Page I of 18 File No. EL/7.1.108/ZS Specification No.

RDSO/PE/SPEC/AC/0177
Rev.01 -2013

i-ll'<d~'<<f>I'<
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

~EfR 3i~<f>(rlj TfRq)

~lj~
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS

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soo ~IR!<idfe'T 14~1~

SPECIFICATION FOR HIGH CAPACITY INTER VEHICULAR COUPLER UNIT (500

AMPS. RATING) FOR EOG TYPE AC COACHES/POWER CARS/ LOCOS

am.~-~.arr.;-.:ft.t.;~ ~l~-~-/om ('<'l'm.01)-2013

RDSO/PE/SPEC/AC/0177 (Rev.01 )-2013

S. No. Date of Revision Reason

amendment
1 29.11 .2021 1 Change of the material of socket
housing assembly from aluminum to
stainless steel & revised the some
drgs for use in locomotives.

ai:1,sil~a
APPROVED

PED/PS &EMU

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Rev.01 -2013

Index

Clause No. Description Page

No.
1.0 Scope 3
2.0 Governino Specifications 3-4
3.0 Basic General Requirements & Service Conditons 5
4.0 Design and Technical Requirements 6-8
5.0 Material of components 8-9
6.0 Marking 10
7.0 Tests 10-14
8.0 Technical Data 14
9.0 Manufacturer's responsibility 15
10.0 Warranty period and liability 15
11 .0 Infringement of patent right 15
12.0 Schedule of Technical Requirement (STR) 15
13.0 Maintenance Manual 15
14.0 Enclosurers 16
-- Annexure-A 17
-- Distribution List 18

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SPECIFICATION FOR HIGH CAPACITY INTER VEHICULAR (IV) COUPLER UNIT (500
AMPS. RATING)FOR EOG TYPE AC COACHES/POWER CARS/ LOCOMOTIVES

FOREWARD

At present Rajdhani/Shatabdi trains are working on End on Generation (EOG) system .

Power generated in the power car at the ends of the rake is fed to each coach of the
rake through inter vehicular coupler. The existing Inter Vehicular (IV) couplers used in
LHB AC Coaches (Rajdhani/shatabdi trains) are rated for 400 Amps, which is suitable
for 18-19 LHB coaches. For rake having 24 number LHB AC coaches, there is need to
enhance the current carrying capacity of the inter vehicular couplerup to 500 Amps.
Therefore, it has been decided to develop high capacity Inter Vehicular Coupler for use
in LHB type rake having 24 numbers EOG type coaches.

Most of the Electric loco shed of Zonal Railways have reported the failures of breakage
of socket of the IV coupler (500 Amp) fitted in Electric Loco. Failures are of mainly related
to breakage of Aluminum housing flashing and locking of coupler pins, lever tie bow gap,
etc, which affects the reliability of HOG operations.

Western Railway has reported the failures of Inter Vehicular (IV) couplers of WAP7 locos
provided with Hotel Load Converters (HLC), in which it is mentioned that the failures in
IV couplers are mainly attributed to breakage of body/base of IV coupler and damage of
phase pins. Western Railway has suggested that the Aluminum cast housing to Grade
4600 confirming to IS 617 as per RDSO's specification no. RDSO/PE/SPEC/AC/0177-
2013(Rev-0) needs a material quality review for better performance.

Therefore, keeping in view of high failure of socket assembly due to breakage of

Aluminum housing, flashing and locking of coupler pins, lever tie bow gap, etc used in
loco has been reviewed::. This specification has been revised keeping the change in the
material of socket assembly from Aluminum casting to Stainless steel.

1.0 SCOPE

1.1 This specification covers the design, manufacture and test requirement of IV coupler
unit for EOG type AC coaches/locos for transmission of 3 phase, 5 wires, 750 V, 50 Hz
power supply from power car to individual coaches.

1.2 SCOPE OF SUPPLY

The scope of supply for each IV coupler unit shall include the following unless otherwise
stipulated in the tender:
A) For coaches and Power cars

1 Jumper plug assembly 2 Nos.

2 Couplinq socket assembly 2 Nos.
3 Dummy socket assembly 2 Nos.
4 Jumper cable duly crimped with each jumper plug and covered 2.6 meters
with flexible poly_amide conduits and its fittings.
5 Jumper cables duly crimped with each coupler socket 400mm

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B) For Loco side

1 Coupling socket assembly for loco 4 Nos

2 Jumper cables duly crimped with each coupler socket 1 meter or
suitable length
2.0 GOVERNING SPECIFICATION

2.1 The IV coupler unit shall, unless otherwise Specified here in, conform to the Indian
Standards Specification/lEC 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.
S.N Standards Description
1 ASTM A351/Gr-CF8 Specification for stainless steel casting
2 . IS: 319 Free cutting leaded brass bars, rods and sections
3 IS: 613 Copper rods & bars for electrical purposes
4 IS: 617
Cast Aluminum & its alloys ingots and casting for
qeneral enqineering purpose.
5. IS:4454(1V) and IS:7906(1) Cold rolled springs (stainless spring steel wires
and (11) grade 2)
6 AISl-304 Specification for Stainless steel Bars & section
7. IEC 60947-1 2004 Specification for low voltage switchgear and control
gear - part 1 General rules.
8. IEC: 60529-1 Classification of degree of protection provided by
enclosures.
9. UIC: 532 Electric power supply for trains taken from the train
vehicle
10. UIC: 554-1 Power supply to electrical equipments on stationary
railway vehicles from local mains system or another
source of energy at 220 V or 380 V, 50 Hz
11 . DIN EN 15085-2-2008 Welding of Railway vehicles Part - 2: Qualification
of manufacturer of welded rolling stock materials,
Quality Assurance.
12. EIA 364E-2008/IEC Method 2009.1 - Cable pull out
60352
13. EIA 364E-2008/IEC Method 2014 - Contact engagement and separation
60352 force
14. RDSO/PE/SPEC/AC/013 Flexible polyamide conduits with its accessories.
8-2009(Rev-1 ) or latest
15. ELRS/SPEC/ELC/0019 Electron beam cable
(Rev-4 r-Feb-2018 or
_{latest)

2.2 Any deviation from this specification proposed by the firm, 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.

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3.0 BASIC GENERAL REQUIREMENTS AND SERVICE CONDITIONS

3.1. The IV coupler unit shall be suitable for rugged service normally to be met within Railway
Rolling Stock, where coaches/locos are expected to run up to a maximum speed of 200
kmph in varying climatic conditions existing throughout India as under:-

Ambient -4 to 55deg C
AveraQe ambient 35 deQ . C
Train speed 200 Km/h
Relative Humidity Upto98%
Altitude Max 1200 m above sea level
Atmosphere Extremely dusty and desert weather. The dust contents in the air
may reach as hiah value as 1.6 mQ/cubic meter.
Annual rain fall Verv heavy in certain areas: between 1750 to 6250 mm.
Coastal area The equipment shall be designed to work in humid salt laden and
corrosive atmosphere. The maximum values of the condition
shall be as under :
Maximum pH value 8.5
Sulphate 7 mg/liter
Max. concentration 6 mg/liter
of chlorine
Max. conductivity 130 micro siemens/cm
Shocks and Vibration The IV coupler shall withstand satisfactorily vibrations and shocks
normally 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
('a' being the value of acceleration due to aravity)

3.2. The supplier shall be fully responsible for ensuring that all equipments forming part of
the supply are entirely fit for purpose 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 write the complete IV coupler unit design and ensure that it is
compatible with, and will, in no way, compromise, the design and performance of IV
coupler unit of this supply.

3.3 The supplier shall provide "In the field" service support during the guarantee period."

3.4 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 IV coupler
unit.

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

3.6 Should the IV coupler unit fail to achieve these requirements, then the unit shall be
modified at the supplier's expense and within a time scale to be with
purchaser/consignee/ROSO.
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4.0 DESIGN AND TECHNICAL REQUIREMENTS

4.1 The mounting dimensions of Jumper plug assembly, Coupling socket assembly and
(Dummy) socket assembly of the coupler shall generally confirm to RCF drawing no.
LW71301 alt a, LW71300 alt nil , LW 71302 alt nil respectively. The dimensions of other
parts like insulating base, design of pin contact & socket contact, circular ribs around
contact pin holes of plug assembly and sub-assemblies shall be approved at design
stage. The jumper plug assembly shall be in one piece.

For locomotives, socket housing shall be of stainless steel casting along with some
associateds drgs has been revised as per following RDSO's drawing:
• RDSO's drawing no. RDSO/PE/SK/AC/0226-2021 (Rev-0) for Socket assembly for
locomotives.
• RDSO's drawing no. RDSO/PE/SK/AC/0227-2021 (Rev-0) of hinged cover for
socket assembly for locomotives.
• RDSO's drawing no.RDSO/PE/SK/AC/0228-2021 (Rev-0) of complete ratchet
assembly for locomotives.
• RDSO's drawing no. RDSO/PE/SK/AC/0235-2021 (Rev-0) of sealing ring gasket
for locomotives .
• All the other relevant Drgs of Socket assembly for locomotives will remain same.

4.2 Insulating base for jumper plug shall be modified by providing circular rib of 2mm height
and thickness around each contact pins hole on mating surface area to increase
creepage distance as per drawing no. LW71304 Alt "c".

4.3 There shall be 5mm collar in the upper half of socket housing assembly as per drawing
no. LW71306 Alt "b" for coach and for locos as per RDSO's drawing no.
RDSO/PE/SK/AC/0226-2021 (Rev-0).

4.4 The hinged cover for socket assembly shall as per drawing no. LW71309 Alt "a" & for
locos as per RDSO's drawing no. RDSO/PE/SK/AC/0227-2021 (Rev-0) and blind socket
housing shall be as per drawing no. LW71341 Alt "b".

4.5 The jumper plug housing shall be as per drawing no. LW71380 alt nil.

4.6 The fixed/mobile contact pins shall be rated for a continuous current rating as detailed
below :

Phase (R, Y, B) 500 AMPS at 0.8 P.F, 750 V, 50 Hz.

Neutral (N) 400 Amos at 0.8 P.F, 750 V, 50 Hz.
Earth pin (E) 260 Amps at 0.8 P.F., 750 V, 50 Hz.
Control pins (C1&C2) 25 Amos at 0.8 P.F., 750 V, 50 Hz.

Above current ratings are taken at 50°C ambient temperature.

4. 7 Th_e terminal connectio~s on jumper plug unit and coupling unit shall be of crimping type
~u1tabl~ for the appropriate sizes ?f cables. Heat shrinkable polyolefin sleeves or similar
insulating mate~1al shall be provided over the terminations of each core of cable to
prevent any accidental contact between the adjacent terminals.
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4.8 The complete coupler assembly shall have IP protection IP65 as per IEC 60529(1atest
version) .

4. 9 There shall be a provision of bus bar on the cover of coupling socket for shorting of
control contacts (C1 & C2) when they are not in use.

4.10 The dummy socket shall be used when plug is not connected between coach to coach
and shall have terminals for control contacts shorted with the help of 4 mm 2 electron
beam cable. The electron beam cable shall be as per ROSO specification
ELRS/SPEC/ELC/0019 (Rev-4)-Feb-2018 or latest. Suitable locking arrangement shall
be provided so that the plug does not come out due to its own weight and vibration.

4.11 Locking arrangement shall be provided on the IV coupler socket and dummy socket so
the inserter/extractor ratchet arrangement does not disengage due to its own weight
(including inter connecting cables) and vibration encountered in service during running
of the train.

4.12 The design of the coupler unit shall be of waterproof construction and when the jumper
plug and coupling socket are coupled together they shall be completely water tight so
that water does not find access to the internal assembly. The coupler assembly shall be
provided with fire retardant high quality neoprene I EPDM gasket between the mating
surfaces to avoid water ingress. It shall be ensured that in any circumstances,
neoprene/EPDM rubber gasket between the mating surfaces could not come out.

4.13 Plug pin contact and socket contact shall be of self-adjusting type, so that they align
themselves to establish a firm contact between pins & socket tube by providing multi
point contacts. The displacement, loosening and extraction of the spring shall be
checked after 500 mating cycles.

4.14 With a view to ensure interchangeability, all parts shall strictly conform to the
requirement of the detail drawing of each component prepared by the firm and duly
approved by ROSO so that the corresponding part of one coupler unit can be assembled
in any other make coupler unit and shall also apply to manufacture of the component
spares for all sub-assemblies of the coupler unit.

4.15 The insulating material shall have the fire/flammability retardant property of VO when
tested as per UL94. The manufacturer shall submit the certificate from any NABL
approved laboratory.

4.16 ~eces~ary pa~ition/bridges shall be !11ade _in_jumper plug and coupling socket. The
insulating ~arners sh_all be m~ulded ~1th main insulating base in one single piece. Firm
shall submit the detailed drawing during prototype testing to the inspecting official.

4.17 Cabl~ -~~all be crim~ed at minimum 4 points in plug pins & socket tubes, so that
poss1b1ht1es of loosening of c~ble & presence of_air may be eliminated during service.
The arrangement to escape air from the tube & pins shall be provided.

4.18 The cables shall be crimped on both plug pins and socket tubes. The crimp; k t
shall be of appropriate size to match the cables. A heat shri'nkable fire ngtsodc e
po lytefl'in sIeeve sha11 be prov1'ded covering
· some portion of lugs and cables.
• re ar ant

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4.19 There shall be a suitable guide in plug and socket to ensure its mating in one direction
only.

4.20 Notching of size 20 x 20 x4mm shall be provided on the screw side of the pins to lock
with the slot provided in insulation base and thus prevent the rotation of the pins during
assembly. This shall be as per RCF drawing no. LW 71303 Alt-b, LW 71304 Alt-c, LW
71316 Alt-b, LW 71318 Alt-b, LW 71337 Alt-b.

4.21 Stainless steel fasteners as per SS 304 shall be provided to prevent from corrosion &
rusting .

4.22 The coupler unit shall have seven (7) pin contacts in the plug pin and corresponding
seven (7) socket pin contacts in the socket.

4.23 The identification, size & length of jumper cable shall be as under:
S. Circuit/identification Cable size Length of Length of jumper cable
N in mm2 jumper cable on socket side
on plug side
1. R- Phase 150 2.6 meters 400 millimeters
2. Y- Phase 150 2.6 meters 400 millimeters
3. 8- Phase 150 2.6 meters 400 millimeters
4. N - Neutral 95 2.6 meters 400 millimeters
5. E- Earth 70 2.6 meters 400 millimeters
6 Body earth 35 10"
7. 8"
C-1 Control 4.0 2.6 meters
8. C-2 Control 400 millimeters
4.0 2.6 meters 400 millimeters

The jumper cables shall be electron beam cables as per ROSO specification
ELRS/SPEC/ELC/0019 (Rev 4.)-Feb-2018 or latest.

4.24 Fire retardant, halogen free polyamide flexible conduit along with their accessories shall
be used. The flexible polyamide conduit and its accessories shall confirm to
RDSO/PE/SPEC/AC/0138-2009(Rev-1) or latest.

4.25 Terminals for phases, neutral, earth & control shall be suitably marked with legible letters
(R, Y, 8, N, E, C1 & C2) corresponding to the letter (1, 2, 3, 4, SE, 7 & 1O) on the
insulating base in prescribed color.

4.26 The tip diameter of fixed contact pin C1 & C2 shall be as per drawing LW 71338Alt 'a'.

4.27 The drawing for mobile contacts, fixed contacts and insulator blocks shall be as per LW
71316 Alt-b and LW 71318Alt-b, and the material of the flexible braided wire shall be
suitable for 500Amps current rating at 50°C ambient temperature.

5.0 MATERIAL OF COMPONENTS

5.1 The fixed and mobile contacts shall be made of tough pitch copper as per IS: 613 with
silver cadmium oxide tips. The material of the spring inside the mobile contacts shall be
SS 304 with CF-8 grade. The pin contact and socket contact shall be made of cop r
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with silver plating . The thickness of plating shall not be less than 1.0 microns. All pins
shall be silver plated for atmoshpheric protection from moisture and oxidation.

5.2 The control pins contact shall be made of brass as per IS:319 with silver plating having
thickness of 1.0 microns.

5.3 The housing of jumper plug, coupling socket and dummy socket along with covers shall
be protected against rust by giving suitable anti-corrosive and anti-rust treatment with
epoxy based powder to shade No. 632 (DA gray) of M/s Nerolac or equivalent to meet
the service condition as specified in clause 3.0. Before the application of primer, all the
surfaces shall be thoroughly cleaned repeatedly with cleaning agent to ensure removal
of rust and greasiness etc. The detailed process to clean surfaces shall be furnished by
the firm.

5.5 The compression springs must withstand minimum 1 million load cycles.

5.6 A compression spring should be preferably designed buckle proof.

5.7 The load test shall be in accordance clause no. 7.1 of IS: 7906(part-ll) and compression
test as per clause no.7 of IS: 7906(part-I).

5.8 The coupler socket, plug housing, dummy socket housing and their covers shall be made
of die cast Aluminum grade 4600 confirming to IS: 617. Firm will submit the material
conformity to the specification along with its test report from any NABL accredited
laboratory during prototype inspection. If any other material is used for housing of IV
coupler, it shall be require prior approval of ROSO. Firm shall submit the comparative
technical justification to ROSO for approval. Coupling socket housing for locos shall be
made of stainless steel with Grade CF-8 as per ASTM A 351 .

5.9 The assembly of coupler unit shall be provided with an inserter/extractor ratchet
arrangement to enable insertion and extraction of the coupler plug

5.10 The complete ratchet assembly shall be made of stainless steel (SS304) as per RCF
drawing no. LW 71330 Alt "a" for coaches and as per RDSO's drawing no. ·
RDSO/PE/SK/AC/0228-2021 (Rev-0) for locomotives.

5.11 The insulating base plate shall be of FRP/SMC materials and properties of FRP/SMC
components or any other insulating material suitable for withstanding continuous
temperature of 50°C above the ambient at full load shall be furnished to ROSO.

5.12 The cleating for securing of feeder cables in plug housing assembly shall be of fire
retardant high quality neoprene/ EPDM gasket with UL 94 VO (drawing no.LW 71374
Alt nil) .

5.13 The material of the 'O' ring of the mating surface between socket and plug shall be
neoprene/EPDM with UL 94 VO.

5.14 The complete material used in IV coupler shall be of fire retardant properties.

5.15 The material of the contacts confirming to the specifications and relevant latest
standards shall be submitted by the firm.

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6.0 MARKING:

6.1 The IV coupler assembly shall be marked with the following information at suitable
location.

Make/rating
Serial No.
Month and year of manufacture
Specification No.

7.0 TESTS

7.1 Type test:

7.1.1 Only after the detail drawings & the design of coupler and its accessories 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. During the process of manufacture of the equipment, if the purchaser so
desires, he may conduct/repeat any of the routine or additional tests to satisfy himself
that the quality of the module being manufactured is of the required standards.

7.1.2 The test protocol indicating relevant clause of the test, condition of the test, specified
value and observed value of the parameter for IV coupler shall be submitted by the firm
before offering the sample for testing.

7.1 .3 The type tests shall be carried out by ROSO representative on prototype unit either
totally or in part under the following conditions without any additional cost:

• A manufacturer undertakes to manufacture for the first time as per this specification
• An important change in the designof equipment has been introduced.
Specification is modified necessitating re-designing of equipment.
• Unsatisfactory performance reported by user Railways.
Resumption of production after an interruption of more than two years.

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

7.1 .5 The suitability of the IV coupler unit shall be ascertained by inspection & bench test at
the firm's premises, that in stationary coach/locos and service trial of the coach/locos.

7.1.6 The tests shall be carried out at the works of the manufacturer or a reputed testing
laboratory in presence of Indian Railway representative on the prototype unit of the IV
coupler unit as per the relevant governing specifications. Manufacturer shall have all
possible necessary arrangement for testing of IV coupler.

7.2 Routine test:

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7.2.1 Routine tests are to be carried out on each unit to verify that properties & design of the
product are in the line to those measured during type test. Proper documentation of
routine tests results shall be made available by the firm and will be produced before the
inspecting official on demand.

7.3 Acceptance test:

7.3.1 Every unit of Inter Vehicle coupler shall be subjected to acceptance tests as given in
clause no. 7.4 or sample picked up by inspecting official at manufacturer's works
nominated by purchaser/ROSO.

7.3.2 Manufacturer, on demand by inspecting official shall produce the internal/routine test
report carried out by manufacturer.

7.3.3 All the tests shall be carried out at firms premises and manufacturer's cost. Inspecting
official shall witness the test on each unit. A copy of these internal tests conducted by
the firm shall be supplied to the inspecting/purchasing authority. Not withstanding above
ROSO reserves the right to have these equipments also tested as per the specification
and mentioned standards at any reputed house in India at firm's cost.

7.4 Test description

Type Routine Accept-
S.N. Description of test Cl No.
test test ance test
Yes Yes Yes
1. Dimensional and visual 7.4.1
inspection

7.4.2 Yes Yes Yes

2. Milivolt test (Voltage drop

3.
test)
Temoerature rise test 7.4.3 Yes Yes --
7.4.4 Yes Yes Yes
4. Insulation resistance test
7.4.5 Yes Yes Yes
5.
6.
Hiqh voltaqe test
Cable oull out 7.4.6 Yes - ---
7. Test on spring 7 and 7.1 of Yes - Yes
IS:7906(1)
&(II)
8. Contact pressure test for 7.4.7 Yes - -
individual fixed/mobile
contacts
9. Matina cvcle test 7.4.8 Yes - -
10. Salt foa test 7.4.9 Yes - -
11 . Clearance & creepage 7.4.10 Yes - -
distance test
12. Deoree of orotection test 7.4.11 Yes - Yes*
13 Endurance test 7.4.12 Yes - -
14. Test for withstanding 7.4.13 Yes - -
shock & vibration

* Tests to be done on annually basis from NABL accredited lab.

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NOTE:

1. Testing/measuring instruments shall be duly calibrated fromany NABL recognized

laboratory and shall be furnished during type test.
2. Acceptance tests to be conducted on 5% unit of the lot offered, subject to minimum 2
sets.

7.4.1 Dimensional and visual inspection

The coupler assembly and its components shall be inspected visually and the
dimensions shall be measured and recorded as per the relevant drawings approved by
ROSO. The castings shall be free from cracks, blow holes and shall have smooth finish.
Firm shall also submit the detailed chemical report of the chemical analysis of the
material confirming to the specification from reputed govt /NABL accredited lab.

7.4.2 Milivolt drop test

The Milivolt drop shall be measured across the terminals by passing the rated current
when the steady state condition is achieved. The steady state condition is reached when
last 3 consecutive readings are approximately constant. The Milivolt drop between two
contacts should not be more than 45 Milivolt.

7.4.3 Temperature rise test

,This test shall be conducted with all the cable connected to their respective terminals
and lug inserted in socket tube and alternating current of the value shown in the table
shall be passed through phase, neutral, earth & control pins for a period of three hours
at an ambient temperature of 50°C. Firm shall create the facility to maintain the ambient
of 50 °C. The temperature rise of the terminals shall not exceed 50°C, when measured
with thermocouple or any other means (such as laser thermometer etc).

S.N Nomenclature of contact Test current(Am p)

1 Phase 650
L Neutral 520
3 Earth 340
4 Control 32

7.4.4 Insulation Resistance (IR) test

Th~ insulation resistance sh~II be meas_ured by 1500 V,DCmegger. The insulation

resistance shall be measured tn the following combinations:

• Between all live poles connected together and earth & housing .
• Between each live pole ( inclusive of earth & neutral) and housing
• Between live pole as R-Y,Y-B,R-B,R-E,R-N etc. ·

In each case, the IR shall not be less than 100 M n before HV and after HV test.

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7.4.5 High voltage (HV) test

H' h voltage test shall be conducted by applying test voltage and the combination
b~~een different poles as mentioned below in table.

S.N Description Test voltaQe Duration

1. Phase to phase 4.5 KV One minute
2. Phase to neutral 4.5 KV One minute
3. Phase to earth 4.5 KV One minute
4. Phase to control 2.5 KV One minute
5. Control to earth 2.5 KV One minute
6. Control to control 2.5 KV One minute
The IR value recorded after the test shall not be less than 100 M'O.

7.4.6 Cable pull - out test

Cable pull out test shall be conducted as per EIA 364E-2008/IEC 60352-2 to determine
the axial tensile load.

7.4.7 Contact pressure test for individual fixed/mobile contacts

The contact pressure test shall be conducted on the pins by applying a force on the pins
longitudinally and measuring the deflection of compression in the springs. The pressure
exerted and deflection thus resulted shall not be more than the values indicated below:-
S.N Pressure/load/weight on the pin
1. Maximum deflection
12kg
5.0mm
2. 18 kq
7.0mm
7.4.8 Mating cycle test

A) for Coach & Power car

In this test, 500 cycles of surface mating shall be carried out by connecting and
disconnecting the plug and socket of IV coupler. After completing 500 cycles, the coupler
shall be subjected to IR test, HV test, contact engagement & separation force test
andMillivolt test as per relevant Para's of this specification.

8) For Locomotives
I~ this te~t, 1000 cycles of surface mating shall be carried out by connecting and
disconnecting the plug and socket of IV coupler at 50°C. After completing 1000 cycles
the coupler shal_l _be subjected to IR test, HV test, contact engagement & separatio~
force test and M1ll1volt test as per relevant Para's of this specification.
7.4.9 Salt fog test

The complete unit is subjected to pass 96 hours salt fog test as per ASTM 117 8/IEC
60512-1 1-6.

7.4.10 Clearance & creepage distance test

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The Clearance &creepage distance shall be measured between various parts as

mentioned in annexure - A. The creepage distance shall be as per pollution degree 4,
material group II (Table XV) , whereas the clearance shall be as per class A, pollution
degree 4 (Table XIII) specified in IEC 60947 -1.

7.4.11 Degree of protection test

Degree of protection for the complete unit shall be got tested by the firm from any NABL
recognized laboratory as per IEC 60529 conforming to IP-65. The test results shall be
submitted at the time of prototype testing. This test shall be conducted after vibration
withstanding test and test to simulate the effect of shunting shock, specified in clauses
7.4.13 & 7.4.14.

7.4.12 Endurance test

The endurance test shall be conducted on the complete unit when the plug and socket
are connected together and an alternating current of 500 Amps, having sine wave form
of 50 Hz, shall be applied for a period of minimum 10 hrs (for Coaches & Power Cars)
and 24 hours for locomotives only at an ambient temperature of 50°C. After completion
of the test, the contact tips shall be checked visually for any sign of pitted contact tip and
contact resistance.

7.4.13 Test for withstanding shock and vibration

Test for withstanding vibration for the complete unit shall be got tested by the firm either
in-house or from any Govt. /NABL accredited laboratory as per IEC 61373 location 'O'
cat. 1, class 'A' as mentioned in Annexure -C of IEC 61373.The test results shall be
submitted at the time of prototype testing .The 18 shocks (three positive and three
negative in each of the three orthogonal planes) shall be applied to the equipment as
per clause No.10.6 of IEC 61373.

8.0 TECHNICAL DATA

8.1 The technical information as per Annexure A "Questionnaire on offer of IV Coupler"

complete in all respect should be furnished before prototype test.

8.2 The firm shall indicate its compliance or otherwise against each clause and sub-clause
of the technical specification and submit before prototype test.

8.3 The manufacturer shall also supply the following drawings in CAD software:

a) Dimensional drawings of complete plug and socket assembly along with ratchet
assembly.

b) Component drawings in line with RCF drawings enclosed with specifications along with
the material and specification.

c) One set of the following documents will be supplied with every 50 units:-

i) Operating and trouble-shooting manual.

ii) Parts illustrated catalogue-indicating sources.
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9.0 Manufacturer's responsibility

The manufacturer's responsibility will extend to the following:

9.1 The supplier shall supply the detailed instructions for proper inst_allatio~ of the equip~ent
on Rolling stock. For this purpose, the supplier shall depute his engineers/supervisors
to purchaser's site during installation of the equipment.

9.2 The supplier shall be responsible for commissioning, testing and field trials of the
equipment in service and depute team of engineers/supervisors for this purpose during
developmental stage.

9.3 The supplier shall be responsible for carrying out improvements and modifications at his
own expense on all the equipments supplied, provided such
modifications/improvements are decided to be necessary for meeting the requirements
of reliability, performance and safety etc., jointly by manufacturer and purchaser.

9.4 For the purpose of technical decisions on improvements/ modifications etc. on

equipment, the final authority from the purchaser's side will be ROSO.

10.0 Warranty period and liability

The supplier/manufacturer shall be responsible for any damage to the products due to
defective design, materials and workmanship for a period as per Indian Railway stores
(IRS) condition of contract.

11.0 Infringement of patent right

Indian Ra ilways 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 notmentioned herein which may cause
such a dispute. The entire responsibility to settle any such disputes/matters lieswith the
manufacturer/ supplier.

Details / design/documents given by them are not infringing any IPR and they are
responsible in absolute and fullmeasure instead of railways for any such violations. Data,
specifications and other IP as generated out of interactionwith railways shall not be
unilaterally used without the consent of ROSO and right of Railways / ROSO on such IP
isacceptable to them .

12.0 Schedule of Technical Requirement (STR)

12.1 Firm intended to manufacture and supply of IV coupler to Indian railway should have all
the manufacturing& testing facilities as per RDSO's STR No. RDSO/PE/AC/STR/0033-
2011 (Rev-0) or latest.

13.0 Maintenance Manual

13.1 Firm will submit the general maintenance recommendations on maintenance

requirement of the unit, which should contain periodicity, work content and justific · n
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for each maintenance requirement. Firm will also submit the catalogue indicating
sources during prototype test.

14.0 Enclosures

a) Annexure A: Questionnaire on offer for IV coupler.

b) Drawing of jumper plug assembly LW 71301 Alt "a"
c) Drawing of Coupling socket assembly LW 71300 Alt "nil"
d) Drawing of blind socket assembly LW 71302 Alt "nil"
e) Drawing of jumper plug housing LW 71380 Alt "nil".
f) Drawing of insulating base for jumper plug LW71304 Alt "c".
g) Drawing of socket housing assembly LW71306 Alt "b"
h) Drawing of hinged cover for socket assembly LW71309 Alt "a"
i) Drawing of blind socket housing no. LW71341 Alt "b".
j) Drwaing of socket housing for locomotives RDSO/PE/SK/AC/0226-2021 (Rev-0).
k) Drawing of hinged cover for socket assembly for locomotives RDSO/PE/SK/AC/0227-
2021 (Rev-0). ·
I) Drawing of complete ratchet assembly for locomotives RDSO/PE/SK/AC/0228-2021
(Rev-0).
m) Drawing of sealing ring gasket for iocomotives RDSO/PE/SK/AC/0235-2021 (Rev-0).

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ANNEXURE - A

QUESTIONNAIRE ON OFFER FOR IV COUPLER FOR LHB EOG TYPE AC COACHES

(To be furnished by the firm at the time of prototype testing)

S.No. Description To be furnished by the firm

1. Manufacturer's name & Address
2 Model/Type
3. Rating
a) Voltage
b) Current
c) Power factor
4. Temperature rise at rated current
5. Cable pull out
6. Material and parameters of the
spring
7. Mating cycle
8. Weight
a) Plug assembly
b) Socket assembly
c) Blind Socket assembly
d) Total wt.of Plug, socket &
blind socket with cables
e) Socket assembly for
locomotives
9. Materials along with relevant
specification & drawing
a) Plug assembly
b) Socket assembly
c) Ratchet assembly
d) Blind Socket assembly
e) Fixed contact pin
f) socket Tube
g) Control pin
h) Socket assembly for
locomotives
i) Ratchet assembly for
locomotives
10. Degree of protection for complete
coupler unit

Note: All the columns ~hall be filled in along with the relevant documents, drawings, specifications
and other details.

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DISTRIBUTION
CHIEF ELECTRICAL LOCO/ SERVICE/ DESIGN ENGINEER:
1 Northern Railway, Baroda House, New Delhi - 110 001 .
2 Central Railway, II Floor, Parcel office, CST Mumbai -500 001.
3 Eastern Railway, Fairlie Place, Kolkata 700 001 .
4 South Eastern Railway, Garden Reach, Kolkata - 700 043
5 Southern Railway, Park Town , Chennai - 600 003 .
6 Western Railway, Churchoate, Mumbai 500 020.
7 South Central Railway, Rail Nilavam, Secunderabad - 500 371.
8 East Central Railway, OiqhiDistt- Vaishali, Hajipur Bihar- 844 101 .
9 North Central Railway, Subedaroani, Allahabad- 211 001 .
10 South Western Railway, 1s1 Floor, ORM Office, Hubli 580 020
11 South East Central Railwav, Bilaspur.495004
12 North East Frontier Railwav, Maligaon, Guwahati - 781001
13 North Eastern Railway, Gorakhpur 273001
14 North Western Railway, Jaipur 302006
15 West Central Railway, Jabalour 482001
16 East Coast Railway, Bhuvneshwar, Orrisa 751016
17 Konkan Railwav, BelapurBhavan, Sector-11, Belaour, Mumbai -500614
18 Metro Railwav, 33 /1 J.L. Nehru road, Kolkata- 700071
19 lnteoral coach factory, Perambur, Chennai - 600038
20 Rail Coach Factory, Kaourthala (Punjab) - 144 602
21 Rail Coach Factory, Lalaani, Bareilly (U.P) - 144 602
CHIEF WORKS MANAGER:
1 Matunaa Workshop, Central Railway, Mumbai 500 019.
2 Liluah Workshop, Eastern Railway, Howrah
3 C&W Workshop , Northern Railway, Alambagh, Lucknow-226 05
4 C & W Workshop,N. Riv., Jagdhari - 135 002
5 Mechanical Workshop, NER, Gorakhpur - 273 012
6 Carraige Workshop, Southern Railway, Perambur, Avanavaram, Chennai-600023.
7 SCR, Lallagudda Workshoo, Lallaguda, Secunderabad - 500017
8 Carriaqe Workshop, Western Railway, Lower Parel, Mumbai-500013
9 CRWS, W. C. Railway, Nishatoura, Bhopal-462010
10 Carriaqe Workshop, NW Riv,. Ajmer - 305001
11 Carriage Repair Workshoo, Gadag Road, SWR, Hubli - 580 020
12 Carriaqe Workshop, S.W. Railway, Mysore Vishwanath.
13 Carriaoe Workshop, SE Riv., Kharaaour - 721301
14 New Bonaaioaon , Railway Workshop, Dangtal, Distt. Bonoaioaon, Assam-783380
15 Carriaae and Waqon Workshop, N. C. Riv., Jhansi - 248003
16 Carriaae and Wagon Workshop, WC Riv., Kota - 325002
17 Carriage and Wagon Workshoo, Eeastern Rly., Liluha - 711204
18 Carriage and Wagon Workshoo, W. Rly., Pratap Naqar, Vadodara - 390004
19 Carriage and Wagon Workshoo, N Rly., Amritsar - 143001
20 Central Workshop, Goldenrock, S. Rly. , Trichi - 620004
OTHERS:
1 Director, IRIEEN, Nasik Road (Maharashtra). - 422101
2 Senior Professor (Elect.\, Railway Staff Colleoe, Lalbaua, Vadodara. - 390004
3 Director, IRCAMTECH, Maharaipur, Gwalior - 474 020.

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