GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

SPECIFICATION FOR

ROOF MOUNTED AC PACKAGE UNIT FOR

AIR-CONDITIONED COACHES

No. : ELPS/SPEC/AC/03 (REV. 1)

AUGUST 1999

RESEARCH DESIGNS AND STANDARAD ORGANISATION MANAK NAGAR, LUCKNOW – 226 011

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

RESEARCH DESIGNS AND STANDARDS ORGANISATION MANAK NAGAR – 226 011

RDSO Specification No. : ELPS/SPEC/AC/03 (Rev. 1) – August 1999 SPECIFICATION FOR ROOF MOUNTED A/C PACKAGE UNIT

FOR AIR – CONDITIONED COACHES 1.0 SCOPE 1.1 This specification lays down the technical requirements, design,

manufacture, supply, test and trial of Roof Mounted A/C Package Units (RMPUs) for Indian Railway air-conditioned coaches. This specification supersedes RDSO earlier Spec. No.

ELPS/SPEC/AC/01 of April 1994 and also it is revision of RDSO Specification No. ELPS/SPEC/AC/03 of Aug’ 95 incorporating earlier amendments No. 1 & 2.

1.2 SCOPE OF SUPPLY

The scope of supply for each Roof Mounted A/C Package Unit shall include the followings unless otherwise stipulated in the tender.

1.2.1 Hermetically sealed compressors at : 2 Nos. (or) Scroll compressors : 2 Nos. 1.2.2. ‘U’ loop copper connectors at : 4 Nos. suction and discharge of (2 for

each compressors. Compressor) 1.2.3. Condenser coil units : 2 Nos. 1.2.4. Condenser fan motors : 2 Nos. 1.2.5. Condenser fans : 2 Nos. 1.2.6. Evaporator cooling coil units : 1 No.

1.2.7. Evaporator blower fan motor : 2 Nos. with both end extend shaft 1.2.8. Evaporator blower fans : 2 Nos. 1.2.9. Capillaries/expansion valves : 2 Nos. 1.2.10. Dehydrators cum filters : 2 Nos. 1.2.11. Accumulators : 2 Nos. 1.2.12. Fresh air filters : 2 Nos. 1.2.13. Return air filters : 2 Nos. 1.2.14. Three phase stainless steel heater : 2 Set. elements with/without fins of not less than 3 KW capacity 1.2.15. Cooling & Heating thermostats : 1 Set. 1.2.16. High pressure cutout (manual reset type) : 2 Nos. 1.2.17. Low pressure cut out (auto reset type) : 2 Nos. 1.2.18. Vane relays with mounting brackets : 2 Nos. 1.2.19. Overheat protectors for heaters : 2 Nos. 1.2.20. Stainless steel drip trays complete with arrangement of drainage of condensate water. 1.2.21. Compressor anti-vibration mountings : as reqd. 1.2.22. Condenser motor anti-vibration mounting : as reqd. 1.2.23. Anti-vibration mounting pads required : 6 Nos. for installation for RMPU on roof structure. 1.2.24. Bellows with metallic frame at both ends : 3 Nos. Note : Make of the various components / equipment shall be as per Annexure – I. Prior approval of RDSO should be obtained for any change. 1.3. A/C. Control Panel

The control panel shall confirm to RDSO specification No. ELPS/SPEC/AC/04 (Rev. 2) of August 1999. Tenderer shall separately quote for the control panel. Control panel shall be procured along with the RMPU.

1.4. Power Supply 1.4.1. The Roof Mounted A/C package Unit shall be suitable to work

from 415V, AC, 3 phase, 50 Hz. Sinusoidal/PWM power supply obtained from DG Sets installed in generator car on EOG type AC coaches / 25 KVA inverter (110V DC / 415 V – 3 Phase AC) on SG type AC coaches. The ELPS/Spec. 20/04/Rev. 5 (Aug’ 99). The control circuit shall be suitable to work on 110 V AC 50 Hz. Sinusoidal / PWM power supply on EOG/SG type AC coaches obtained through a step down transformer (415/110 V AC) installed in control panel.

1.4.2. Din Rail mounted stud type terminal blocks, circular shell type

electrical connectors as per RDSO Drg. No. SKEL 4391 sheet 5/6 (enclosed with RDSO specification No. ELPS/SPEC/AC/04 (Rev. 2) for AC control panel of Roof Mounted A/C Package Units) shall be used. The insulating material used for terminal blocks shall be FRP (Fire retardant properties) qualifying the test as per annexure II (Sheet I & II). Harness numbers shall be strictly as per above mentioned drawing.

1.4.3. Power cables at 415 V and control cables at 110 V shall run in

separate flexible non-metallic conduits from RMPU to it’s control panel.

1.4.4. The flexible non-metallic conduit shall confirm to IS : 6946 – 1973. 1.4.5. Flexible Elastomeric cables shall be used for power and control

cables in the package unit. The cable shall confirm to composition clause 6 of RDSO specification No. SPEC/E-14/01 Part 1 (Rev. 2) Feb’ 1993. Cables shall be procured from RDSO approved supplier.

1.4.6. 37 Pin circular shell electrical connector for control connection

shall be used for both Roof Mounted A/C Package Unit and AC control panel.

1.4.7. The cable shall be of following colors :

415 Volts R Phase Red Y Phase Yellow B Phase Blue

110 Volts Phase White Return Black 1.5 The RMPU shall be installed on the coach by the

purchase/consignee. However the supplier shall associate in testing. Commissioning of The RMPU to the satisfaction of purchaser/consignee.

2.0 GOVERNING SPECIFICATION 2.1 The Roof Mounted A/C Package Unit Shall, unless other wise Specified here in, confirm to the Indian Standards Specification/ IEC recommendations as indicated below and the Indian Electricity rules, wherever applicable. In case there is any revision / amendment to these specifications/rules/recommendations, the latest version shall be applicable.

IS : 325-1996 “Three phase induction motor’. (Fifth Revision)

IS : 659-1964 “safety code for air-conditioning” (Revised)

Amendment – 1 IS : 732-1989 “Code of practice for electrical wiring and

installation” (third Revision). IS : 1359-1992 Specification of electroplated coatings of tin. IS : 1364-1992 “Precision and semi-precision hexagonal

bolts, (Pt. 1 to 5) screw, nuts and lock nuts,” (Third revision) IS : 1424-1983 “Cotton canvas (Third Revision) with

amendment No. 2.

IS : 1745-1978 “Petroleum hydrocarbon solvent” (Second Revision).

IS : 4237-1982 “General requirements for switch gear and control

gear for voltage not exceeding 1000V AC or 1200 V DC.” (First Revision)

IS : 4691-1985 “Degree of protection provided by enclosures for

rotation electrical machinery.” (First Revision). IS : 5493-1981 “dimension for wrought copper and copper alloy

tubes.” (First Revision).

IS : 6946-1973 “Flexible (Pliable) non-metallic con duirs for electrical installations.” (Amendment No. 1).

IS : 10773-1995 “Wrought copper tubes for refrigeration air-

conditioning purposes.” IEC : 77-1968 “Rules for Electric traction equipments”.

2.2 Any deviation from this specification proposed by the tenderer, aimed to improve upon the performance, Utility and reliability / efficiency of the equipment will be given due consideration, provided full particulars of the deviations with justification are furnished. In such a case, the tenderer shall quote according to this specification

and deviation of any, proposed by him. Shall be quoted as an alternative. In case of any contradiction between the provisions of ISS/IEC and this specification, the later shall prevail.

3.0 BASIC GENERAL REQUIREMENTS AND SERVICE

CONDITIONS 3.1. Environmental conditions :

Maximum ambient air temp : 57 deg.C. Average ambient air temp. : 35 Deg. C. Maximum relative humidity : 100%

Atmosphere : Extremely dusty and desert weather and desert terrain in certain areas. The dust content in air may reach as high values as 1.6 mg/m cub. Coastal area : The equipment shall be design to work in coastal area in humidity salt laden and corrossive atmosphere. The maximum value of the condition will be as under ; Max. PH Value 8.5 Sulphate 7 mg/litre Max Concentration 6 mg/litre of chlorine Max. conductivity 130 micro- Semen/CM Annual rainfall: Ranging Between 1750 to 6250 mm Altitudes: Not exceeding 1200 m

3.2. The Roof Mounted A/C Package Unit shall be suitable for rugged

service normally to be met within Railway Rolling Stock, where coaches are expected to run upto a maximum speed of 160 kmph in varying climatic conditions existing throughout India.

3.3 The supplier shall be fully responsible for ensuring that all equipment

forming part of the supply is entirely fit for propose and no part of this specification shall in any way remove or reduce this obligation in this respect. In addition, it is the supplier’s responsibility to under wire the complete air-conditioning system design and ensure that it is compatible with, and will, in no way, compromise, the design and performance of RMPU of this supply.

3.4 The supplier shall provide “In the field” service support during the guarantee period.

3.5 The supplier shall supply any purpose built or special tools or equipment that may be necessary for the correct operation, servicing, testing or installation of the air – conditioning equipment (Excluding normal refrigeration servicing equipment).

3.6 The supplier will provide assistance, both material and technical, in the development of the system as a whole to ensure that when this RMPU is installed as part of the integrated vehicle system the performance of the system meets or exceeds the requirements specified.

3.6.1 Should the RMPU fail to achieve these requirements, then the RMPU shall be modified at the supplier’s expense and within a time scale to be agreed with purchaser/consignee/RDSO.

4.0 TECHNICAL REQUIREMENTS 4.1 The Roof Mounted A/C Package Units shall be able to work satisfactorily of the “Self Generating” (SG) type/”End-On- Generation” (EOG) type of A/C Coaches.

(i). Self Generating type coaches are provided with bogie mounted alternators and rectifying cum regulator equipment to give DC output of 130 V+/- 5%. An inverter is provided to convert this available DC supply to 415 VAC (+/-5%), 3 phase, 50 Hz. PWM power supply. The compressor, condenser & evaporator blower motors shall be suitable to work through VVVF control or direct on line.

(ii). On EOG type of coaches, 415 V AC (+/-5%), 3 phase, 50 Hz

Sinusoidal power supply is available which is obtained from Generator Cars attached at either the end of the EOG rake. In this case the blower motor shall be started directly on line whereas condenser and compressor motor may be started directly on line or through reduced voltage method.

4.2. Roof Mounted A/C Package units should give rated capacity to air

condition of coaches under following condition: -

Summer Condition Dry Bulb Wet Bulb %RH

Outside (Dry summer) 50 deg. C 25 deg. C Outside (Wet summer) 40 deg. C 28 deg. C Inside (Dry & wet) 22 to 25 deg. C - 60-40 Winter condition Outside 4 deg. C Inside 21 deg. C

4.2.1 The design of the RMPU shall be such as to restrict relative

humidity to 60% maximum inside the air-conditioned compartment under any circumstances.

4.2.2 The RMPU shall be capable to work even with one condenser fan

and cooling capacity so obtained shall not be less than 75% of rated capacity.

4.2.3 The refrigeration system shall comprise of two circuits i.e. two

sealed/scroll compressors, two condensers & two cooling coils cum heaters.

4.3 Vibration and shocks :

The RMPU as well as control panel shall withstand satisfactory vibrations and shock normally encountered in service as indicated blow:- (a) Maximum vertical acceleration - 1.0 g (b) Maximum lateral acceleration - 0.5 g. (c ) Maximum longitudinal acceleration - 3.0 g. (‘g’ being the value of acceleration due to gravity) The vibrations are of sine wave from and frequency of vibrations is between 1 Hz and 50 Hz. The amplitude ‘a’ expressed in mm is given as a function of ‘f’ by a=25/f for value of ‘f’ from 1 to 10 Hz. And a=250/f²for the value of ‘F’ exceeding 10 Hz. And upto 50 Hz.

4.4 General constructional requirements Roof Mounted A/C Package Unit outline diagram shall generally confirm to RCF Drg. No. CC 90012 alt. “e” using two compressors.

To prevent corrosion structural and all other sheet metal work for a Roof Mounted A/C Package Unit should be made from corrosion resistant grade 304 of stainless steel including housing sheet and structural materials. Welded zone may be given necessary treatment after fabrication. Such steel work need not to be painted after fabrication. The stainless steel sheet used for housing shall be of 20 SWG.

Manufacturer shall obtain prior approval of structural drawing and general layout drawing before manufacturing RMPU.

4.5 All the equipment shall be capable of continuous operation

without detriment or the operation of cutouts, circuits breakers or over-loads in ambient temperature between 0 deg. C and 57 deg. C and relative humidity upto 100%

4.6 The Roof Mounted A/C Package Unit shall be self-supporting and will

not from part of the vehicle structure. For the RMPU a separate structural frame shall be employed which will not relay on the housings of any of the installed components or equipments or equipment for rigidity and strength. Guards shall not from part of the structure.

4.7 RMPU shall be capable of being handled by overhead lifting gear

without sustaining damage. Suitable lifting brackets for this purpose shall be provided as shown in the drawing. The supplier shall state the special handling requirement, if any.

The actual weight of the AC Package unit shall not exceed 750 Kg.

4.8 The RMPU shall be so designed that is interfaces with the vehicles so

as not to allow rain water, washing plant fluid and condensate to enter in to the vehicle> The connection of supply air opening to the main duct and return air opening to the coach shall be through bellows with metallic frame on both ends. The bellows should be despatchable from

the package unit as well as from duct side. The connection of the coach duct and the package unit to bellows should be through nuts/bolts/screw. Bellows should be of superior quality preferably of woven material to IS : 1424-1983 (Third Revision) Amendment No. 2.

Bellows as well as their connections with the package unit should be waterproof and fire retardant. Bellows proposed to be used should have prior approval of RDSO.

4.9 The design and layout of RMPU shall be such as to prevent water traps

even if the vehicle is stopped on the slope or cant. Proper water drainage arrangement shall also be provided. Each drip tray shall have drain hole fitted with drain pipe towards condenser’s side. Drain pipe to drain out condensate water from drip trays to through should be integral part of the drip tray and with suitable trap at free end, if required, to prevent the condensate water being sucked in by blower and thrown in the supply air duct.

4.9.1 Drip trays provided under cooling coils to collect condensate water

should be of stainless steel and should have a depth not less than 60 mm.

No external connections/fittings shall be provided by the purchaser while installing.

4.10 No material shall be used in the construction of the RMPU that is

liable to be adversely affected by vibration, damp, rotting or growth of moulds. No timber shall used. Use of asbestos is prohibited. Fire retardant materials only should be used. No material shall be used that will support infestation of any kind.

The RMPU shall be as light as possible without reducing reliability.

4.11 The evaporator compartment of the AC package unit shall be

watertight and there should be no leakage of water into the evaporator compartment from outside as well as from bottom of the RMPU when tested for water tightness.

4.12 The acoustic noise level generated by the running of RMPU in

installed condition shall be as low as possible and not raise the

resultant noise level inside the air-conditioned compartment to an uncomfortable level. Condenser fans and compressors shall have anti-vibration resilient mountings to avoid structure borne noise transmission into the coach.

4.13 A protective wire mesh guard shall be provided over the package unit

covering entire condenser portion and over condenser fans. Protective guard shall be made from stainless steel wire of OD not less than 3 mm. The Clearance between the top of the condenser fan and guard should not be less than 25 mm. The guard shall be in three or more pieces for ease in handling. The compartment containing cooling coils/heaters blower fan shall be thermally insulated from all sides, top and bottom.

4.13.1 The Insulating material used shall be of fire retardant type preferably,

resin bonded fibre glass or fibre retardant polyethylene or combination of both or any other suitable material. The insulating material shall be sandwiched and jacketed between two layers of stainless steel sheets duly sealed on all the sides to avoid peeling/failing of the insulating material. Manufacturer should obtain prior approval from RDSO/Purchaser for other type of Insulating material proposed to be used

4.14 Equipment/components needing service attention shall be easily

accessible from inside of the coach through the access doors. The blower fan unit with motor should be accessible and removable from the bottom. It should be provided with a wire rope of adequate size / strength to prevent falling down. The servicing/replacement of pressure cutouts, attention to vane relay heater unit and filter should be possible from inside of the coach trough access doors. The bottom cover/access doors should be leak proof secured by industrial locks or latches for easy and quick removal. The access doors should be provided with gaskets all around. The gasket shall be made of neoprene or superior quality of rubber. The cover under the blower however, should be screwed instead of nuts and bolts for positive sealing. Suitable hinged opening will be available in the false ceiling in the coach for the access as indicated above.

4.15 The evaporator blower should be designed for air delevary at 20 mm

static head of water gauge.

4.16 Major equipment/components shall be replaceable on a unit change basis.

4.17 Various equipments used shall have clear marking/rating plates. 4.18 It shall be possible for the attendant to effect manual override of the

control system but with the provision that the RMPU shall be prevent from operating in a condition where damage could occur.

4.19 RMPU should work on vapour compression refrigeration system with

R-22 (Mono Cloro di fluoro methane) refrigerant. 4.20 The design philosophy shall be of no leaks and a sealed system (with

sealed or scroll compressors). 4.21 RMPU shall be installed above the false ceiling under the coach roof

with condenser portion exposed. The condensing temperature should be minimum possible.

4.22 The compressor, suitable for a traction environment (Rolling stock

application only, shall be employed The refrigerant compressors shall have adequate capacity at 60 deg. C condensing temp. maximum and 5 deg. C suction temperature.

4.23 The rating of Roof mounted A/C Package unit shall not be less then

6.5 TR as per conditions of clause 4.2 of dry summer conditions. However the refrigerant capacity above 6.5 TR will be preferred keeping the maximum power consumption of the RMPU and control panel below 13.0 KW.

4.23.1 The offer having higher efficiency (TR/KW) will be preferred. 4.24 Heat exchange coils of condenser and evaporator shall be made from

copper tubes, copper fins and copper bends. 4.24.1 The heat rejection capacity of refrigerant condenser shall match the

capacity of air-conditioning system. 4.24.2 All copper parts of the coils shall be tinned with minimum local

thickness of 15 microns confirming to classification Sn 15 of IS : 1359-1992.

4.24.3 Single fin construction should be adopted so that one fin is there for

all the rows of the tubes to avoid possibility of misalignment and accumulation of dust over fins.

4.24.4 The fins should be uniformly distributed throughout the entire the

length of the tubes. Spacers should be used to maintain uniform distance between the fins during manufacturing before expansion of the tubes.

4.24.5 There should be adequate grip of the fins over the tubes and the fins

should have flared collers so that during vibrations, the fins do not come closer and coller of the fin is not able to go inside the hole of mechanically expanded.

4.24.6 Fresh air quantity & Fresh/Return Air Filters. 4.24.7 The requirement of fresh air inside the compartment is as follows :

A/C First Class 0.7m³/min/person A/c Sleeper & A/C Chair car 0.35 m³/min/person

4.24.8 Keeping in view the above requirement of fresh air quantity of

fresh air per package unit should not be less than 17.5 m cub/min. 4.24.9 Individual dampers shall be provided for fresh air. It should be

possible to control the fresh air and return air quantity independently. Arrangement should be available to lock the fresh and return air dampers at any position.

4.24.10 Adjustment of dampers with locking arrangement should be

possible from inside of the coach, even during run. The openings shall not get disturbed on their own.

4.24.11 It should be possible to access/replace fresh air filters from the

bottom of the unit. 4.24.12 Cleanable dry type fresh/return air filters shall be provided in the

RMPU filters shall be secured by latches and not by nut/bolts so that it is easy to remove them from their location for cleaning.

Fresh air filter size shall be 230 (H) x 260 (W) x 60 (T) mm. Thickness of return air filter shall be 50 mm.

4.24.13 The technical requirements of fresh and return air filters shall be as

under:

Application Flow Velocity Resistance Resistance Rate ft per min when clean with dust (max) (Max) Concerntration 2 Mg/M (WG) m cub/ ft./min mm (WG) mm (WG) minute (Max) (Max.) Fresh Air 10 300 4 12 Return Air 30 500 3 10

4.24.14 The filter shall be capable of being clean with a jet of water/air/suitable cleaning agent, which may be indicated by the manufacturer.

4.24.15 In full assembled condition the filters should be flame proof and

shall be tested as per Annexure II. 4.24.16 The filter media used shall be of synthetic non-woven polyester

covered on both sides with high density polyethylene (HDP) with not dip GI wire mesh and crimped in the form of foldings. The thickness of non-woven polyester and the number of folds and the size of wire mesh shall be chosen so as to meet the technical requirements.

4.24.17 The opening provided for entry of fresh air in RMPU should be

covered by expanded metal (jali) of 5 mm size to prevent entry of leaves etc.

4.25 Thermostats : 4.25.1 Thermostats (preferably electronics type) for cooling and heating

shall be provided.

4.25.2 Setting of thermostats shall be as under : Low Medium High Cooling 24 deg. C 24 deg. C 26 deg. C Heating 19 deg. C 19 deg. C 21 deg. C

Note: In case the RMPU is provided on AC 1st class coach, the low setting thermostats of 22 deg. C for cooling and 17 deg. C for heating shall be provided by the coach builders.

4.25.3 The cut-in shall occur within +/-0.2 deg. C of the set value of

thermostat. The differential between cut-in and cut-out tempreture shall be 1.0 deg. C minimum and 2 deg. C maximum.

4.26 Similarly thermostats HP/LP cutouts, overheat protector, should be so

located that attention/replacement shall be possible without any difficulty.

4.27 The RMPU’s frame shall have arrangements for vibration isolation

from the coach. Compressor shall have anti-vibration resilient mountings.

4.28 Refrigerant copper piping shall be as short as possible. All joints shall

be brazed/welded. The material of the copper piping shall confirm to soft annealed grade copper to IS : 10773-1983 and dimensional requirements to IS : 5493-1981 (First Rev.) subject to minimum thickness of 1.0 mm.

4.29 Manufacturer shall furnish the weight of the package unit and shall

also supply layout sketch showing distribution of weight of equipments inside the package unit to study the balancing aspect. Balancing Calculation shall also be furnished by the manufacturers.

4.30 Each refrigeration system shall be protected by suitable safety devices

separately. 4.31 The fan blades of condenser fan and runner of evaporator blower

should be dynamically balance.

4.32 Air shall be drawn (not blown) over cooling coils (i.e. suck-through arrangement). Arrangement shall be made to prevent sucking of condensate water by evaporator blower unit.

4.33 The evaporator blower fan motor shall be capable of operating

continuously in any air temperature and under the effects of any radiant from heater bank that may be experienced in normal operation.

4.34 Fan Impellers shall be directly coupled to their respective motors. 4.35 An expansion valve or capillary tube, and filter-cum-dehydrator unit

shall be connected into liquid refrigerant pipeline. 4.36 The evaporator unit shall contain adequately rated heater units for

heating during winter. These heaters shall be of highest reliability standard to obviate any fire hazards. Stainless steel tube heaters with or without fins shall be provided.

4.37 The cover of terminal boxes of all motors should have gasket all

around as well as grommets at cable entry points to prevent any ingress of moisture.

4.38 A wide differential, self resetting over-heat protector shall fitted to de-

energise the electric heater bank in the RMPU in the event of restricted air flow over the elements or due to any other causes with could lead to excessive heater bank temperature resulting in the potential hazards.

The OHP shall be set to operate at 180 deg. C max.

4.39 The motors used on RMPUs shall be of following ratings :

Condenser fan motor 1 HP, 1000 RPM (Synchronous speed), frame size: 90L suitable for flange mounting.

Evaporator blower 1.5 HP, 1500 RPM (Synchronous

speed), frame size: 90L suitable for foot mounting.

4.39.1 Motors provided in Roof Mounted AC Package Unit shall be

continuously rated and shall confirm to the requirement given in

Annexure IV. Shaft to be used with condenser fan motor and evaporator blower fan motor shall confirm to RDSO drawing RDSO/PE/SK/AC/4533-99 (Rev.0) & RDSO/PE/SK/AC/4532.99 (Rev. 0) respectively.

4.40 The compressors shall be provided with high/low pressure cutouts to

avoid working of compressor beyond permissible pressures. High-pressure cutouts shall be manual reset type whereas low-pressure cutout shall be auto reset type. HP cutout will be set at 415+/- 15 psi and low-pressure cutout at 35+/-5 psi.

4.41 Compressors, all motors and frame of RMPU shall be provided with

suitable flexible braided copper jumpers with crimped sockets on either end for double earthing

. 4.42 Cable should be so laid frame of RMPU that removal of any defective

cable is easily possible. 4.43 Cables shall be crimped at both ends with suitable terminal copper lugs

Heat shrinkable type PVC sleeve will be provided over lugs & on the joints so that sleeves do not get dislodged. Interlocked type cable markers shall be provided to identify a particular cable.

4.44 Clearance and creepage distance shall be maintained as per IS: 4237-

1982. 4.45 Metallic pads of adequate height shall be provided at the bottom of the

package unit as shown in general arrangement drawing to avoid direct contact with floor when lying on the floor.

4.46 Vane relay shall generally confirm to RDSO drawing No. SKEL 4428

(enclosed at Annexure-VI) and its mountings brackets for holding vane relay and thermostats shall confirm to RDSO drawing No. SKEL – 4429 (enclosed at Annexure – VII). The holding bracket shall be so located that the vane relay flapper is nearer to return air entry. The provision for mounting & holding thermostat (s) shall be made at both the return air entries.

4.47 MARKING:

The RMPU shall be marked with the following information in the front : Type/Make Serial No. Month and year of manufacture Weight

5.0 TESTS 5.1. Type test:

Only after all the design and drawings have been approved and clearance given to this effect, the manufacturer shall take up the manufacture of the prototype unit. It is to be clearly understood that any change required to be done in the prototype or any additional test other than those specified herein, are required to be conducted on the prototype unit or its components, they shall be done expeditiously. During the process of manufacture of the equipment , if the purchaser/RDSO so additional test to satisfy himself that the quality of RMPU being manufactured is of the requisite standards. The suitability of Roof Mounted A/C Package Unit shall be ascertained by inspection, bench test at firm’s works, that is, in stationary coach and service trail of the coach. Subject to arrangement between user and manufacturer some or all type test shall be repeated once in two years by RDSO and purchaser on sample basis. So as to confirm the quality of the product to meet the specified requirements. In additional, the manufacturer shall repeat the type test to be witnessed by representative of RDSO and purchaser either totally or in part in following cases without any additional cost:-

- Modification of the equipment likely to effect its function. - Failure or vibration established during type or acceptance

test. - Resumption of production after an interruption of more than

two years.

Investigation test are intended to obtain additional information regarding the performance of the product. They shall be specially requested either by the user or by the manufacturer.

RDSO may conduct surprise check on manufacturing process and quality control alongwith any of the tests to ensure quality of product and its conformance to RDSO’s specification. The following test shall be carried out at the works of the manufacturer or at a reputed testing laboratory in presence of Indian Railway’s representative on the prototype unit of RMPU as per relevant governing specifications modified or amplified as under:- i). Dimensional & Visual

inspection (Clause 5.1.1) ii). Test for water tightness (Clause 5.1.2) a). Rain test (Clause 5.1.2.1) b). Test for drainage of condensate water (Clause 5.1.2.2) iii). Electrical test (Clause 5.1.3) Insulation resistance & High voltage test (Clause 5.1.3.1) Voltage change test (Clause 5.1.3.2) Frequency change test (Clause 5.1.3.3) High temp. Start up test (Clause 5.1.3.4) iv). Fresh air quantity test (Clause 5.1.4) v). Conditioned air delivery test (Clause 5.1.5) vi). Cooling capacity test (Clause 5.1.6) vii). Measuring of power (Clause 5.1.7) viii). Heating capacity test (Clause 5.1.8) ix). Test for withstanding vibration (Clause 5.1.9) x). Test for simulate the effect of shunting shock (Clause 5.1.10) 5.1.1 Dimension & Visual Inspection

It shall be done for checking the overall dimensions, location of lifting hooks, material of filters, accessibility of blower motors, filters, vane relay, thermostats & protective devices, quality of welding in RMPU.

5.1.2 Test for water tightness

The RMPU shall be tested by the manufacturer for water tightness as per test arrangement and test programme described below:

5.1.2.1 Rain test:

The water tightness of the body and electrical equipment boxes mounted outside the body shall be inspected at all opening, doors, covers, cover strip or crevices which might allow penetration of water or snow. A distinction shall be made between the water tightness of openings air inlet etc., which depends primarily on erection and the condition of joints. i). A check on the water tightness of openings shall from type test. It shall be carried out for a period of 30 minutes with all fan running under artificial rain of an intensity not less than 60 mm per minute. The angle of rain will be 45 degree towards evaporator compartment from condenser side. ii). A check on the water tightness of covers shall be conducted. It shall be carried out by means of a jet of 6 to 10 mm internal diameter, at a distance of 2 meters and a pressure of 1 bar with all fans running and then at a pressure of 1 bar with all fans running and then at a pressure of 3 bars with the fans stopped. The water shall be sprayed on each cover/side minimum for 15 minutes. iii). In each case, the penetration of water shall be slight, and not be of such nature as to have an adverse effect on cabling and electrical equipment, or any other equipment necessary for maintaining the vehicle in proper working order.

5.1.2.2 Test for drainage of condensate water:

The test will be conducted to see the efficiency of condensate water drain out system from the AC Package unit with blower motor in working condition.

5.1.3 Electrical test

5.1.3.1 Insulation Resistance:

Insulation resistance of compressor/motors shall not be less than 100 mega-ohms with Dc 1000 V megger in all the weather conditions.

5.1.3.2 High Voltage test:

Work test certificate from original equipment manufacturer (OEM) certifying the equipment to withstand a voltage of 2000 V AC for one minute shall be furnished.

5.1.3.3 Voltage Change test:

During the normal operation of the RMPU under cooling capacity test (Clause 5.1.6) condition and high temperature condition the power source voltage will be changed to 375 V AC to 460 V AC. The RMPU shall operate without significant change of discharge and suction pressure.

5.1.3.4 Frequency change test:

During the normal operation of the equipment at standard condition and high temp. condition. The power source frequency shall be changed to 47.5 to 52.5 hz.

5.1.3.5 High temperature start up test:

The condenser room temperature shall be maintained at 57 deg. C. The RMPU shall be made to run for one hour as per clause 5.1.5 dry summer conditions. The unit should work satisfactorily without tripping of any of the protective devices (Clause 4.5).

5.1.4 Fresh air quantity test:

Measurements of fresh air quantity shall be made when fresh air openings are fully open and fresh air should be measured at 415-5% volts i.e. at 394 Volts.

5.1.5 Conditioned air delivery test : a). Manufacturer shall furnish test certificate from a reputed test laboratory for the suitability of filters as laid down in Clause No. 4.28. b). This test shall be conducted by adjusting static head at 20 mm. WG over conditioned room air. c). Air velocity measurements shall be recorded at both return air filters. Both fresh air filters shall be closed.]

5.1.6 Cooling Capacity test :

i). This test shall be made in following conditions keeping static head of supply air at 20 mm WG. Test condition Condition Condition Created in hot Created in cold Chamber Chamber (Dry summer 50 deg. C (DB) 25 deg. C (DB) condition 25 deg. C (WB) 16 deg. C (WB) ii). Cooling capacity from evaporator side shall be calculated as under :- 60 x Q x (E2 – E1) C = --------------------- S Where C = Cooling capacity (K. Cal/h) evaporator side. Q = Conditioned air quantity (m³/min) of

Evaporator blower fan. E1 = Enthalpy of supply air (K.Cal/kg) E2 = Enthalpy of return air (K.Cal/Kg) S = Specific volume of supply air m³/Kg.

iii). Cooling capacity from condenser side shall also be determined as under: - 360 x Qc x (E3 – E4) Cc = -------------------------- - (Et x 0.86) Sc Where CC = Condenser side total cooling capacity (K. cal/hr.) Qc = Air flow rate over condenser per minute E3 = Enthalpy of air entering condenser (K. cal/kg) E4 = Specific Volume of air flowing over the condenser

(m³/kg.). Et = Total power input to module in watts. 5.1.7 Measurement of power

In type test total power input RMPU as well as to each of the motors shall be recorded. Above measurement shall also be recorded while doing air delivery test under routine test.

5.1.8 Heating capacity test

Measures KW rating of heater provided. 5.1.9 Test for withstanding vibration: -

This test shall be done as per IEC: 77. 5.1.10 Test to simulate the effect of shunting shocks: -

This test shall be done as per IEC: 77 5.1.11 Work test certificate from the motors manufacturers shall be

furnished for IP55 degree of protection. 5.2 Routine Tests

Routine tests are to be carried out of verify that properties of the product of corresponding to those measured during type tests. Following routine tests are to be performed by the manufacturer on each equipment :- i). Dimensional and visual inspection (Clause 5.1.1) ii). Test for water tightness (Clause 5.1.2) iii). Fresh air quantity test (Clause 5.1.4) iv). Cooling capacity test (Clause 5.1.6)

v). Measurement of power (Clause 5.1.7) vi). Electrical test (Clause 5.1.3) Manufacturer shall submit a copy of above test results in respect of each RMPU to inspecting authority.

5.3 Acceptance tests:

Every Roof Mounted A/C Package Unit shall be subjected to acceptance test at the manufacturer’s works at given below:

i). Dimensional and visual inspection (Clause 5.1.1) ii). Test for water tightness (Clause 5.1.2) iii). Fresh air quantity test (Clause 5.1.4) iv). Conditioned air delivery test (Clause 5.1.5) v). Measurement of power (Clause 5.1.7) vi). Electrical test (Clause 5.1.3) Vii).Test for water tightness (Clause 5.1.2) Note : 1. Conditioned test and fresh air quantity test and measurement of power shall be conducted on 20% of the lot offered subject to minimum of two, selected at random.

2. Voltage change test (Clause 5.1.3.2) Frequency change test

(Clause 5.1.3.3) and High temperature start-up test (Clause 5.1.3.4) shall be conducted on 20% of the lot offered subject to minimum of two, selected at random.

6.0 Technical Data 6.1.1 The technical information as per Annexure III “ Questionnaire on

offer of Roof Mounted A/C Package Unit” complete in all respect should be furnished with offer by the tenderer.

6.1.2 The tenderer shall indicate their compliance or other wise against

each clause and sub-clause of the technical specification and submit with the offer. The tenderer shall for this purpose. Enclose a separate statement, if necessary, indicating the Annexure and clause reference and compliance or otherwise.

6.1.3 The manufacturer shall submit complete design details of condenser coil and evaporator coil alongwith basis of capacity selected before prototype RMPU is offered. Necessary calculation shall also be submitted.

6.1.4 The manufacturer shall also supply following drawings :

1. Layout drawing showing important dimensions of RMPU showing locations of various equipments, refrigerant piping alongwith its holdings.

2. Structural frame drawing showing size of various sections used & gauge of stainless steel sheet provided.

3. Dimensional drawings of fresh and air return filters. 7.0 Operating Instructions/Maintenance Manual : 7.1. One set of the followings will be supplied with each RMPU. 7.2. Operating and trouble shooting manual. 7.3. Maintenance manual containing detailed instructions for servicing and

repairs of :-

i). Compressor ii). Air cooled condenser iii). Evaporator iv). Filters v). Heaters vi). Motors

7.4 Parts illustrated catalogue-indicating sources. 8.0 Guarantee 8.1 RMPU shall be guaranteed against design and manufacturing defects

for a period of 12 months from the date of commissioning or 18 months from date of supply which ever comes first. Defects shall be analysed and properly investigated. Corrective modifications as required shall be carried out on all units supplied. During the pendency of the warranty period manufacturer’s Engineers and/or Technical staff may be called upon by the user Railway to attend to any such problems/defects at terminal Railway junctions and also at carriage A/C maintenance depots of Railways as well as at purchaser’s work.

All consumable like gas, electrodes etc. and equipments like vaccum pumps etc. shall be arranged by the manufacturer for carrying out alterations/modification during guarantee period.

9.0 Infringement of Patent Right.

Indian Railways shall not be responsible for infringement of Patent rights arising due to similarity in design, manufacturing process, use of components in design/development/manufacturing of RMPU and/or any other factor which may cause such dispute. The responsibility to settle any such issue will rest with the manufacturer.

10.0 Infrastructure for power Assurance

The facilities considered essential to be available with the firm for the manufacture quality and reliable product are indicated in Annexure – V. Tenderer shall confirm the availability of these facilities along with their tender offer.

11.0 Training

The contactor shall undertake to train, free of cost the supervisors & staff of the Indian Railways for operation, maintenance, fault finding, repair of offered RMPUs under guidance of skilled engineers, during the first year of the service of the RMPUs. The number of supervisor to be trained against a contract will be indicated by the accepting authority. The wages and allowances of each Railway supervisor nominated for training shall be paid by the purchaser. The purchaser shall bear the cost of the passage to and for from the place of training for the Railway supervisor.

12.0 Service Engineers

The successful tenderer shall be required to make available the services of his engineer/engineers free of cost to which performance of the equipment in service periodically and also carry necessary repairs or replacement under warranty obligations. The necessary spares needed for replacement during service should be available with the service engineers at minimum six of the following important terminal stations covering entire Indian railways network :

Delhi, Calcutta, Chennai, Mumbai, Secundrabad, Guwahati, Gorakhpur, Amritsar, Jammu Tawi and Banaglore etc.

13.0 Enclosures 13.1 Annexure I : Acceptance make of requirements. 13.2 Annexure II : Fire retardant test 13.3 Annexure III: Questionnaire on offer for Roof Mounted

AC Package. 13.4 Annexure IV : Specification for 3 phase electric motors

for use on Roof Mounted AC Package Units.

13.5 Annexure V : Infrastructure Quality Assurance 13.6 Outline of Roof Mounted AC Package Unit RCF drg. No. CC 90012

alt. ‘e’ with two compressors. 13.7 Mounting arrangement of Roof Mounted AC Package Unit RCF

Drg. No. CC 44225 & AE 44225 13.8 RDSO drgs No. SKEL 4428 & SKEL 4429 for vane relay and it’s

mounting bracket. 13.9 RDSO drg. No. RDSO/PE/SK/AC/4533/99 (Rec. 0) &

RDSO/PE/SK/AC/4532/99 (Rev.0) for shafts of condenser fan & evaporator blower fan motor respectively.

Annexure 1 to ELPS/SPEC/AC/03 (Rev. 1)

(Clause 1.2.24)

ACCEPTABLE MAKES OF EQUIPMENT

S. No. Description Quantity Make 1 Hermetically sealed 2 Nos. Maneurope Compressors Or Scroll compressor 2 U loop copper connectors 4 Nos. ---- at suction & discharge of compressors (2 for each compressor) 3 Condenser unit 2 Nos. ---- 4 Condenser fan motor 2 Nos. ABB, NGEF, CGL 5 Condenser fan 2 Nos. ----- 6 Cooling coil 2 Nos. ----- 7 Blower fan motor with 1 No. ABB,NGEL, CGL double extend shaft 8 Blower fan 2 Nos. ----- 9 Capillary system with 2 Sets ----- dehydrator/Expansion valve. 10 Three phase stainless 2 Nos ----- steel heater element with/Without stainless steel fins 11 Thermostats Mercury – in - 1 Set A. Paul glass tape (Set of 3 cooling & 3 heating) or Electronic Type 1 Set As approved by

RDSO 12 High pressure cut out 2 Nos. INDFOSS/ Ranutrol/

Ranco. S. No. Description Quantity Make 13 Low pressure cut out 2 Nos. INDFOSS/ Ranutrol/ Ranco. 14 Vane relay 2 Nos ----- 15 Overheat Protector 2 Nos ----- 16 Stainless steel drip 2 Nos ----- tray for evaporator coil 17 Compressor anti- As -----

vibration mountingrequired 18 Condenser motor anti- As -----

Vibration mounting required 19 Anti-vibration 6 Nos. ----- mounting pads for overall package Unit 20 Copper piping As reqd. ----- 21 Water proof bellows 3 Nos. preferably made of fire retardant of wovan material with metallic material to frame at both ends IS : 1424-1983 22 Fresh & Return filters 2 each Usha Filters.

Annexure II to

ELPS/SPEC/AC/03 (Rev. 1) (Clause 1.4.2)

(Sheet 1)

FIRE RETARDANT TEST

One half of the body of specimen shall be subjected to the luminous batswing flame, preferably supplied by a Bunsen burner. The specimen shall be held with the flat side up at an angle of 45 deg. to the horizental as shown in the fig. The frame shall be of 25 mm in width across the tips. The flame shall be applied to the specimen at the lower end for 30 seconds and removed for 30 seconds and then applied again to the same end for the second period of 30 seconds and then removed again. This test shall be carried out with both the surfaces facing the flame.

Should the specimen get ignited, it shall not continue to burn for more

than 50 seconds after the flame has been finally removed.

Annexure II to

ELPS/SPEC/AC/03 (Rev. 1) (Clause 6.1.1)

QUESTIONNAIRE ON OFFER FOR ROOF MOUNTED A/C PACKAGE UNIT A). A/C PACKAGE UNIT i). A/c Package unit model/type ii). Make of the Manufacturer iii). Cooling capacity of the unit offered at 5 deg. C evaporating temperature and 60 deg. C

condensing temperature. iv). Over all dimensions a). Length along the coach b). Width across the coach c). Height v). Weight of package unit vi). Refrigerant used vii). Conditioned air out put and static head in water gauge viii). Fresh air quantity ix). Total power input for the unit under condition at a). Cooling b). Heating x). Starting duty a). Starting current with duration xi). Rated voltage, frequency and phase of power supply input xii). Full load current at a). Rated voltage b). Minimum voltage B). COMPRESSOR UNIT Compressor

i). Maker’s name ii). Type/Model No. iii). Refrigeration capacity at 5 deg. C suction and 60 deg. C discharge temperature iv). Name of refrigerant v). Power required to drive

compressor at specified Conditions at (iii) above

vi). Power required under speci- fied conditions in KW per ton of refrigeration at (iii) above vii) Nos of cylinders in compressor viii) Rated speed ix) Type of bearings x) Valves

a) Details of Nos of Valves b) Manufacturers Name

xi) Drawing/sketch No. xii) Pressure cut outs

a) Make b) Type c) Rage d) Differential setting available e) Contract available f) Rating of contract

xiii) Drawing/Sketch No. xiv) Total weight of assembled

Compressor unit xv) Overall dimensions of

Compressor unit xvi) Details of spares xvii) Normal working voltage xviii) Rated speed xix) Rated current

a) At rated voltage b) At minimum voltage

xx) Frequency xxi) Phase xxii) Type cooling xxiii) Class of insulation

xxiv) Type of enclosure xxv) Efficiency at full load xxvi) Peak current with duration

at starting xxix) Direction of rotation xxx) Starting torque/full load torque developed xxxi) Details of anti vibration mountings provided C). REFRIGERANT CONDENSER UNIT i) Maker’s name ii) Type model No. iii) Heat rejection capacity

Kcal/hr.) at condensing Temperature 60 deg. C

iv) Cooling air temperature a) Inlet b) Out let

v) Total nos of tubes vi) Total nos of tubes per row vii) Nos of rows viii) Material and diameter of tubes ix) Material and size of bends x) No. of fins per 25 mm xi) Gap between fins xii) Material and gauge of fins xiii) Type of fins xiv) Total cooling surface area of fins

And tubes together in sq. mm xv) Nos. & Details of fins

a) Inlet pipe size b) Outlet pipe size

xvi) Corrosion treatment xvii) Method of cleaning xviii) Overall dimensions xix) Face area in sq. mm xx) Drawing/sketch including mounting details xxi) Weight of condenser unit D) CONDENSER FAN

i) Manufacturer’s name ii) Type of mountings iii) Nos. of fans iv) Air displacement v) Nos. and material of blades vi) Type of bearing vii) Face velocity of air blown

Over the condenser viii) Material and nos. of fan blades ix) Drawing sketch No. x) Weight of the fan E) CONDENSER FAN MOTORS i) Manufacturer’s name ii) Type of model and make iii) Nominal voltage iv) Rated speed v) Continuous rating (HP/KW) vi) Rated current

a) At rated voltage b) At minimum voltage

vii) Frequency viii) Phase ix) Type of cooling x) Type of insulation xi) Type of enclosures xii) Efficiency at full load xiii) Peak current with duration at starting xiv) Ambient temperature xv) Weight xvi) Direction of rotation xvii) Starting torque/full load torque xviii) Coupling arrangement of fan and motor xix) Degree of protection provided for enclosures xx) Details of anti-vibration mounting provided xxi) Frame size xxii) Shaft details F) ACCUMULATOR

i) Storage capacity ii) Material iii) Protection against corrosion G) DEHYDRATOR – CUM – FILTER i) Manufacturer’s name ii) Type model no. iii) Frequency of replacement H) EVAPORATOR UNIT, BLOWER FAN

& EXPANSION VALUE/ CAPILLARY Evaporator i) Maker’s Name ii) Type/model no. iii) Refrigeration effects (cal/hr) at

Evaporation temperature of 5 deg. C

iv) Rated heater capacity v) Total numbers of tubes of cooling vi) Number of rows vii) Number of tubes per row viii) Material and size of tubes ix) Number and size of bends x) Number of fins per 25 mm xi) Gap between tubes xii) Material and gauge of fins xiii) Type of fins xiv) Total cooling surface area

of tubes and fins together xv) Face area xvi) Detail of condensate water drip tray xvii) Corrosion treatment xviii) Overall dimensions xix) Drawing/sketch No. xx) Weight xxi) Detail of heater

a) Rating b) Type

xxii) Detail of distributor type and size xxiii) Expansion Valve

a) Make and type b) Rated output for 5 deg. C

SST/60 deg. C/DT xxiv) Details of capillary I) BLOWER i) Manufacturer’s name ii) Type model no. iii) Number of fans iv) Displacement of fans (m-cub/hr.) v) Number and material of impeller vi) Type of bearing vii) Face velocity of air blown over the

Cooling coil viii) Static heat (WG) ix) Pressure drop across the coil (WG) x) Runner xi) Weight J) BLOWER FAN MOTOR i) Manufacturer’s name ii) Type/model and make iii) Nominal voltage iv) Rated speed v) Continuous rating (HP/KW) vi) Rated current

a) At rated current b) At minimum voltage

vii) Frequency viii) Phase ix) Type of cooling x) Class of insulation xi) Type of enclosure xii) Efficiency at full load xiii) Peak current with duration of starting xiv) Ambient temperature xv) Weight

xvi) Drawing of winding with complete details xvii) Direction of rotation xviii) Starting torque/full load torque xix) Degree of protection provided xx) Detail of anti-vibration mounting provided xxi) Frame size xxii) Shaft details K) CONTROL i) Type of Thermostat ii) Location of thermostat iii) Temperature setting for cooling and heating iv) Differential in deg. C for cut-in & cut-out of

Thermostat v) Detail of HP cutout vi) Detail of LP cutout vii) HP setting for cutout viii) LP setting for cutout ix) Details of over heat protector L) FILTERS i) Type of filter (Dry/wet ii) Overall dimensions iii) Filtration area iv) Filtering medium v) Filtration efficiency vi) Resistance drop across filter vii) Dust holding capacity viii) Air flow rate capacity ix) Method and frequency of clearing M) MOUNTING AND OTHER DETAILS i) Mounting details of the package unit

Offered design and structural frame Details

ii) Protection require on the coach roof For safety of Rook Mounted AC Package Unit against rain, water filling of coaches

And damage from the travelling public/ Staff

iii) Draining arrangement for the condensate water

iv) Details and dimensions for access doors and locking arrangement for attention to : a) Fresh air filter b) Return air filter c) Thermostats d) Opening arrangement for maintenance/

Attention e) Cut outs f) Blower fan motor

v) Lifting arrangement for mounting and Dismantling the unit from the coach

N) MATERIAL SPECFICATION, DIA AND THE

HICKNESS OF THE REFRIGERANT PIPE i) Liquid line ii) Discharge line iii) Suction line

Annexure IV to

ELPS/SPEC/AC/03 (Rev. 1) (Clause No. 4.40)

Specification for 3 phase AC electric motors for use on Roof Mounted air-conditioned Package Units. 1.0 FOREWARD 1.1 This specification is for 3 phase induction motors for driving

refrigerant compressors, condenser fans and evaporator blower fans. 1.2 The motor shall be suitable to work on three phase. 50 Hz PWM

power supply obtained from V DC (input) to 415 V 3 Phase AC (output) inverter.

1.3 In preparing specification assistance has been taken from the following specifications.

IS : 226 – 1975 Structural steel (Standard Quality) (Fifth

Revision). IS : 325 – 1996 Specification for 3 phase induction motors

(Fifth Rev.) IS : 1231-1974 Dimensions of 3 phase foot mounted

induction motors (Third Revision) Amendments – 4.

IS : 1570 (Pt. 2) Carbon steels (unalloyed steels) (First - 1979 Rev.) IS : 1572 – 1986 Electroplating of cadmium on iron & steel

(Second Rev.) IS : 2223-1983 Dimensions of flange mounted AC induction

motor (Fifth Rev.) Amendment – 2. IS : 13730 (Pt. 13) Polyester os Polyestermide over coated with

polyemide – imide enameled round copper winding wires with temperature class 200.

IS : 11184 – 1984 Enameled and varnish bonded glass fibre covered round winding copper wires (Amendments. 1)

IS : 349-1991 Rules for rotating machines for rail and road vehicles.

IS : 4691-1985 Degree of protection provided by enclosures for rotating electrical machinery. (First Revision)

IS : 12075-1989 Mechanical vibration of rotating electrical machines.

1.4 For ensuring satisfactory design of the motor, it is necessary for the motor manufacturer to consult the manufacturer of the driven equipments. It shall be the responsibility of motor manufacturer to get necessary details directly from the firm supplying the driven equipments.

2.0 SERVICE CONDITIONS 2.1 Ambient temperature – the ambient temperature of air at the inlet to

the motors will be 0 to 65 deg. c (maximum) with relative humidity varying upto 100%

2.2 Maximum altitude – 1200 meters above mean sea level. 2.3 The equipment and mounting arrangement shall be of rebust design for

rolling stock duty and shall withstand satisfactorily the vibrations and shocks normally encountered in service as indicated below :-

a). Maximum vertical acceleration 1.0 g. b). maximum transverse acceleration 2.0 g. c). Maximum longitudinal acceleration 3.0 g.

due to shock

2.3.1 The vibrations are of sine wave form and the frequency of vibration is between 1 Hz and 50 Hz. The amplitude a, expressed in millimeters is given as a function of f, by the equations – a = 25/f for values of f form 1 Hz to 10 Hz. a = 250/f² For values of f exceeding 10 Hz and upto

50 Hz. 2.3.2 In the direction corresponding to the longitudinal movement of the

vehicle, the equipment is subjected for 2 min. to 50 Hz vibration of such a value that the maximum acceleration is equal to 3 g (amplitude a = 0.3 mm)

Note : Form the point of view of withstanding the vibrations and shocks of levels as indicated above, the manufacturer shall take all necessary factors in to consideration while designing various parts e.g. shaft bearings mounting arrangement etc, and other necessary mechanical features.

3.0 TYPE OF ENCLOSURES 3.1 The degree of protection as per IS : 4691 – for the motors shall be IP –

55 (TEFC) 4.0 FRAME CONSTRUCTION AND MOUNTING 4.1 Standard frames sizes as per IS : 1231/2223 shall be used. 5.0 TERMINAL BOX 5.1 Three terminals for supply connections shall be brought out in a

terminal box on the side of the motor. The terminals shall be clearly marked RYB by embossing on the terminal block to obtain the correct direction of rotation with the supply phase sequence of RYB. Adequate creepage distance shall be provided between terminals. Suitable compression cable type glands shall be provided to accommodate the supply cables. The terminal box should have a degree of protection IP-54, and the arrangement shall be subject to prior approval of RDSO.

5.2 Terminal block shall be made of epoxy reinforced glass confirming to

BS-3815 and have the following additional characteristics: -

-It shall be anti-moisture absorbent and free from porosity.

It shall not deteriorate when working continuously at an ambient of 65 deg. C and when tested at 120 deg. C for 24 hours. The terminal block will have conducting part which should be made cadmium plated steel as per IS : 226 and IS : 1572 and all the threaded portions should be mechanically strong, so that even with 1000 operations of tightening and loosening, the threads should not wear out nor shall there be any loosening of the inserts. The terminal stud threads shall not wear out even after 1000 operations of tightening and

loosening at the specified torque. The terminal block design shall be as per RDSO sketch No. SKEL – 2784 A (enclosed). Bekelite or Hylem terminal boards shall not be used for terminal box.

5.3 TERMINAL LEADS 5.3.1 Terminal leads shall be of fibre glass sleeve covered silicon rubber

flexible copper cable confirming to IS : 9968 Pt. 1 and BS-6007 of 1100 V grade suitable for temperature from 10 deg. C to 200 deg. C. The minimum sizes are given below.

i) for 5-10 HP motors : 84/0.3 (6 mm²) ii) For 0.75 to 2 HP : 56/0.3 (4 mm²)

The flexible leads shall be capable of withstanding Die-electric value of 5 KV for one minute.

5.3.2 Silver brazed joints /fused for connecting terminal leads and winding wire shall only be used. Soldered joints are not acceptable. Winding wires shall in no case be brought to the terminal block directly.

5.3.3 The leads shall be tied securely on the stator overhang of the winding at their exit from motor stator overhang.

5.3.4 Flexible cable shall be well gripped by the Insulated cable lug while doing crimping.

5.3.5 A compression type (rubber) gland shall be used for securing the flexible leads at the entry of terminal block and rubber grommet should also be used.

5.3.6 The crimped socket and joint shall comply with BS : 4579, Part – I. 5.3.7 Terminal sockets used shall be of annealed electrolytic copper. The

minimum radius between palm and tube shall be 2 mm. Thickness of socket tube shall be atleast 1 mm.

6.0 STATOR CONSTRUCTION 6.1 The stator winding shall be suitably strengthened mechanically

and vaccum pressure impregnated with solventless insulating resin to resist vibrations and the effects of lubrication oil fumes, dust and moisture. The motors shall preferably be designed with maximum possible air gaps (not) less than 0.5 mm to ensure good performance

under minor shaft deformation or vibrations Dummy stampings shall be suitably tack welded at tooth portion on all teeth, after mounting on stator. This is to ensure that end lamination do not open out in service, which could lead to insulation failure on account of electro magnetic vibrations generated in them.

6.2 Rotor Construction

Dynamically balanced, and pressure die cast Aluminum alloy rotors shall be used.

6.3 Shaft Shaft material used shall be EN-8/EN-9 to IS : 1570 – 1979 suitably heat treated to achieve improved hardness to avoid wear and tear in service.

Various shaft dimensions such as surface finish shoulder and fillet shall be as per recommendations of the bearing manufacturers.

6.4 Bearings

The bearing design shall have following features : i) In addition to provisions of required interference tolerance on

bearing housings, the bearing covers shall grip the bearing faces to prevent outer race rotation in the housing for fixed bearings. Floating side of the bearing shall be suitably preloaded.

ii) The minimum L10 life of bearings shall be 1,00,000 hours. L10 life design shall be worked out based on parameters as per clause 2.

iii) Only SKF bearings shall be sued. Only sealed low friction seal RZ type bearing shall be sued for all the motors and it should meet the requirements of L10 life in para (ii) above.

6.4.1 All bearings shall be inspected for boundary dimensions, radial

clearance, free running surface finish etc. The bearings shall be checked with shock pulse meter for noise/vibration. All bearings shall have radial clearance of “C3”.

6.4.2 Simple gap type seals with lybrinth and two or more grooves in the bearings covers shall be provided to ensure proper retention of grease.

7.0 WINDING WIRES 7.1 Winding wires used for winding of motors shall be of following type. Dual coated enameled winding wires as per IS : 13730-13-1993. Dual coat means that base coat with polystermide enamel MT533.39A & top coat with Allothem 602.35 of Dr, Beck & Co. only. The enamel thickness shall comply with IS : 13730 Pt. 0 Section M (I) & (ii) mentioned above 7.2 The test on enameled winding wires shall be conducted as per IS :

13778 part 1 to 6. Separate documentation for these tests shall be maintained by the manufacturers, indicating the winding wire supply particulars. The tests on dual coat wire supply particulars. The tests on dual coat wire shall be conducted as per IS : 13730-13-1993.

7.3 Winding wires shall be procured only from RDSO approved sources. 8.0 IMPREGNATION 8.1 Vaccum pressure impregnation (VPI) process shall preferably be

adopted, with Dr. Beck & Co.’s solventless unsaturated polyertermide (UP) impregnating resin Dobec-on FT 1052/2005/500 EK.

8.2 The winding shall be subjected to pressure impregnation as per recommended procedure of varnish manufacturer.

9.0 WINDING 9.1 The star point of the winding shall be formed inside the stator

overhand. The star point shall be adequately brazed and insulated ensuring best workmanship. On the brazed joint apply general electric RTV sealant and over tape with two layers of half lap “Fusa Flex” 76593 tape (Supplier (GE) and seal the joint with a heat gun.

9.2 Coil overhangs in the stator winding shall be adequately secured with glass cord and stagger taped and each coil emerging from the slot shall be covered with ½ lap impregnated glass tape of size 0.3 x 20 mm.

Alternatively coil separator similar to the phase separators may be provided between adjacent coil emerging from the slot.

10.0 SLOT/INTERPHASE INSULATION 10.1 Nomex-polyster Nomex (with calendered Nomex) shall be used for

slot liner and wedge separator. Uncalendered nomex (Nomex 411) shall be used for inter layer and interphase insulation. Epoxy bonded glass fiber laminates shall be used for slot wedges. The materials used and insulation system as a whole shall correspond; to class 155. However for compressor motor, Nomex Kapton Nomex shall be sued which is suitable for class 180.

11.0 TEMPERATURE RISE 11.1 Th steady state temperature rise of stator windings above ambient of

65 deg. C during continuous duty at rated output at all voltage (ie 415 V) with +/- shall not exceed in following limits.

70 deg. C - For enameled winding used in condenser fan

motors and blower fan motor with 155 class insulating material.

80 deg. C - For enameled winding used with 180 class

insulating material in refrigerant compressors. 12.0 FINISH 12.1 The motor shall be treated suitably for rust removal and coated with

anti-rust primer and finished with two coats of battleship grey paint. 13.0 MARKINGS 13.1 Name plate – each motor shall have name plate containing the

following in formations.

a) Manufacturer’s name, type and serial number b) Rated voltage and voltage range. c) Winding connections d) Rated frequency e) Rated current

f) Rated speed g) Rated output in KW and HP. h) Class of insulation i) Weight

13.2 Direction of rotation – An arrow indicating the correct direction of

rotation with the supply phases RYB connected to the corresponding terminals marked on the terminal box shall permanently fixed on the motor body.

14.0 TEST 14.1 The motors shall be required to pass all the tests indicated in IS : 325 –

1991. However type test supply voltage shall be form PWM source. 15.0 DETAILS TO BE SUBMITTED BY THE MANUFACTURER 15.1 Manufacturer of Roof Mounted AC package Unit will get details as

per above clauses from the motor manufacturer and submit to RDSO and purchaser in addition to compliance/non-compliance statement for each clause for approval alongwith the test results of each lot against the purchase order. In addition any additional information required at any time by RDSO will be submitted by RMPU manufacturer. The RMPU manufacturer will arrange for type testing to be witnessed by RDSO atleast once a year.

ANNEXURE – V to ELPS/SPEC/AC/03/ (Rev. 1)

(Clause 10.0)

INFRASTUCTURE FOR QUALITY ASSURANCE (ESSENTIAL FACILITIES REQUIRED FOR

MANUFACTURING RMPUS)

A. Machinaries & Plats capable for processing stainless steel used during

manufacturing

a) Stainless steel processing Machines. 1. Shearing Machines 2. Hydraulic/Pneumatic/Power press 3. Drill Machine 4. Punching machine 5. Bending machine 6. Lathe machine 7. Dynamic balancing machine 8. Grinding machine and portable grinder 9. Jigs & Fixture suitable for welding levelling and mounting.

b). Welding /Brazing Machines 10. TIG & MIG welding machine 11. Spot welding machine 12. Brazing machines

B. Tool and Plants

1. Vaccum pump 2. Leak testing tank 3. Air compressor with reservoir 4. Refrigerant charges arrangement 5. Tool and dies suitable for stainless steel processing 6. Measuring tapes

7. Vernier calliper 8. Standard measuring gauge 9. Screw gauge 10. Hand lamp 11. Other had tools like spanner, pipe bending machine etc.

C. Testing Facilities

1. Rain test arrangement as per RMPU’s specification Clause 5.1.2.1.

2. 1000 V dc megger/Insulator tester 3. DA set for frequency change test 4. Power supply arrangement for obtaining variable voltage (415 –

5% ) and variable frequency (50 Hz +/- 3%) 5. Electronic leak detector. 6. Capacity test arrangement :

Test room comprising of hot and cold chambers of size 5m x5m (approx.) each with arrangement to maintain 50 deg. C (WB) respectively. Raised plateform for keeping RMPU for capacity test. Equipment installed in room to maintain specified room condition i.e. Heater and humidifier. Dry and wet bulb thermometer 6 Nos. Pressure gauge Micrometer Watt meter Power factor meter Volt meter Amp. Meter Tongue tester Frequency meter Mano-meter

D. Transport Facilities 14 Mobile trolley and hoist 15 Fork lifter

E. PERSONNELS & THEIR EXPERIENCE

1. Firm should have qualified personnels in the field of design,

manufacturing and testing of refrigeration system, electrical panels and quality control

2. Firm should have qualified personnel’s in the field of brazing of copper to copper, copper to brass and copper to steel refrigerant pipes and welding on stainless steel, having the experience not less than 5 years.

3. Firm should produce their proposed quality assurance plan (QAP) in respect of procurement of raw material, manufacturing and in-house inspection and testing on RMPUs.

F. R & D FACILITIES

The firm should have R & D facilities to investigate into the various types of failures and evalve necessary remedial measures to avoid failures in future.

G. OTHER FACILITEIS

1. DG set of adequate capacity as stand/by power supply. 2. Power supply arrangement for testing RMPUs and their sub-

assemblies should be identical to the supply which is available on SG AC coaches i.e. inverter supply (desirable). In this connection Clause 4.1 of RDSO/SPEC/AC03 Rev. 1 of Aug. 1999 with amendment No. 1 and 2 Clause 4 of RDSO/SPEC/AC/04 Rev. 2 of Aug. 1999 may be seen for better understanding.

Note : If this facility is not available, the firm has to ensure to arrange above power supply (i.e. identical to supply available on SG AC coaches) within one year from the date of clearance prototype.

3. The firm should be ISO approved (desirable).

Note : The firm should obtain ISO approval within one year

from the date of approval of the prototype if not ISO approved at the time of placement of development order. However, preference for

registration will be given to ISO approved firm. The new firms will be considered initially for educational order and will be considered for regular basis only after successful field trails and after obtaining ISO-9000 certification.

4. Truck/Lorry for transportation of material and finished product

(desirable). 5. The firm should have the capacity for manufacturing atleast 100

RMPUs and its control panel per year. 6. Full fledged coil manufacturing facilities, if firm intends to

manufacture coil themselves (desirable).

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