Page 1 of 40

SPECIFICATION FOR IGBT BASED “TRACTION CONVERTER”

FOR
THREE PHASE LOCOMOTIVES
SPECIFICATION NO CLW/ES /3/IGBT/0486 ALT - C

Total no of pages: 40
February - 2014

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 2 of 40

ALTERATION RECORD SHEET

Amendment Date of Page Alteration Changes Authority

in clause no. amendment No
1.2 30-05-2011 05 A - Power converter with the vehicle control *
electronics on a bus system conforming to
published open standard is added.
1.5 30-05-2011 05 A - More abbreviations are added. *
1.6 30-06-2011 06 A - IEC 61133 has been added in the table. **
1.7 30-05-2011 07 A - Clause 1.7.1 & 1.7.2 are deleted and list of *
required documents are merged under clause
1.7 only.
1.8 30-05-2011 08 A - Clause 1.8.1 for supplier responsibility is added. *
1.9.1 & 1.9.3 30-05-2011 09 A - Clause 1.9.1 appeared twice and it is corrected. *
- Clause 1.9.2 is replaced by 1.9.3.
- Clause 1.9.3 given in the old version is deleted.
2.1.3 30-05-2011 13 A - Clause 2.1.3, duty cycle is replaced by *
adhesion requirements.
- Clause 2.1.4 is deleted.
2.2.1 30-05-2011 13 A - Overhead traction supply voltage is modified. *
2.2.2 30-06-2011 13 A - The traction converter shall deliver constant * & **
power of 2368 kW for WAG-9/WAP-7 and 2105
kW for WAP-5 between 22.5 kV and 27.5 kV of
OHE voltage is added.
2.3 (vii) 30-05-2011 14 A - The line “After taking into account 25% choking *
of filters and radiator fins” is deleted.
2.3 (ix) 30-05-2011 14 A - Clause is modified. The converter shall be *
protected against dust and water.
2.3 (xii) 30-06-2011 14-15 A - Clause is modified. **
2.3 (xiii) 30-05-2011 16 A - Clause is modified. *
2.3 (xiv) 30-05-2011 16 A - Proposed dimensions are deleted from the *
clause.
2.3(xv) 30-05-2011 16 A - Clause is modified. *
2.3(xvi & xvii) 30-05-2011 16 A - The word “Bidder” is replaced by Supplier. *
2.3 (xviii) to 2.3 30-05-2011 16 A - These clauses are added. *
(xxi)
2.5 30-05-2011 17 A - Interference current values are modified. ***
2.6 30-05-2011 18 A - Clause is modified. *
2.7 30-05-2011 18 A - The proposed converter shall be water cooled... *
is added in the clause.
2.8.2 30-05-2011 18 A - Clause is modified. *
2.9 & 2.10 30-05-2011 19 A - These clauses for control equipment integration *

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 3 of 40
and mechanical integration are added.
Chapter 4 30-05-2011 21 A - Scope of supply is modified. *
Chapter 5 30-06-2011 22 - A - Tests & trials clauses are rearranged and *&**
25 modified.
Appendix-6 30-05-2011 31-32 A - Appendix-6 has been added to include drawing *
of the active speed sensor.
Appendix-7 30-05-2011 33 A - Appendix-7 has been added to include drawing *
of the speed sensor tooth wheel ring.
Appendix-8 30-05-2011 34-36 A - Appendix-8 has been added to include *
the foot print of GTO based traction converter.
2.5 29-11-12 17 B - Sl. No. 4.0 of the table in clause 2.5 is modified. ***
2.11 29-11-12 19 B - Clause no. 2.11 is added as “Training”. *
Chapter 4 29-11-12 21 B - Sl. Nos.3, 8, 9,10,11,12 & 15 are modified. *
Chapter 4 29-11-12 21 B - Sl. No.16 is added. *
2.3(v) 20-02-14 14 C - Line “front cover of the converter….to #
minimum” has been added.
2.3 (xii)(b) 20-02-14 15 C - Word “DDS recording” has been added. #
2.3 (xix) 20-02-14 16 C - Clause has been modified. #
2.3 (xx) 20-02-14 16 C - Line “Supplier shall use transformer links…. ” #
has been added.
2.3(xxi) 20-02-14 17 C - Line “Supplier shall use transformer links…. ” #
has been added.
2.6 20-02-14 18 C - Clause has been modified. #
2.7 20-02-14 19 C - Clause has been modified. #
2.12 20-02-14 20 C - Clause has been added. #
2.13 20-02-14 20-21 C - Clause has been added. #
2.14 20-02-14 21 C - Clause has been added. #
Chapter 4 20-02-14 23 B - Sl. Nos. 3, 6, & 16 have been modified. #

* = Modified by Dy.CEE (Con)/TU-II

** = Modified by vide RDSO’s Letter no. EL/11.5.5/1/IGBT dated 30.06.2011.
*** = Modified by vide RDSO’s Letter no. EL/11.5.5/6 dated 26.05.2010, EL/11.5.5/1/IGBT dated
31.10.2011 & EL/11.5.5/1/IGBT dated 18.11.2011.
# = Modified as per Minutes of Meeting held in CLW for standardisation of traction converter on dated
18.10.2013.

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 4 of 40
‘Table of Contents’

Chapter Description Page No.

No.
1 General 5

2 Technical Specification 10

3 Climatic and Environmental Conditions 20

4 Scope of Supply 21

5 Tests & Trials 22

6 Appendices 26

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 5 of 40
CHAPTER 1- GENERAL

1.1 Indian Railways (IR) is currently manufacturing electric locomotives employing 3-phase propulsion based
on the GTO Thyristor technology. Considering the issue of obsolescence of GTO Thyristor and the
inherent technological benefits of Insulated Gate Bipolar Transistor (IGBT), Indian Railways plans to
implement IGBT based 3-phase traction converter on its 3-phase locomotives WAG9, WAP5 and WAP7.
This specification defines requirements for replacement of the GTO converters by IGBT converter
including all necessary adaptations.

1.2 This specification is intended to define the technical requirements of IGBT based traction converter as a
superior functional replacement of the existing GTO based traction converter, retaining the other
existing parts as much as possible. Necessary adaptations, wherever required, come under the scope of
this tender. The IGBT version shall be compatible to existing Micas-S2 based vehicle control unit (VCU)
and suitable for retro fitment on existing 3 phase locomotives.

IR intends to go for open control system (IEC61375) for vehicle control and would like to integrate, in
future, the traction converter with the vehicle control electronics on a bus system conforming to
published open standard (IEC61375). The design of traction converter shall keep this aspect in view.

1.3 The existing three phase Traction Motors 6FXA 7059 and 6FRA 6068 and the existing Transformers LOT
6500 and LOT 7500 shall be retained. Two series resonant chokes available in the existing transformer
also are to be used. The leading characteristics of IR’s 3-phase locomotives, the Transformers and
Traction Motors and are appended at Appendix 1 and 3. Use of the existing choke has to be mandatory
since transformer is to be retained.

1.4 The tenderer is expected to study in detail the existing interface of the GTO Converter with the remaining
equipment on the locomotive (e.g., Traction motor, it’s speed and temperature sensors, Transformer
with it’s Series Resonant Choke, Harmonic Filter, Cooling arrangement, Vehicle Control Unit etc.). The
tenderer is also expected to study in detail the existing machine room layout, ducting, cable routing etc.
on the locomotive. Site visit for this purpose shall be arranged on prior intimation to CLW. It shall be
deemed that the firm knows all the relevant aspects at the time of making offer.

1.5 ABBREVIATIONS:

IR - Indian Railways
RDSO - Research Designs & Standards Organisation
CLW - Chittaranjan Locomotive Works
Tenderer - Firm/companies participating in the tender
Supplier - The successful tenderer for supply of the equipment
VCU - Vehicle Control Unit
GTO - Gate Turn Off Thyristor
IGBT - Insulated Gate Bipolar Transistor
BoM - Bill of Material
VCB - Vacuum circuit Breaker

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 6 of 40
TM - Traction Motor
CON - Converter
Aux - Auxiliaries
FLG - Fahrzeulelt gert (German) – Engl. VCU – Vehicle Control Unit
SLG - Engine Control Unit
DCU - Drive Control Unit
TE/BE - Tractive effort/Braking effort
S&T - Signal and Telecommunication
Sub Supplier - Any person, firm or company from whom the supplier may obtain any materials or
fittings to be used for the works.
Purchaser - The President of the Republic of India as represented by the Railways
organisation entering into the contract
Inspecting
Officer - The person, firm or department nominated to inspect the converters or the
representative of the inspecting officer so nominated.
1.6 STANDARDS:
This Particular Specification is based on the following Normative References. Only those
revisions shall be taken, which are valid on the date of signing the contract. In addition to
the following, relevant ToT documents shall also be referred wherever required.

Standards Title
IEC 60077-1 Railway applications – Rolling Stock General Rules
IEC 61287-1 Railway applications – Power converters installed on rolling stock
IEC 60571 Specific rules concerning the electronic control part of converters.
IEC 61373 Railway applications – Rolling stock equipment – shock and vibration test
IEC 60310 Traction transformers and inductors on board rolling stock
EN 50121-3-2 Railway applications – Electromagnetic compatibility
(CENELEC) Part 3-2: Rolling stock - Apparatus
EN 50121-2 Railway applications – Electromagnetic compatibility
(CENELEC) Part 2 : Emission of the whole railway system to the outside world.
IEC –61375-1 Electric Railway Equipment-Train Bus
Part –1 : Train communication network.
EN 50153 Railway applications – Rolling stock – Protective actions against electrical
hazards

EN 60529 Protection classes of cases (IP-Code)

IEC 61133 Railway applications – Testing of rolling stock

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 7 of 40

1.7 Documentation

Following documents shall be submitted by each tenderer along with the offer for evaluation:

Schematic Circuit diagram

Functional Description

System design concept

Communication protocol and software structure description alongwith compatibility with the
locomotive control system.

Mechanical interface diagram and compliance to existing mechanics

Clause by clause compliance

Calculation and simulation results of system behaviour, including interference to the S&T circuits

Credentials with details of supply made of such/similar items.

Data sheets for devices and other equipment proposed alongwith detailed description of supply
proposed

Salient features and advantages of the offered system

Details of technical support and training offered.

Recommended list of spares with cost for 3-year maintenance after warranty alongwith full
drawing/design and details of OEM.

List of special tools, jigs and fixtures needed for assembly, testing, commissioning, maintenance and
repair alongwith full technical specifications and probable suppliers.

Logistics proposed for warranty support within India.

Declaration for long-term support by the tenderer.

Guaranteed values of efficiency of devices/subassemblies and assemblies

Calculation to withstand short circuit current under fault conditions

Details of short time rating of the converter

Expected efficiency with respect to vehicle load/speed alongwith calculations

Technical details of the devices proposed to be used.

Technical documentation explaining the complete scheme, characteristics, diagnostics, protection
and control etc.

Detailed drawings of each system/sub-system with interface details.

Design calculations for selection of devices, cooling systems and various subsystems, establishing the
adequacy of the components selected.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 8 of 40

Complete BOM / technical specification of components with source of supply.

Cooling system design description and cooling fluid data

Mechanical drawings, mounting arrangement, weight, details of mounting accessories

Procedure for parameter alteration, software downloading, diagnostic uploading, analysis etc.

Schedule maintenance activities with periodicity.

Maintenance, Trouble shooting and repair manual in soft form & hard copy.

All calculations evaluated on the basis of software simulations shall be supported by sample
calculations.

The tenderer shall wholly and completely be responsible for the performance of the complete
equipment.

The 3D models of all the cubicles, compatible to NX platform.
IRIS/ISO 9000 certification.1.8
INFRINGEMENT OF PATENT RIGHTS:
Indian Railway shall not be responsible for infringement of patent rights arising due to
similarity in design, manufacturing process, components used in design, development
and manufacturing of inverter and any other factor, which may be cause of such dispute.
The responsibility to settle any issue lies with the manufacturer.

1.8.1 SUPPLIER’S RESPONSIBILITY

The Supplier’s responsibility shall be extended to the following:

The supplier shall supply detailed instructions for proper installation of the equipment on locomotive.
For this purpose the supplier shall also depute his representative during installation and commissioning
of the Converter in the locomotive.

The supplier shall arrange to carry out detailed test & performance proving jointly with CLW.

The supplier shall also quote for special tools, testing jigs, and instruments, which may be required for
troubleshooting and maintenance of the converter separately.

The supplier shall also submit on demand repair charges for the cards. A separate contract shall be
executed by the Railways with the contractor for the repairs.

The supplier shall supply suitable software for off-line analysis of diagnostic data downloaded from the
converter.

The design shall be developed as per requirement given in the specification.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 9 of 40
1.9 Warranty

1.9.1 The contractor shall warrant that everything to be furnished under the contract shall be free from
defects and faults in design, material, workmanship and manufacture, and shall be of the highest grade
and consistent with the established and generally accepted standards for stores of the type ordered and
in full conformity with the contract and samples, if any, and shall, if operable, operate properly according
to the contract.

1.9.2 The warranty for the stores to be supplied under this contract shall be 42 months from delivery or 36
months from date of satisfactory commissioning and acceptance test of the stores, whichever is earlier.
The contractor shall immediately on receipt of notice of defect depute his engineer to start action for
rectification of defects under warranty.

1.9.3 In the eventuality of major design modifications during the currency of the warranty period, the warranty
for such components shall be extended for such period as is mutually agreed.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 10 of 40
CHAPTER 2- TECHNICAL SPECIFICATION

2.1 Performance Parameters

2.1.1 The present characteristics of WAG-9, WAG-9H, WAP-7 and WAP-5 locomotives with GTO based
propulsion are as given below:

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 11 of 40

500

WAG9

400

TE(kN)

BE(kN)

300
Tractive / Braking Effort (kN)

200

100

0
0 20 40 60 80 100 120

-100

-200

-300
Speed (km/h)

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SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 12 of 40

WAP7
300
Tractive / Braking Effort (kN)

200

100

0
0 50 100 150
-100

-200 Speed (km ph )

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 13 of 40

300
WAP5
250

200

150
Tractive / Braking Effort (kN)

100

50

0
0 50 100 150 200
-50

-100

-150

-200
Speed (Km/h)

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 14 of 40
2.1.2 With adoption of IGBT based traction converter, using the same traction motors and gears and pinions,
the tractive effort / braking Effort curve of WAG-9, WAG-9H,WAP-7 and WAP-5 locomotives shall match
the existing curves. In addition, the IGBT Traction Converter shall have capability to generate 510 KN
starting tractive effort on WAG-9H locomotive having axle load of 22.0t.

The drive control electronics shall have an installed protection against sustained overloads of the
converter and connected drive system so as to prevent damage.

2.1.3 Adhesion requirements:

The design of the adhesion control shall be optimised for maximum utilisation of adhesion factor and
shall be such that it is capable of generating the required starting tractive effort under dry rail
conditions. The supplier shall state the value of maximum starting tractive effort that shall be developed
under dry rail conditions and also under all weather conditions, which shall be demonstrated during
testing. The adhesion control system shall be capable of giving high adhesion through a wheel slip
control system of proven performance. The objective shall be to maximise the delivered draw bar pull
through control system in conjunction with sanding. The achievable running adhesion characteristics
shall be made available. The formulae for linking adhesion characteristics with the operating speed shall
be indicated.

2.2 Overhead Traction Supply

2.2.1 The overhead voltage is 25kV AC 50Hz, single phase. The supply voltage is fed to the traction transformer
through a Vacuum Circuit Breaker (VCB). The transformer output is to be connected to the traction
converter. The overhead traction supply is subjected to variations as under:
Nominal Voltage - 25 kV, single phase, AC
Maximum Voltage - 27.5 kV AC
Minimum Voltage - 19 kV AC
Occasional Maximum - 31 kV
Occasional Minimum - 16.5 kV
Supply Frequency - 50Hz+ (8%)

The occasional maximum and Occasional minimum voltage may persist for 30 min.

2.2.2 The traction converter shall deliver constant power of 2368 kW for WAG-9/WAP-7 locomotive and 2105
kW for WAP-5 locomotive between OHE voltage of 22.5 kV and 27.5 kV. The design calculation shall
establish the same. Variation of Power over 27.5 kV and below 22.5 kV shall be submitted. However,
design calculations shall be based on OHE voltage of 25 kV.

2.2.3 The transformer output voltage shall vary in accordance with the overhead supply. The details of the
transformer and VCB used are given in Appendix-1 and Appendix-4 respectively. The traction converter
offered shall be designed to withstand the voltage variations mentioned above.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 15 of 40

2.3 Technical requirements:

i) The system and equipment shall be of proven latest technology specially adopted for application to
meet the performance requirements under environmental conditions specified in this Chapter 3.
Adequate margin shall be built in the design, particularly to take care of condition of high ambient
temperatures, dusty condition, high humidity prevailing in India. The equipment, sub-system and their
mounting arrangement shall be designed to withstand satisfactorily vibration and shocks encountered in
service as specification in relevant IEC publications unless otherwise prescribed.
ii) The converter shall be designed and operated to achieve near unity power factor and minimum
harmonic interference current from OHE. The input power factor shall be close to unity within the line
voltage range from 19 kV to 27.5 kV at all speeds of operation of the locomotive. The maximum
interference current permitted is specified in Para 2.5 of this specification.
iii) In design and construction, reliability and maintainability shall be of paramount consideration. Tenderer
shall submit reliability calculations indicating MTBF for different devices, cards and sub-assemblies.
Adequate margin shall be provided to take into account ambient conditions prevailing in India. The
components are to be sourced from reputed firms.
iv) High efficiency of equipment shall be important consideration, next only to high reliability. The
components and technology used shall ensure very high efficiency of the converter. Tenderer shall
furnish the expected efficiency with respect to vehicle load/speed with necessary calculations.
v) Modular constructions shall be adopted wherever considered possible. Easy access for
inspection/maintenance and minimum maintenance requirement shall be given special consideration in
design and layout. Front cover of the converter shall be light weight and number of fixing bolts to be
restricted to minimum (say 3-4 nos) for ease in maintenance. Traction Converter shall be designed such a
way so that Transformer bushings are visible after opening of traction converter front cover to check any
oil leakage from bushing to prevent fire.
vi) Semi-conductor devices rating shall be selected so as to provide margin of 25% vis-à-vis
design/calculated current and voltage values under worst operating conditions after taking into account
voltage jumps and current surges on account of inductance and capacitance in the circuit.
vii) The design calculations of worst case temperature rise of equipment shall be made. A safety margin of at
least 100C shall be kept with respect to maximum permissible junction temperature of power devices
declared by the manufacturer under the ambient condition specified in this specification.
viii) The converter/inverter system shall be capable of withstanding the maximum short circuit current under
fault conditions and these shall be established through calculations. The converter / inverter system shall
also be designed to withstand extreme disturbances like short-circuit / open circuit etc. at all points of
input / output interfaces with locomotive, without any failure.
ix) Converter control electronics and IGBT modules enclosures shall comply with IP 54. The panel sheets
used for fabrication shall be of SST grade 304 as per ASTM-A240 with thickness of 2.5mm to 3mm. The
cabinet door material may be used aluminium alloy for light weight of the door.
x) All equipment shall be adequately earthed, insulated, screened or enclosed. They shall be provided with
essential interlocks and keys as may be adequate to ensure the protection of the equipment and safety
of those concerned with its operation and maintenance.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 16 of 40
xi) The electronic card shall be mechanically coded to ensure that insertion of card in wrong slot is not
possible.
xii) Following special features shall be provided in the traction converter to maximise the performance and
reliability and minimise possibilities of the locomotive being stalled in the section:

(a) Desired control scheme: Control system of the traction converter shall be suitably designed to get
considerably better performance and overall service reliability and shall include followings:
I. There shall be an independent drive converter per axle.

II. Suitable redundancy shall be built in the vital PCBs, particularly connected with safety, so that in
the event of their failure the likelihood of the Locomotive becoming inoperative or its
performance being degraded is minimised.

III. Only dry type capacitors (having self-healing property) shall be used for DC link / harmonic filter /
resonant circuits.

(b) The existing fault screen of the driver (fault messages displayed on driver display) and DDS recording
shall remain same with the adoption of IGBT traction converter except for following new messages
needed due to individual axle control:

• Motor 1 – Bogie 1 isolated – reduced traction/braking

• Motor 2 – Bogie 1 isolated – reduced traction/braking
• Motor 3 – Bogie 1 isolated – reduced traction/braking
• Line converter 1 – Bogie 1 isolated – reduced traction/braking
• Line converter 2 – Bogie 1 isolated – reduced traction/braking
• Motor 1 – Bogie 2 isolated – reduced traction/braking
• Motor 2 – Bogie 2 isolated – reduced traction/braking
• Motor 3 – Bogie 2 isolated – reduced traction/braking
• Line converter 1 – Bogie 2 isolated – reduced traction/braking
• Line converter 2 – Bogie 2 isolated – reduced traction/braking

The generation and adoption of these new messages and other DDS messages as a result of new
control of the converter shall be responsibility of the Supplier.

(c) In the event of breakdown of any component or basic unit of the traction converter, it shall be
possible to continue to haul the train with the least reduction possible in its services, operating within
restricted but permissible conditions. The basic principles and procedures to be followed in the event
of a breakdown shall be:

I. Breakdown of the drive side converter of traction converter(except for short circuit of IGBTs) or
electrical failure of traction motor:

The traction power of the converter shall only be reduced by 1/3rd (one third).

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 17 of 40
II. Failure of drive controller unit or power supply of the drive controller unit or gate unit or gate unit
power supply of a drive side converter of traction converter:

The traction power of the converter shall only be reduced by 1/3rd (one third).

III. Failure of one speed sensor:

The operation of the locomotive shall not be degraded and all traction motors shall remain
operational.

xiii) The electronics of the traction converter shall be suitably placed to avoid the effect of heat radiation of
sun coming from roof top of the locomotive.
xiv) All the proposed equipments shall not violate the given space envelopes of the equipment to be
replaced.
xv) Existing principle of the machine room ventilation shall be kept unchanged. The Supplier shall propose
enhancements on the system if indicated for better reliability of the whole system.
xvi) Existing motor and gear shall be retained. The supplier shall provide IR with all necessary manufacturing
drawings for necessary adaptations.
xvii) Supplier shall endeavour to supply lubricants available in India.
xviii) Coolant used for the traction converter shall be within the scope of the supplier.
xix) Speed sensor and associated accessories:
I. Power supply for the speed sensor shall be from the electronic card of the converter. Presently 2
(two) shielded cables, each having single twisted pair are used in the loco machine room for speed
sensor. Same arrangement of cable shall be retained.
II. Active speed Sensor with 120 tooth wheel ring shall be provided.
III. Speed sensor shall confirm to latest CLW specification supplied by CLW.

Following shall be within the scope of supply of the Supplier:

• Active speed sensor with existing mechanical interface. The drawing of the speed sensor is provided
in appendix-6.
• Tooth wheel with existing mechanical interface. The drawing of the tooth wheel is provided in
appendix-7.
• The sensor plate shall also be within the scope of the supply. The drawings of the plate shall be
supplied by CLW.
• Suitable male and female parts of the speed sensor connectors at the sensor plate shall also be within
the scope of supply of the Supplier.
• The connector at the converter end shall also be within the scope of supply of the firm if the existing
connector is not retained.
• Speed Sensor connection point at traction Converter should be given in the middle of electronics
chamber.
• The sensor shall be embedded with all electronics circuitry in a STAINLESS STEEL HOUSING in active
speed sensors.
• The sensor output frequency shall be proportional to the speed of the locomotive and the duty cycle
shall be 50±10%.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 18 of 40
• Cables should come out from stainless steel housing with strain relievers to avoid ingress of dust and
water. The sensors should have completely independent channel such that in case of failure in any
component in one channel, the other channel is not affected in any way.
• Provision of zener diode along with metal oxide variastor (MOV) to act as nonlinear surge suppressor
in case of surge and transients, which may appear in the cable between the sensor and converter
electronics.
• Use of 12V power supply with Microcontroller as signal transformer in the control circuit of the
sensor. This will facilitate the use of similar control logic/algorithm for the sensor supplied by
different vendors.

xx) Existing input power connection from Transformer terminal to Converter terminal is to be used. Supplier
shall use transformer links & flexible links similar to GTO as per latest CLW specification.
xxi) MCB in HB panels & Connectors in the converter side for 3-phase 415 V auxiliary supply, i.e., for
pump/fan etc, in the Traction Converter shall be in the firm’s scope of supply. Pump/fan shall be integral
part of the converter. Existing MCB of 16A in HB panel used in GTO based converter shall be replaced by
2A MCB at the time of installation of IGBT based traction converter.
MCBs within the traction converter shall be avoided for protection of cooling pump. In case, the MCB
trips, it is not possible to reset the same by the loco driver. There shall be provision for resetting of MCB
from outside the converter.

xxii) Standard cable length as in the GTO loco shall be adopted for cooling pump connection.

Loom no. Cable length(m)

230 13.5
341 14.5

2.4 Converter Output

The motor converter output current ripple shall be such as to keep the torque pulsations and traction
motor heating to a minimum. It is the contractor’s responsibility to make sure that output quality of the
Traction Converter is entirely suitable for the existing traction motors. The motor converter shall
generate the 3-phase output with higher pulsating frequencies and improved pulse pattern than with the
existing GTO system.

2.5 Interferences

(i) The electric and electronic apparatus used in propulsion system shall comply emission and immunity
aspects of EMC to CENELEC standard EN-50121-3-2. The internal EMC shall cover a combination of
earthing shielding and isolation of interference sources so that conducted and radiated noises are
properly segregated or suppressed and no other equipment is affected due to operation of power
converter.
(ii) The harmonic currents injected in the overhead supply system (as also the track return current) shall
introduce voltage harmonics on power supply and shall interfere with signal and telecom circuits. The

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 19 of 40
following interference current in the input current shall not be exceeded at any point in the operating
envelope of the locomotive:

Interference Current Limit

1.0 Psophometric current 10.0 A
2.0 DC component 4.7 A
3.0 Second Harmonic component (100 Hz) 8.5 A
4.0 1400 Hz up to 5000 Hz 400 mA
5.1 >5000 Hz up to 32000 Hz 270 mA
5.2 39500 Hz up to 43500 Hz 270 mA

(iii) The Supplier shall undertake FFT (Fast Fourier Transformation) analysis of the total current from 1400Hz
to 5000Hz and 5kHz to 50kHz separately to find out the frequencies which produce the highest currents
within each bandwidth. In the frequency bands >32000Hz to <39500Hz and >43500Hz to 50000Hz the
frequencies at which the current values exceed 270mA shall be identified. This test shall be included
within the tests listed within Chapter 5 and the results shall be provided in type test report.
(iv) EN 50238 includes interference current limits for track circuits and axle counters. Where these overall
interference current limits are more onerous than those stated above, these limits shall be applied.
(v) The Supplier shall submit the simulated values of these interference currents during design evaluation
stage.
(vi) The existing transformer, which is to be used, is provided with a filter winding as given in the schematic
diagram. The resistance and inductance values of the windings have been given in the Appendix - 1. The
filter resistor and filter capacitor ratings are 2800 V, 0.2 ohm/40 KW & 0.2 ohm/60KW and 0.4 mF,
2500V, 80A(bank capacity) respectively. During single bogie operation, filter adaptation contactor (8.2) is
opened, thereby, introducing an additional resistor. During normal operation, contactor 8.2 remains
closed. The existing harmonic filter has to be considered while designing the system for interference
limits. It is expected that with higher switching frequency of IGBT, this shall be sufficient to meet the
stipulated harmonics requirements.

2.6 Mechanical Dimensions

Dimensions of the existing traction converter are 3000 X 1100 X 2087 mm (LxWxH). Under no
circumstances, the dimensions of the converter including cooling pump shall not exceed envelop
provided below:

Length(mm) Width(mm) Height(mm) Height under VCB and HOM

2500 1100 2087 1925

Detailed dimensional drawings of the existing converter shall be made available to the Tenderer at CLW.
Drawing of the proposed foot print of the Traction Converter and mounting points are provided in

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 20 of 40
Appendix-8. No intermediate frame shall be allowed for mounting of traction converter as a separate
part of converter.

The existing weight of GTO based traction converter is 3330 Kgs. The weight of IGBT based traction
converter shall not exceed this weight.

2.7 Cooling

The Present GTO Converter uses forced oil cooling. There is a common aluminium alloy heat exchanger
module for both GTO based traction converter and transformer but with different circuits. One cooling
circuit is used for traction converter oil and other for transformer oil. The blower is common. There are
two such cooling units, one for each bogie.
The proposed converter shall be water cooled (water mixed with ethylene glycol). The scope of supply of
required quantity of coolant lies with the supplier.
Visibility of coolant level shall be provided in conservator of the converter and there shall be sufficient
gap between maximum & minimum level. There shall also be a drain cock on the converter side to
prevent spillage of coolant.
The supplier shall use the existing radiator. For this purpose, the supplier shall use the existing heat
exchanger for cooling the traction converter coolant. It shall have to be established from the calculations
that the existing heat exchanger is suitable for cooling the converter’s coolant. However, if the same is
not possible then the scope of supply of the new suitable exchanger, which shall fit within the existing
floor layout available, shall lie with the Supplier. Detailed design calculation of cooling system and its
efficiency shall be furnished by the Tenderer. Minimum coolant flow rate, which shall give the desired
cooling, shall be mentioned. The detailed drawings of the existing system shall be obtained from CLW by
the Tenderer.

2.8 Interfaces between converter and control equipment

2.8.1 The Traction converter has to work with the existing Vehicle Control Unit, which is based on MICAS S2
control & communication (C&C) system of M/s. Bombardier Transportation. The tenderer shall give a
suitable interface to the existing VCU. All the control and communication functionalities of the existing
Traction Converter shall be met by the proposed IGBT based Traction Converter. Modified software
suitable for the converter shall be within the scope of supply.

2.8.2 The traction converter shall be ready for use with upcoming TCN compliant VCU which is as per CLW
specification No.-C-D&D/TCN/VCU/HW/MICAS-S2/VER3. Specification shall be made available to the
Tenderer at CLW.

2.8.3 Presently the complete vehicle level software source code and programming tools used are with IR. The
proposed changes in VCU shall not dilute IR’s control over the vehicle level software & tools in terms of
their ability to carry out changes on their own, or shall not impact the existing preparedness in terms of
rendering acquired skills & tools un-usable. Thus changes if any, made shall be done in association with
CLW and validated by RDSO following present practice of IR. However, the primary responsibility of the

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 21 of 40
software changes & integration for both Co-Co and Bo-Bo type locomotives shall be on the tenderer. The
MICAS-S2 C&C is administered over MPB card based diagnostic system. Changes in VCU shall not
necessitate a separate tool for VCU. The converter may have a tool of its own for its diagnostic &
troubleshooting. Existing versions of tools used are as under:

# Tool Version # Tool Version

1 MIC Project 3.8 4 MIC Info 7.1.3
2 MIC View 4.6.1 5 MIC Bus 3.5
3 MIC Download 4.5.4

2.9 Control equipment integration

All the connectors for control signal of the IGBT traction converter bus station shall be similar to one
used in existing GTO based traction converter. Supplier has to use the same connectors for control signal
of the proposed IGBT based traction converter. Details shall be available from CLW.

2.10 Mechanical integration

IGBT based traction converter shall be retro fitment of existing GTO based traction converter. So the
Mounting arrangement of IGBT based traction converter shall be kept unchanged to the existing GTO
based traction converter.

2.11 Training: The Supplier shall organize training of 200 mandays at CLW and at their factory premises for
Railways (CLW and Zonal Railways). Supplier shall arrange for training modules, trainer as well as all
logistics for the trainees. The cost of training shall be included in the offer. The detail of training shall be
worked out during contract finalization stage/design approval stage.

2.12 Orientation of Traction Motors:

Standard orientation of Traction Motors to be adopted as in existing GTO based traction converter. The
same configuration shall be used by CLW for the connection of Traction Motors. The orientation of
Traction Motors shall be as follow.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 22 of 40
2.13 Sequence of Motor Terminals:
The standard sequence of motor terminals at the converter end shall be adopted. The suppliers have to
adopt motor terminal layout as follow.

w u v w w

v v

u u

Supplier shall adopt the same lengths of power cable for traction motor connection as in case of GTO
based converter.

Loom no Motor No. Length of power cable (m)

116 Motor(M1) 9.0
133 Motor(M2) 7.0
148 Motor(M3) 5.5

147 Motor(M6) 9.0

145 Motor(M5) 7.0
149 Motor(M4) 5.5

2.14 Length of Control Cable:

Supplier shall adopt the standard lengths of the following control cable connection as in case of GTO
based converter.
Loom No. Cable length(m)
323(SB1 to SR1) 7.5
324(SB1 to SR1) 7.5
328(SB1 to SR2) 16.0
344(SB2 to SR2) 8.0
341(connection 21.0
between SR1 & SR2 (Optic fibre cable will be used for better communication).

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 23 of 40
2.15 Software Requirement:
a) The supplier shall ensure backward compatibility of software with the existing diagnostic tool
used by Indian Railways. All the parameters, which are accessible with the existing diagnostic
tool, shall be accessible in the same way.
b) Any change in MICAS-S2 software for adaptation with IGBT Traction Converter shall require to be
pre-approved by CLW/RDSO. The changed software along with the source code and
comprehensive details of changes shall be submitted to CLW. The responsibility of change shall
be on supplier.
c) Indian Railway is installing new systems like Graphical DDU, Radio Remote Control and Remote
Diagnostic System on locomotives. Supplier shall provide full cooperation for adoptability of
these systems with their Traction Converter. The cooperation may include minor design changes
in Traction Converter, hardware modifications and software changes.
d) Supplier shall ensure complete interoperability of Traction Converter with GTO Auxiliary
Converter, Auxiliary Converter of other makes and VCUs. CLW/RDSO may specify some
requirement to ensure interoperability from time to time and such requirement shall be
complied by supplier.
e) The initialization time for GTO based Traction Converter is 6 sec. The initialization time for IGBT
based Traction Converter shall be kept between 20 sec to 25 sec.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 24 of 40
CHAPTER 3- CLIMATIC & ENVIRONMENTAL CONDITION

3.1 Temperature

Maximum temperature inside stabled Locomotive under sun : 75 deg. C

Maximum temperature inside working loco : 55 deg. C
(Temperature inside working locomotive may reach 60 deg. C)
Minimum temperature : -5 deg. C
The equipment shall be able to start up at the maximum specified temperature inside the locomotive
without any pre-cooling requirement.

3.2 Humidity: Upto 100% during rainy season.

3.3 Altitude: Upto 1776 m above mean sea level.

3.4 Rainfall: Very heavy in certain areas. The propulsion equipment shall be designed suitably.

3.5 Atmosphere during hot weather: Extremely dusty and desert terrain in certain areas. The dust
concentration in air may reach a high value of 1.6 mg/cub. In many iron ore and coalmine areas, the dust
concentration is very high affecting the filter and air ventilation system.

3.6. Coastal area: The equipment shall be designed to work in coastal area in humidity and salt laden and
corrosive atmosphere. The maximum values of the condition shall be as follows:
a) Maximum pH value : 8.5
b) Sulphate : 7 mg per litre
c) Max. concentration of chlorine : 6 mg per litre
d) Maximum conductivity : 130 micro siemens /CM

3.7 Vibration: The equipment shall be designed to withstand the vibrations and shock encountered in service
satisfactorily as specified in IEC 61287 and 60571 publication for the converter and electronic
equipments.

3.8 Electromagnetic Pollution – High degree of electromagnetic pollution is anticipated in locomotive

machine room, where the equipment shall be mounted. Necessary precaution shall be taken in this
regard.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 25 of 40
CHAPTER 4 - SCOPE OF SUPPLY

The following shall be scope of supplies.

SL Item Description Quantity

No. per locoset
1 IGBT based traction converter with its control system. 2 nos.
2 Hardware and software Interface with vehicle control Unit. 1 set
3 An unified Window based Diagnostic tool for downloading the software, viewing 01 no. per 5 loco sets
and changing the parameters, trouble shooting for IGBT as well as GTO based of converter or part
Traction Converter control system along with permanent user licence. thereof.
4 Active speed Sensor with tooth wheel ring, Cable & connectors, etc. 1 set
( Ref. Clause 2.3( xix) of chapter-2)
5 MCB in HB panels & Connectors in the converter side for 3-phase 415 V auxiliary 1 set
supply in the Traction Converter. (Ref. Clause 2.3( xxi) of chapter-2)
6 Deleted
7 Coolant used for the traction converter(Ref. Clause2.7 of chapter-2)
8 Software update along with the source code for the vehicle control if modification
is carried out.
9 Performance proving of the above equipment.
10 Installation Drawings, Maintenance, Operation and Repair manual in A4 size paper 01 set per locoset of
and in English language only (hard copy and soft copy both) converter.
11 Training on assembly, testing, commissioning, operation, maintenance and repair
to IR personnel (Ref. Clause 2.11 of chapter-2).
12 Training in software parameter settings, fault diagnostic and analysis (Ref. Clause
2.11 of chapter-2).
13 Special tools and jigs for maintenance. 01 set per 5 locosets
of converter or part
thereof.
14 Spares like all kinds of power supply modules, IGBT modules, gate driver units, 01 converter set per 5
complete electronic PCB cards for maintenance locosets of converter
or part thereof.
15 Pump for filing of coolant in the Converter. 1 no. per 5 loco sets of
converter or part
thereof.
16 Lifting jigs of traction converter 1 no. per 5 loco sets of
The lifting arrangement of the converter should be similar as in case of GTO converter or part
converter so as to have one tackler for lifting of converters. thereof.

If the firm is supplying the traction converter first time then the installation & commissioning shall be the
responsibility of the firm. The special tools, machines, instruments and other facilities, which are required for
installation and commissioning of the system and are not available in CLW, shall be supported by tenderer.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 26 of 40
CHAPTER 5 -TESTS & TRIALS

TYPE TEST:

5.1 Prototype tests shall be performed on one unit (manufactured as per design) to verify that the product t
meets the requirements specified and agreed upon between users & manufacturer. Series manufacture
shall commence only after successful prototype tests.

Type test shall be repeated in following cases.

 First time supply to IR.

 Modification of equipment, which is likely to affect its function.
 Failure or variations established during type or routine test.
 At the time of indigenisation, if the firm has supplied the product with foreign collaboration
originally.
5.2 The converter shall be tested in accordance with IEC 61287, (Including all optional tests) & the control
electronics shall be tested as per IEC 60571. (Including the following optional test –performance test (cl.
10.2.2), dry heat test (Cl. 10.2.4 to be done at 80 0 C), damp heat cyclic test (Cl 10.2.5), salt mist test (Cl.
10.2.10).
5.3 The list of tests to be carried out, as per IEC 61287, is as follows:

Sl. Clause no. Description Remarks

No
1. 4.5.3.2 Verification of Dimensions and Tolerances
2. 4.5.3.3 Weighing
3. 4.5.3.5 Cooling system performance tests
a
4. 4.5.3.5.3 Check of effectiveness of air filers X
5. 4.5.3.6 Tests of mechanical and electrical protection and measuring
equipment
a
6. 4.5.3.8 Test of the degree of protection X
7. 4.5.3.9 Communication Test
8. 4.5.3.10 Acoustic Noise Measurement
9. 4.5.3.11 Temperature Rise Test
10. 4.5.3.12 Power loss determination
11. 4.5.3.13 Supply over voltage and transient energy
a
12. 4.5.3.14 Sudden variation of load X
a
13. 4.5.3.17 Partial Discharge Test X
14. 4.5.3.18 Safety Requirements
15. 4.5.3.19 Vibration and Shock
16. 4.5.3.20 Electromagnetic compatibility
17. 4.5.3.21 Step change of line voltage test
18. 4.5.3.22 Short-time supply interruption test
a
19. 4.5.3.23 Current-sharing Test X
a
X = The execution of the test is subject to agreement between the manufacturer and the user.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 27 of 40
5.4 After fitment of the converter in the locomotive, the following type tests shall be performed in
accordance with IEC 61133:
Sl. Clause no. Description Remarks
No
A. Static Tests
1. 8.17 Traction system tests
2. 8.18.1 Operability and Maintainability
3.
B. Dynamic Tests
1. 9.2.1 Traction performance test
2. 9.4.1.6 Wheel slide protection
3. 9.4.1.8 Electrical braking test
4. 9.7 Speed regulation test
C. Other Tests
1. - Slip/slide (adhesion) test on dry track
2. - Slip/slide (adhesion) test on wet track
3. - Efficiency
4 - Verification of input power factor
5. - Reference and actual torque matching
6 - Temperature rise test

5.5 The prototype units shall be inspected & tested by the engineers of RDSO and CLW at the factory premises
or at mutually decided venue where all the facilities shall be made available for carrying out the prototype
test. The equipments shall be kept in field trials for a period of six months. The RDSO engineers shall
associate and witness the tests in the locomotive also till they are successfully completed. Any defects
noticed / design improvement found necessary as a result of the test / trial shall be carried out by the
tenderer in the least possible time. Serial production shall only start after successful trial run on loco and
clearance to this effect given by RDSO.

Routine Test:

5.6 Routine tests are to be carried out to verify that properties of the product correspond to those measured
during type tests. Routine test are to be carried out by the manufacturer on each equipment.
5.7 The converter shall be routine tested in accordance with IEC 61287, (Including all optional tests) & the
control electronics shall be tested as per IEC 60571. (Including the following optional test –dry heat test (Cl.
10.2.4 to be done at 80 deg. C), damp heat cyclic test (Cl 10.2.5).
5.8 The list of tests to be carried out is as(Test as per IEC 61287) follows:

Sl. No Clause no. Description Remarks

1. 4.5.3.1 Visual Inspection
2. 4.5.3.4 Marking Inspection
3. 4.5.3.5.4 Leakage Test
4. 4.5.3.6 Tests of mechanical and electrical protection and
measuring equipment
5. 4.5.3.7 Light Load Test

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 28 of 40
a
6. 4.5.3.15 Insulation Resistance Test X
7. 4.5.3.16 Dielectric Test
Xa = The execution of the test is subject to agreement between the manufacturer and the user.

Other points to be followed:

5.8 The suppliers shall submit complete test programme for type test to CLW & RDSO and routine test to
CLW before the test for its approval. Supplier shall carry out the test as per mutually agreed test
programme at his own cost.

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

5.10 Authorized representative of CLW may conduct surprise check on manufacturing process and quality
control along with any of the test to ensure quality of product and its conformance to specification.

5.11 INSTRUMENTATION –
(a) All the instruments used for testing shall be duly calibrated. The calibration certificates are to be
shown to inspecting authority on demand.
(b) Value of the fundamental component and THD of inverter output shall be measured by power
analyser during the prototype test at various mutually decided preset points in traction and braking
modes. True value of output voltage is also to be measured for record.
(c) Input power factor and the efficiency shall be measured using power analyzer at rated load.

5.12 Clarifications with respect to certain tests are given below:

(a) Visual inspection –The object of visual inspection is to check that the equipment is free from defects and
the equipment are as per approved drawing. Bill of materials shall be submitted. The make, rating of
equipments, subassemblies shall be checked with the details as per approved design document. If a
change is needed in make or in rating of important equipments, sub-assemblies, it shall be intimated and
shall have the approval of RDSO. All the important dimensions shall be measured and shall be in
permissible tolerance.

(b) Power loss determination test – This test shall be done at voltage corresponding to 22 .5 kV in OHE. The
efficiency shall be measured at full and 80 % of load.

(c) Earth fault - Simulate the earth fault by connecting a suitable resistor between cubicle frame and output
phases. The Power Converter shall not trip and earth fault indication shall be in “OFF” state till the
leakage current is less than limit approved as part of design proposal submitted by the tenderer.

(d) Burn in test -- The cards used on the equipment shall be subjected to burn-in 80 hours as per the
temperature cycle in Appendix - 5. The cards shall be kept energized during the test. Functional test of

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 29 of 40
each card shall be carried out after the burn in test. (Pl. refer Clause 10.2.13 of IEC 60571). This shall be
part of internal test by manufacturer, whose results shall be submitted during routine test.

(e) Cooling test – The purpose of this test is to verify that the cooling of various components / assemblies.
The parameters for measurement to check efficacy of cooling system shall be decided based on scheme
proposed as part of design proposal.

(f) Insulation resistance and Dielectric test -- The insulation resistance with 1000 V megger shall not be less
than 100 M ohms at 70 % RH for all the circuits. The dielectric test shall be carried out after shorting
semiconductor device, pulse transformer earthed, earthed special cards, if necessary before applying
dielectric voltage. The level of dielectric voltage shall be as per IEC 61287.

(g) Temperature rise test – Itshould be conducted as per IEC 61133 after the fitment of the Traction
converter in the Locomotives. The temperature rise shall be recorded by temperature detectors
mounted at the specified reference points on the body of semiconductors, capacitors, and other
components as agreed between purchaser and manufacturer. The maximum recorded temperature
under worst conditions shall be corrected for 55 degree C and compared with maximum permissible
temperature. (for power devices at junction). The thermal margin available shall be compared with the
safety margin declared by the manufacturer. The temperature of the power devices shall have a margin
of minimum 10 degree C.

h) Damp heat test – Function test of each card shall be carried out after the damp heat test.

5.13 Signalling and Interference tests:-

Tests to determine the levels of interference with the traction power supply and Signal and
Telecommunication equipments and facilities to prove that these are within acceptable limits.
(Reference to chapter-2, clause 2.5)

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 30 of 40

CHAPTER -6 (APPENDICES)
APPENDIX – 1
DETAILS OF TRACTION TRANSFORMER
(NOT IN THE SCOPE OF SUPPLY)

SN Parameter Value
1 Type LOT-6500 / LOT 7500
2 Original Design Secheron SA
3 Windings
Traction 4
Auxiliary 1
Filter 1
Hotel Load 2
4 Frequency (f nom) 50 Hz
5 Primary Voltage
Maximum 30.0 kV
Nominal 25.0 kV
Minimum 17.5 kV
6 Voltage Ratings (at 25.0 kV Catenary)
Traction 1269V
Auxiliary 1000V
Filter 1154V
Hotel Load* 960 V
7 Current Ratings
HT 261.25 A/311A
Traction 4 x 1142 A
Auxiliary 334 A
Filter 347 A
Hotel Load* 2 x 648 A
8 Thermal Ratings
Primary 6531 kVA/7775 kVA
Traction 4 x 1449 kVA
Filter 400 kVA
Hotel Load* 2 x 622.5 kVA
9 Winding Data
Traction 37.0 mΩ, 2.1 mH + 15%
Auxiliary 60.0 mΩ, 0.43 mH
Filter 19.0 mΩ, 0.29 mH
Hotel Load* 11.0 mΩ, 0.65 mH

* Hotel Load winding is available only in LOT 7500

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 31 of 40

APPENDIX – 2

SALIENT DATA OF LOCOMOTIVES

SN Characteristics Unit WAP-5 WAP-7 WAG-9 WAG-9H
1 Guaranteed performance at 22.5 kV and half-worn wheels
1.1 Max. service speed Kmph 160 140 100 90
1.2 Cont. rated speed kmph 50 70 50 50
1.3 Starting tractive effort kN 258 322 460 510
1.4 Cont. rated Tractive KN 220 228 325 325
Effort (0-50 kmph) (0-71 kmph) (0-50 kmph) (0-50 kmph)
1.5 Cont. rated power at KW 4000 4500 4500 4500
wheel rim (80-160 kmph) (71-140 kmph) (50-100 kmph) (50-100 kmph)
1.6 Max. regenerative KN 160 182 260 260
braking effort (10-90 kmph) (10-89 kmph) (10-62 kmph) (10-62 kmph)
2 Axle Arrangement - Bo-Bo Co-Co Co-Co Co-Co
3 Gear Ratio 3.941 3.6 5.1 5.1
4 Traction Motor type - 6FXA 7059 6FRA 6068 6FRA 6068 6FRA 6068
5 No. of Traction Motors - 4 6 6 6

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 32 of 40

APPENDIX-3

CHARACTERISTICS OF TRACTION MOTORS

SN Characteristics Unit 6FXA 7059 6FRA 6068

1 Continuous Rating
1.1 Shaft output kW 1150 850
1.2 Nominal voltage V 2180 2180
1.3 Current A 370 270
1.4 Speed rpm 1585 1283
1.5 Torque Nm 6930 6330
1.6 Frequency Hz 80 65
1.7 Power Factor - 0.86 0.88
2 One Hour Rating
2.1 Shaft output kW 1150 850
2.2 Nominal voltage V 2044 2089
2.3 Current A 396 290
2.4 Speed rpm 1485 1135
2.5 Torque Nm 7420 7140
2.6 Frequency Hz 75 57.5
2.7 Power Factor - 0.86 0.86
3 Short Time Overload Rating
3.1 Shaft output kW 1150 850
3.2 Nominal voltage V 1540 1660
3.3 Current A 540 370
3.4 Speed rpm 1107 892
3.5 Torque Nm 9920 9100
3.6 Frequency Hz 56.5 45.7
3.7 Power Factor - 0.85 0.86
4 Max. speed rpm 3174 2584
5 Temperature sensor 2 Pt. 100 resistance elements installed in stator tooth.
6 Speed sensor Wiegand transmitter system with transmitter ring for 120
pulses per rotor revolution.

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 33 of 40

APPENDIX-4

CHARACTERISTICS OF VCB

SN Parameter Value
1 Type Single bottle
2 Original Design Secheron, Alstom
3 Number of Poles Single
4 Control System Electro-pneumatic
5 Rated operational voltage (Ue) 27.5 kV
6 Nominal voltage (Un) 25 kV
7 Dielectric test voltage 75 kV
8 Rated impulse withstand voltage (Uimp) 175 kV
9 Conventional free air thermal current (lth) 1000A
10 Rated frequency 50/60 Hz
11 Rated breaking capacity 16 kA
12 Opening time 30 to 60 milli-sec
13 Auxiliary voltage 110 V DC
14 Number of auxiliary contacts 4+4
15 Air Supply Pressure 4.5 – 10 bar
16 Approximate weight 140 Kg (Approximately)

….

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 34 of 40

APPENDIX – 5

BURN-IN TEST
Tem perature
in Degrees Temperature Cycle
+700C

0
+25 C

00C

-250C
1.4 2.1 5.2 5.5 9.1 9.4 12.5 13.2 15
Time (Hrs)
0.1=10 Min
1.55 5.27 5.42 9,17 9.32 12.57 13.12 14.41

On
Off

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 35 of 40

APPENDIX – 6

Drawing of the Active speed sensor

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 36 of 40
APPENDIX – 6

Isometric View of Speed Sensor

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 37 of 40

APPENDIX – 7
Drawing of the tooth wheel ring

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 38 of 40

Appedix-8

Foot print of IGBT based traction Converter:

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 39 of 40

Appedix-8
Drawing of IGBT based traction Converter

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II
 Page 40 of 40

Drawing of IGBT based traction Converter

APPENDIX – 8

PREP.BY. CHECKED .BY

SPECIFICATION SSE/D&D AEE/D&D
FOR
IGBT BASED CENTRE FOR DESIGN & DEVELOPMENT
TRACTION CHITTARANJAN LOCOMOTIVE WORKS
CONVERTER WEST BENGAL, INDIA
FOR NO: CLW/ES/3/ IGBT/0486
3-PHASE LOCO ALT A B C
APPROVED BY
DY. CEE/CON/TU-II