Page 1 of 27 File No. EL/ 7.1.108/SBC Spec. No RDSO/PE/SPEC/AC/0185 -2015 (Rev.

0)

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

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RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS

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SPECIFICATION FOR SET OF PANELS FOR NON AC LHB
EOG COACHES

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Spec. No. RDSO/PE/SPEC/AC/0185 – 2015 (Rev.’0’)

S. No. Date of amendment Revision Reason

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APPROVED

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Executive Director/PS&EMU

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Page 2 of 27 File No. EL/ 7.1.108/SBC Spec. No RDSO/PE/SPEC/AC/0185 -2015 (Rev. 0)

INDEX

Clause Description Page

No. No.
1.0 Foreword 3
2.0 Scope of supply 3
3.0 Governing specifications 3
4.0 Operating and service conditions 4
5.0 Constructional requirements 5
6.0 Tests 9
7.0 Schedule of tests 10
8.0 Description of tests 11
9.0 Technical data 14
10.0 Commissioning 14
11.0 Supplier’s responsibility 14
12.0 Marking and packing 15
13.0 Guarantee and Warranty 16
14.0 Training 16
15.0 Infringement of patent right 16
16.0 Service engineers 16
17.0 Cartel formation 17
18.0 Annexures 18
Annexure A :Undertaking against Cartel formation 17
Annexure B : Bill of material 18
Annexure C: Harness chart for LHB type EOG AC coaches
Annexure D: Codification chart
Annexure E: List of wiring diagram
Annexure F : List of drawings
Annexure G : List of connectors

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1.0 FOREWORD

1.1 This specification is for design, manufacture, testing and supply of Switch Board
Cabinet consisting all the power/control switchgear related to coach lighting,
pump control etc. for LHB EOG NON-AC Coaches suitable for 3 phase, 750 volts,
50 Hz train line system.
1.2 The quality, aesthetics, design and overall workmanship of Switch board cabinet
as a whole shall be to international standards and the quality of existing LHB
equipment shall be considered prime basis.
1.3 Firm shall have adequate experience of design, development and manufacturing
of similar complex panels on CNC machines and shall be capable of developing
materials to the required quality and standards.
1.4 The firm shall maintain date-wise in-house quality control system and in-house
quality control records etc. for in stage process inspection and testing and the
same shall be made available to the inspecting official during type testing.
1.5 It will be the responsibility of the supplier to ensure and confirm that the
equipment/part purchase from other vendor are as per relevant standard and
original manufacturer last certificate are being obtained by the firm and are
tested. Firm shall also keep record of in-house inspection.
1.6 The existing approved vendors of RDSO for this item shall ensure compliance to
this specification within six months from the date of issue of this specification.

1.7 SCOPE OF SUPPLY:

S.No Item description Qty/Coach

1 Set of Panels for LHB EOG Non AC coaches 1 set
consisting of :
i) High Voltage Cubicle(1 no.)
ii) Low voltage panel (1 no.)
iii) Battery charger box (1 no.)

3.0 GOVERNING SPECIFICATIONS

Manufacturers should have the following standards in compliance of the specification:

IS:13947(Pt.1)-1993 1Low voltage switchgear and control gear Part-I General rules.

IS:13947(Pt.3)-1993 Part-3- Switches, disconnections and fuse combination units.

IS:8623-1993 Pt.-1 Low voltage switchgear and control gear assemblies:

Part-I Requirements for the type tested and partially type tested
assemblies.
IS:10118-1982 Code of practice for selection, installation and maintenance of
the switchgear and the control gear.
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IS:13703-1993 Low voltage fuses for voltages not exceeding 1000 volts or
1500 volts DC.

IEC 61373 Shock and Vibration test

IS:1248 Pt.II-1983 Direct acting indicating analog electrical measuring instruments

and their accessories (ammeter and voltmeters).

IS:1248 Pt.II-1983 Direct acting indicating analog electrical measuring instruments

and their accessories (ammeter and voltmeters).

IS:8828-1996 Electrical accessories, circuit breakers for over current

protection for household and similar installations.

IS:1573-1986 Electroplated coatings of Zinc on Iron and Steel.

IS:1364-1992 Hexagon head bolts, screws and nuts of product grades A & B.

UIC 550 Power supply installation for Passenger stock.

Any deviation from this specification proposed by the manufacturer , aimed to improve
upon the performance, utility and reliability/efficiency of the component/panel will be
given due consideration, provided full particulars of the deviation with justification are
furnished.

4.0 OPERATING & SERVICE CONDITIONS

The switch board cabinet and its components shall perform satisfactorily in the
following environmental conditions & shall be sturdy and suitable for the following
service conditions normally to be met in service on Railway coaches:

Ambient - 10 to 55 deg C
Temperature under 70 deg. C
sun inside stable
coach
Train speed 200 Km/h
Relative Humidity Maximum Up to 98%
Altitude Max 1200 m above sea level
Atmosphere Extremely dusty and desert weather. The dust contents in the
air may reach as high value as 1.6 mg/cubic meter.
Annual rain fall Annual rainfall ranging between 1750 mm to 6250 mm.
Atmosphere i) The equipment shall be designed to work in saline
atmosphere in coastal areas having continued exposure to salt
laden airborne contaminants like smoke and chemical vapors
and also in industrially polluted zones:
Maximum pH value 8.5

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Sulphate 7 mg/liter
Max. concentration 6 mg/liter
of chlorine
Max. conductivity 130 micro Siemens /cm
ii) Extremely dusty and arid climate/desert terrain in certain
areas. The dust contain in air may be attain values up to
1.6mg/m3
Shocks and The equipment, system and their mounting arrangement shall
Vibration be designed to withstand satisfactorily the shock and vibration
encountered in service as indicated below:

a) Max. vertical acceleration - 3.0 g

b) Max. lateral acceleration - 3.0 g
c) Max. longitudinal acceleration - 3.0 g
(‘g’ being the value of acceleration due to gravity)
Operating The equipment should function satisfactorily near 25 KV AC
Train/Electrical electric traction. It should not be susceptible to malfunction due
Environment to interference from overhead traction power supply lines or
under abnormal conditions such as overloads and faults in the
electrical circuits of the coach.

5.0 CONSTRUCTIONAL REQUIREMENTS:

5.1 The set of panels comprises of the various cubicles consisting of power and
control switchgear consisting of following:

S.no. Item Drawing no. Dimension

i H.V. cubicle LS71200 2000(L)X550(D)X525(H)
(underslung) (draft)
ii Battery charger box LS71104 alt. 900(L)X750(D)X500(H)
(underslung) ‘a’
iii Low voltage panel LS70300 500(L)X130(D)X1850(H)
(on-board) (draft) (mounting angle 125mm)

No positive tolerances are allowed. However, negative tolerances shall be

governed by MDG0008. The

5.2 The cubicles shall consist of welded stainless steel construction TIG welded to
make complete frame with dimensions as indicated in the respective drawings.

5.3 Panel shall conform to IS:6911 (latest revision), 2mm thick as indicated in the
respective drawings

5.4 The on-board cabinet shall conform to CRCA sheet of thickness 2 mm

conforming to IS:513 ( Latest Edition ) as indicated in the drawing. The on-board
panel shall be powder coated to Siemens Grey shade no 6102/08038 of M/s
Nerolac Paints or 877 of M/s Berger Paints, after giving surface treatment.
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5.5 The dimensions/mounting/general layout of the switch board cabinet shall be

conforming to drawing as per clause 5.1. The drawings annexed are for general
guidance only. For change in layout for manufacturing/improving the aesthetics
from maintenance point of view, the manufacturer shall take prior approval.

5.6 Most critical safety component in the panels is wide-band contactors. No

deviation shall be given for these contactors. Inspecting agency shall specifically
check this aspect that these contactors regarding make of these.

5.7 Suitable PVC alleys/duct with snap-in element of M/s. L&T/AKG/Panduit shall be
provided for cable traversing as indicated in the drawings. Whenever the cables
shall cross the door/passage area, the cables shall be covered by self
extinguishing and halogen free PMAJACK braiding/nylon jacket (polyamide 6.6)
of M/s PMA or equivalent approved make.

5.8 All the devices fitted in the panel shall allow access for easy maintenance of all
the equipments from the front of the panel.

5.9 The location and size of the hinges shall be as per the respective drawing for the
cubicles.

5.10 The internal wiring shall be done with Halogen free electron beam irradiated
cables conforming to RDSO specification no ELRS/SPEC/ELC/0019 Rev-2. The
size/type of cables shall be as indicated in drawing no. LS70117. All
cables/wiring/Sleeves shall be of color coded according to phases for
identification. Control wiring and power cables shall be segregated according to
the voltages and adequately secured with cable ties.

5.11 All components provided inside the panel shall be identified by screen/photo
printed or computer generated designation labels/legend marking plates. These
should be mounted near the concerned component duly ensuring visibility.
Circuits and components shall also be provided with the name plates indicating
the operation/function of the switches/circuits. Contactors and circuit codification
diagram (with glass fuses details) shall be identified by aluminum anodized
legend plates by adhesive of approved make on back side of front doors.
Balance indicating/measuring switchgear/devices installed on front door shall be
identified by aluminum anodized legend plates by adhesive of approved make on
the front doors itself. No riveting is allowed on front door.

5.12 a) The outgoing/incoming terminal connections shall be brought out to a

adequately rated cage clamp type terminal block/MCB.
b) The terminal blocks shall be located for easy access as indicated in the
drawings.
c) Separators/intermediate plates shall be provided between adjacent terminal
blocks, wherever required.

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d) All cables leading to a terminal block shall be properly secured/ clamped

before termination.
e) It shall be ensured that not more than two wires are terminated at one point.
f) The power panel shall be complete with all necessary crimping sockets and
ferrules for ready connections. Rings type copper crimping sockets shall be used
for cable sizes up to 1.5 sqmm otherwise tubular crimping sockets shall be used
with suitable palm size to prevent loose connections during vibrations. Only
copper crimping sockets of approved make and conforming to the requirements
of RCF specification no. EDTS 200 and EDTS 201 shall be used. Crimping sockets
of size smaller than 16 sqmm shall be with metal reinforcement.
g) Marking ferrules shall be of computer generated type for easy identification of
the cables with the help of shrinking sleeves (self extinguishing) of suitable size
horizontally printed or with the help of mintmark carrier/label of M/s.
Tyco/Penduit/Pheonix only.
h) All cut-outs wherein cables enter/exit the switch board cabinet shall be
provided with V-grooved fire retardant rubber grommets/edge protection sleeves
of reputed make from protection against sharp edges.

5.13 Two earthing terminals shall be provided on the panel on diagonally opposite
ends. For earthing two braided copper cable of 25 sq.mm and 300 mm in length
each duly crimped shall be supplied with the panel. Earthing of the metal
parts/sub-assemblies inside the panel shall also be done as indicated with
suitable wire size as determined vide clause 7.4.3.1.7 (a) of IS:8623(Pt-I)-1993.

5.14 Manufacturer’s name plate indicating name and address, Sr. No. of the panel,
Specification no. month and year of manufacturer and weight shall be fixed on
the front door of the panel.

5.15 Danger Notice plate shall be screen printed or sticker shall be provided on front
of the panel door conforming to IS: 2551-82 for 750V.

5.16 The Power/Control connections of the switch board cabinet shall be as per wiring
diagram to drawing LS70117.

5.17 Care shall be taken to achieve a neat and symmetrical layout.

5.18 Only makes mentioned in the bill of material as per Annexure-A shall be used.
For any deviation prior approval from RDSO shall be taken.

5.19 All the equipment fitted in the panel shall be easily accessible for
replacement/checking.

5.20 All rotary switches shall conform to IS: 13947 (Pt-III)-93 and shall be suitable for
universal mounting.

5.21 All fasteners used shall be zinc plated and passivated according to IS: 1573-86
and conforming to IS: 1364-92.
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5.22 All the components/ equipments/ materials including paint shall be fire retardant.
Panel manufacturer shall certify this requirement.

5.23 General and safety requirements shall be governed by IS: 13947 (Pt-I)-93 and
IS: 8623-1993.

5.24 The general construction of the switch board cabinet shall be such as to keep the
various voltage levels separated against each other as far as possible.

5.25 High Voltage cubicle :

5.25.1 A disconnecting and earthing device and high voltage fuses (Main fuses) shall be
located as indicated in the drawing. The main function of this device is to
separate the two feeders (input supply) and simultaneously earthing 750V AC
network of the coach. The connection to this unit shall be made/ removed by
removing the perforated metal sheet provided on the front of the disconnecting
and earthing device.

5.25.2 Mounting plate for Main contactors (K1 & K2) and other switchgear shall be
provided on the back of the cubicle with cage clamp connectors on the front as
indicated in the drawing.

5.25.3 Contactors for the pump along with controller (not in the scope of supply) shall
be provided inside the cubicle along with cage clamp connectors.

5.25.4 A control Rotary switch shall be provided for Local-Remote for maintenance.

5.25.5 Wheel slide protection is not in the scope of supply of power panel manufacturer,
however, space shall be provided for the same in the panel along with the
connectors for connections.

5.26 Regulated Battery Charger Cubicle :

5.26.1 The cubicle shall house the regulated Battery charger along with the battery
connectors for dc paralleling of the battery.

5.26.2 The interconnecting cables for the Charger shall be supplied loose along with
cage clamp connectors as indicated in the drawing.

5.27 On-Board Rotary switch Panel

5.27.1 The on-board panel shall house the AC and DC rotary switches, HRC fuses etc for
distribution of lights, fan etc as per the schematic/wiring diagram LS70300
(Draft).

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5.27.1 The rotary switch for feeder selection shall be provided in the on-board panel.

5.27.2 The connectors and fuses for the mobile charging socket shall be provided in the
panel.

6.0 TESTS

6.1 Only after the drawings and the design have been approved and the clearance given
to this effect, the manufacturer shall take up the manufacture of the prototype. It is to
be clearly understood that any changes, required to be done in the prototype or any
additional tests other than specified herein are required to be conducted on the
prototype unit or its components, they shall be done expeditiously. The required
testing facilities for inspection & testing shall be available at firm’s premises.

6.2 Firm’s internal testing shall be done by qualified person & submitted the test results to
RDSO.

6.3 The type tests shall be carried out by RDSO representative on prototype unit either
totally or in part under the following conditions without any additional cost:

a) A manufacturer undertakes to manufacture for the first time as per this

specification.
b) An important change in design details of switch board cabinet has been
introduced.
c) Specification is modified necessitating the re- designing of equipment.
d) Unsatisfactory performance reported from user Railways.
e) Resumption of production after an interruption of more than two years.

6.4 RDSO may conduct surprise checks on the manufacturing process and quality control
along with any of the tests to ensure quality of product and its conformance to RDSO
specification.

6.5 The firm shall maintain date-wise in-house quality control system and in-house quality
control records etc. for in stage process inspection and testing at the same along with
QAP shall be made available to the inspecting official during type testing.

6.6 Inspecting Agency/Rites shall carry out the tests in manufacturer premises as per
acceptance & routine tests specified in tender specification. Check list consisting of
testing details /measurements and acceptability shall be prepared and submitted
along with inspection certificate to production units (PUs).

6.7 TYPE TESTS:

All the type tests mentioned in clause no. 7.0 shall be carried out on a prototype unit.
The firm manufacturing for the first time shall get the prototype approved from RDSO.
The prototype test shall be undertaken either totally or in part on Switch Board
Cabinet as per clause no. 7.0 under the following conditions without any additional
cost :-
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(i) A new variant of Switch Board Cabinet is introduced by existing manufacturer.

(ii) A fundamental change in design is introduced and modification of Switch Board
Cabinet likely to affect its function.
(iii) Failure or variations established during type test.
(iv) Resumptions of production after an interruption of more than two years.
(v) Specification is amended or revised.
(vi) During Quality audit if required.
(vii) In any other condition, whenever RDSO/Purchaser feels necessity of the test.

6.8 ROUTINE TESTS:

Routine tests mentioned in clause no. 7.0 shall be carried out on each unit by the
manufacturer at his works to ensure compliance with the specification and the
drawings.

6.9 ACCEPTANCE TESTS:

Acceptance test mentioned in clause no. 7.0 are to be carried out by an inspecting
authority nominated by the purchaser at the works of the manufacturer, on the sample
picked up by the inspecting authority. All the acceptance tests shall be carried out at
firm’s premises at the manufacturer’s cost. Inspecting officer will witness the tests. A
copy of the internal tests conducted by the firm shall be supplied to
inspecting/purchasing authority.

7.0 SCHEDULE OF TESTS :

Tests as mentioned in table below shall be carried out as per respective clause of IS:
8623 (Pt-I)-1993.

SN Clause Tests Type Routine Accept-

of Test Test ance
IS:8623 Test
1. 8.3.1 Visual inspection, including inspection of Yes Yes Yes
wiring and electrical operation test
2. 8.2.1 Temperature rise test Yes No No
3. 8.2.6 Mechanical operation and sequence test Yes Yes Yes
4. 8.2.5 Test for verification of clearance and creep- Yes Yes Yes
age distances
5. 8.2.2 Test for verification of dielectric Yes Yes Yes
properties
6. 8.3.4 Test for verification of insulation resistance Yes Yes Yes
7. 8.3.3 Checking of electrical continuity Yes Yes Yes
8. 8.2.4 Verification for effectiveness of protective Yes Yes Yes
circuits

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9. IEC Vibration & shock test of Low voltage panel, Yes No No

61373 high voltage panel and battery charger
panel.
10. IS 13947 Water ingress protection test for HV Yes No No
panel and battery charger panel.
11. --- Check for satisfactory operation of Yes Yes Yes
rotary switches by rotating 10 times
clockwise and 10 times anticlockwise.
(WTC of rotary switches of OEM shall
be checked by inspecting authority)
12. --- Check for BOM and proof of material Yes Yes Yes
as per spec. with proof of invoices.

7.1 The accuracy of measuring instruments used for both type and routine tests shall be of
class 0.5.

7.2 For the commissioning of first panel, panel manufacturer shall depute his staff at
production unit (PUs) for interface with respect of items falling in RCF/ICF/PU scope
of supply.

8.0 DESCRIPTION OF TESTS:

8.1 Visual inspection including inspection of wiring and electrical operation test:

The test shall include visual inspection of control panel, overall dimensions, marking
and general layout of housing, earthing, colour coding as mentioned in the specification
& drawings. Electrical operations shall also be checked as per concerned drawings and
prepared test protocol.

General workmanship of Switch Board Cabinet and its accessories such as MPCB,
MCB, fuse, relay, contactor, connector, cable etc shall be checked.

8.2 Temperature rise test:

Temperature rise test of the Switch Board Cabinet shall be carried out as per clause no.
8.2.1 of IS 8623 Pt -1. The firm should submit the test protocol for temperature rise test
in advance to RDSO.

8.3 Mechanical operation and sequence test:

This type test shall not be made on such devices of the assembly which have already
been type-tested according to their relevant specifications provided their mechanical
operation is not impaired by their mounting.

For those parts which need a type test, satisfactory mechanical operation shall be
verified after installation in the assembly. The number of the operating cycles shall be
50.
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Note: In the case of withdrawable functional units, the cycle shall be from the
connected to the disconnected position and back to the connected position.

At the same time, the operation of the mechanical interlocks associated with these
movements shall be checked. The test is considered to have been passed if the
operating conditions of the apparatus, interlocks etc. have not been impaired and if the
effort required for operation is practically the same as before the test.

8.4 Test for verification of clearance and creepage distances:

Electrical/cable alley shall be mounted keeping in mind the RCF drawing no. LS70117
of latest alteration for maintaining clearance and creepage distance.

8.5 Test for verification of di-electric properties:

The control panel shall be tested with 3KV test set between live parts and earthed
body.

Applied voltage Time Result Condition Leakage

current
3 KV 60 seconds Should disconnected Should be
withstand equipments- noted
the test for DC-DC converter
one minute Insulation monitoring
relay & SDS type
wago relay

8.6 Test for verification of insulation resistance

During testing, insulation controllers have to be disconnected. All the MPCBs/MCBs

shall be kept in the OFF position. Insulation resistance shall be measured with direct
current. Measuring voltage and minimum insulation resistance values are given in the
single test items. The HV test shall be done with AC (50 Hz) which shall be gradually
increasing (applied for one minute). The test is considered pass if no electric
breakdown or flashover occurs.

Insulation resistance test shall be carried out on all the circuits. The meggering voltage
and the value of the insulation for the various circuits shall be given as under-

SN Rated circuit Meggering Insulation resistance

voltage voltage value
1 750 volts AC 1000 V DC Not less than 5 M ohms
2 415 volts AC 500 V DC Not less than 3 M ohms
3 230 volts AC 500 V DC Not less than 2 M ohms
4 190 volts AC 500 V DC Not less than 2 M ohms
5 110 volts AC 500 V DC Not less than 2 M ohms
6 24 volts AC 500 V DC Not less than 2 M ohms

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8.7 Checking of electrical continuity:

Continuity of protective circuits shall be ensured by effective interconnections either

directly or by means of protective conductors. In particular, screwed connections shall
be checked for adequate contact, possibly by random tests.

When a part of Switch Board Cabinet is removed from the enclosure, for example for
routine maintenance, the protective circuits for the remainder of the Switch Board
Cabinet shall not be interrupted.

Means used for assembling the various metals parts of Switch Board Cabinet are
considered sufficient for ensuring continuity of protective circuits if the precautions
taken, guarantee permanent good conductivity and a current carrying capacity sufficient
to withstand the earth fault current that may flow in Switch board cabinet.

For lids, doors cover plates and the like, the usual metal screwed connections and
metal hinges are considered sufficient to ensure continuity provided that no electrical
equipment is attached to them.

All parts of protective circuit within the Switch Board Cabinet shall be so designed that
they are capable of withstanding the highest thermal and dynamic stresses that may
occur at the place of installation of Switch Board Cabinet.

8.8 Verification for effectiveness of protective circuits:

It shall be verified that the different exposed conductive parts of the assembly are
effectively connected to the protective circuit in accordance with some requirements. A
protective circuit in an assembly consists of either a separate protective conductor or
the conductive structural parts or both. It provides the following-

(i) Protection against the consequences of faults within the assembly.

(ii) Protections against the consequences of faults in external circuits supplied through
the assembly.

8.9 Shock & Vibration test:

Shock & vibration test of high voltage panel and battery charger panel shall be conducted
as per category 1, class B & location D given in Annexure B of IEC 61373 – 2010 from any
NABL accredited agency.

8.10 Water Ingress protection test:

High voltage (HV) panel and Battery charger panel (excluding top opening) shall be IP65
protected as per IS 13947 (latest edition). Suitable gasket shall be provided on the lower
opening.

8.11 Check for satisfactory operation of rotary switch:

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Rotary switches shall be checked for satisfactory operation by rotating 10 times clockwise
and 10 times anticlockwise. Work Test Certificate (WTC) of rotary switches of OEM shall be
checked by inspecting authority.

8.12 Check for BOM:

(i) Bill of Material (BOM) used in Switch Board Cabinet as given in Annexure-A (description,
make, part no./ Catalog no. of each item) shall be checked. Work Test certificates(WTC)
in respect of the following shall be submitted by the firm during prototype testing.

1. MCBs/MPCBs
2. Wide band contactors
3. Rotary switches
4. Overload relays
5. Control transformer
6. Earthing & disconnecting device
7. H.T fuses

(ii) In view of updating of the various catalogue/technical data sheets resulting in

discontinuation/Non-availability of a particular make/part no; the firm shall take prior
approval from RDSO for alternate part no. of a particular make before effecting bulk
supplies.

(iii) Proforma in voice of all major items shall be supplied along with each supply of material.

9.0 TECHNICAL DATA

9.1 The manufacturer shall submit complete design details of SBC and its fittings,
necessary calculation, if any shall also be submitted.

9.2 The manufacturer shall also supply following:

a) Component drawings in CAD software in line with RCF drawings enclosed

with specification along with the material and specification.
b) One set of the following will be supplied with every 10 units.
i) Operating and trouble-shooting manual.
ii) Parts illustrated catalogue-indicating sources.

10.0 COMMISSIONING:

Firm shall be responsible for commissioning of prototype unit in one coach at

Production Units(PUs). The modification in Switch Board Cabinet shall be compatible
with the coach harness provided for various circuits. Firm shall prove out the scheme
in one coach for proper functioning of all related equipments.

11.0 Supplier’s responsibility

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11.1 The Switch Board Cabinet shall be suitable for rugged service conditions normally to
be met within Railway rolling stocks, where coaches are expected to run up to a
maximum speed of 200 kmph in varying climatic conditions existing throughout India.

11.2 The supplier shall be fully responsible for ensuring that all equipments forming part of
the supply is entirely fit for the purpose and no part of this specification shall in any
way remove or reduce his obligation in this respect. In addition, it is the supplier’s
responsibility to underwrite the complete switchgear system design and ensure that it
is compatible with and will, in no way, compromise the design and performance of
switch board cabinet of his supply.

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

11.3 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 equipment
of the switch board cabinet.

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

11.5 If the Switch Board Cabinet fails to achieve these requirements, the Switch Board
Cabinet shall be modified at the supplier’s expense and within a time scale to be
agreed with purchaser/consignee/RDSO.

12.0 MARKING AND PACKING

12.1 All the switch board cabinet and its main component/accessories shall be provided
with a name/rating plate on the enclosure. The following information shall be available
either by etching process or by engraving or screen- printed at the front door on each
panel:

a) Name and Address of the manufacturer.

b) Month of the manufacture.
c) Serial number of panel.
d) Specification number.
e) Hardware version
f) Schematic/Connection diagram /fittings arrangement of the equipment on the
side of the cover/body.

The first two digits shall indicate the year of manufacture and next two digits shall
indicate month. Further next four digits shall indicate manufacturing serial number.

12.2 The name/identification plates shall be of bright anodized aluminium with black letters
embossed or etched on white background. These plates shall be fitted by riveting. The
nameplate shall indicate the month and year of supply in addition to the usual
information.
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12.3 All components provided inside the panel shall be identified by screen/photo printed or
computer generated designation labels/legend marking plates. These should be
mounted near the concerned component duly ensuring visibility. Circuits and
components shall also be provided with the name plates indicating the
operation/function of the switches/circuits. Contactors and circuit codification diagram
(with glass fuse details ) shall be identified by aluminium anodized legend plates by
adhesive of approved make on back side of left hand front doors. Balance
indicating/measuring switchgear /devices installed on front door shall be identified by
aluminium anodized legend plates by adhesive of approved make on the front doors
itself. No riveting is allowed on front door.

12.4 Danger Notice plate shall be screen printed or sticker shall be provided on front of the
lower panel door conforming to IS:2551-82 for 750V.

12.5 The switch board cabinet and its sub assemblies shall be packed in thermacole boxes
and the empty spaces shall be filled with suitable filling material. Before keeping in the
thermocole box, the SBC shall be wrapped with bubble sheet. The SBC shall be finally
packed in a wooden case of sufficient strength, so that it can withstand bumps and
jerks encountered in road/rail journey.

13.0 GUARANTEE/WARRANTY

Guarantee/Warranty obligation of the equipment shall be as per IRS condition of

contract.

14.0 TRAINING

The contractor shall undertake to train, free of cost, the supervisors & staff of the
Indian Railways for operation, maintenance, fault finding, trouble shooting, repair of the
offered Switch Board Cabinet under the guidance of the skilled engineers as and when
asked for by Railways.

15.0 INFRINGEMENT OF PATENT RIGHT

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

15.2 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.

16.0 SERVICE ENGINEERS

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The manufacturer 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 all the zonal Railways Head Quarter &
Production Units to cover entire Indian Railways network. The service engineers shall
be fully conversant with Switch Board Cabinet & electrical circuitry employed in Switch
Board Cabinet.

17.0 CARTEL FORMATION

The firm will not engage cartel formation with other firms and will also submit a
declaration in this regard as per attached Annexure –A.

18.0 ENCLOSURES:

Sr. Drawing/ Document Description

No. No.
1. LS71200 (draft) HV cubicle
2. LS71104 alt. ‘a’ Regulated Battery Charger Cubicle
3. LS70300 (draft) Low voltage on-board Rotary switch Panel.
4. LS70117 ( sheet 1/5- Schematic wiring diagram for Switch Board Cabinet for
alt c, sheet 2/5- alt b, LHB EOG Non-AC coaches
sheet 3/5 to 5/5 – alt
a)
5. RDSO/PE/SK/TL/0179- Schematic single line wiring diagram for LHB type non
2014 (rev. 1) AC EOG coaches
6. Annexure-A Bill of Material
7. Annexure-B Terminal for HV cubicle
8. Annexure-D Performa for undertaking against cartel formation
9. EDTS-200, Rev. ’NIL’, Specification for Tubular Crimping Sockets’ for E-beam
Am-1 (or latest) cables
10. EDTS-201, Rev. ’A’, Specification for ‘Ring Tongue type’ crimping sockets for
Am-1 (or latest) E-beam cables
11. LS71105 Terminal codification for battery charger cubicle

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Annexure- A
Bill of Material (BOM) for Set of panels

S.N Gr Item Description Drawing/Catalogue Make Place of

no. Installation
HIGH VOLTAGE CUBICLE
1 12 F01 High voltage fuse (with holder) net 2038603+2138601 of Siba /EFEN/ SIF50
1 M/s Siba Ferraz/ETI/Bussm
Current Rating: 25 A AC ann/GE/L&T/
Voltage: 1000 V AC Siemens
2 12 F02 High voltage fuse (with holder) net 2038603+2138601 of Siba /EFEN/ SIF51
1 M/s Siba Ferraz/ETI/Bussm
Current Rating: 25 A, ann/GE/L&T/
Voltage: 1000 V AC Siemens
3 12 F03 High voltage fuse (with holder) net 2038603+2138601 of Siba /EFEN/ SIF52
1 M/s Siba Ferraz/ETI/Bussm
Current Rating: 25 A, ann/GE/L&T/
Voltage: 1000 V AC Siemens
4 12 F04 High voltage fuse (with holder) net 2038603+2138601 of Siba /EFEN/ SIF53
2 M/s Siba Ferraz/ETI/Bussm
Current Rating: 25 A, ann/GE/L&T/
Voltage: 1000 V AC Siemens
5 12 F05 High voltage fuse (with holder) net 2038603+2138601 of Siba /EFEN/ SIF54
2 M/s Siba Ferraz/ETI/Bussm
Current Rating: 25 A, ann/GE/L&T/
Voltage: 1000 V AC Siemens
6 12 F06 High voltage fuse (with holder) net 2038603+2138601 of Siba /EFEN/ SIF55
2 M/s Siba Ferraz/ETI/Bussm
Current Rating: 25 A, ann/GE/L&T/
Voltage: 1000 V AC Siemens
7 12 F13 Fuse 5x20 mm (fuse clamp)net-1 282-122 (clamp) Wago/
control, 1 amps Wickmann/
RS/Ferraz
Weidmuller
Phoenix
8 12 F14 Fuse 5x20 mm (fuse clamp)net-2 282-122 (clamp) Wago/
control Wickmann/
1 amps RS/Ferraz
Weidmuller
Phoenix
9 12 F15 Low voltage fuse (with holder) for 3NH-3030+3NA7- Siba /EFEN/ S1F47
transformer (secondary) 805-0RC OF M/s. Ferraz/ETI/Bussm
Current Rating: 16 A, Siemens ann/GE/L&T/
Voltage: 500 V AC Siemens

10 12 F16 Low voltage fuse (with holder) for 3NH-3030+3NA7- Siba /EFEN/ S1F48
transformer (secondary) 805-0RC OF M/s. Ferraz/ETI/Bussm
Current Rating: 16 A, Siemens ann/GE/L&T/
Voltage: 500 V AC Siemens
Breaking Capacity: 100kA
11 12 F17 Low voltage fuse (with holder) for 3NH-3030+3NA7- Siba /EFEN/ S1F49
transformer (secondary) 805-0RC OF M/s. Ferraz/ETI/Bussm
Current Rating: 16 A, Siemens ann/GE/L&T/
Voltage: 500 V AC Siemens
Breaking Capacity: 100kA
12 12 A1 Disconnecting and earthing device, M137.0827407 of M/s Schaltbau/ S1A2
8 pole , 2 way, no-OFF on load 63A Schaltbau or cat no. Salzer/L&T
750V AC (1000V insulation), 2 73342SLB32LOGBS
NO+2NC with heavy handle and S of M/s L&T/ Salzer

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pad locking arrangement in earth

position, mounted in a stainless
steel enclosure suitable for AC23
duty conforming to IS 13947/IEC
947
13 21 K01 Voltage phase control BD 9080, CM-MPN Dold/Carlo S1K03
net 1 .72 of M/s ABB, Gavazzi/ABB
3AC, 750V, aux. voltage 24-60V
AC/DC
14 21 K02 Voltage phase control BD 9080, CM-MPN Dold/Carlo S1K04
net 2 .72 of M/s ABB, Gavazzi/ABB
3AC, 750V, aux. voltage 24-60V
AC/DC
15 28 K01 Drop out delay time relay CT-ARS.12 ABB S1K
ARS time tron ,UC24-240V 7PV0722-1BV20 or SIEMENS 5
Anti skid 7PV0732-1AV20
16 31 F03 Fuse 5x20 mm (fuse clamp at the 282128/281- 418 Wago/ S1F63
X1.2) (clamp) Wickmann/
anti skid device T 6.3A RS/Ferraz
Weidmuller/
Phoenix
17 32 F04 Fuse 5x20 mm (fuse clamp at the 282128/281 418 Wago/ S1F65
X1.2) (clamp) Wickmann/
anti skid device T 6.3A RS/Ferraz
Weidmuller/
Phoenix
18 32 K01 Feeder Contactor for Net 1, AF 50-40-00 + CA5- ABB/Schneider/ S1K01
Voltage Rating : 750 V AC, 22E+RV5/240 of M/s Siemens/L&T
Current Rating: 50 A, ABB
Main Pole: 4 NO,
Aux. contact: 2 NO + 2NC
Control Voltage: 110 V AC,
With surge suppressor
19 32 K02 Feeder Contactor for Net 1, AF 50-40-00 + CA5- ABB/Schneider/ S1K02
Voltage Rating : 750 V AC, 22E+RV5/240 of M/s Siemens/L&T
Current Rating: 50 A, ABB
Main Pole: 4 NO,
Aux. contact: 2 NO + 2NC
Control Voltage: 110 V AC,
With surge suppressor
25 32 S01 Rotary switch with marking “I-0-II“ 3SB5000-2DB01 Siemens/ S1S02
net 1 - Local main supply - net 2 + TEKNIC/GE/ (RSW-1)
(change over switch with 0-position 3SB5400-0A of Salzer/GE/Kaycee
3-pole) siemens
61153SCB03TDYR L&T
26 33 Q1 MPCB for water pump MBS 25 with MS116-1.6, HK1-11 ABB S1F21
aux. contact (1NO+1NC) and Schneider
terminal block db, GV2-ME06+GV-AE11
Current rating: 1.6 A 3RV1011-1AA10 or Siemens
Thermal release range: 1-1.6 A 3VU1340-0MG00
Voltage Rating: 415 V 1NO+1NC:3RV1901-
Breaking Capacity: 50kA 1A or 3VU9131-
Pole: 3 P 3AA00
ST41894OOOO L&T
+ ST41945OOOO
27 32 S07 Toggle switch 0-1 3SB3 000-2KA11 Siemens S1S01
Power supply ON/OFF 3SB3 901-0AC L&T (SALZER)
With socket and 2 NC 3SB3 400-0D TEKNIC
61006-S6-B19-11- SALZER
FH-BB-OFF-ON
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29 93 F01 Fuse 5x20 mm (fuse clamp at the 282128/281 418 Wago/ S1F58
X1.2) (clamp) Wickmann/
Insulation control T 2A RS/Ferraz
Weidmuller/
Phoenix
30 93 F02 Fuse 5x20 mm (fuse clamp at the 282128/281 418 Wago/ S1F59
X1.2) (clamp) Wickmann/
Insulation control T 2A RS/Ferraz
Weidmuller/
Phoenix
31 12 T1 Control transformer(T1) 100 VA, PUs approved
750V/110V, 5.2 KV insulation, sources
Class H, suitable for rolling stock
32 12 T2 Control transformer(T2) 100 VA, PUs approved
750V/110V, 5.2 KV insulation, sources
Class H, suitable for rolling stock
33 Fuses (with holder), 1A, 1.2 KV AC, Siba /EFEN/
Qty - 4 nos Ferraz/ETI/Bussm
ann/GE/L&T/
Siemens/ABB
34 Fuses (with holder), 1A, 250 V AC, Siba /EFEN/
Qty - 4 nos Ferraz/ETI/Bussm
ann/GE/L&T/
Siemens/ABB
35 33 K06 Auxiliary Contactor (with diode) for TKC631Z-62 + ABB S1K24
Water Pump: RVBC6-250V DC
Contacts: 3 NO + 1 NC CA2-KN31FD Schneider
Control Voltage: 77-143 V DC 3RH2131-1BF40 Siemens
36 33 K07 Auxiliary Contactor (with diode) for TKC631Z-62 + ABB S1K25
Water Pump: RVBC6-250V DC
Contacts: 3 NO + 1 NC CA2-KN31FD Schneider
Control Voltage: 77-143V DC 3RH2131-1BF40 Siemens
37 X1 Terminal blocks for high voltage Wago/Phoenix/We S1X1.1
cubicle idmuller

REGULATED BATTERY CHARGER CUBICLE

1 X3 Terminal block X3 Drawing no. LS70105 Wago/Phoenix/We

idmuller
ON-BOARD LV CUBICLE
1 RSW-1 AC Rotary switch, 250 V, 40 A, 3- Siemens/
Pole, with on-off TEKNIC/GE/
Salzer/GE/Kaycee
2 RSW-2 AC Rotary switch for fans, 250 V, Siemens/
25 A, 3-Pole, with on-off TEKNIC/GE/
Salzer/GE/Kaycee
3 RSW-3 AC Rotary switch for lights, 250 V, Siemens/
25 A, 3-Pole, with on-off TEKNIC/GE/
Salzer/GE/Kaycee
4 RSW-4 Rotary switch with marking “I-0-II“ 61153SCB03TDYR of Siemens/
net 1 - Local main supply - net 2 Salzer, 3SB5000- TEKNIC/GE/
(change over switch with 0-position 2DB01+3SB5400-0A Salzer/GE/Kaycee
3-pole) of siemens
5 RSW-5 Cam operated ON/OFF rotary Siemens/
switch, 0-1 power supply ON-OFF, TEKNIC/GE/
2 pole Salzer/GE/Kaycee
6 Low voltage main fuse (with Siemens/ABB/
holder), 25 A, 250 V AC, Qty - 3 Wohner-Italweber

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nos. /Ferraz/Siba

7 Low voltage fuse (with holder) for Siemens/ABB/

laptop/Mobile charging sockets, 10 Wohner-Italweber
A, 250 V AC, Qty - 3 nos. /Ferraz/Siba

8 Low voltage fuse (with holder) for Siemens/ABB/

fan circuits, 6 A, 250 V AC, Qty - 6 Wohner-Italweber
nos. /Ferraz/Siba

9 Low voltage fuse (with holder) for Siemens/ABB/

AC lights, 2 A, 250 V AC, Qty - 3 Wohner-Italweber
nos. /Ferraz/Siba

10 Low voltage fuse (with holder) for Siemens/ABB/

exhaust fans, 2 A, 250 V AC, Qty - Wohner-Italweber
3 nos. /Ferraz/Siba

11 Low voltage fuse (with holder), Siemens/ABB/

Spare, 10 A, 250 V AC, Qty - 3 Wohner-Italweber
nos. /Ferraz/Siba

12 RCBO, 16 amps. 30mA Siemens/MDS/Le

grand
13 DC Rotary switch for lights, 250 V, PU approved
40 A, 2 way with off sources
14 DC Rotary switch for EFT, 250 V, PU approved
40 A, 2 way with off sources
15 DC HRC fuse for lights, 250 V, 16 Siemens/ABB/
A, bolted connections Wohner-Italweber
/Ferraz/Siba
16 DC HRC fuse for EFT, 250 V, 16 A, Siemens/ABB/
bolted connections Wohner-Italweber
/Ferraz/Siba
17 DC HRC fuse with base for supply Siemens/ABB/
from RBC, 250 V, 32 A, Qty – 2 Wohner-Italweber
nos. /Ferraz/Siba
18 DC HRC fuse with base for Siemens/ABB/
emergency lights, 250 V, 2 A, Qty- Wohner-Italweber
2nos. /Ferraz/Siba
19 DC HRC fuse with base for Siemens/ABB/
Destination Board, 250 V, 2 A, Wohner-Italweber
Qty-2nos. /Ferraz/Siba
20 DC HRC fuse with base for Siemens/ABB/
Passenger information system Wohner-Italweber
(PIS), 250 V, 2 A, Qty-2nos. /Ferraz/Siba
21 DC HRC fuse with base as spares, Siemens/ABB/
250 V, 2 A, Qty-2nos. Wohner-Italweber
/Ferraz/Siba
MISCELLANEOUS
1 PVC alleys L&T/AKG
2 Halogen free e-beam irradiated RDSO spec. No. RDSO approped
cables of various sizes ELRS/SPEC/ELC/ sources
0019 (Rev.2) or latest
3 Multiple accessories like locks, DIRAK or
hinges, handles etc. equivalent
imported make
4 Computer generated ferrules Tyco/Phoenix/Pen
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duit
5 Cable jackets PMA Jack/Fedral
Mogul/Warner
Hahm

Note:

1. Inspection agency will check all the components and maintain record for future
reference.
2. Inspection agency shall ensured that switchgears shall be used as per description where
catalogue no. is not mentioned.
3. Calibration certificate of measuring instruments i.e voltmeter, ammeter to be submitted
during inspection.
4. Coloured heat shrinkable sleeves shall be provided as per phase for easy identification.
5. The DIN rail used shall have minimum depth of 15mm.
5. Any deviation on above shall be permitted only with prior approval of RDSO .

------------------------x-------------------x----------------------------------x---------------x-------------------

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Annexure- D

UNDERTAKING AGAINST CARTEL FORMATION

We, ……………………………………. Hereby, give an undertaking that as a Registered

Vendor for manufacture and supply of ……………………………………. will not be a part of a
cartel with other vendors and will be quoting competitive rates in the tenders invited by the
Indian Railway/PUs.

We …………………………… are aware of the fact that the Registering Authority i.e.
RDSO may de-list the name of our firm from the Master List of Approved Vendors if complaint is
received about such cartel formation from any of the Railways/Production Units.

Seal and Signature

(Authorized signatory of the firm)

Date:
Place:
Seal

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