revision of specification / str item name: micro

REVISION OF SPECIFICATION / STR

Item Name: Micro Controller Based Governor (MCBG) for application on Microprocessor Controlled ALCo/DLW 6 Cylinder 251 Series WDS6 D-E locomotives

Specification No: MP.0.1700.04

1. RDSO is reviewing the specification/STR to cater to the latest technological developments in the field, modify clauses not relevant in the present context and making them more enabling with focus on functional requirements.

2. It is requested that your comments / suggestions with regard to improvements /modifications in specification / STR of the abovementioned item may be submitted in the following format along with the justification for the changes required.

Part A: Basic Information

SN Particulars Information

1. Name

2. Designation

3. Professional Qualification

4. Organization / Firm‟s Name

5. Address for Correspondence

6. Contact No.

7. Email ID

8. Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item

8. Whether any technical document/Report/Study to support suggested changes is available / enclosed for better appreciation

Part B: Comments / suggestions on the specification

SN Clause No. of RDSO STR/ Spec

Clause, as it exists in RDSO STR/ Spec

Clause , as it should read after incorporation of comments /suggestions in the RDSO Spec / STR

Justification for changes

Comments may be sent to following address within one month from the date of publication on rdso.indianrailways.gov.in

B P S Bhadoria, Joint Director/MP (EC), Mobile No.-9794863120, E-mail ID: [email protected] Phone no. : 0522-2450020 Fax No. 0522-2453916

Document No: MP.0.1700.04 Revision No: 01-Draft Date Issued: 14/07/2020

Specification Title: Micro Controller Based Governor (MCBG) for application on Microprocessor Controlled ALCo/DLW 6 Cylinder 251 Series WDS6 D-E locomotives

INDIAN RAILWAYS, RESEARCH DESIGNS & STANDARDS ORGANIZATION

Page 1 of 27

LIST OF AMENDMENTS

S. No.

Amendment Date

Revision

Details

1. 1 October 2008

0 First issue

2. July 2020 1 Clause no. 14, Ambient temperature updated as 0 to 55 Deg C instead of 5 to 55 Deg C.

Clause 15 Inspection and Testing updated. Annexure-5 Methodology for inspection and testing of MCBG incorporated. Test Protocol format for prototype test and routine test are incorporated in Annexure 5 of the specification.

Clause No. 16, reference of RDSO document Number MP.M-8.1-1 added.

Clause no. 25, “Vendor changes in approved status” reference of ISO document no. has been incorporated.

Clause 26 & 27 for IPR and Confidentiality has been incorporated.

Make in India Policy has been incorporated at Clause no. 28.




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CONTENTS

PARA NO.

DESCRIPTION PAGE NO.

1 INTRODUCTION 3

2 SCOPE OF SPECIFICATION 3

3 SCOPE OF SUPPLY 3

4 BASIC FUNCTIONS 3

5 AUXILIARY FEATURES 5

6 SAFETY FEATURES/DEVICES 7

7 DIAGNOSTIC AND FAULT LOGGING SYSTEM 8

8 ADJUSTMENT OF VARIOUS ENGINE PARAMETERS 8

9 GOVERNOR OUTPUT SHAFT AND LINKAGE 9

10 MOUNTING ARRANGEMENT 9

11 CONNECTORS 9

12 CABLES 10

13 POWER SUPPLY 10

14 SERVICE CONDITIONS 10

15 INSPECTION AND TESTING 11

16 FIELD TRIALS 11

17 APPROVAL 11

18 WARRANTY 11

19 LITERATURE AND MAINTENANCE INSTRUCTINS 11

20 GOVERNOR TESTING AND CALIBRATION FACILITIES 11

21 INFRASTRUCTURE 12

22 TRAINING 13

23 MAINTENANCE SPARES 13

24 QUALITY ASSURANCE PLAN (QAP) 13

25 VENDOR CHANGES IN APPROVED STATUS 13

26 UNDERTAKING BY EQUIPMENT MANUFACTURER 13

27 DECLARATION OF CONFIDENTIALITY OF SUBMITTED DOCUMENTS BY MANUFACTURERS

14

28 PREFERENCE TO MAKE IN INDIA 14

List of Annexures

Annexure no. Description Page no.

Annexure-1 Fuel Limit Table 15

Annexure-2 Layout of cutout for mounting controller unit in the short hood side wall of driver’s cab

16

Annexure-3 & 4 Input & output cable details of MCBG 17-18

Annexure-5 Methodology for inspection and testing of MCBG 19-27




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MICRO CONTROLLER BASED GOVERNOR (MCBG) FOR APPLICATION ON MICROPROCESSOR CONTROLLED

ALCO/DLW 6 CYLINDER 251 SERIES WDS6 D-E LOCOMOTIVES 1. INTRODUCTION:

The Function of the MCBG is notch wise speed control of the Engine and load control and provides other safety feature for satisfactory performance of Engine. 2. SCOPE OF SPECIFICATION:

This specification covers the technical requirements and general features of MCBG for ALCO/DLW 6 cylinder 251 series diesel engine fitted on microprocessor controlled WDS6 locomotives on new built or fitment on old locomotives. 3. SCOPE OF SUPPLY:

The deliverables to this specification for MCBG shall include:

i. Controller cum display unit ii. Actuator unit iii. Interconnecting cables with connectors as per Annexure-3 and 4. iv. Engine Speed Sensor with mounting bracket and interconnecting cables with

connector (Optional): If MCBG is compatible with Microprocessor based loco controller this item is not required. The Engine Speed signal from Micro Processor system is in the form of square wave and frequency output signal (No. of Teeth x RPM x Gear ratio) /60 and amplitude of 12 Volts. The interfacing of this Engine Speed signal to MCBG is Open collector NPN transistor, maximum 20mA with galvanic isolation.

v. Kit for fitment of the controller unit. 4. BASIC FUNCTIONS: 4.1 Speed Control: The MCBG shall maintain eight engine speed steps commonly, called notches based on input from throttle handle position which generates 4 digital outputs in a particular sequence as shown in as inputs to MCBG. The notch position, corresponding energized wire numbers and engine speed to be maintained is listed in the Table-1. It shall have provision of facility to alter any notch speed, if so required from fuel economy or engine performance considerations. Dropout voltage of relays if provided, at notch input signals should be within 15-18 Volts & pickup Voltage should be above 30 Volts.




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TABLE-1

NOTCH POSITION

WIRES ENERGISED ENGINE SPEED (RPM)

SHUTDOWN 3A 0

Low Idle 15A, 3A 350

Idle/1 - 400

2 15A 500

3 7C 600

4 15A, 7C 700

5 12A, 7C, 3A 800

6 15A, 12A, 7C, 3A 900

7 12A, 7C 1000

8 15A, 12A, 7C 1100

4.2 Speed Stability: MCBG is required to maintain stable engine speed i.e. free from hunting at each notch position in both conditions - with or without load. 4.3 Governor Response: Time taken for speed adjustment from IDLE to FULL speed shall be of the order of 15-20 seconds. For intermediate notch positions, the time taken to adjust engine rpm shall be in the same proportion. 4.4 Load Control: The resistance of the Load Control Rheostat (LCR) resistor or its equivalent for interfacing with microprocessor based control system to latest version of RDSO specification shall be 30.5 ohms. LCP output voltage from MCBG to excitation system shall be 24.4-68.8 VDC for locomotive with microprocessor control system. The characteristics of existing LCR on hydraulic governor are as under:

LCR CHRACTERISTICS

Wiring Lugs Number of Steps Ohms per Step Ohms per Group

1-11 10 0.178 1.78

11-18 7 0.272 1.90

18-21 3 0.272 0.82

21-26 5 0.40 2.00

26-31 5 0.56 2.80

31-36 5 0.72 3.60

36-41 5 0.82 4.10

41-46 5 0.90 4.50

46-54 8 1.125 9.00




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Total 30.50

Rating: Voltage.............................. 72 + 1 V DC Current range..................... 1.75 Amp. Tolerance on resistance value of LCR: Each section + 10% (1-18), (18-36), (36-54) 4.4.1 Load Control Timing: * Load control timing from max. to min. field position change shall be 8.5-11 sec. * Load control timing from min. to max. field position change shall be 25-35 sec. 5. AUXILIARY FEATURES: The MCBG offered shall cater for the following auxiliary features:- 5.1 Air Manifold Pressure Bias Fuel Limiter: The MCBG shall regulate the movement of fuel control shaft as a function of absolute air manifold pressure (boost air pressure). The MCBG shall satisfy the load limit requirements indicated in “Fuel Limit Table” placed as Annexure-1. The system shall however, have the facility of fuel limit adjustment to any other fuel limit curve, if required. The signal for boost air shall be taken from Locomotive Microprocessor control system. In case of no BAP signal to MCBG shall bypass manifold air pressure bias fuel limiting feature and the event shall get recorded in the error log of MCBG and a message stating `fuel limit feature by passed' shall appear on the display. A switch shall be available on the front panel of MCBG to manually bypass the manifold air pressure bias fuel-limiting feature in case erroneous input BAP reading due to some fault. 5.1.1 Boost air pressure (BAP) transducer: Requirements for boost air pressure transducer will be: Working range: 0 to 5 kg/cm2 gauge Temperature of boost air: 1200C max. 5.2 Engine Over Speed Trip Facility: MCBG shall shut down the engine in the event of engine rpm increase beyond a 1241-1250 RPM. 5.2.1 Mechanical and Electronic Engine Over Speed Trip-Test Facility:




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MCBG shall have facility to slowly increase the engine speed above its rated speed for checking the setting of the mechanical over speed trip mechanism over speed trip function of MCBG. It shall be possible to easily revert back to the normal setting of engine speeds. 5.3 Status Display of Engine Parameters:

An industrial robust display shall be provided on the controller unit. The display shall be such that it is clearly visible under day and night conditions from a distance of 2 metres. USB port: (Specification 1.1. Device using Type B connection)

Vibration: Operational 5 to 8 Hz, 0.8"(p-p), 8 to 500 Hz, in X,Y,Z direction, duration: 1hour, 3g

Shock: Operational 40g, 9 msec in 3 directions. The display shall either be a) A bluish green vacuum fluorescent display (VFD) with four lines of 20 characters of 5 mm each. or b) Graphic colour LCD operator interface terminal with QVGA display and touch screen to the following specification • Typical power 8W • Battery: Lithium coin cell. Typical lifetime of 10 years • LCD Display:

Size/Type 5.7 inch/STN

Colours/ Pixels 256/320X240

Brightness/ Backlight 165 cd/m2/20,000 hr typ.

• 5-key keypad: for on-screen menus, Resistive analog touchscreen. On board user memory: 4 MB non-volatile flash memory The display shall be in the format given below: LOP (kg/cm2) FOP (kg/cm2) BAP (kg/cm2)

L . L F . F B . B

N S S S S R R . R H H : M M

NOTCH ENGINE FUEL LCP (hrs:minutes) SPEED (rpm) RACK (mm) 5.4 Fuel Oil Pressure (FOP) Transducer: Requirements of fuel oil pressure transducer will be as under: Working range: 0 to 5 Kg/cm2 gauge Temperature of fuel oil: 55ºC max. 5.5 Lube Oil Pressure (LOP) Transducer: Requirements of lube oil pressure transducer will be as under:




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Working range: 0 to 10 kg/cm2 gauge Temperature of engine lubricating oil: 125º C max. 6. SAFETY FEATURES/DEVICES: Provision shall be kept for the following safety features/devices in the MCBG being offered. 6.1 Low Lube Oil Pressure Shut-Down (LOPS): A safety feature to protect the engine in the event of low lube oil pressure shall be provided to shut down the engine, whenever the lube oil pressure falls below the following stipulated limits:

Notch Engine low LOP settings (kg/sq. cm)

Low Idle 1.1 1.1

Idle/1 1.3 1.3

2 1.5

3 1.9

4 2.3

5 2.8

6 3.2

7 3.7

8 4.1

LOPS setting values are tentative and shall be user settable. It shall be possible to delay the operation of this device at each notch position. The governor shall also have a provision of adjustment of the LOPS setting values independently at each notch position. 6.1.1 Time Delay Feature: A time delay of 40-45 seconds shall be provided in low oil pressure shutdown system at idle/notch-1 speed steps to enable the engine driven lube oil pump to build up the requisite lube oil system pressure while starting the engine. It shall be possible to provide time delay facility at other notches as well. This time delay can be different for different notches. A manual button, which would have to be reset after an LOPS shutdown has occurred must be provided. 6.2 Fail-safe Feature: The MCBG shall be provided with fail-safe feature so as to cause shut-down of the diesel engine by pulling the fuel racks to “NO FUEL” position in case of malfunctioning of the governing equipment. 6.3 Multiple Unit (MU) Operation:




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All WDS6 locomotives provided with MCBG shall be capable of working in single Unit (SU) and Multiple Unit(MU) consist upto 4 locomotives with existing WDS6 equipped with Woodward or micro controller based governors of any make. 7. DIAGNOSTIC AND FAULT LOGGING SYSTEM: 7.1 The MCBG offered shall include suitable fault diagnostic facility to carry out troubleshooting and to assist maintenance personal in the rectification of the defect/ defects. 7.2 Suitable memory to register fault messages with date and time stamp and their retrieval on a laptop personal computer shall be provided. A facility shall be provided to set the current date and time in the MCBG. 7.3 Recording of time spent on each notch for 24 hours shall be made. The sampling interval should not be more than one second. This is required for calculation of load factor of locomotives. For this purpose eight counters shall be provided in MCBG memory for cumulative time spent on each notch in seconds. There should be a provision to read these counters through a laptop personal computer any time to get the cumulative time spent on each of the 8 notches. All these counters should be capable of being reset to zero, at any time, through a laptop personal computer. 8. ADJUSTMENT OF VARIOUS ENGINE PARAMETERS: A simple arrangement shall be provided in the software to adjust the following parameters on the locomotive.

i. Notch wise engine speed ii. Notch wise minimum lube oil pressure for loco shut down. iii. Maximum permissible fuel rack at each notch. iv. Maximum permissible fuel rack in relation to boost air pressure v. Over speed trip setting vi. Gov. response vii. Load control timing from max to min. field position of LCP etc.& min. to max.

field position of LCP etc. viii. PID parameters These adjustments should be possible with a laptop personal computer running in windows environment. A provision shall be made to restrict accessibility to gov. adjustments to avoid misuse. 8.1 Software: Necessary software for adjusting the user settable parameters of the MCBG shall be provided. 9. GOVERNOR OUTPUT SHAFT AND LINKAGE: 9.1 Stroke: The governor output shaft travel shall be of a rotary or linear type. The linkages shall be designed such that the fuel racks have a max travel of 34 mm (approx.). 9.2 Work Capacity: The work capacity of the governor output shaft for actuation of fuel control shaft shall be at least 16.3 Nm (12 ft lb).




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10. MOUNTING ARRANGEMENT: 10.1 Controller and display unit: The dimensions of the electronic controller unit will not exceed 328mm(frontal width including hinges) x 465mm (frontal height including flanges for mounting) x225mm (depth into the nose compartment) and shall not project in the cab more than 70 mm. A cut out of the size 320mm (width) x 403 mm (height) along with 4 holes as shown in the RDSO drawing no. SK.DP-3649, Alt. 2 (Annexure 2) in the short hood sidewall of the driver’s cab will be made available to the supplier for mounting controller and display unit. The controller and display unit shall be designed for front-loading i.e. mounting from the short hood side wall of the driver’s cab. The supplier shall also supply a fitment kit including the beading, brackets for supporting weight etc. Connectors no. MS3102R-20-29-P+GP, MS3102R-12SP-10P+GP, MS3102R-20-27-P+GP and MS3102R-20-16-P+GP shall be fitted on the controller and display unit. The weight of the controller unit shall not be more than 30 kg. The fitment drawing of the controller unit shall be given by the supplier. 10.2 Actuator unit: The actuator along with base will be mounted on the engine block. The dimensions of the actuator shall not exceed 269mm(frontal width) x 442mm x 508mm (height). Its weight shall not exceed 60 kg. The bottom face of actuator unit shall be designed to match governor base to DLW Part No. 10050796. LOP, FOP and BAP transducers, connectors no. MS 3102R-20-16-P+GP and MS 3102R-20-27-P+GP shall be fitted on the actuator unit. 10.3 Numbering: Each actuator and control unit shall contain a number plate indicating (a) Serial number (b) Date of manufacturing (c) Name of manufacturer (d) Model number. The major subassemblies going into each unit should also be numbered and recorded with the supplier for future reference. 11. CONNECTORS: Make: The make of the connectors shall be Allied or Amphenol. 11.1 Connection scheme of connectors at the cable ends: All the connectors at the cable ends shall have one to one connection. 11.2 Connection scheme of connectors for carrying signals from the locomotive to the MCBG: MS3102R-20-29-P+GP (17 pins)

Connector Pin Loco Signal

A 15A

B 12A

C 7C




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D 3A

E 43D/43E

F 29A

G 50

H 4

MS3102R-12SP-10P+GP

Connector Pin Signal

A ESS signal 1

B GND

C Spare

D ESS signal 2

12. CABLES: 12.1 Specification: 1) Insulation grade: EE (1000VAC,RMS) 2) Inner insulation: PTFE 3) Outer insulation: FRLS (Fire retarded low smoke) 4) Inner conductors: Tin plated copper 5) Shield: Wire mesh with 85% coverage (min) 6) Wire size (no of strands in cores): 15(19/28)AWG-(1.5 mm²) 7) No. of twists per meter per pair: 30 nos. min. 8) Capacitance between conductors in a pair: 20 pF per foot max. 9) Dielectric strength 2.5 kVAC, 50 Hz H.V. for 1 min. between cores, core and shield and shield and outer insulation. 13 POWER SUPPLY: The MCBG shall be suitable to work with power supply available on the locomotive as per details given below: BATTERY VOLTAGE: 64 to 50 V DC REGULATED: 72 + 1V DC (Aux. Generator) MINIMUM: During cranking the engine battery voltage may drop to

around 22 V DC for about 0.8 second. 14. SERVICE CONDITIONS: The equipment offered shall be capable of working satisfactorily up to an altitude of 1000 meters above mean sea level, ambient temperature 0 to 55 deg.C (the air temperature inside the engine compartment may reach up to 70 deg.C.), relative humidity up to 95 %. The equipment shall be capable of working satisfactorily in spite of dust, mist, rains, heavy sand storms, presence of oil vapours and radiant heat etc., to which rolling stock is normally exposed in service.




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The equipment shall be designed to withstand, without damage, vibrations and shock encountered in loco. 15. INSPECTION AND TESTING: Refer to Annexure-5. 16. FIELD TRIALS: After successful completion of type tests, the equipments shall be subjected to field

service trials for a specified period. The number of trial equipments, trial period shall

be governed by guidelines (Document no. MP.M-8.1-1) issued by RDSO.

During this period, the performance of governor shall be closely monitored and

evaluated by RDSO for:

Operational performance.

Reliability in service under actual environmental operating conditions.

Practical evaluation of maintainability/accessibility of components.

Modifications found necessary as a result of the tests and trials shall be carried out

by the vendor at his own cost, after the relevant modifications have been approved

by RDSO. The duration of field trials can be increased or curtailed at the discretion of

RDSO.

17. APPROVAL: The final approval of the governor for limited application shall be given by RDSO after successful conclusion of field trials. The approval for unrestricted application would be given after an adequate number of units have given satisfactory performance in the field as per RDSO Document no. MP.M-8.1-1. 18. WARRANTY: The supplier shall provide a warranty for the satisfactory performance for a period of 2 years for all the components of the governor from the date of commissioning. 19. LITERATURE AND MAINTENANCE INSTRUCTIONS: The supplier shall supply sufficient copies of operating instructions, maintenance manual with methods of adjustments and calibration, manufacturing/installation drawings and troubleshooting manual for the complete governor. 20. GOVERNOR TESTING AND CALIBRATION FACILITIES: Detailed procedure for overhauling and subsequent testing/calibration shall be specified by the supplier. Periodicity of schedule maintenance shall clearly be




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indicated. It may be noted that governor is required to give trouble free service for a period of 4 years without any maintenance. 21. INFRASTRUCTURE: The supplier shall have:

i. Dust Free, Air Conditioned and ESD protected environment for PCB Assembly and PCB level Testing.

ii. Component Lead Forming machines / fixtures for PCB Assembly. iii. SMT Assembly Line for SMD components Assembly consisting of Solder

Paste Printer, Automatic Pick and Place Machine and Reflow Soldering Machine.

iv. Temperature Controlled Wave Soldering Machine with Auto Fluxing Facility for Leaded components Soldering.

v. Ultrasonic Cleaning Machine for cleaning of flux residues from PCBs. vi. Customized Test Jigs / Fixtures for PCB level Functional Testing. vii. Digital / Analog IC Testers for Inspection of the Incoming material. viii. Dual Channel, 200MHz Digital Storage Oscilloscope ix. 5 ½ digit Digital Multimeter. x. Hot and Cold Chamber for Temperature Cycling Test for the PCBs xi. Pressure Pump with Calibrated Digital Pressure Indicator of minimum

accuracy of 0.05 % of Full Scale reading. xii. CNC Lathe and CNC Milling Machines for precision components

manufacturing. xiii. Gear Hobbing Machine with Microscope Attachment. xiv. Check Master – Gear Rolling Tester with Accessories, for Inspection of

Gears. xv. Digital Vernier Calipers, 0-300mm, LC0.01mm xvi. Vernier Height Gauge, 0-1000mm, L.C.0.02mm xvii. Flange Micrometer 0-25mm, 75-100mm, 100-125mm L.C. 0.01mm xviii. Test Equipment for measuring Plating, Painting and Powder Coating

Thickness. xix. Special Assembly Rig for Assembly of Rack and Pinion Box and Gear Box. xx. Custom Built Test Rig for Functional Testing of the complete MCBG System.

xxi. Custom Built Test Rig for measuring the work capacity of the Actuator Unit.

xxii. Engine Test Bed for simulated functional testing of all the functions of MCBG

in close loop in load and no load condition with speed measurement facility

through tacho generator as well as hall effect type speed sensor.

xxiii. All India service network to ensure action within 12 hours on any problem

reported by user railway.

xxiv. Permanently employed mechanical, electrical and electronics engineers with

not less than 5 years’ experience in their respective fields like electrical,

mechanical, electrical and electronics design, machine shop, fabrication etc.




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22. TRAINING:

The supplier of the MCBG shall impart necessary on-site training to the relevant

railway personnel, about the assembly, installation, operation, maintenance, setting

of user settable parameters and troubleshooting of the MCBG.

23. MAINTENANCE SPARES:

The supplier is also expected to supply spares, tools, testing and calibration

equipment, jigs and fixtures, which will be required for maintenance and

adjustments. The supplier shall ensure continuous availability of spares for

maintenance of the governors. Adequate warning shall be given to the purchasers

and RDSO in case some spares are at the verge of becoming obsolete and

unavailable.

24. QUALITY ASSURANCE PLAN (QAP):

A quality assurance plan (QAP) that outlines the suppliers’ quality assurance in order

to obtain a quality product shall be submitted to RDSO for approval. The QAP shall

be prepared on the lines as indicated in ISO: 9001:2000.

25. VENDOR CHANGES IN APPROVED STATUS: All the provisions contained in RDSO’s ISO procedures laid down in document no. QO-D-8.1-11, dated 01.07.2020 (titled: “Vendor changes in approved status”) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vendor/ vendors in the contract floated by Railways to maintain quality of products supplied to Railways.

26. UNDERTAKING BY EQUIPMENT MANUFACTURER

Vendor shall provide a signed copy of the undertaking on “INFRINGEMENT OF PATENT RIGHTS”. The undertaking shall be as under

Indian Railways shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, use of similar components in the design & development of this item and any other factor not mentioned herein which may cause such a dispute. The entire responsibility to settle any such disputes/matters lies with the manufacturer/ supplier.

Details / design/documents given by them are not infringing any IPR and they are responsible in absolute and full measure instead of railways for any such violations. Data, specifications and other IP as generated out of interaction with railways shall not be unilaterally used without the consent of RDSO and right of Railways / RDSO on such IP is acceptable to them.




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27. DECLARATION OF CONFIDENTIALITY OF SUBMITTED DOCUMENTS BY MANUFACTURERS

While submitting a new proposal/design, manufacturer must classify their documents confidentiality declaration, such as

This document and its contents are the property of M/s XYZ(Name of the vendor) or its subsidiaries. This document contains confidential proprietary information. The reproduction, distribution, utilization or the communication of this document or any part thereof, without express authorization is strictly prohibited. Offenders will be held liable for the payment of damages. Indian Railways/RDSO is granted right to use, copy and distribute this document for the use of inspection, operation, maintenance and repair etc.

28. PREFERENCE TO MAKE IN INDIA

The Government of India policy on “Make in India” shall apply.

XXXXXXXXXXX




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Annexure-1

FUEL LIMIT TABLE

BAP (bar) Fuel rack settings

0 17

0.2 21

0.4 23

0.6 25

0.8 26

1.0 27

1.2 28

1.4 29

1.6 Max.

1.8 Max.




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Annexure-2



Annexure-3

INPUT & OUTPUT CABLE BETWEEN MCBG CONTROL UNIT TO LOCO TERMINAL BOARD

SHIELD

Connector type Connector Pin no. Locomotive wire number Length of cable Connector type

MS3108F-20-29S+GP

(17 PIN)

A 15A

As per actual requirement

(10 core)

Loco TB

B 12A

C 7C

D 3A

E 43D/43E

F 29A

G 50

H 4

CABLE BETWEEN MCBG CONTROL UNIT AND ACTUATOR UNIT Two nos.

Connector type Length of cable Connector type

MS3108F-20-27S+GP (14 PIN)

As per actual requirement (14 core)

MS3108F-20-27S+GP (14 PIN)

Connector type Length of cable Connector type

MS3108F-20-16S+GP (9 PIN)

As per actual requirement (9 core)

MS3108F-20-16S+GP (9 PIN)



Annexure-4

ENGINE SPEED SIGNAL CABLE BETWEEN MCBG CONTROL UNIT AND MCBG INTERFACE OF MICROPROCESSOR

CONTROL SYSTEM

Connector type Connector Pin no. Signal Length of cable Connector type

MS3108F-12SP-10S +GP

(4 pin)

MCBG side

A ESS signal 1 As per actual requirement

(4 core)

MS3106F-16-9PX

(4 pin)

(MCBG interface side)

B GND

C Spare

D ESS signal 2




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Annexure-5

METHODOLOGY FOR INSPECTION AND TESTING OF MCBG

Inspection and testing of the equipment to be supplied by the supplier will be carried out in the following stages. The supplier will provide without any extra charge, the material equipment, tools and any other assistance which the purchaser or his nominee may consider necessary for any test and examination which he or his nominee shall require to conduct at the supplier’s premises and will pay all costs attendant to them. A. Type Test Plan for Micro Controller Based Governor Following table summarizes the type test of the equipment/system as per IEC 60571(Latest):

S. No Standard Test Name Test Location Test Result/Re

marks

1. IEC 60571 - 12.2.2 Visual Inspection At firm’s premises/NABL Labs

Pass/Fail

2. IEC 60571 - 12.2.10.2

Insulation Measurement Test

At firm’s premises/NABL Labs

Pass/Fail

3. IEC 60571 - 12.2.10.3

Voltage Withstand Test At firm’s premises/NABL Labs

Pass/Fail

4. IEC 60571 - 7.2.6 Reverse Polarity Test At firm’s premises/NABL Labs

Pass/Fail

5. IEC 60571 - 5.1.1.2 Voltage Variation Test At firm’s premises/NABL Labs

Pass/Fail

6. IEC 60571 - 12.2.3 Performance Test with Simulator


Pass/Fail

7. IEC 60571 - 12.2.6 Damp Heat Test At firm’s premises/NABL Labs

Pass/Fail

8. IEC 60571 - 12.2.4 Cooling Test At firm’s premises/NABL Labs

Pass/Fail

9. IEC 60571 - 12.2.5 Dry Heat Test At firm’s premises/NABL Labs

Pass/Fail

10. IEC 60571 -

12.2.8.1

Surge Voltage Test At firm’s premises/NABL Labs

Pass/Fail

11. IEC 60571 – 12.2.12 & IEC61373-Cat.1-Class-B

Vibration and Shock Test At firm’s premises/NABL Labs

Pass/Fail




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marks

12. IEC 60571 - 12.2.8.3

Transient Burst Susceptibility Test


Pass/Fail

13. IEC 60571 - 12.2.9.1

Radio Frequency Susceptibility Test


Pass/Fail

14. IEC 60571 - 12.2.9.2

Radio Frequency Emission Test

15. IEC 60571-12.2.11 Salt Mist Test At firm’s premises/NABL Labs

Pass/Fail

16. IEC 60571-12.2.13 Water Tightness Test At firm’s premises/NABL Labs

Pass/Fail

17. IEC 60571-12.2.14 Equipment Stress Screening Test


Pass/Fail

18. IEC 60571-12.2.15 Low temperature storage test


Pass/Fail

1. Visual Inspection as per clause 12.2.2 of IEC 60571

a. Physical Dimensional Check

The Physical dimensions are to be measured and recorded as per the RDSO approved drawing.

b. Equipment Number plate verification:

Equipment number plate is to be verified.

c. Power ON check:

This check is to ensure that the system is working normal when the rated input voltage is connected to the system.

2. Insulation Measurement test as per clause 12.2.10.2 of IEC 60571

All the Input / Output pins of the unit are shorted together. All the Cards are removed from the respective enclosures.

The Insulation Resistance is measured through a 500V DC Megger between the body of unit and above pins.

The value should be >100 Meg Ohms.

3. Voltage Withstand (Di-Electric) Test as per clause 12.2.10.3 of IEC 60571

All the Input / Output pins of the unit are shorted together.

A test voltage of 1000V ac was applied by gradually increasing the voltage amplitude to set limit and maintained at that level for 1 min.




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Observations

No disruptive discharge or flash over should occur.The system should work satisfactorily.

IR Test after Dielectric Test

Repeat the “Insulation Resistance Test” after the Dielectric test once again and record the Insulation Resistance Values. Values of insulation resistance should not deteriorate much.

4. Reversal of Polarity as per clause 7.2.6 of IEC 60571

The equipment is connected with 72V DC in Reverse Polarity at the Power Supply input Terminals and kept in that condition for one minute.

The equipment is then connected with normal polarity of 72V DC and status LEDs are to be verified

Observations

No damage to the equipment because of reverse polarity.

The equipment found working normally after reverse polarity test.

5. Effect of Voltage Variation Test as per clause 5.1.1.2 of IEC 60571

The equipment is connected to a variable DC source with normal polarity and the voltage is set to 50V DC, (0.7 times of the rated voltage 72V DC).

Status LEDs are to be verified

Then the voltage is slowly increased and set at 90V DC (1.25 times of the rated voltage 72V DC).

Status LEDs are again to be verified

Finally the voltage is set to rated voltage of 72V DC.

Status LEDs are to be verified.

There should be no damage to the equipment or malfunctioning because of voltage variations.

The equipment should work satisfactorily in all above conditions.

6. Performance Test as per clause 12.2.3 of IEC 60571

Performance test or functionality of the system as per clause 4 to clause 10 of this specification is to be checked by RDSO on Simulator/test bed at the firm’s premises.

7. Damp Heat test as per clause 12.2.6 of IEC 60571

Test was carried out as per IEC 60068-2-30, Test db. With +55°C as upper temperature limit and 2 cycles of 24 hours.

The equipment was placed in the test chamber without powering ON.

A functional performance test was carried out at the beginning of second cycle.

After test was completed, equipment was allowed to recover to ambient conditions.




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An Insulation Measurement and Di-electric Test was carried out.

Observations

No damage to the equipment or malfunctioning because of Damp Heat.

The equipment was working satisfactorily during Damp Heat Test.

The Insulation Resistance was measured and found value >100 M Ohms.

No disruptive discharge or flash over in the Di-electric test.

8. Cooling start Test as per clause 12.2.4 of IEC 60571

This test to be carried out in accordance with IEC 60068-2-1

The equipment is placed in a cold chamber without any voltage applied condition.

The temperature is lowered from ambient to -0±2°C gradually.

Once the the temperature in the chamber is stabilized at -0±2°C, the equipment is retained in the chamber about 2 hours at that temperature.

The equipment is then powered up after approx 5 to 10 minutes.

There should not be any damage to the equipment.

Status LEDs are to be verified.

Observations:

No damage found to the equipment because of Cooling start test.

The equipment is working satisfactorily.

9. Dry Heat test as per clause 12.2.5 of IEC 60571

This test is carried out in accordance with IEC60068-2-2,

The equipment is connected with 72V DC in normal polarity and placed in a hot chamber.

The temperature is raised from ambient to 70±2°C.

Equipment is kept in this condition for 6 hours, after stabilization of temperature.

Status LEDs are verified as per sl. no. at the end of 6 hours period.

There should not be any damages to the equipment after the test.

Observations:

No damage to the equipment because of Dry Heat Test.

The equipment is working satisfactorily after the test.

10. Surge Voltage test as per clause 12.2.8.1 of IEC 60571




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The surge waveform shall be generated and tested using the generator and waveform as specified in IEC 62236-3-2:2008

Surge Voltage was applied at BP and BN pins of working equipment.

Status LEDs are to be verified after the test.

There should not be any damage to the equipment.

Observations:

No damage observed to the equipment because of Surge Voltage Test.

The equipment is working satisfactorily after the test.

11. Vibration, Shock and bump test as per clause 12.2.12 of IEC 60571

The complete cubicle with its mounting arrangements shall be subjected to the tests indicated in IEC 61373.

There should not be any damages to the equipment after the test.

Observations:

No damage to the equipment because of test.

The equipment was working satisfactorily after the test.

12. Transient Burst Susceptibility test as per 12.2.8.3 of IEC 60571

Test voltage of 2KV, 5/50 nS, 5KHz as per IEC 62236-3-2:2008 was used for testing.

The test was carried out in working condition of equipment as per procedure of IEC 61000-4-4.

Observations:

No damage observed to the equipment because of test.

The equipment was working satisfactorily after the test.

13. Radio Frequency Interference Immunity test as per 12.2.9.1 of IEC 60571

Radiated Radio Frequency Interference test was performance with 10V/m (r.m.s) severity as per IEC IEC61000-4-6

The equipments were kept energized during the test.

Observations:

For conducted disturbances induced by radio frequencies fields, refer to IEC 62236-3-2:2008 (Table 7 and Table 8).




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For radiated disturbances induced by radio frequencies fields, refer to IEC 62236-3-2:2008 (Table 9).

14. Radio Frequency Interference Emission test as per 12.2.9.2 of IEC 60571

Radio Frequency Interference emission test was performance as per IEC IEC62236-3-2:2008

The equipments were kept energized during the test.

The test will be carried out at ETDC/NABL Lab.

Observations:

The equipment shall be tested to the requirements as specified in IEC 62236-3-2:2008 (Table 3, Table 4, Table 5, and Table 6). 15. Salt Mist Test as per IEC 60571-12.2.11

Salt solution

The solution for producing the salt mist shall be prepared by dissolving (50 ± 1) g sodium chloride (NaCl) analytical reagent quality, in distilled or demineralised water to make up(1 ± 0,02) l of final solution at 20 °C; if the pH does not lie between 6,5 and 7,2, the solution shall be rejected.

Test procedure

During the test, the temperature in the test chamber shall be maintained at (35 ± 2) °C.

The solution and the air used to produce the salt mist shall have a temperature equal to that of the test chamber.

The equipment should be tested in the manner in which they are expected to be used, i.e. protective covers should be in position and the equipment arranged, as nearly as possible, inthe position it will occupy in actual use.

The test chamber shall be kept closed and spraying of the salt solution shall continue without interruption during the whole conditioning period.

The period shall be:

– for class ST2: 16 h;

At the end of the test, the equipment shall be washed in running tap water for 5 min, rinsed in distilled or demineralised water, then dried to remove droplets of water and stored under standard atmospheric conditions of the testing area for not less than 1 h, no more than 2 h.

After that, the equipment is subjected to a visual examination.

Observations:

No major damage shall occur.

A performance check shall not show any failure or damage nor any results which are beyond the specified tolerances.




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16. Water tightness test as per IEC 60571-12.2.13

As electronic equipment is generally mounted either inside the body of the vehicle or in boxes outside, there is no need to carry out water tightness tests, apart from exceptional cases to be defined between user and manufacturer.

17. Equipment stress screening test as per IEC 60571-12.2.14

A screening procedure to be applied to completed equipment or a part of it, for the purpose of eliminating dormant manufacturing or component defects.

Burn-in test

After mounting of components, the populated PCB cards kept in proper chassis in energized condition shall be burnt in for minimum 45 hrs at +70 deg. C and - 25 deg C as per the cycle at figure above, wherever specified in the main specification. The PCBs will be tested for functionality to the extent possible during the burn-in test. This will be mutually decided. 18. Low temperature storage test as per IEC 60571-12.2.15

This test shall be in accordance with IEC 60068-2-1.

The temperature value for the test shall be –40 °C and the time period shall be 16 h minimum.

After recovery, a performance check shall be carried out at ambient temperature.

Observations:

No damage shall occur,

The functional check does not show any failure nor any results beyond the specified




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tolerances.

B. Functional test: These tests will be carried out under simulated conditions at supplier’s premises to establish that the governor is functioning as per the specification. The detailed functional test plan may vary from vendor to vendor based on their design. Hence, vendor shall submit the detailed functional test plan as per their design meeting the functional requirement of the specification for approval by RDSO before prototype test. On satisfactory completion of environmental and functional tests, the prototypes will be subjected to Loco Validation tests.

C. Loco Validation test After successful prototype test as given above, the prototype shall be subjected to loco validation test which includes load box test, checking of functional test, Route run trials, etc. Functional test of the MCBG should be carried out to verify the functional requirements of the specification stated at Clause 4 to 9. The detailed functional test plan may vary from vendor to vendor based on their design. Hence, vendor shall submit the detailed functional test plan as per their design meeting the functional requirement of the specification for approval by RDSO before prototype test. Loco validation test will consist of following.

The maximum instantaneous variation in engine speed expressed as percentage of rated speed, after sudden variation of load from the rated value to zero must not exceed 10% of the rated speed.

Possible faults will be created to test the fail safe features of the governor (to be listed out by the supplier and got approved by RDSO).

On satisfactory completion of the performance tests, the MCBG will be cleared by the inspecting

authority for field trials.

D. Routine Test Plan This test is to be conducted for the system other than prototype. This is the subset of type test mentioned above. Following test is required to be conducted for routine test plan. The sampling plan as per IS: 2500, Level-I should be adopted for selecting the samples against the lot and determining the acceptance/rejection of lot based on Routine test result.


marks

1. IEC 60571 - 12.2.2 Visual Inspection At firm’s premises/NABL Labs

Pass/Fail

2. IEC 60571 - 12.2.10.2

Insulation Measurement Test


Pass/Fail

3. IEC 60571 - 12.2.10.3

Voltage Withstand Test At firm’s premises/NABL Labs

Pass/Fail

4. IEC 60571 - 7.2.6 Reverse Polarity Test At firm’s premises/NABL Labs

Pass/Fail




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marks

5. IEC 60571 - 5.1.1.2 Voltage Variation Test At firm’s premises/NABL Labs

Pass/Fail

6. IEC 60571 - 12.2.3 Performance Test with Simulator


Pass/Fail

Note: The Test plan given above is the minimum requirement and strictly governed by IEC 60571. The latest edition of IEC 60571 shall apply mutatis mutandis to this Test plan. The test other than above as specified may also be considered with mutual agreement between vendor and Vendor approving authority, if desired so.

revision of specification / str item name: micro

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