as it is driving
 Input under voltage <300Volts load consisting of coils also.
 Input over voltage >480Volts M/s Electrowaves:- Accepted.
 Reverse polarity for both output  Reverse polarity for both output circuits Downloading of faults
Not accepted. circuits  Earth leakage for both lines of two output through only USB port.
Charger ON condition already circuits.
 Input single phasing
is indicated. Also one RBC shall be provided with self-checking watch dog
 Output short circuit
potential free contact for feature and facility to down load data through USB
 Over Temperature
faulty condition is port on commercially available USB pen drive only
 Output overvoltage >135V
provisioned in clause No.5.22. which can directly download the data in text/MS
 Over current
Office.
 Earth leakage for both lines of
M/s Star:-
two output circuits.
Suggested option is the display of last faults in key pad
Diagnostic system shall be capable of
and for logged faults only USB downloading.
Accepted. recording at least last 300 latest faults with
real time clock with override feature i.e. first M/s PI Ghaziabad:-
Clause modified  Reverse polarity at battery/DC terminal
incorporating- Following come first out FIFO).There shall not be
provision for deletion or clearing of the  Earth leakage in DC side only
indications through 5 mm RBC shall be provided with self-checking watch dog
LEDs of any colour other faults data.
RBC shall be provided with self-checking feature and facility to down load data through USB
than RED visible through UV port on commercially available USB pen drive only
resistant and fire retardant watch dog feature and facility to down load
which can directly download the data in text/MS
ultrasonic transparent poly data through USB port on commercially
Office as per formats of spec. for easy analysis.
carbonate sheet on front door available USB pen drive and RS-
There shall not be any external s/w required to
of the unit (up to 135 mm 232/Ethernet port.
down load data and analysis the data.
from the top) shall be M/s Hitachi:-
provided. Battery not healthy HHPE recommended to use USB which is used as pen
and Emergency mode ON drive or PC interface for downloading the fault.
indications added.
the semiconductor devices shall have a safety shall be compared with the safety margin declared by
margin of minimum 100C. the manufacturer. Under loading conditions as
Temperature of the transformer/inductor specifiedabove, the corrected temperature of the
shall not exceed 135ºC when corrected to 55 0 semiconductor devices shall have a safety margin of
C and the corrected temperature shall have a minimum 10°C.
safety margin of minimum 100C. Temperature of the transformer /inductor shall not
The temperature rise in the exceed 155 °C when corrected to 55°C and the
Not Accepted.
inductors/transformer windings shall also be corrected temperature shall have a safety margin of
measured by resistance method. minimum 10°C.
The temperature rise in the inductors/transformer
Accepted.
windings shall also be measured by resistance method
Due to Emergency mode
preferably.
operation feature Clause
M/s Powernetics:-
modified incorporating Total
As we are using class H transformer/inducter, so the
weight shall not exceed 100
temperature on it to be 155°C after correction.
kg.
M/s PI Ghaziabad:-
25% outer surface area of heat sinks shall be
Not Accepted. covered with insulating material during this test.
RBC shall be loaded to full load current corresponding
to 35 A DC rating with minimum input voltage of
insulating material 350V AC± 5volts. The temperature rise shall be
during this test for better recorded with the help of temperature recorder having
formance.. at least 12-14 sensors mounted at the specified
reference points on the body of semiconductors,
transformer/inductor, filter capacitors and other
components till stabilization of the temperature at all
the locations. The maximum-recorded
temperatureunder worst loading conditions shall be
corrected for 55ºC and compared with maximum
permissible temperature. The thermal margin available
shall be compared with the safety margin declared by
the manufacturer. Under loading conditions as
specifiedabove, the corrected temperature of the
semiconductor devices shall have a safety margin of
minimum 10°C.
Temperature of the transformer /inductor shall not
exceed 150 °C when corrected to 55°C and the

9.16 The water proof-ness test shall be done on
the unit by dipping the equipment in water
for one hour under de-energized condition
leaving 135mm from the top. Water shall not
enter into the unit. Transformer/inductor
cubicle (if designed as a separate cubicle /
compartment) with IP-65 protection, shall be
tested accordingly.
9.19 The input voltage shall be reduced below
300V and the RBC shall switch “OFF” prior
to 298 volt and automatically switch “ON”
after the input voltage exceeds 302 volts. The
input voltage shall be increased beyond 480
V AC and the RBC shall switch “OFF” prior
to 482 Volts. The voltage shall be further
raised to 510V AC and maintained for two
minutes. There shall be no damage to any of
the components of the RBC. The RBC shall
automatically switch “ON’ when the voltage
is reduced below 480 V AC but before 478
V.
Above input under voltage/ over voltage
test shall be carried out on full load i.e.35
Amps.
9.26 Over voltage protection shall be provided to
avoid the equipment supplying high voltage
beyond the 135 Volts. Tripping of the RBC
should be set at 135±2 V DC.
9.27 Detection of earth leakage of more than 30
mA in each line of both output circuits shall
be tested by creating high resistance earths.
Tripping of the respective circuit by bridging
both positive and negative lines (through
resistance to produce leakage current of more
than 30 mA) of output circuits will also be
verified. Leakage currents at which
indication comes or tripping takes place shall
be noted for future reference.
corrected temperature shall have a safety margin of Input under voltage test should be carried out at 35% of
minimum 10°C. load, as the under-voltage limit is 300VAC.
The temperature rise in the inductors/transformer M/s Hitachi:-
windings shall also be measured by resistance method RBC unit will sustain with 100% load upto 350V &
preferably. under voltage test conducted with 35% load from 350V
M/s Electrowaves:- Accepted. to 300V or event of single phasing.
Protection against ingress of dust and water shall be Clause modified M/s PI Ghaziabad:-
IP65. incorporating-The water The input voltage shall be reduced below 300V and the
M/s Rishab:- proof-ness test shall be done RBC shall switch “OFF” prior to 298 volt and
This box is totally enclosed & there is no ventilation. on the RBC underslung unit automatically switch “ON” after the input voltage
So, it should be only either IP67 or IP65, i.e. one by dipping the equipment in exceeds 302 volts. The input voltage shall be increased
standard to be followed. Otherwise, it gets difficult to water for one hour under de- beyond 480 V AC and the RBC shall switch “OFF”
test. energized condition leaving prior to 482 Volts. The voltage shall be further raised to
M/s PI Ghaziabad:- 135mm from the top. Water 510V AC and maintained for two minutes. There shall
Protection against ingress of dust and water shall be shall not enter into the unit. be no damage to any of the components of the RBC.
IP65. The RBC shall automatically switch “ON’ when the
M/s ICElectrical:- Accepted. voltage is reduced below 480 V AC but before 478 V.
We suggest to kept input under voltage & over voltage Last para replaced as the Above input under voltage test shall be carried out
limit on 300±5V & 480±5V respectively (less than2% following:- at reduced load i.e.12.25 Amps. And shall be locked
of set point) considering three phase input source Input under voltage test also in trip condition after three consecutive restart
stiffness, wire length and voltage drop at full load. shall be carried out at reduced attempt if low voltage condition is still present.
M/s Electrowaves:- load-35% i.e.12.25 Amps or 9.22 EMI/EMC test shall be conducted as per M/s PI Ghaziabad:- Not Accepted.
The input voltage shall be reduced below 300V and the event of single phasing. And relevant clauses as mentioned in the IEC: EMI/EMC test shall be conducted as per relevant EMI/EMC test shall be
RBC shall switch “OFF” prior to 298 volt and shall be locked in trip 61000 clauses as mentioned in the IEC: 61000 with Level-1 & conducted as per relevant
automatically switch “ON” after the input voltage condition after three Performance criteria-C clauses as mentioned in the
exceeds 302 volts. The input voltage shall be increased consecutive restart attempt at M/s Electrowaves:- IEC: 61000 with Severity
beyond 480 V AC and the RBC shall switch “OFF” on interval of 5 second if low EMI/EMC test shall be conducted as per relevant Level-3 &
prior to 482 Volts. The voltage shall be further raised to voltage condition is still clauses as mentioned in the IEC: 61000 with Level-1 & Performance/acceptancecriteri
510V AC and maintained for two minutes. There shall present Performance criteria-C a-A. Clause modified
be no damage to any of the components of the RBC. accordingly.
The RBC shall automatically switch “ON’ when the 9.25 Reverse polarity protection shall be provided M/s ABB:- Partially accepted.
voltage is reduced below 480 V AC but before 478 V. at battery & load terminal. The RBC shall With reverse connection of battery, battery charger Clause modified
Input under voltage test also shall be carried out at sense the reverse polarity and shall trip the cannot protect the battery current to flow because of incorporating-Reverse
reduced load i.e.12.25 Amps. And shall be locked in respective circuit. battery get short circuit through output rectifier diode polarity protection shall be
trip condition after three consecutive restart and battery charger cannot play any role to restrict it, provided for battery circuit.
attempt if low voltage condition is still present. since there is no control device in the path. This will The RBC shall sense the
M/s Powernetics:- reverse polarity and shall trip
happen, even battery charger is in off condition or the respective circuit. positive and negative outputs so that current through
control off condition. Hence recommended deleting sensing network is greater than 30 mA to detect earth
this clause. fault and as earth fault indication is required for
M/s Star:- individual positive and negative.
Reverse polarity protection is normally used for battery 1.Please clarify the test method for individual earth
circuit and is recommended to delete the protection fault test method for positive and negative.Line
requirement for DC load circuit. separately and earth fault indicator functionsseparately
M/s AAL:- for positive and negative.
Reverse polarity protection shall be provided at battery 2.What is the test method for “insulation resistance
& load terminal. However complete system will trip method” at output port positive and negative line
after sensing of reverse polarity. because there will be a bias circuit between earth and
M/s Powernetics:- output positive & negative line separately to detect
Only applicable for the battery. Detection impossible earth fault on these line and indicating separately very
for a passive load. less
M/s ICElectrical:- Accepted. 3.As earth leakage threshold current is very less so
Output over voltage trip suggest to kept at least Clause modified. there shall be probability of false tripping of during
136±2V, beyond the maximum operating voltage limit disturbance of these floating positive and negative
135VDC. output.
M/s PI Ghaziabad:- Not Accepted. M/s Electrowaves:-
Detection of earth leakage of more than 30 mA in each Earth leakage detection for Detection of earth leakage of more than 30 mA in each
line of both output circuits shall be tested by creating both positive & negative lines line of both output circuits shall be tested by creating
high resistance earth,spath. of battery & other load circuit high resistance earthpath.
M/s AAL:- are required. M/s Powernetics:-
RBC shall function normally in case of leakage on any Single earth fault, leakage from either positive or
one of the line (positive or negative) but shall trip negative bus.
respective circuit in the event of leakage on both lines New test Clause added Emergency mode operation
of that circuit”.These lines should be removed from test-A fault is created in the
specification because positive and negative terminals main circuit and it will be
shall have common earth leakage reference as it is checked if Emergency mode
driving load consisting of coils also. as per clause No. 6.2 comes
M/s Hind:- into operation and Emergency
Single earth fault will be provided. mode indication glows.
M/s ICElectrical:-
As per requirement of earth leakage detection is current
based scheme and it is required for both individual Battery health status test
positive and negative output wires. During test method The RBC shall be switched
as stated to connect bridging resistance through off (zero output) for an hour

11.1 Firms having core competency in the field of
designing and manufacturing of similar
IGBT/SiC based electronic equipment shall
only be considered for registration in RDSO.
The firm should have manufactured and
supplied at least 100 units of such equipment
of at least 2 kVA rating during last three
years and shall produce documentary
evidence for orders executed of such
equipment indicating PO No., description,
rating, type of power devices (IGBT/SiC)
etc.
and 35 A loads will be
transferred on Battery
attached. RBC will monitor
battery voltage and the battery
health status feature as per
clause No. 6.1 will be
verified.
M/s Rishab:_ Accepted.
We have experience in designing & manufacturing Clause modified
microprocessor based servo voltage correctors from incorporating-. Firms having
last 4 years. We have manufactured & supplied about core competency in the field
350 Nos with rating from 5 KVA to 140 KVA with of designing and
various configurations like 3Phase to 1Phase, 3Phase to manufacturing of similar
3Phase & 1Phase to 1Phase. Majority of these have IGBT/SiC/MOSFET/Thyrist
been supplied to MNCs like Emerson Network Power or based electronic equipment
India Pvt. Ltd. and Consul Power Solutions which in shall only be considered for
turn has installed in various private sector & public registration in RDSO. The
sector units, in India & Abroad. The product is robust firm should have
and very reliable & is performing very well in the field. manufactured and supplied at
We would like you to know that we had already least 100 units of such
applied approval for 4.5 KW as per RDSO Specn No: equipment of at least 2 kVA
RDSO/PE/SPEC/AC/0183 (REV-0) 2015 earlier. rating during last three years
But this application was closed by RDSO due to some and shall produce
shortfall of compliances. With respect to RDSO STR documentary evidence for
criteria, we have now completed our compliance. orders executed of such
While submitting this approval file at RDSO, we were equipment indicating PO No.,
working simultaneously on the product development description, rating, type of
which is now 80% completed with a fresh approach power devices
and prototype will be fully ready in next 6-8 weeks. It (IGBT/SiC/MOSFET/Thyris
is also our observation that this restricted criteria was tor) etc.
not a part of the earlier specification for 6.5KW RBC
Specn No: RDSO/PE/SPEC/AC/0129-2009, REV-01
or latest & 4.5 KW Rev 0, hence we request you to
kindly waive this point for us.
We have been designing & manufacturing transformers
for the UPS industry for last 16 years. We are known
for our quality, consistency & reliability. We can
assure excellent quality with very close monitoring
through our lean manufacturing & control systems
which has been implemented from last 4 years, at M/s
Rishab Industries through a program jointly conducted
under Ministry of MSME, National Productivity
Council and MCCIA Pune. These Systems are being
followed for our existing products. Hence, it is our
humble submission that our experience with
microprocessor based technology should be considered
as our qualification criteria and we should be given an
opportunity. We are also in process of development of
emergency battery charger for LHB coaches &
chargers for various other applications using MOSFET
&SCR.We request you to kindly add the experience of
electronic products with MOSFET & SCR as criteria
for qualification. We would like to mention here that
we have successfully developed & approved 9kva,
15kva and 60kva transformers to the utmost
satisfaction of RDSO. We have also developed
&approved a 15kva Tranella-15 transformer for
locomotives application.
It is requested to also include MOSFET & SCR in the
final revised specification in the same clause.
11.2 The facilities ofitem 1 & 5 shall be available M/s Electrowaves:- Accepted.
with both the manufacturer and sub-vendor. The facilities of item 1 & 2 shall be available with Relevant clause modified
RDSO may visit the premises of sub-vendor both the manufacturer and sub-vendor. RDSO may accordingly.
engaged by the firm for PCB assembly. visit the premises of sub-vendor engaged by the firm
for PCB assembly. The firm shall arrange the
assessment visit of RDSO official to the
sub-vendor’s premises.
M/s Rishab:_
We have understood &all required facilities/ testing
facilities, machinery and plant will be complied as per
schedule of technical requirements and the
specifications.
It is mentioned in specification that the facilities of
item 1 & 5 shall be available with both the

manufacturer and sub-vendor.

12.0 The complete RBC shall be warranted for a
satisfactory performance for a period of 60
months from the date of commissioning or
72 months from the date of supply whichever
is earlier.
Ann-1 Switchgear-GE/ABB/C&S
We have submission that for Point No.
5 (i.e. Automatic/light beam guided component
insertion machine for PCBs), since it is going to be outsourced
from the sub-vendor, it is not necessary
to have the same at our (i.e. manufacturer) premises.
M/s PI Ghaziabad:- Not accepted.
The complete RBC shall be warranted for a satisfactory In all power electronics items
performance for a period of 24 months from the date warranty of 5 years have been
of commissioning or 36 months from the date of given and same warranty
supply whichever is earlier. Any design defect, clause also are included in
defective material, underrated component used, etc. exist item i.e. battery chargers
have to be corrected and merely replacement of for static & rolling stock
defective parts will not be considered adequate. applications and 400mm
Complete investigation report of each major defect sweep BLDC fan etc.
/failure shall be submitted to RDSO. After the
completion of warranty period AMC shall be given
to OEM for better performance.
M/s Electrowaves:-
The complete RBC shall be warranted for a satisfactory
performance for a period of 24 months from the date
of commissioning or 36 months from the date of
supply whichever is earlier. Any design defect,
defective material, underrated component used, etc.
have to be corrected and merely replacement of
defective parts will not be considered adequate.
Complete investigation report of each major defect
/failure shall be submitted to RDSO. After the
completion of warranty period AMC shall be given to
OEM for better performance.
M/s Hind:- Accepted.
Please add- Siemens, L&T and Schneider Relevant annexure-1 modified
M/s L&T:- accordingly as in spec of
Please add make L&T for contactor and MCB/MCCB other equipment, these makes
are appearing.