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RDSO/PE/SPEC/PS/ 0100(REV. 0)-2008, Amdt-2

TECHNICAL SPECIFICATION FOR DOUBLE-CAPPED TUBULAR T5 FLUORESCENT LAMPS, T5 LUMINAIRE & ELECTRONIC BALLAST

S. N.

Date of Amdt. & No.

Rev. Reason of amendment

1. 11.01.2010Amndt-1

0

i) Clause “2.6 of Section - IA, IB and IC”, “clauses 4.3, 4.4 and 4.5 of Section-IA”, “clauses IIC & IID of Section-II”, and “clauses IIIA and IIIB of Section–III”, deleted.

ii) Clauses “2.4 and 6.1 of Section –IA, IB and IC”, “clauses 5, 12 & 16 of Section-IIA and IIB”, “clauses 7, 8, & 9 of Section-III- D (i) & (ii)”, and “clauses III-C & III-E of Section-III” amended.

iii) Clause 3.1, “Annexure-A – 19”, “Ballast Description Table, clauses 17, 18, 19 & 20 of Section-IIA”, and “clauses A1, A2, A3, A4, B1 and B2 of Section-III-”, added.

2. ...07.2010Amndt-2

0

Approved by

Executive Director (EM)

Verified by

Director (EM)


I N D E X

Clause No.

Description Page No.

Foreword 31.0 Scope 32.0 Reference standards 53.0 General conditions 5SECTION I – Specification for T5 tubular fan 8A 28W high efficiency T5 tubular fluorescent lamps 81.0 Dimensions 82.0 Mechanical 83.0 Electrical and cathode 84.0 Colour and Photometry 95.0 Rated Luminous flux 96.0 Rated life 107.0 Starting 10B 54 W T5 tubular fluorescent lamps 101.0 Dimension 102.0 Mechanical 103.0 Electrical and cathode 114.0 Colour and Photometry 115.0 Rated Luminous flux 126.0 Rated life 127.0 Starting 12C 14 W, T5 tubular fluorescent lamps 131.0 Dimension 132.0 Mechanical 133.0 Electrical and cathode 134.0 Colour and Photometry 145.0 Rated Luminous flux 146.0 Rated life 157.0 Starting 15D General requirements for all lamps 151.0 Safety 152.0 Tests 15Section II Specification for electronic ballast for T5 lamps 18A High frequency electronic ballast for T-5 lamps 18B General requirements for all type of electronic ballast 191.0 Abnormal conditions 192.0 Infrastructure for quality assurance 203.0 Mandatory relevant standards/Test certificates 20Section III - Specification for T5 luminaries 21A1 Specification for luminaire of single 28 W, T5 fluorescent tubular

lamps with Reflector21

A2 Specification for Luminaire of single 28W, T-5, Fluorescent tubular lamps without Reflector

24

A3 Specification for Luminaire of single 28W, T-5, Fluorescent tubular lamps with Acrylic cover.

25

A4 Specification for Powder coated CRCA sheet Luminaire of single 28W, T-5, Fluorescent tubular lamps.

27

B1 Specification of mirror optic fittings for double T-5, 28W tubular lamps

28


B2 Specification for mirror optic fitting for double T-5 4 x 14 W Tubular Lamps.

30

C Specification for enclosed luminaire suitable for twin T-5, 28W linear fluorescent lamps.

32

D Specifications for street lights luminaries 33E General requirements for luminaire 371.0 Tests 382.0 Infrastructure for quality assurance 39


TECHNICAL SPECIFICATION FOR DOUBLE-CAPPED TUBULAR T5 FLUORESCENT LAMPS, ELECTRONIC BALLAST & T5 LUMINAIRES

0.0 Foreword

The T5 lamp is an increasingly popular development in fluorescent lighting and are being used world wide. The T5 technology has now stabilized and in order to take advantage of improved technology and to improve illumination, life, efficiency, reliability of lighting fittings to be used and with view to standardize fluorescent lamp including luminaire and its accessories for adoption in Indian railway establishment this specification has been prepared. Since T5 lamps are always used with electronic ballast in its control gear the use of indoor and outdoor lighting fittings with these lamps will result in energy saving and will get categorised as environment friendly changeover to better technology.

1.0 Scope

This specification covers the design, manufacturing and testing of 14W/24W/28W/54W T5 tubular fluorescent lamps complete with luminaries, mounting accessories and electronic ballast for working under the operational and environmental conditions encountered during service.

The specifications are as per the below sections: Section References

Item

Section I 14/24/28/54W High efficiency T5 lampsSection II High frequency electronic ballast for T5 lampsSection III Type A General requirements for T-5 luminairies.Type B Addition features with PVC housing channel

with/without Acrylic coverType C Addition features for powder coated CRCA sheet

luminaire of T5 fluorescent tubular lampsType D Addition features for mirror optic fitting for T5

Tubular lampsType E Addition features for Enclosed luminaire

Type F Addition features for T-5luminaries suitable for street lights

2.0 Reference standards

IEC-60081 Double-capped T5 Tubular Fluorescent Lamps – Performance specification.

IS: 2418 (Pt.I to IV) Specification for T5 Tubular Fluorescent Lamps for General Lighting Services.

IEC 60061-1 Lamp caps and holders together with gauges for the control of interchangeability and safety – Part 1: Lamp caps.


IEC 61195 Double-capped T5 Tubular Fluorescent Lamps – Safety specifications.

IS: 5081 Specification for glass tube for fluorescent lamps.

EN 50 285 Specification for energy efficiencyCouncil Directive 98/11/EC

Annex IV For energy efficiency

EN 55015 RFI <30MHzEN 61000-3-2 HarmonicsEN 61547 ImmunityEN 61347-2-3 SafetyEN 60929 PerformanceIEC 68-2-6FcIEC 68-2-9Eb

Vibration & bump test

IEC 60598-2-1 Fixed general purpose luminaireIEC 60598-1 General requirement and testsCISPR 15 Limit and methods of measurement of radio

disturbance characteristicsIEC 61000-3-2 Limits for Harmonic current emission - THD

< 10%IEC 60068-2-38 Specification for Permitted Humidity TestIS 13021 Specification for AC Supplied Electronic

Ballasts for Tubular Fluorescent Lamps IS 10322 Specification for the luminaire

Note: Latest version of all the standards shall be applicable.

3.0 General Conditions:

The T5 Tubular Fluorescent Lamps including its fitting complete with luminaries, mounting accessories and electronic ballast shall be suitable for working under the following environmental and operational conditions encountered during service:

3.1 Environmental Conditions:

Maximum ambient air temperature

55ºC

Minimum ambient air temperature

-5ºC(Temperature may dip to -10ºC in J&K area.)

Max. Relative humidity 100 %Atmosphere Extremely dusty and desert weather

and desert terrain in certain areas. The dust contents in air may reach as high values as 1.6mg/m cub.

Coastal area The equipment shall be designed to work in corrosive atmosphere

The maximum value of the condition in the coastal area will be as under:


Max. ph value 8.5Sulphate 7 mg/litreMax. concentration of chlorine 6 mg/litreMax. conductivity 130 micro siemen /cmAnnual rainfall Ranging between 1750 to 6250 mm

with thunder stormAltitude Not exceeding 1200 m (altitude

may vary up to 2000 m in J&K area.)Vibration and shocks Maximum vertical acceleration 3.0g

Maximum lateral acceleration 3.0g Maximum longitudinal acceleration 3.0 g (‘g’ being the value of acceleration due to gravity)

3.2 The T5 Tubular Fluorescent Lamp including its fitting complete with luminaries, mounting accessories and electronic ballast shall be suitable for rugged service in above mentioned varying climatic conditions existing throughout India. The design of fitting including all accessories shall be suitable to work in the vicinity of 25KV, 50 Hz traction system.

3.3 The complete luminaire for outdoor application shall be protected against dust and water as per IP-65. All other types of luminaries shall conform to IP-21.

3.4 Acoustic Noise Measurement

The sound pressure level of the complete luminaire shall not be more than 55dB (A) and sound pressure level of electronic ballast with a FTL connected at a distance of 1 meter away from the equipment shall not be more than 55dB (A) in all the direction. Tests shall be performed at No-load and Full load. However, the manufacturer shall endeavour to reduce the noise level below 55dB (A).

3.5 Guarantee

1. The T-5 lamp shall be guaranteed for satisfactory performance for a period of 24 months from the date of commissioning or 30 months from the date of supply whichever is earlier.

2. The T-5 luminaire(fitting) and ballast shall be guaranteed for satisfactory performance for a period of 60 months from the date of commissioning or 72 months from the date of supply whichever is earlier.

.3.6 Approval procedure

3.6.1While seeking approval, the firm shall submit a sample to the production unit/RDSO along with test results, circuit diagrams and dimensional drawings for luminaire, fluorescent lamp and ballast separately. The prototype testing shall be got done at manufacturer’s works. In case, testing facilities for environmental/surge/Vibration & shock test is not available, the same shall be tested at any NABL/Government approved testing Laboratories and the result shall be submitted to RDSO, Lucknow.


3.6.2The manufacturer shall also submit details like make, type, reliability grade, rating and loading of various electronic components used. The temperature rise of the various components under the most adverse conditions shall also be declared.

3.6.3After completion of the prototype tests and submission of the sample along-with the technical details as indicated above, the luminaire complete with lamp and ballast, fluorescent lamp and ballast shall be considered for approval.

3.7 Withdrawal of approval

The approval granted to the manufacturer is liable to be withdrawn in the event of noticing any change at a later date in the design or change from the bill of material as approved earlier without seeking RDSO's approval or using components of inferior specification/quality compromising with the reliability.

Railway has to monitor the performance of fluorescent lamp w.r.t. burning hour being obtained and report to the supplier at every six months and information to RDSO, Lucknow.

3.8 After Sales Service :

The manufacturers/suppliers of T-5 lamps, luminaires & ballast must have a complaint redressal system mechanism through on-line complaint registration on their website or toll free number for lodging complaint round the clock.

3.9 Prequalification criteria for manufacturers/suppliers:

The pre-qualification criteria for manufacturers/suppliers of all the lamps, luminaires or ballasts are given in Annexure—A of the specification.


SECTION I

SPECIFICATION FOR T5 TUBULAR LAMPS

A. High efficiency T5 tubular fluorescent lamps

1.0 Dimensions

Rated watt 14 W & 24W 28 W & 54WNominal dimensions

550 mm x 16 mm

1150 mm x 16 mm

Base phase to base phase

549.0 mm max.

1149.0 mm max.

Base phase to end of opposite cap pins

556.1mm max.553.7mm min.

1156.1mm max.1153.7mm min.

From ends of opposite pin

563.2mm max.

1163.2mm max.

Diameters 17.0 mm max. 17.0 mm max.Cap G-5 G-5

2.0 Mechanical

2.1 Angular displacement of the planes of the cap pins on both ends of a lamp shall not be more than 6 deg. The dimensions of caps on a finished lamp shall conform to IEC 60061-1.

2.2 Both the pins (excluding flanges) of the two caps of a finished lamp shall pass simultaneously, freely without winding, through parallel slots, suitably spaced longitudinally to receive the lamp. The slot shall be 2.87 mm wide.

2.3 The caps shall be attached to the tubes strong enough to withstand torsion test as specified below both initially and at the end of the life test.

2.4 Mechanical Strength: Lamp shall withstand the torsion test carried out in accordance with IEC: 61195 with the torsion moment of 0.5 Nm applied gradually.

2.5 The shell of the lamp shall be of lead –free glass. The caps shall be resistant to atmospheric corrosion and withstand the test specified.

2.6 The lamp shall be environment friendly having a single-layer tri-phosphor coating and mercury content shall meet the following:

Lamps 14 W 24 W 28 W 54 WMercury content ≤2 mg ≤2 mg ≤2 mg ≤2.3 mg

2.7 It shall have a highly efficient 3-band fluorescent coating specially designed for operation with electronic gear and suitable for dimming.


3.0 Electrical and cathode (characteristic tests shall be conducted as per annexure B of IEC 60081-97/latest).

3.1 The insulation resistance between the shell and the contacts of cap shall not be less than 2 mega ohms measured with a 500V DC megger.

3.2 The contacts shall be evenly soldered or welded or punched to ensure satisfactory engagement and electrical contact in the appropriate holder.

3.3 T-5 lamps should comply to the following Cathode characteristics as per IEC 60081:-

Property / Lamps 14 W 24 W 28 W 54 WTest current, A 0.160 A 0.350 A 0.160 A 0.480 AResistance at each cathode, in ohms ( Ω)

Rated 40 12 40 8Minimum 30 9 30 6Maximum 50 15 50 10

3.4 T-5 lamps should comply to the following Electrical characteristics as per IEC 60081:-

Property/Lamps 14 W 24 W 28 W 54 WFrequency, kHz 20 - 26 20 - 26 20 - 26 20 - 26Rated lamp voltage (r.m.s.)

86 V 77 V 166 V 120 V

lamp voltage (r.m.s.) 76 V 69 V 149 V 110 Vlamp voltage (r.m.s.) 96 V 85 V 183 V 130 VRated lamp current 0.165 A 0.295 A 0.170 A 0.455 A

4.0 Colour and photometry (Photometric test shall be conducted as per Annexure B of IEC 60081-97.)

4.1 The Reference Ballast, complying to IEC 60081, should have the following characteristics :-

T5 lamp at 25 degree CLamp 14 W 24 W 28 W 54 WFrequency, kHz 20 - 26 20 - 26 20 - 26 20 - 26Rated Voltage, V 167V 150V 329V 235VCalibration current, A

0.170A 0.300A 0.170A 0.460A

Resistance in ohms, ( Ω)

500 Ω 250 Ω 950 Ω 255 Ω

4.2 Rated luminous flux and colour with reference ballast shall be as under: -

T5 lamp of color 4000K at 25 degree C

T5 lamp of color 6500K at 25 degree C

Lamps 14 W 24 W 28 W 54 W 14 W 24 W 28 W 54 WRated Luminous

1200 lumen

1750 lumens

2600 lumen

4450 lumen

1100 lumen

1600 lumens

2400 lumen

4100 lumen


Flux s s s s s sColour Designation

Cool – white

Cool - white

Cool - white

Cool - white

Cool Day Light

Cool Day Light

Cool Day Light

Cool Day Light

Colour Temperature

4000 deg. K

4000 deg. K

4000 deg. K

4000 deg. K

6000 deg. K

6000 deg. K

6000 deg. K

6000 deg. K

Colour Rendering Index (Ra)

> 80 > 80 > 80 > 80 > 80 > 80 > 80 > 80

Chromaticity Coordinates

x– 0.380

x – 0.380

x – 0.380

x – 0.380

x– 0.317

x– 0.317

x– 0.317

x– 0.317

y– 0.380

y – 0.380

y – 0.380

y – 0.380

y– 0.337

y– 0.337

y– 0.337

y– 0.337

4.3 The maximum luminous flux for T-5 lamps shall be obtained at an ambient temperature of 34 IEC 60081 specifies the tests to be conducted at standard conditions of 25°C. and 38 IEC 60081 specifies the tests to be conducted at standard conditions of 25°C.. Typical luminous flux values at 35 IEC 60081 specifies the tests to be conducted at standard conditions of 25°C. are as follows

Sr.No. Colour temperature in degree K

14W 24W 28W 54W

1 4000 1350 2000 2900 50002. 6500 1300 1570 2750 4750

5.1 Rated luminous flux (The lumen test shall be done as per Annexure C of IEC 60081-97.)

It is the quantity derived from radiant flux by evaluating the radiation according to its action upon the CIE standard photometric observer. The unit of luminous flux is lumens.

5.2 The initial reading of the chromaticity co-ordinates x & y shall be within 5 SDCM (Standards Deviation for Colour Matching) from the standardized rated value as per Annex. D of IEC 60081 - 1997.

5.3 The initial reading of the general colour-rendering index (Ra) shall not be less than the rated value decreased by 3.

5.4 The lumen maintenance of the lamp shall not be less than 92% of the initial lumen after 2000 burning hours, 88% of the initial lumen after 5000 hours, 85% of the initial lumen after 10,000 hours.

6.0 Rated life

It is defined as the number of burning hours after which 50% of the lamps survive under controlled burning conditions.


6.1 Rated life shall not be less than 20,000 Hrs on a preheat/warm ballast and IEC cycle (a three hours cycle ie 165 minutes on , 15 minutes off)

6.2 The lumen maintenance & life test shall be done as per Annexure C of IEC 60081-97.

7.0 Starting

7.1 Starting test shall be conducted as per Annexure A of IEC 60081-97.

7.2 T-5 lamps should comply to the following Starting characteristics as per IEC 60081:-

T5 lamp at 25 degree CLamp 14 W 24 W 28 W 54 WFrequency, kHz 20 - 26 20 - 26 20 - 26 20 - 26Starting Aid Distance, mm

6 6 6 6

Preheat Current, A 0.210A 0.440A 0.210A 0.720APreheat Time, sec 2 2 2 2Open Ckt Voltage (r.m.s), V

230V 250V 375V 520V

Starting Time, sec 0.1 0.1 0.1 0.1

B. General requirements for all lamps

1.0 Safety

All the lamps shall comply with the safety requirements as per IEC 61195.

Note: Initial readings in the specification means starting characteristics of a lamp, measured before ageing, and the electrical, photometric & cathode characteristics of a lamp, measured at the end of the 100 hours ageing period.

2.0 Tests

Sampling for tests (type, acceptance and routine) shall be done as per IS-2418.The tests shall be conducted by consignee/ purchaser or representative of consignee/ purchaser at firm’s premises. The following test shall be conducted:

Sl. No

Name of test Requirement Ref.

Type Test

Routine Test

Acceptance Test

Method


.

1.0VISUAL EXAMINATION

1.0 DIMENSION

a) DimensionRDSO Spec. Clause 1.0 Sec. I

IEC 60081-97 Clause 1.5.3

2.0 MECHANICAL

a)

Angular Displacement of CAP Pin

RDSO Spec. Clause 2.1 Sec. I

IEC 60061-1

b)

Mechanical Strength: Torsion


IEC 61195

c)Lead Free Glass*


-----

d)Mercury Content*


-----

3.0ELECTRICAL and CATHODE

a)

Insulation resistance between Shell & Contacts of Cap

RDSO Spec. Clause 3.1 Sec.I

IEC 61195 Clause 2.4.1

b)Cathode Resistance


IEC 60081-97 Clause 1.5.5. & Annex. Bc)

Initial Lamp Voltage


4.0COLOUR & PHOTOMETRY

a)Rated Luminous flux


IEC 60081-97 Clause 1.5.6 & Annex. B

b)Colour Temperature

c) CRI

d)Lumen Output at 25 Deg C


5.0

RATED LUMINOUS FLUX

a)Chromaticity Coordinate


IEC 60081-97 Clause 1.5.6 & Annex. Bb) Initial CRI Value


c)

Lumen maintenance*


IEC 60081-97 Annex. C

6.0 RATED LIFE a) Rated Life* RDSO Spec. IEC


Clause 6.1 Sec. I60081-97 Annex. C

7.0 Starting

a)

Starting TestRDSO Spec. Clause 7.1 Sec.I

IEC 60081-97 Clause 1.5.4 & annex A.

* Certificates should be submitted for the same

2.1 Marking

The following information shall be distinctly and indelibly marked on the lamp.

i) Trademark and/or name of manufacturerii) Rated wattiii) Colour designationiv) Rated luminous flux in lumen or marking to indicate the luminous flux

as per manufacturer’s catalogue

Moreover, the manufacturer should indicate that the following should also be indicated on the cover of the packing of each T-5 lamp.

i) Indian Railway Insignia ii) Month/Year of manufactureiii) Rated luminous flux in lumins.

2.2 Facilities required for T-5 Lamps

The essential facilities required at manufacturing set up, the testing faculties which the suppliers should process in house and quality certification required are mentioned in Annexure ‘A’ Part I.

2.3 Mandatory test reports to be furnished by supplier along with the offer;

At the time of bidding, the supplier must submit test reports preferably from an independent NABL/Government approved laboratory for the following:

i) Lumen output after 100 burning hours and 2000, 5000, 10000, 15000 & 20000 burning hours .each.

ii) Lumen depreciation after 100 burning hours and 2000 , 5000, 10000, 15000 & 20000 burning hours .burning hours each.

If the reports are not from approved Laboratories, the certificates supplied need to be authenticated.

*********


SECTION II

Specification for electronic ballast for T5 lamps

This section prescribes the requirements of electronic ballast for operation of T5 fluorescent lamps without the need of starters, chokes and capacitors. It covers the following designated type of electronic ballasts:

A. High frequency electronic ballast for T5 lamps

To have better reliability, there shall be a separate ballast for each lamp. Hence, a 2X28W luminaire will have two separate ballasts and 4x14W luminaire will have 4 separate ballasts which will be dedicated for each lamp.

S.No.

Description Type of Ballast1X14

W1X24

W1X28

W1X54

WIntegrated for 1X28W

1. Rated Voltage

240V ac/ 50Hz (with 15% ripple current)

2. Rated Current(max.

0.08A 0.12A 0.18A 0.28A 0.18A

3. Input voltage

180 to 265V AC

4. Power consumptiona) Ballast 3W 4W 4W 7W 4Wb) Complete

Assembly17W 28W 32W 61W 32W

5. Power Factor 0.98 0.98 0.98 0.98 0.976. Temperature

range-10oC to 50oC

1. Power consumption - Power consumption of ballast shall be as low as possible and shall not exceed as specified in table above & total power consumption including lamps shall also not exceed as specified in table above.

2. In case of mains voltage fluctuation within 202-254V the luminous flux shall change by maximum of 2%.

3. There shall be over voltage withstanding for 48 Hrs at 320V and 2Hrs at 350V at 60oC. During last 15 minutes, the circuit shall be switched ON (at 350V) /OFF at least 10 times and there shall be no malfunctioning of the ballast and the ballast shall function normally. During acceptance tests, the ballast should be tested at 350V for 2 hours at 60oC and the circuit shall be switched ON ( at 350V )/ OFF at least 10 times and there shall be no mal-functioning of ballast and the ballast shall work normally.


4. There shall be an automatic restart after lamp replacement or with a voltage dip down to 30% in duration of 10 mains cycles.

5. The operating frequency shall be > 42 KHz and waveform shall be quasi-sine wave.

6. Operating Voltage – The operating voltage range on which the ballasts should work shall be 135V to 300280V. The ballasts should be able to comply to all requirements mentioned in table above and other test requirements for the input voltage range i.e., 180V to 265V though it should also be able to work( ignite the lamp and maintain it) from 135V to 300V.

7. Illumination efficiency – The ballast factor shall be more than 0.95.

8. Abnormal condition protection: The ballast shall have protection circuit in case of faulty lamp is connected.

9. Moisture resistance & insulation protection - After storage of 48Hrs at 91-95% relative humidity and 20-30ºC the insulation resistance shall be >2 M ohm with 500V DC megger.

10. Surge/Immunity/Dips/Burst test: The ballast shall comply with as per IEC 61547.

11. Power factor – The power factor of ac electronic ballast shall be greater than as specified in table above at rated voltage of 240V ac 50Hz ±3%.

12. Starting time: The ballast shall be warm start ballast as per IEC 60929. Ignition time shall less than 2 seconds.

13. Total harmonic Distortion: The ballast shall conform to IEC 61000-3-2 and have total harmonic distortion of < 10%. However, the ballast shall meet the individual harmonics requirements as per IS: 13021 (Pt.-2).

14. Safety: The electronic ballast shall be complying with IEC 61347-2-3 for safety and IEC 929 for performance standards.

15. It shall have a Tolerance of Safety of +/-10% i.e. the range shall be 198-264V.

16. The ballast shall be designed for a max case temp of 75 ºC.

17. Construction: The ballast shall be of light weight steel sheet/plastic/fibre & powder coated painted

18. The Fast switching cycle (average, 1min/3min on/off) shall be >=6000 times (for 1 burner).

19. The crest factor shall be less than 1.7.

20. The section of internal wiring shall exceed 0.5mm square.


21. Abnormal conditions

21.1 Removal of Lamp

During operation of the electronic ballast with fluorescent lightlamp, the lamp will be removed from the fitting for a period of one six hours without switching “OFF” the supply. At the end of this period the lamp shall be reconnected and shall start and operate normal.

21.2 Lamp fails to start (cathode intact electrically)

With the appropriate dummy cathode resistor connected in place of each lamp cathode, electronic ballast shall operate at the maximum value of the voltage range for one hour. At the end of this period, the resistor shall be removed and the specified lamp shall be connected and it shall start and operate normally.

21.3 Incorrect Wiring

There shall be no ballast failure in case of incorrect wiring at lamp side.

21.4 Electrode Broken/Emitter Exhausted

The electronic ballast shall have a safety feature of a stop circuit in case of electrode being broken or emitter exhausted.

21.5 The electronic ballast shall be designed to withstand short circuit across the ac output terminals, overload and failure of electronic components without any fire hazards.

21.6 The current drawn from the supply at any of the voltages in the voltage range, shall not be more than 115% of the value obtained at the rated voltage.

*******


B. General Requirements for all type of electronic ballast

2.0 Mandatory Relevant Standards/Test Certificates

The supplier shall provide Test certificate from NABL/government approved laboratories along with the offer. The test on the ballast shall be conducted as per the following standards:

2.1 For electronic ballasts 1x28W, 2 x 28 W, 2 x 54 W and 4x14W 14W, 24W, 28W, 54W for T5 Lamps

i) RFI < 30 Mhz EN 55015ii) Harmonics EN 61000-3-2iii) Immunity EN 61547iv) Safety EN 61347-2-3v) Performance EN 60929vi) Vibration & bump test IEC 68-2-6FcIEC 68-2-9Eb

******


S. No.

Description Type Test

Routine Test

Acceptance Test

Method

1 Visual Examination 2 Rated Current

(max.) As per IEC 60929

3 Power consumption As per IEC 609294 Power Factor As per IEC 609295 Operating

frequency and wave form

6 Illumination efficiency

As per IEC 60929

7 Surge/Immunity/Dips/ Burst test

As per IEC 61547, CISPR 15

8 Starting time As per IEC 60929, 60081

9 Total harmonic Distortion and individual harmonics

As per IEC 61000-3-2

10 Crest factor As per IEC 6092911 Moisture resistance

& insulation As per IEC 61347-

112 Electric strength As per IEC 61347-

113 Abnormal condition

protection

13.1 Removal of lamp As per IEC 61347-1

13.2 Lamp fails to start (cathode intact electrically)

As per IEC 61347-1

13.3 Incorrect Wiring As per IEC 61347-1

13.4 Electrode Broken/Emitter Exhausted

As per IEC 61347-1

13.5 Short Ckt, etc As per Clause 21.5of Section II of specs

14 Creepage distance & clearance

As per IEC 61347-1

15 Resistance to heat, fire & tracking

As per IEC 61347-1

16 Resistance to corrosion

As per IEC 61347-1

17 Change of Luminous Flux

As per Clause 2 of Section II of specification


18 Overvoltage withstanding


19 Fast Switch Cycle * As per Clause 18 of Section II of specification

20 Operating voltage range


* Test to be done on one random sample per lot


Section III

This section prescribes the requirements of different type of luminaries for T5 fluorescent lamps. Since various types of luminaires are available in market andwhich will further be added on time to time by the various manufacturers and the users have different type of requirements for different environments, general requirements for different materials / uses in different fitting have been given. The users may decide the type of luminaire that he intends to use for his application.

A. General requirements for T-5 luminairies

1. It shall be luminaire suitable for T-5 fluorescent Lamp.

2. Luminaire shall be in form of a batten enclosing all the gear components inside the batten.

3. The gear along the other accessories shall have in built electronic ballast, which may be a separate ballast or integrated ballast with luminaire as per requirement.

4. The type of fitting or housing channel shall be specified by users e.g. PVC channels, CRC channel, with reflector, without reflector etc.

5. The Lamp holder shall be G5 type.

6. The material used in end caps for contact with pins of lamps should be made of phosphor bronze.

7. The fixing clamp shall be sturdy to avoid its falling during sudden pressure of wind generated while passage of train etc.

8. Base, cap end caps and other caps shall be made of fire retardant & heat resistantce plastic parts which meet the requirements specified in IEC/IS specifications.

9. Fitting shall be provided with an insulated ion cable for mains connector.

10. Suitable mounting arrangement as specified by user shall be provided. The mounting instructions shall be provided along withon every luminaire.

11. The fitting shall be packed in a poly bag, besides the be outer cord board box.

12. The luminaire shall confirm to IEC 60598-2 with regards to approbation requirements.

13. The photometric results obtained during type testing shall remain benchmark for the further photometric tests done later for that type of luminaire of same that manufacturer.


B. Addition features for luminaires of T5 fluorescent tubular lamps with PVC housing channel with/without Acrylic cover.

1. The housing channel shall be sturdy, non conductive and made up of corrosion & rust free PVC.

2. The fitting shall conform to electrical insulation class II which eliminates the necessity of separate earthing.

3. Fitting shall be suitable for mounting on wall, ceiling, as well as suspension.

C. Addition features for powder coated CRCA sheet luminaire of T5 fluorescent tubular lamps

1) Luminaries shall be in from of a 0.5mm CRCA channel wired with electronic ballast inside.

2) All the sheet metal parts shall be pretreated by seven tank process and powder coated using epoxy polyester powder in a conveyrised coating booth .

3) The housing channel shall be powder coated with coating thickness of 45-65

micron and colour shall be gloss white.

4) The powder coatedr CRCA sheet channel should have specially designed plastic end supports for lamp holders.

5) The fitting shall conform to electrical insulation class I with provision of separate earthing bush.

6) Fitting shall be suitable for mounting on wall, ceiling, as well as suspension.

7) Termination: The luminaire shall be complete with Gears and pre-wired upto a terminal block.

8) The luminaires shall have replacable ballast. D. Addition features for mirror optic fitting for T5 Tubular lamps

1. Mounting: The luminaire shall be suitable for surface mounting as well as suspension/recess mounting.

2. Termination: The luminaire shall be complete with Gears and pre-wired upto a terminal block.

3. Optical System - High efficiency mirror assembly of high quality imported pre anodized aluminum with faceted side reflector and white diffused lamella .For ease of re-lamping it shall be fixed with the housing by specially designed spring mechanism so that it can be hinged also from one side .

4. Mounting - There shall be a provision for suspension/recess mounting through 19mm dia conduit via 2 nos. EVA grommets or direct fixing by screws on ceiling.

5. The mirror used shall be efficiency mirror optic of high quality aluminum with faceted side reflectors and diffuse white lamellae, twelve in number.

6. The optical compartment shall comprise of a special gear cover cum reflector that enhances efficiency.


7. The optical system shall be fixed on the luminaire by a specially designed robust clip-on mechanism and can be hinged to the housing during re-lamping / maintenance.

8. Housing of luminaire shall behave rigid. There shall be a provision for suspension through 19 mm conduit via 2 nos. of ethyl vinyl acetate grommets or direct on surface.

E. Addition features for Enclosed luminaire suitable for T5 linear fluorescent

lamps Ooutdoor Application).

It is generally suitable for the Indian Railways platforms/open areas

1. It shall be made with CRCA sheet as per Clause C B of this section.2. The luminaire shall be able to withstand functional shock, vandalism, dust and

water jet proof . 3. The housing shall be made of polycarbonate with min thickness of 1.6mm and

cover shall be of UV stabilized polycarbonate with min thickness of 1.3mm. The cover shall be of clear polycarbonate and have serrated patterns.

4. The luminaire shall have an IP rating of IP65. 5. The luminaire shall have a impact resistance of IK08 level6. All external hardware including toggles shall be of stainless steel7. The reflector shall be of powder coating for better reflectivity.8. The gear tray containing all the accessories shall be made of 0.5mm cold rolled

rust free stainless steel and shall be replaceable. 9. The gear tray shall accommodate all electrical accessories comprising of electronic

ballast.10. Mounting shall be decided based on requirement.11. The housing shall be fabricated from sheet aluminum stove enameled white.

F. Addition features for T-5luminaries suitable for street lights

1. It shall be made with CRCA sheet as per Clause CB of this section.

2. The housing shall be fabricated from sheet aluminum stove enameled white.

3. The end caps shall be made of impact-resistant engineering plastic for sturdy and excellent corrosion-resistant construction.

4. The Gear tray cum reflector shall be made of CRCA sheet steel epoxy powder-coated white.

5. The Gear tray shall accommodate all electrical accessories comprising of electronic ballast.

6. The Acrylic cover shall be made from clear methyl methacrylate sheet.

7. Six or more numbers of toggles shall be provided for fixing the acrylic cover on to the canopy of the luminaire.

8. It shall suitable for side mounting with the help of U clamps provided on the canopy for pole diameter of max. 28mm outer dia or pipe mounting arrangement or pipe fixing.


9. The Luminaire shall be protected against ingress of dust and moisture with rubber gaskets provided in the housing.

10. The gear tray shall accommodate all electrical accessories comprising of electronic ballast.

11. It shall conform to IP65 Applications.

G. Tests General requirements for luminaires

This shall applicable to following luminaires :-

Sections Luminaire type A1 With Reflector

A2 Without Reflector A3 With Acrylic Cover

A4 Powder Coated CRCA Sheet B1 Mirror Optics Luminaire C Enclosed Luminaire D-(I) Street Lighting Luminaire


Sampling for acceptance test as per IS 2418. The tests shall be conducted by consignee by purchaser or representative of consignee by purchaser at firm’s premises. The following tests shall be conducted:-

S. No.

Description Type Test

Routine Test

Acceptance Test

Method

1 Visual Examination

2 Provision for Earthing

As per IEC 60598-1

3 Protection against Electric Shock

As per IEC 60598-1

4 Resistance to dust, objects and moisture

As per IEC 60529

57 Insulation resistance

As per IEC 60598-1

68 Electric strength As per IEC 60598-179 Endurance test As per IEC 60598-1

180 Thermal test (normal)

As per IEC 60598-1

119 Thermal test (abnormal)

As per IEC 60598-1

102 Resistance to heat

102.1

Ball pressure test As per IEC 60598-1 Clause 13.2

131 Resistance to flame and ignition

13.11

needle-flame test As per IEC 60598-1 Clause 13.2

113.2

glow-wire As per IEC 60598-1 Clause 13.2

142 Resistance to tracking

As per IEC 60598-1 Clause 13.2

135 Mechanical strength

As per IEC 60598-1 Clause 4.13

164 Resistance to corrosion

As per IEC 60598-1 Clause 4.18 and clause 8 of IS 10322(part 4)

157 Photometry


1.0 Tests

1.1 Prototype

Before execution of the first order, the supplier shall submit 2 samples for evaluation and only after the prototype is cleared / approved, the production / supply shall commence. The bulk supply shall be identical to the approved prototype.

1.2 Type test

1.2.1 Visual test

Visual checks for workmanship and dimensional verifications and constructional requirements as per clause 3 of the specification shall be made.

1.2.2 Earthing continuity

The luminaire shall be tested as per IEC 60598-1. Metal parts of the luminaire which are accessible when the luminaire has been mounted or is opened for replacement of lamp or for cleaning purposes , and which may become live in the event of an insulation fault , shall be permanently and reliably connected to an earthing contact .

1.2.3 Insulation resistance

The luminaire shall be tested as per IEC 60598-1. The Insulation resistance shall be measured with D.C. voltage of 500 V, 1 Min. after application of the voltage .The Insulation resistance shall not be less than 2 MΩ.

1.2.4 Endurance test

The luminaire shall be tested as per IEC 60598-1Under conditions representing cyclic heating and cooling in service, the luminaire shall not become unsafe or fail prematurely.

1.2.5 Thermal test (normal)

The luminaire shall be tested as per IEC 60598-1 clause no. 12.4.1.Under conditions representing normal service , no part of the luminaire including the lamp, supply wiring within the luminaire , or the mounting surface shall attain a temperature which would impair safety . In the test none of the temperatures shall exceed the appropriate temperature values of the components and basic materials used in the luminaires .

1.2.6 Thermal test (abnormal)

The luminaire shall be tested as per IEC 60598 under conditions representing abnormal service conditions parts of the luminaire and the mounting surface shall not exceed the appropriate temperature. Values


of the components and basic materials used in the luminaire and the wiring within the luminaire shall not become unsafe.

1.2.7 Resistance to corrosion

The luminaire shall be tested as per IS 10322(PART4). All the sheet metal parts which might cause the luminaire to become unsafe , shall be adequately protected against rusting .After the test their surface shall show no signs of rust .

1.2.8 Photometry

Photometric data shall be declared at the time of approval. The same LOR and distribution will be maintained during supply.

Note: Typical polar curves shown in the specification are for guideline only. However, deviation shall not be more than ±5%.

1.2.9 Drop test

The cartoon strength shall withstand the Free drop at 6 faces and one corner without any damage to the product . The drop height is a function of the gross weight of the cartoon.

1.3 Acceptance test

The following tests shall be conducted for acceptance test:

1) Visual verification2) High voltage 3) Insulation resistance4) Earthing continuity.5) Photometry 6) Drop test

1.4 Repeated type tests

Type test shall be repeated at every three to five years by the production unit / Zonal Railway/ RDSO on two samples selected at random from a lot subjected to execution of order of minimum 10000 nos.


ANNEXURE -A

The Manufacturer/supplier of all the lamp, luminaire or ballasts shall meet following criteria:

1.0 The manufacturer/ supplier should have an experience of at least 5 years in the lighting industry and ISO: 9001 Certification.

2.0 The manufacturer/supplier shall have in-house facility for testing of lamp, luminaire and ballasts in India as per annexure ________ of facilities to be available with manufacturer / supplier.

3.0 The Manufacturer/supplier shall have in-house lighting design expertise with relevant photometric data of light fixtures for arriving at the luminaire type and quantity for a given application area.


4.0 The lamp manufacturer with international repute shall have testing facilities in India also.

5.0 The manufacturer/ supplier should have a MOU/agreement with their vendor for the outsourced item(s) i.e. one or more of tube, ballast and fitting. The overall responsibility of the product, however, shall be that of the supplier who applies for registration.

6.0 The manufacture of T-5 lamp, ballast and luminaire shall be under strict supervision and quality control of the supplier/brand owner.

7.0 The manufacture/supplier should have at least four service centers spanning whole of Indian Railways

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Annexure – A B (I) I Facilities required for T-5 Lamps

A) Infrastructure facilities:

The manufacturing facility shall meet the following requirements & relevant certificates shall be produced :-

i) OHSAS18001: 1999ii) ISO 9001: 2000iii) ISO 140001: 2004

Firm quoting for supply against Railway’s tender shall possess the manufacturing and testing facilities for each item as per Annexure A.

B Test facilities which the supplier shall possess in In-house to determine:

i) Light output of the lampii) Life of the lampiii) Lumen depreciation

C) Essential facilities (machineries, plants & testing equipment) for manufacturing of double-capped T-5 tubular fluorescent lamps:

S.N. Description of M&P and Testing equipment Qty. (Min.)

Manufacturing facilities 1. Glass tube cleaning and coating machine 12. Burning machine/ Baking machine 13. Wiping machine 14. Marking machine 15. Flare making machine6. Stem machine with auto loading of flare, lead in wire, exhaust tube & center

lead wire for mounting the anode ring and with auto unloading.1

7. Automatic filament mounting machine with auto/manual stem loading and automatic wire cutting, wire spreading, wire shaping, lead in wire (LIW) flattening, hook forming, filament clamping, filament stretching, cathode coating, cathode drying and coil compressing, with auto-unloader on mount unloading conveyor.

1

8. Sealing machine. 19. Exhaust machine/pumping machine. 110. High frequency testing machine 111. Capping cement mixing machine 112. Cap filling machine 113. Capping machine 114. Activator machine/Flasher machine 115. Insulation tester 116. Packing machine 1Quality Control Equipment1. Photometric integrator 12. Life test rake 13. Aging test rake 14. Torsion test equipment for caps 15. Go/No Go gauges for G 5cap 16. Reference ballast 14W/28W/54W 17. Photometer calorimeter 1


8. Lamp length gauge 19. Argon filled pressure measuring equipment 110. Digital micro ohm meter 111. Insulation tester 112. Voltage stabilizer 113. Vacuum pump 114. Constant voltage stabilizer 115. Cap heat testing unit 116. Micrometer for thickness of lead in wire 117. Magnifying glass 118. Vernier dial gauge 119. Fluidity meter for capping cement/Cement expansion test by heating 120. Polar scope for measuring strain in glass 121. Tension balance to control emitter weight 122. Mercury distillation facilities 123. Viscosity equipmentStand by power supply arrangement 1. Diesel Generating set of minimum of 15 KVA 1

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Annexure – A (II)

II Facilities required for T-5 Ballasts

A) Infrastructure for Quality Assurance: for T-5 Electronic Ballast

The following facilities are considered desirable for the manufacture of quality and reliable product.

i) Variable regulated DC supply up to 200 Volts DC ii) Component lead forming machines (manual / automatic)iii) Wave soldering machine iv) Dual channel 20 MHz Oscilloscope (Storage type oscilloscope

preferable).v) Temperature sensors for measurement of temperaturevi) Suitable test equipment for measurement of non-sinusoidal supply

parameters.vii) Power factor measurement apparatus (for AC ballast only).

Digital meters for measurement of voltage and currents.viii. 500V DC megger

Graduate engineers should be supervising quality of product.

Annexure – A (III)

III Facilities required for T-5 Luminaires

Infrastructure for Quality Assurance for T-5 Luminaires


The following facilities / machineries are considered essential and shall be available with supplier in house:

Graduate Engineers supervise Quality of product. Supply with CVCF and UPS. Dust Chamber as per IEC 60598-1 Rain Chamber as per IEC 60598-1 Thermal chamber with auto data recording. Endurance test chamber. Megger. Electrical test bench. Digital meter for coating thickness measurement. Photometric lab for conducting photometry of all products Drop test machine Measuring gauges such as Vernier caliper, micrometer, dial gauge etc. Lighting design software (viz. Dialux )

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Documents

100811 T5 Spec Amndd -2