IRS S 93-96 with Amd.1 VALVE REGULATED (SEALED)
Contents
1. 0 10 35 10 60 Page 40 of 41 IRS S 93 96 with Amd 1 Table IV System Float charge Protections Ripple Voltage voltage voltage Over Under Current limit RMS regulatio setting voltage voltage in rated n cut off trip capacity 12 13 5 14 22 9 6 20 2 1 24 27 0 28 44 19 2 20 2 1 60 67 5 71 1 48 0 20 2 1 110 121 5 127 98 86 4 20 2 1 Page 41 of 412. A 10 11 A 10 11 1 A 11 1 1 A 11 1 2 IRS S 93 96 with Amd 1 Ampere hour and watt hour efficiency tests The test shall be carried out as per Cl 12 9 of IS 1651 91 and the AH efficiency shall not be less than 90 and the watt hour efficiency shall not be less than 75 The end point voltage shall be as per Cl 10 4 1 i Test for Voltage during discharge The test shall be carried out as per Cl 12 10 of IS 1651 91 and the samples shall meet the requirements brought out in Cl 12 10 1 of IS 1651 91 Test for Endurance under short circuit conditions This test has to be carried on a minimum of 2 units The capacity of each of the 2 units shall be determined as per Cl 10 4 Recharging shall be done at the manufacturer s recommended rate A short circuit load of 1 8 0 3 m ohm shall be applied to each of the unit for one minute duration The units shall be cooled down and recharged as per manufacturer s instructions Their capacities shall be determined as per Cl 10 4 The capacities measured after the short circuit test shall not be less than 90 of the unit s C19 capacity Test for gas recombination efficiency Gas recombination efficiency is calculated using the fully charged battery after it had finished the 10 hour rate capacity test with the following test conditions Charge The battery for test is charged continuously for 96 hours at a constant current of 0 01 Cio A provided however that the said rechargin
3. apply PART A SCOPE A 1 1 This standard specifies rated AH capacity performance requirements and tests for batteries of valve regulated sealed lead acid type with immobilized electrolyte and chargers for the same Page 1 of 41 IRS S 93 96 with Amd 1 A1 2 The specification covers batteries up to 500AH capacity and is applicable for Monoblock batteries in sizes of 4 6 amp 12 Volts Individual cells of 2V housed in metal trays for ease of stacking Note 1 The VRLA batteries cells shall be charged at a CONSTANT VOLTAGE OF 2 25V PER CELL AS RECOMMENDED BY THE MANUFACTURER WITH CHARGING CURRENT LIMITED TO 1 5 OF THE RATED CAPACITY IN AMPS The battery chargers of voltage and current ratings corresponding to various AH capacities are to be procured as per Part B of this specification The effect of temperature effect on capacity due to storage for long duration determination of state of charge of VRLA batteries installation amp maintenance instruction and other important information about these batteries is brought out in Annexure enclosed to this specification This Annexure however does not form part of this specification A 2 RATING AND DESIGNATION A 2 1 The rating assigned to the cell shall be the capacity expressed in Ampere hours after correction to 27 deg C stated by the manufacturer to be obtainable when the cell is discharged at 10 hour rate c10 a final voltage of 1 75 V A 2 2 DESIGN
4. 105 min If resonance 10 min at each resonant 10 min at each resonant is observed freq freq Condition After this test electrical parameters shall be monitored in addition to physical checks as per Cl 8 11 PACKING AND LABELLING Charger units complete shall be packed in suitable boxes crates strong enough without additional packing to prevent damage or loss to the unit during transit Loose space inside the box crate shall be filled up with suitable packing material It is desirable that the Fragile components such as meters and P C cards are individually packed to prevent damage Page 31 of 41 IRS S 93 96 with Amd 1 B 9 3 Each box shall be legibly marked at one end with code numbers contents quantity and name of manufacturer supplier B 10 INFORMATION TO BE SUPPLIED BY THE PURCHASER a Nominal input voltage b Nominal output voltage and rated output current CI 1 4 c Drawings Dimensions and layout if desired Cl 3 1 d Type of mounting required shelf mounting of floor mounting Cl 3 2 e Whether the charger is being procured for signalling or Telecom or Axle counter installation Cl 5 4 1 amp 5 4 2 kkkkkkkkkkkkk Page 32 of 41 IRS S 93 96 with Amd 1 ANNEXURE GENERAL INFORMATION ABOUT VRLA BATTERIES Effect of Temperature on VRLA batteries The lead acid batteries both conventional as well as VRLA batteries are normally designed to give the full rated capacity and the expected life
5. at the operating temperature of 27 deg C When the operating temperature is higher than 27 deg C the positive grid corrosion rate increases This is due to ARRHENIUS principle which states that the rate of chemical reactions doubles for every 10 degC rise in ambient temperature Thus the effect of temperature is same on both the conventional as well as VRLA batteries But the effect of increased temperature is more pronounced on VRLA batteries because of less volume of electrolyte available and also because there is no addition of electrolyte during the usage of the battery It is said that the life of VRLA batteries gets reduced by 50 for every 10 deg C rise in ambient temperature For example if designed life for a particular VRLA battery is 10 years at 27 deg C it becomes 5 years at 37 deg C The relationship between ambient temperature and life is given in figure 2 Effect on Capacity when stored for long duration A fully charged battery looses capacity when stored This process of capacity loss is called as self discharge The various parameters that effect the self discharge are the Lead alloys used for positive and negative grids the purity of raw materials used in the manufacturing process the processing techniques employed and the storage conditions at the site Considering the above the capacity loss for VRLA batteries is around 1 per week Further depending on the temperature at which these batteries are stored the loss of c
6. carried out without connecting batteries Over and under Voltage protection a DC over voltage protection In case output DC voltage exceeds 2 37V cell the over voltage protection shall operate amp shut off the charger output which can be restored through reset push button b DC under voltage Red LED indication shall appear with audible alarm re settable when no charger output voltage is available although AC supply is available At 1 9V cell red indication Run DG set shall appear with audible alarm non resettable type This indication shall appear in float boost mode of working The potential free contact shall be provided on the front panel of the charger cabinet to allow easy access for its use at site The alarm indications shall remain lit until the AC supply is restored Alarm indication shall work even if mains fail Page 22 of 41 B 6 B 6 1 B 6 2 B 6 3 B 6 4 B 6 5 B 6 6 B 6 7 B 6 8 IRS S 93 96 with Amd 1 Marking The marking indications labels shall not be affected ruing climatic tests All marking indications shall be easily legible and durable Where the marking is by use of labels the labels shall be metallic or screen printed These shall be firmly stuck and shall not be capable of being removed by hand easily Durability of a marking shall be checked by rubbing the marking by hand for 15 Sec with a piece of cloth soaked with petroleum spirit This requirement shall also be met a
7. generated ml per 1 AH at 25 deg C 101 3 kPa 1013 mbar Page 11 of 41 IRS S 93 96 with Amd 1 A 12 Information to be supplied by the purchaser i Nominal voltage ii Capacity in AH at the 10 hour rate iii Mono block type or stackable single cell type iv No of cells per battery for stackable cells v Cell Battery designation in accordance with the standard vi Accessories and spares required if any Table Il Capacities and final cell voltages at various rates of discharge at 27 deg C Rate of discharge Capacity expressed as of C 10 End cell voltage capacity rating C 1 50 0 1 67 C 2 63 3 1 67 C 3 71 7 1 70 C 4 78 2 1 74 C 5 83 3 1 74 C 10 100 0 1 75 kkkkkkkkkkkkkkkkk Page 12 of 41 B 1 B 1 1 B1 2 B 14 IRS S 93 96 with Amd 1 Part B CHARGER FOR VALVE REGULATED SEALED LEAD ACID STATIONARY BATTERY Scope This specification lays down the requirements and tests for battery chargers for use in Railway S amp T installations for charging of Valve Regulated sealed Lead acid stationary Secondary cells batteries The battery chargers covered in this specification are self regulating type capable of giving constant output voltage for the full input range of 160 270V AC and load current varying from 10 to 100 with temperature compensation Whenever the AC input voltage goes below 155V or above 275 the AC supply to the charger is disconnected and
8. mounting type as specified by the purchaser The charger shall be of robust construction They shall be housed in shelf supporting cubicles made of cold rolled close annealed mild steel sheet of thickness not less than 1 6 mm The cubicles shall be adequately ventilated Ventilating openings shall be less than 3 mm size for protection against entry of lizards etc The cubicles shall conform to IP 31 type of protection as specified in table of specification no IS 2147 1962 The charger cubicles shall be treated with zinc chromate primer followed by electrostatic epoxy powder coating paint finish passivation shall be done through seven stage process Small metal parts such as nuts bolts ad washers shall be either galvanised or chrome plated All other metal parts of the charger shall be plated for prot3ection against corrosion The layout of the components and wiring shall be such that all parts are easily accessible for inspection repairs and replacement The AC input portion shall be clearly isolated and protected to prevent accidental contact All cables and wires used for wiring shall conform to specification No IRS S 76 92 and shall be procured from RDSO approved suppliers The cables and wires used shall be neatly secured in position by bunching and strapping Aluminium wires shall not be used The gauge of wiring shall be such that the current density does not exceed 3 Amps mm The colour scheme used for wiring shall conform to n
9. of procurement of components shall be given Transformer and chokes The main transformer shall be double wound and shall conform to category 3 Cl 3 1 of IS 6297 Pt Il 1973 Class B or higher grade insulating material shall be used The transformers and chokes shall be vacuum impregnated When tested in accordance with cl 6 2 1 6 of IS 6297 Pt Il 71 the main transformer shall show an insulation resistance of not less than 1000 Meg ohms This value shall not fall below 500 Meg ohms at the end of climatic tests as per cl 8 13 The maximum permissible rise in temperature above ambient shall be 65 deg C for transformers and chokes The gauge of winding copper wire shall be such that the current density does not exceed 2Amp sq mm Rectifying elements The charges shall use silicon diodes and or silicon controlled rectifier bipolar transistors MOSFETs for rectification The rectifier cells and stacks shall comply with IS 3895 66 They shall be suitably protected against surges The rectifier stacks shall be connected for full wave rectification The stacks shall be of robust construction and of adequate rating The Page 15 of 41 B 4 2 3 B 4 2 4 B 4 2 5 B 4 3 B 4 3 1 B 4 3 2 B 4 3 3 B 4 3 4 B 4 3 5 B 4 3 6 IRS S 93 96 with Amd 1 temperature rise above ambient shall not exceed 50 deg C or 20 deg C less than that specified by the manufacturer which ever is less The current rating of po
10. standard sizes of Mono block construction 4V up to 300AH capacity 6V up to 200AH capacity 12V up to 120AH capacity as and required by the purchaser Stackable single cells 2V cells of capacities 20 40 80 100 120 200 300 400 500 AH The cells shall be housed in metal trays to facilitate stacking to form the required battery bank 20 40 amp 80AH cells should also be individually for track circuit applications if required by the purchaser Containers The container shall be made in a suitable flame retardant plastic material and be so designed as to minimize flexing of surfaces under internal operating pressures The containers shall be enclosed in epoxy coated steel trays The steel trays shall be so designed as to make both vertical and horizontal stacking of cells batteries possible The container lid material shall be resistant to sulphuric acid Lids Covers The Lid cover shall be made in a suitable flame retarding plastic material compatible with the container material and shall be welded to the container by heat sealing or any other suitable technique Page 3 of 41 A 3 4 A 3 4 1 A 3 4 2 A 3 5 A 3 5 1 A 3 5 2 A 3 6 A 3 7 IRS S 93 96 with Amd 1 The complete container along with lid cover shall be able to withstand without fracture for 5 hours at 25 deg C an internal pressure of 5 times the normal operating pressure declared by the manufacturer The complete design includes the pillar to li
11. ATION The cell shall be designated by symbols given below arranged in the following sequence Type of positive AH rating of cells as Type of container as in VRLA plate as in Cl 2 2 1 in Cl 2 2 2 Cl 2 2 3 NOTES 1 A 2 2 1 A 2 2 2 The plates are not replaced in this type of construction therefore this designation does not include the number of positive plates and The designation of partially plated cells is not being standardized because partial plating of cells in this type of construction is not done The positive plate shall be designated by the letter F or T to indicate Flat tubular type The capacity rating shall be indicated by a number equal to the capacity in Page 2 of 41 A 2 2 3 A 3 A3 1 A 3 1 1 A 3 1 2 A 3 2 A 3 2 1 A 3 2 2 A 3 2 3 A 3 3 IRS S 93 96 with Amd 1 The material of the container shall be designated by the letter P indicative of plastic container The material of the container shall be Polypropylene copolymer or similar material of equivalent low permeability to water vapour P Plastics Example F 400 P VRLA designates a Valve Regulated Lead acid cell Battery having flat pasted positive plates and a capacity of 400AH at 10 hour rate in plastic container Polypropylene Copolymer 9PPCP shall be denoted bythe letter P only CONSTRUCTIONAL REQUIREMENTS The maintenance free valve regulated lead acid batteries shall be made in
12. Amd 1 Burning in After mounting of components the populated PCB cards kept in proper chassis in energized condition shall be burnt in for 168 hours at 60 deg C The distribution of the power supply on the cards should be such that different voltage tracks 0 5V etc follow the same route as far as possible The track of power supplies should be as thick and wide as possible Meters Each charger shall be provided with a DC ammeter to indicate the total current delivered by the charger The ammeter shall be of the moving coil type mounted flush with the casing on the front panel The range of the ammeter scale shall be 125 to 150 of the rated output current of the charger The rated output current of the charger shall be indicated on the meter scale by a distinct green marking An arrangement shall be provided so that it may possible to read on ammeter either the total current of the charger or current drawn by the battery set Each charger shall be provided with a DC Voltmeter to indicate the output voltage of the charger The Voltmeter shall be of the moving coil type mounted flush with the casing on the front panel The range of the Voltmeter scale shall be 150 to 175 of the nominal output voltage of the charger The limits of voltage in float mode of working as specified in Cl 5 6 1 shall be indicated on the meter scale by a green band The meters shall conform to Cl 1 1 1 c of IS 2419 and shall be of accuracy class 1 5 or bet
13. IRS S 93 96 with Amd 1 GOVERNMENT OF INDIA MINISTRY OF RAILWAYS Railway Board INDIAN RAILWAY STANDARD SPECIFICATION FOR VALVE REGULATED SEALED LEAD ACID STATIONARY BATTERY amp CHARGER 0 1 0 2 0 3 0 4 0 5 A 1 FOR RAILWAY S amp T INSTALATIONS FOREWORD This specification is issued under the fixed serial No S 93 followed by the year of original adoption as standard or in the case of revision the year of last revision This specification requires reference to the following standards IS 1885 Pt VIII 1986 Electro technical vocabulary Part VII Secondary Cells and Batteries IS 1651 91 Stationary cells and batteries Lead acid type IS 266 77 Sulphuric acid IRS S 23 Electrical Signalling amp Interlocking Equipment BS 6290 Pt IV 1987 British standard specification for Lead acid valve regulated sealed type batteries IRS S 86 92 Battery chargers for S amp T equipment Whenever in this specification any of the above mentioned specifications are referred by number only without mentioning the year of issue the latest issue of that specification is implied otherwise the particular issue referred to is meant This specification is intended chiefly to cover the technical provisions and does not include all the necessary requirements of the contract For the purpose of this specification the terminology given in IRS S 23 whenever applicable IS 1885 Part VIII 1986 and IRS S 86 92 shall
14. MENTS All the cells batteries shall be designed for continuous full load operation under i Temperature from 0 to 55 deg C under dry heat conditions ii Relative humidity up to 95 with temperature going up to 40 deg C The batteries shall be non spillable and shall be capable of being used in any position The design of the battery shall be such that the generation of gas due to chemical reaction is effectively controlled and allows recombination within the battery of over 99 of the gas generated during the normal usage The efficiency of the recombination shall be tested Valve The valve referred in CI 3 6 shall be so designed that it operates at the pressure between 2 psi to 9 psi to release the excess gas and re seal automatically as soon as the gas pressure within the cell drops to atmospheric value All the cells shall be subjected to pressure test up to 10 psi The self discharge rate at room temperature shall not be more than 5 of the rated capacity per month Page 6 of 41 A 10 A 10 1 A 10 1 1 A 10 1 2 A 10 1 3 IRS S 93 96 with Amd 1 Tests Classification of tests Type tests The following shall constitute type test and shall be carried out in the given sequence a Verification of constructional requirements b Verification of marking and packing c Verification of dimensions d Test for capacity e Test for charge retention f Endurance test g Ampere hour and watt hour efficiency t
15. Nominal input voltage 230V b 270V c 160V Boost working Set the charger to boost mode of working by means of the selector switch mentioned in Cl 4 5 2 Set the voltage to 2 3V cell using boost pot and record readings for line and load variations Line voltages of 160V 230V and 270V and load variations from 25 50 75 and 100 The charger shall fulfil the requirements of no load current power factor efficiency ripple voltage voltage stability under float mode of working and Page 28 of 41 B 8 11 4 B 8 12 B8 12 1 B 8 12 2 B 8 12 3 B 13 B 13 1 IRS S 93 96 with Amd 1 current voltage stability under boost mode of working as given in different clauses of this specification The charger may also be tested by actually connecting it to a set of batteries TEST FOR PROTECTIVE DEVICES Overload Short circuit During this all fuses of the charger shall be short circuited Charger shall be connected AC input voltage of 270V Output terminals shall be short circuited through a suitable arrangement Steady short circuit current shall be measured It should not exceed rated current 10 There shall not be any damage to charger Working of overload short circuit Indication alarms will also be checked This shall be achieved by controlling output current and voltage under short circuit condition and not by switching off under short circuit condition and not by switching off the input output voltage under short circuit
16. PC AT 27 DEG C Modern constant voltage output charging equipment is recommended for the floating charger method of operation of batteries This type of charger properly adjusted to the recommended float and boost voltages Ref Annexure A and following recommended surveillance procedures will assist in obtaining consistent serviceability and optimum life The charging current for the battery should be limited to 20 of its nominal AH capacity After the battery has been given its freshening charge the charger should be adjusted to provide the recommended float voltage at the battery terminals Page 36 of 41 IRS S 93 96 with Amd 1 Do not use float voltage lower or higher than those recommended This will result in reduced capacity and or reduced battery life Check and record battery terminal voltage montly If normal battery float voltage is above or below the recommended value adjust charger to provide proper voltage as measured at the battery terminals Important It is preferable to have the following characteristics in the battery charger being used with these batteries h High Voltage cur off at 2 37 VPC i Low voltage trip at 1 60 VPC j Voltage ripple to be limited to 2 rms k Voltage regulation to be limited to 1 I Battery charging current shall be limited to a maximum of 20 of the 10 hour rated battery capacity in Amps Page 37 of 41 Table IRS S 93 96 with Amd 1 State of charge Open C
17. S S 93 96 with Amd 1 Current control In the float mode the charger shall be able to give current as required by the batteries cells when the voltage is fixed at 2 25V per cell The current however shall not exceed the value set by current control potentiometer Cl 4 5 3 The overall watt efficiency shall not be less than 70 for chargers of 500 watts or more rated output power amp 65 for chargers of less than 500 watts rated output power in all modes of working For chargers of 12V current up to 40A the overall watt efficiency shall not be less than 60 The power factor shall not be worse than 0 7 lagging in all modes of working a input AC terminals at full load without connecting PF correcting capacitors The no load current of the charger shall not be more than 10 of the rated input current under float mode with input voltage variation as specified in Clause 5 1 In case of AC mains failure the reverse leakage current from the battery through the chargers shall not exceed 50mA The measurement shall be taken after disconnecting the meter on the output side The charger should have soft start feature whereby on energisation the output voltage should build up slowly in approximately 10 seconds eliminating all starting surges The charger should have good transient response For a 25 to 75 change in load the undershoot overshoot in output should come down within 10 of the output voltage within 250 mS This test will be
18. apacity due to self discharge varies The self discharge rate doubles for every 10 deg C rise in temperature resulting in loss of capacity In order to get optimum performance from thee batteries the following course of action may be resorted to i Always store the batteries in covered area away from direct sunlight rain storm dust etc ii As far as possible store the batteries at temperatures of 25 deg C to 32 deg C in a clean and dry location iii VRLA batteries when stored for long duration i e between the date of shipment and date of installation a freshening charge should be given once very six months If the above procedure is followed the effect on capacity when stored forlong duration is negligible However the period for giving freshening charge get a shortened if these batteries are stored at elevated temperatures The table below gives the storage interval at various elevated temperatures before which a freshening charge is to be given Page 33 of 41 IRS S 93 96 with Amd 1 S No Temperature in Deg C Storage interval in months 1 2 6 0 2 37 4 5 3 42 3 0 4 47 2 25 5 52 1 5 Determination of state of charge of VRLA batteries In conventional flooded batteries the specific gravity of the electrolyte gives a fairly good indication of the state of charge of the battery However in a VRLA battery it is not possible to measure the specific gravity of the electrolyte since it is compl
19. automatically reconnected whenever AC supply is restored in the range 155 275V The nominal output voltage and the rated output current of the charger are required to be specified by the purchaser Note No 1 Recommended current limit for chargers of some of the standard capacity secondary cells in use on Railways are given below SN Cell cap C 10 Rate Recommended current Max permissible Amps Hrs rating of charger load Amps 1 20 2 4 2 2 40 4 8 4 3 80 8 16 8 4 120 12 24 12 5 200 20 40 20 6 300 30 60 30 7 400 40 80 40 8 500 50 100 50 Note No 2 The current ratings of 5 10 15 20 25 30 50 60 75 80 amp 100 and nominal voltage ratings of 12 24 36 48 60 110 amp 220 volts are recommended for adoption by Railways This will help in standardizing the equipment and ultimately in testing and Maintenance Page 13 of 41 B 2 B 3 B 3 1 B 3 2 B 3 3 B 3 4 B 3 5 B 3 6 B 3 7 B 3 8 B 3 9 IRS S 93 96 with Amd 1 Terminology For the purpose of this specification the terminology given in IRS S 23 amp IRS S 86 92 shall apply Construction The chargers shall conform to drawings dimensions and layout if any specified by the purchaser The chargers shall be of natural air cooled type and shall be suitable for indoor use in the cabins where the maximum ambient temperature may reach 55 deg C The chargers shall be of shelf or floor
20. condition Reverse Battery connection A fully charged battery shall be connected in reverse polarity to output terminals of charger There shall be no emission of smoke or undue temperature rise of any component of charger Working of corresponding indication alarm will also be checked All the protection alarms shall be within tolerance of 0 02V cell for voltage and 1 in case of current CLIMATIC TESTS The climatic tests shall consists of i Change in temperature test IS 9000 Part XIV Section II Low temperature 5 C 3 C High temperature 70 C 2 C Rate of change in temp 1 C min Duration 3 hrs at each temp 5 C amp 70 C Cycle 3 Condition Fully functional during test ii Dry Heat Test Dry heat test as per IS 9000 Part III Section III Temperature 70 C Duration 16 hrs Condition Fully functional during test Page 29 of 41 IRS S 93 96 with Amd 1 iii Cold Test IS 9000 Part II Section III Temperature 5 C 3 C Duration 2 hrs Condition Fully functional during test iv Damp Heat test Cyclic As per IS 9000 Part V Section amp II Upper temperature 40 C 2 C Humidity 95 max Cycles 6 Condition Fully functional during one hour period towards end of each cycle v Damp Heat Steady state Storage as per IS 9000 Part IV Temperature 40 C 2 C Humidity 93 2 3 C
21. d seal which shall be designed to remain gas tight and electrolyte tight during the designed life of the battery Pillar seal Assembly The pillar to lid seal shall be designed to remain gas tight and electrolyte tight during the designed life of the unit The terminals shall conform to clause 3 2 of BS 6290 Part 4 of 1987 Separators The separators used shall be porous to electrolyte but electrically insulating Sufficient separator overlap to the edges of the plates shall be provided to prevent short circuits forming between the edges of adjacent plates These shall be either made of glass or synthetic material having high acid absorption capabilities and shall be resistant to sulphuric acid Separators shall meet the following requirement The uncompressed water absorption of the separator shall be atleast 5 gm of water gm of separator material Requirement of wicking test on separators a The total wicking height shall not be less than 25 inches in 24 hours b The minimum water content at 5 inches height shall be atleast 5 grams of water per gram of separator c The weight of water per gram shall be at least 90 of the value at 5 inches when checked at a height of 18 inches Valve The valve shall operate at the specified pressure and tolerance limits The valve shall not allow ingress of air into the unit The vent plug used shall be explosion resistant and self re sealing and pressure regulating type Vent plug shall be
22. est h Test for voltage during discharge i Test for endurance under short circuit conditions j Test for gas recombination efficiency For conducting type tests eight units shall be taken Dimensional checks verification of constructional requirements and capacity test shall be done for all the units Remaining tests shall be done as per the following table Test Samples Numbers 1 2 3 4 5 6 7 8 a Test for capacity X X X X xX X xX xX b Voltage during discharge X X 4 c AH amp WH efficiency test X X 4 d Test for charge retention X XxX 4 e Endurance test X XI 4 f Endurance under short circuit X X g Test for gas recombination efficiency X If any of the samples fails in the relevant type test testing authority may call for fresh samples not exceeding twice the original number and subject them again to all tests or test in which the failure has occurred as agreed between the manufacturer and the buyer If there is any failure in any of the re test the type shall be considered as not having passed the requirements of this standard All tests shall be carried out at an ambient temperature of 27 deg C 5 deg C At the time of initial type test the manufacturer shall submit authenticated test results of the specified minimum charge discharge cyc
23. etely absorbed in the spun glass microporous separator and the battery is sealed The terminal voltage of the battery is directly related to the concentration of the electrolyte Therefore if one were to measure the open circuit voltage of the battery the state of charge can be determined The open circuit voltage OCV readings should be taken after 24 hours of discontinuing charging The OCV value is co related to the stage of charge of VRLA batteries as per table I Sometimes it may not be possible to disconnect the batteries from service for 24 hours and then check the OCVs Then the pattern of charging current delivered by a temperature compensated voltage regulated charger after a discharge provides the alternate method for determining the full state of charge The temperature compensation factor is 3 mv per cell deg C rise above the ambient temperature 27 deg C Under normal conditions the batteries are floated at around 2 25V per cell i e ina 24V system 12 cells are floated at 27 V During charging as the cells approach full charge the battery voltage rise to approach the charger output voltage i e 27V and the charging current decreases to the float current value of around 50mA 100 AH for VRLA batteries So when the charging current has stabilized at the float current for three consecutive hours or the voltage across the battery bank terminals is constant for six consecutive hours the battery bank can be considered as having reac
24. f PCB cards and motherboard shall be as per currently available technology There should be no deformity in the PCB cards or the motherboard due to mounting of heavy components or due to ageing effect Track Width The track width shall be 0 5mm nominal In no case it should be less than 0 3mm Lesser width for use of SMD technology may be considered Spacing between tracks Spacing between tracks shall be 0 5mm nominal and in no case it shall be less than 0 3mm Lesser width for use of SMD technology may be considered The PCB shall be specifically designed to suit the circuitry used and no extra wires or jumpers shall be used for interconnection of components on the PCB The components shall be soldered with wave soldering machine shall have specific approval of RDSO Lucknow Page 16 of 41 B 4 3 7 B 4 3 8 B 4 3 9 B 4 3 10 B 4 3 11 B 4 3 12 B 4 3 13 IRS S 93 96 with Amd 1 The cards shall be provided with testing points and the corresponding voltages waveforms shall be indicated in the fault diagnostic procedure and service manual to facilitate testing and fault tracing Conformal coatings Assembled amp tested PCB should be given a conformal coating to enable them for functioning under adverse environmental conditions The coating material should be properly chosen to protect the assembly from the following hazards Humidity Dust and dirt Airborne contaminants like smoke and chemical vapours Conducting par
25. fter completion of climatic tests All marking indications shall be placed in the vicinity of the components to which they refer and shall not be placed on removable parts if these parts can be replaced in such a way that the marking indications can become misleading The words INDIAN RAILWAY PROPERTY shall be indelibly etched engraved on the charger at a conspicuous position the size of letter shall be chosen depending upon the size of the charger cubicle but shall not be less than 20 mm high in any case Each charger shall be provided with a rating plate fixed outside at a conspicuous position The rating plate shall be clearly and indelibly etched engraved or anodized and shall show the following information a Name or trade mark of manufacturer b IRS number c Nominal Ac input voltage and frequency d Nominal DC output current e Nominal DC output voltage f Serial number amp year of manufacture g Installation for which meant i e signal Telecom Axle counter SS The AC line terminal shall be indicated by the letter L and neutral terminal by the letter N Earth terminal may be indicated either by letter E or by symbol The designation of the components mounted on the front panel and their operating positions shall be indicated by engraved metal or plastic labels The direction of rotation of voltage current controlling potentiometers shall be indicated by use of arrows The ratin
26. g is not made in case where the battery after ocnducting the over charge performance test has already been fully recharged Gas collection Gases are collected in the way as illustrated in figure 1 below Ballcry Page 10 of 41 A 11 1 3 A 11 1 4 A 11 1 5 A 11 1 6 A 11 1 7 IRS S 93 96 with Amd 1 Additional charge Within one hour after completion of charge specified in 11 1 1 above charge continuously at a constant current of 0 005 C410 A Time for gas collection One hour right after charging Duration of gas collection One hour during the additional charge Ambient temperature of the battery 27 5 deg C Calculation of gas recombination efficiency From the liberated gases collected to 27 deg C 101 3 kPa 1013 mbar per 1 AH charged as per 11 1 1 above during which gases are collected and the gas recombination efficiency is calculated by the following equation V PIP x 298 t 273 x V Q Where V Amount of liberated gas ml ah as converted to 27 deg C 101 3 kPa 1013 mbar per AH of charged electricity P Ambient atmospheric pressure kPa mbar mmHg Po 101 3 in case unit of P is kPa 1013 when expressed by mbar and 760 when by mmHg t Ambient temperature of the measuring cylinder V Volume of gases collected ml Q Electricity charged during gas collection AH Gas recombination efficiency 1 v 684 x 100 Where 684 is a theoretical volume of gases
27. ghout the test the rated load current shall be maintained Once the temperature equilibrium has been reached the temperature of the rectifying diodes thyristors power transistors resistors zener diodes electric junction carrying more than 5 Amp current shall be measured by means of thermometer thermo couple type without disconnecting the load The thermo couple used for determining the temperature rise of the different components shall be attached to the back of a small blackened disc of copper or brass 15mm in diameter and 1 mm thick which is flush with the surface of component Then the charger shall be switched off and hot resistance of the winding of main transformer chokes shall be measured within one minute of switching off The temperature rise of the winding shall be computed by the following formula T Ro R eles 234 5 T4 T2 Th R1 Where T is the temperature rise R1 is the resistance at the beginning of the test R2 is the resistance at the end of the test T is the room temperature at the beginning of the test T2is the room temperature at the end of the test Page 27 of 41 B 8 11 B 8 11 1 B 8 11 2 B 8 11 3 IRS S 93 96 with Amd 1 SN Components Max permissible temperature rise above ambient temperature 1 Transformer amp choke 60 deg C for class B insulation or 99 deg C for class F insulation 2 Silicon Diodes SCRs 50 deg C or 20 deg C less than specified by manufact
28. gs of the fuses used shall be clearly marked on their base plates Where the removable fuse carriers are interchangeable they must also be individually identified The main components inside the charger and the input and output terminals shall be clearly marked and identified Page 23 of 41 B 7 B 7 1 B 72 B 8 B 8 1 B 8 2 B 8 2 1 B 8 3 B 8 3 1 IRS S 93 96 with Amd 1 Instruction Manual Two copies of instruction manual shall be supplied with each charger The manual shall include the following information a Installation and operating instructions b Guaranteed performance data and technical and other particulars of the charger c Wiring diagrams showing components and their identification markings d List of al components used in the manufacture of charger and their values e Trouble shooting procedures f Explanatory notes on operation maintenance and adjustment procedure g Any other information which the manufacturer may like to give The instruction and Maintenance manual should be tied up on the inner side of the cover which shall be opened at the site for cable termination Test and Requirements Conditions of Tests Unless otherwise specified all tests shall be carried out at ambient atmospheric conditions For inspection of material relevant clauses of IRS S 23 shall also apply Test equipment The ammeter and Voltmeters used in the tests shall be of an accuracy class equa
29. hed full state of charge If the charging voltage has been set at a value higher than 2 25V but equal to or less than 2 30 VPC so as to reduce the charging time it is normal practice to reduce the charging voltage to the float value of 2 25V after 12 hours Then the float current will soon stabilise and the above method can be adopted for determining the state of charge As a ready recknoner table II gives state of charge vs float charge voltage for 12 24 60 110 amp 2V sets Able Ill gives state of charge vs On discharge voltage for a 12V set Table IV gives recommended float charge voltages and protection limits for 12 24 60 and 110V sets Page 34 of 41 IRS S 93 96 with Amd 1 S No Item Nominal required value Float voltages terminals setting at battery 2 25 x No of cells Volts 24V system 27V 110V system 123 75V 54 cell system 121 5V Boost voltage terminals setting at battery 2 3V x No of cells Volts For 24V system 27 6V For 110V system 126 5V For 54 cell system 124 2V Normal battery charging current when battery put inot charge after discharge 10 of AH capacity eg 100AH battery to be charged at 10A current Maximum battery charging current when battery put in to charger after discharge 20 of AH capacity Ripple content in DC voltage when measured with True RMS Multimeter at battery terminal Should be less than 2 rms 0 48 rms Max for 24V
30. id Do not attempt to dismantle the battery Do not tamper with safety valves Do not over tighten the terminal bolts Do not boost charge the batteries for more than 12 hours Do not allow any metal objects to rest on the battery or fall across the battery terminals Do not boost charge the batteries for more than 12 hours Do not mix the batteries of different capacities or makes 9 Do not mix ordinary conventional low maintenance batteries with maintenance free VRLA batteries Dog AWN oo N b Maintenance and operation General Batteries are rated to an end cell voltage of 1 75 VPC at all rates of discharge Floating charge method In this type of operation the battery is connected in parallel with a constant voltage charger and the critical load circuits The charger should be capable of maintaining the required constant voltage of battery terminals and also supply normal connected load where applicable This sustains the battery in a fully charged condition and also makes it available to resume the emergency power requirements in the event of an AC power interruption of charge failure Float and Boost voltages Given below are the float and boost voltages per cell recommended for the POWER STACK battery system The average Volts per cell 9VPC value of the series string should be set tot he recommended voltage under float and boost conditions RECOMMENDED FLOAT VOLTAGE 2 25 VPC AT 27 DEG C RECOMMENDED BOOST VOLTAGE 2 30 V
31. inery and Test instruments shall be available with the manufacturer to ensure compliance to the approved QAP MARKING The following information shall be indelibly and durably marked on outside of each battery cells i Manufacturer s type and trade name followed by ii S No of the battery cell iii AH capacity of the battery at 10 hour rate iv Month and year of manufacture PACKING Manufacturers shall be responsible for safe transportation of cells battery which should be packed and delivered in good condition to consignee at his depot If there is any damage manufacturer shall replace the damaged cell battery free of cost Page 5 of 41 A 8 A 8 1 A 8 2 A 9 A 9 1 A 9 2 A 9 3 A 9 4 A 9 4 1 A 9 4 2 A 9 5 IRS S 93 96 with Amd 1 MANUAL OF INSTRUCTIONS Two copies of instruction manual of initial treatment and routine maintenance during service shall be supplied by the manufacturer along with every set of battery Instruction manual is to be prepared using good quality paper with clear and handsome printing using modern facilities like electronic typewriters printer of DTP The manual still have a_ thick polythene sheet cover with plastic spiral binding or comb binding n addition an instruction card containing the following information shall be provided along with each battery cell a Designation of cell battery b AH capacity c Nominal voltage d Charging voltage OPERATIONAL REQUIRE
32. ing tests Lot size Sample size except for temperature Sample size for rise test amp Induced HV test temperature rise test amp Induced HV test 2 8 2 1 For acceptance of the 9 15 3 1 lot there shall be no 16 25 5 2 failure 26 50 8 2 51 100 13 3 101 150 20 3 151 200 32 3 Routine tests Following shall constitute routine tests and shall be conducted by manufacturer on every battery charger and test results will be submitted during the inspection a Visual Inspection Cl 8 6 b Insulation resistance of main transformer Cl 8 7 c Insulation resistance complete of charger Cl 8 7 d Performance test Cl 8 11 The performance test may be carried out only at normal input voltage during the routine test Visual Inspection The charger shall be visually inspected to ensure compliance with the relevant requirements of clauses 3 4 5 amp 6 Page 25 of 41 B 8 7 B 8 8 B 8 9 IRS S 93 96 with Amd 1 Insulation Resistance test This test shall be carried out a Before high voltage test b After high voltage test c After induced high voltage test for main transformer only d After the temperature rise test when charger has attained ambient temperature and e After the climatic tests have been completed The measurement shall be made at a potential of not less than 500V DC The insulation shall be measured between a AC line terminals and earth b DC line termina
33. ircuit voltage 0 05 amp 0 02 100 2 15 90 2 13 80 2 11 70 2 09 60 2 07 50 2 05 40 2 03 30 2 01 20 1 99 10 1 97 0 1 95 Page 38 of 41 Table Il IRS S 93 96 with Amd 1 SOC Vs Float Charge Voltage SOC System Voltage 12V 24V 60V 110V 2V 0 12 00 12 24 23 00 24 48 60 00 61 02 108 0 110 16 2 00 2 04 10 12 30 12 54 24 6 24 8 61 05 62 07 110 7 112 86 2 05 2 09 20 12 54 12 78 25 8 25 56 62 07 63 09 112 86 115 2 2 09 2 13 30 12 78 13 02 25 56 26 04 63 09 65 01 115 2 117 18 2 13 2 17 40 13 02 13 14 26 04 26 28 65 01 65 07 117 18 118 26 2 17 2 19 50 13 08 13 26 26 16 26 52 65 04 66 03 117 72 119 34 2 18 2 21 60 13 2 13 88 26 4 26 76 66 00 66 09 118 8 120 42 2 20 2 23 70 13 32 13 44 26 64 26 88 66 06 67 02 119 88 120 96 2 22 2 24 80 13 38 13 5 26 76 27 0 66 09 67 05 120 42 121 5 2 23 2 25 90 13 44 13 53 26 88 27 06 67 02 67 65 120 96 121 7 2 24 2 255 110 13 47 13 554 26 94 27 108 67 35 67 77 121 23 121 986 2 245 2 259 Page 39 of 41 IRS S 93 96 with Amd 1 Table Ill STATE OF CAHRGE Vs ON DISHARGE VOLTAGE for a 12V battery State of charge On Discharge voltage 100 12 65 12 90 90 12 55 12 80 80 12 40 12 70 70 12 25 12 55 60 12 10 12 40 50 11 95 12 25 40 11 80 12 10 30 11 55 11 85 20 11 25 11 55 10 10 60 11 15
34. l to at least 0 5 of IS 1248 1968 Type tests The following shall comprise type tests and shall be carried out in the given sequence a Visual Inspection Cl 8 6 b Insulation resistance test Cl 8 7 c Applied high voltage test Cl 8 8 d Induced high voltage test Cl 8 9 e Temperature rise test Cl 8 10 f Performance test Cl 8 11 g Test for protective devices Cl 8 12 h Climatic tests Cl 8 13 i Endurance test Only one charger of each type and output rating shall be tested for this purpose The charger shall successfully pass all the type tests for proving conformity with this specification If the charger fails in any of the type test the purchaser or his nominee at his discretion may call for another charger of the same type and output rating subject it to all tests or to the test s in which failure occurred No failure shall be permitted in the repeat test s Page 24 of 41 B 8 4 B 8 4 1 B 8 5 B 8 5 1 B 8 6 IRS S 93 96 with Amd 1 Acceptance tests The following shall comprise acceptance tests a Visual Inspection Cl 8 6 b Insulation resistance test Cl 8 7 c Applied high voltage test Cl 8 8 d Induced high voltage test Cl 8 9 e Temperature rise test Cl 8 10 f Performance test Cl 8 11 g Test for protective devices Cl 8 12 Visual Inspection insulation resistance test and performance test shall be carried out on all chargers The following sampling plan shall be adopted for the remain
35. le life for the cyclic application and similar test results for the float mode application Page 7 of 41 A 10 1 3 A 10 1 4 A 10 1 5 A 10 1 6 A 10 2 A 10 3 A 10 4 A 10 4 1 A 10 4 2 IRS S 93 96 with Amd 1 Acceptance test The following shall constitute the acceptance tests a Marking and packing b Verification of dimensions c Test for capacity d Test for voltages during discharge The acceptance tests shall be performed at the manufacturer s premises by the inspection wing of RDSO on each lot offered The purchaser may at his discretion undertake test for capacity and voltages during discharge after installation of the battery at site Sampling scheme and criteria for acceptance The sampling scheme and criteria for acceptance shall be in accordance with Cl 11 1 of IS 8320 1982 Verification of constructional requirements The cell battery shall meet the requirements specified under Cl A 3 1 A 3 2 A 3 7 amp A 3 9 Verification of marking packing The marking on the cells batteries shall meet the requirements specified in Cl 6 and packing shall meet the requirements of Cl 7 Test for Capacity The test shall be conducted as per Cl 12 5 of IS 1651 91 with following changes i When a fully charged cell is discharged at a constant current 0 1 C19 amperes the discharge shall be stopped when the closed circuit voltage across the cell falls to 1 75 volts ii On the first di
36. ls and earth c AC terminals and DC terminals Value of the insulation resistance when measured at 40 deg C amp RH of 60 shall not be less than 10 Mega ohms for complete battery charger and shall not be less than 1000 Mega ohms for the mains transformer There shall not be any appreciable change in the measured value of insulation resistance before and after induced high voltage test When measured after the battery charger has attained ambient temperature after completion of temperature rise test the insulation resistance will not be less than the limits mentioned above When the test is repeated after the climatic test the value shall not be less than 5 Mega ohms and 500 Mega ohms respectively For measurements of IR values at different temperature and relative humidity the table given in Cl 8 7 1 of IRS S 86 2000 shall be applicable Applied high voltage test The charger shall withstand for one minute without puncture and arching when a test voltage of 2000V rms is applied between a AC line terminals and earth b DC line terminals and earth c Primary and secondary winding of charger transformer The test voltage shall be alternating of approximately sinusoidal wave form and of any frequency between 50 and 100 MHz Printed circuit cards shall be removed and all four terminals of Rectifier Bridge shall be connected together during this test Induced high voltage test The main transformer of the charger with no load shall be con
37. nductors shall be protected with high braking capacity fuses Suitable protection for high voltage surges or short circuits shall be given Any accidental failure of the control card or any of the electronic control regulation circuits the thyristors SCR s MOSFETS POWER Page 19 of 41 B 4 6 10 B 4 6 11 B 5 B 5 1 B 5 2 B 5 3 IRS S 93 96 with Amd 1 TRANSISTORS should be blocked immediately and operation of the unit stopped by tripping the AC input supply to the unit Arrangement shall be provided such that the in case any fault occurs within the charger output terminal DC voltage of the charger shall not exceed 2 35 V cell Chargers of output current rating of 50 Amps and above shall be provided with extra fuses and alarms visual and audible as given below A Fuses i Rectifier elements ii Smoothening condenser B Alarms i Main fuse blown ii Output fuse blown iii Rectifier element fuse blown iv Smoothening condenser fuse blown v Mains on Battery discharging The alarms shall be provided with a resetting button for cutting of the alarm Attention lamp LED which will light up when the fault persists and the audible alarm shall only be reset Facility shall be provided for a single contact which will make for any of these conditions and can be wired externally Performance Requirements Unless otherwise specified the charger shall be suitable for operating on single phase AC supply mains
38. nected to a voltage equal to two times nominal supply voltage the frequency being Page 26 of 41 B 8 10 IRS S 93 96 with Amd 1 equal to two times the rated frequency The voltage shall be raised from 1 3 of maximum value to full value as is consistent with accurate reading of the instrument Full test voltage shall be maintained for one minute and shall then be rapidly reduced to 1 3 of the value before being switched off At the end of the test the transformer shall be tested for the following a Insulation resistance test Cl 8 7 b No load current Cl 5 6 6 The values shall not differ from the specified value Temperature Rise test The cold resistance of transformer and choke winding shall be measured after conditioning the charger until three consecutive temperature readings taken at 30 minutes interval are constant and the constant temperature shall be taken as reference temperature T4 The charger shall be connected to the AC supply mains setting the input voltage at 230V Set the selector switch mentioned in Cl 4 5 2 to the boost charging position A resistive load shall be connected such that the rated DC current flows through the load and output terminal voltage remains at 2 3V per cell The charger shall continue to draw the rated output current till such time the temperature equilibrium is reached i e the temperature variation between 3 successive readings taken at the interval of 30 minutes is less than 1 deg C Throu
39. of 230V nominal and of frequency 50 2Hz Input AC voltage may vary from 160V to 270V Nominal output voltage and rated output current of the chargers shall be as specified by the purchaser The charger shall be rated for continuous output The DC output of the charger shall be smoothened such that the r m s ripple content of the output voltage when delivering the rated output current through a resistive load measure by an oscilloscope true r m s digital multimeter shall not be more than 2 The requirement shall be met in all modes of working The DC output will be temperature compensated to protect the batteries against increase in ambient temperature The temperature compensation factor is 3mV cell deg C at 27 deg C ambient temperature Page 20 of 41 B 5 4 1 B 5 4 2 B 5 5 B 5 6 B 5 6 1 B 5 6 2 IRS S 93 96 with Amd 1 Additional requirement for battery chargers for telecommunication installations The output of the chargers shall not contain psophometric noise voltage of more than 2mV r m s Additional requirements for battery chargers for axle counter installation PARD value ripple and noise of output voltage is specified as under rms value 10mV p p value 50mV Measured by means of storage type 50MHz oscilloscope when delivering rated output current in float mode The chargers shall be designed to deliver continuously the rated output current without damage to or deterioration of the components of the cha
40. ormal conventions and shall be shown in the instruction manual All connectors shall be made through crimped eyelets and shall be numbered with PVC cable marker rings corresponding to the numbers letters shown in the schematic wiring diagrams Soldering shall be used only where use of crimped eyelets is not possible The schematic wiring diagram referred in cl 3 8 shall show all wiring used for interconnecting the main components of the charger This diagram shall be drawn on an anodised aluminium plate of thickness not less than Page 14 of 41 B 3 10 B 3 11 B 3 12 B 3 13 B 4 B 4 1 B 4 1 1 B 4 1 2 B 4 1 3 B 4 1 4 B 4 1 5 B 4 2 B 4 2 1 B 4 2 2 IRS S 93 96 with Amd 1 1mm and size not less than 150 mm x 100 mm and shall be firmly fixed on the inside of the cover of the charger The components provided on the front panel shall be as per drg No SDO RDSO VRLA BC 001 All non current carrying metal parts shall be bonded together and earthed An earth terminal suitable for taking minimum 4 mm dia wire and with suitable marking shall be provided All cable entry holes should be provided with rubber grommets The charger unit shall have separate battery and load terminals for all ratings Components ICs and other components used in the equipment shall be of industrial grade and shall conform to HIREL programme of CDIL or equivalent Capacitor used should be certified for atleast 105 deg C Source
41. rgers Beyond the rated load arrangement shall be such that the current is limited automatically up to the rated current when working in float mode or up to the pre selected value of current regulating the output voltage of the charger As soon as the overload conditions are removed normal voltage should again be obtainable without need for any resetting The chargers shall be suitable for float charging and boost charging mode of working as selected by means of he selector switch mentioned in Clause 4 5 2 Float mode Under this mode of working the charger shall give a d c output voltage 2 25 V per cell Manual adjustment of output voltage over a range of 2 0V to 2 30V per cell shall be possible by voltage control potentiometer Clause 4 5 4 The value of output voltage shall be maintained within 0 02V cell of the set value over the entire range of input AC supply variation Cl 5 1 and output load variation from no load to full load Boost mode Under this mode of working the charger shall be capable of delivering an output current whose magnitude shall be capable of being selected by means of the current control potentiometer The current shall be maintained constant within 5 of the selected value with the input voltage varying between the limits mentioned in cl 5 1 and d c output voltage from 1 75 to 2 4V per cell Page 21 of 41 B 5 6 3 B 5 6 4 B 5 6 5 B 5 6 6 B 5 6 7 B 5 6 8 B 5 6 9 B 5 7 IR
42. scharge the cell shall give not less than 85 of the rated capacity The cell battery shall give 100 rated capacity within 5 discharges Test for capacity may by mutual agreement between the supplier and the purchaser be carried out at rates other than 10 hour rate In such cases a 3 hour rate is recommended Corresponding final voltages are given in the Table Il For the purpose of acceptance the capacity test shall be carried out at one rate only Page 8 of 41 A 10 5 A 10 5 1 A 10 5 2 A 10 6 A 10 6 1 A 10 6 2 A 10 6 3 A 10 6 4 IRS S 93 96 with Amd 1 Test for Charge Retention This test shall be carried out on a minimum number of 2 samples After measuring and recording the capacity in accordance with Cl 10 4 1 amp 10 4 2 the battery shall be charged at a constant voltage of 2 25 V Cell or as recommended by the manufacturer A current limit of not more than 20 of the rated capacity in amperes is permitted which may reduce the voltage in the beginning of the charging The ambient temperature shall be 27 deg C 5 The battery shall be charged for 16 hours or until the charging current has stabilized except for transient fluctuations for a period of 3 hours whichever occurs first After charging the battery it shall be left on open circuit for 30 days and then the battery shall be discharged at 10 hour rate and capacity C shall be determined It shall be corrected to 27 deg C The loss in capaci
43. size to indicate positive and negative terminals respectively The input output and earth terminals shall be provided inside the cubicle and shall be accessible only when the cover is removed The sizes of terminals shall be commensurate with the current rating of their charger All current carrying terminals shall be of brass and shall be plated for protection against corrosion Rating of switches used in the charger shall be atleast more than 50 of the charger rating Indication amp Protective Devices A green LED of 10 mm size to indicate that the input supply is ON shall be prominently provided A red LED of 10mm indication shall be available to indicate reverse connection to the battery The indication shall be located near output battery terminals The charger shall also be protected against damage due to reverse battery connection Separate red LED indications shall be provided to indicate overload and short circuit condition HRC fuses conforming to IS 2208 shall be provided in the DC output circuit In addition to fuses protection against short circuit and overload at output terminals shall be available as envisaged in cl 5 5 Chargers shall be provided with means of protection against spikes in line voltages by providing line surge suppresser MOVRs on the input side Thyristors and electronic subassemblies shall be protected against accidental over voltages whether internal or external in origin Power semico
44. such that it cannot be opened without proper tool Terminal posts Positive and negative plates shall be clearly and unambiguously identifiable Page 4 of 41 A 3 8 A 3 9 A 3 10 A 4 A 4 1 A 5 A 5 1 A 5 2 A5 3 A 6 A 7 IRS S 93 96 with Amd 1 Connectors The connectors used shall conform to Clause 6 5 of IS 1651 91 The internal inter cell connectors used in the battery shall prevent acid creepage through the intercell partition Nuts and Bolts Nuts and bolts for connecting the cells shall be made of copper brass or stainless steel and effectively lead coated to prevent corrosion Stainless steel bolts nuts can be used without lead coating Stainless steel used shall be of special grade which is resistant to sulphuric acid Electrolyte The sulphuric acid and water used for electrolyte for the battery should conform to IS 266 77 and IS 1069 64 respectively QUALITY REQUIREMENTS The materials shall be of the best quality and the workmanship shall be of the highest class as per standards laid by RDSO QUALITY ASSURANCE The batteries shall be manufactured as per quality assurance procedure laid down so as to meet the requirement of the specification The Routine tests shall form a part of the QA procedure and records maintained Amongst other requirements of the specification validation and system monitoring of QA procedure shall form a part of type approval The necessary Plant amp mach
45. system 2 2V rms Max for 110V system Battery charging protection voltage high 2 37 PC i e Voltage trip at 28 44V for 24V system Voltage trip at 130 35V for 110V system Voltage trip at 127 98V for 54 cell system Battery under voltage trip on discharge 1 75V PC i e 24V system should disconnect the load at 21V 110V system should disconnect the load at 9 625V for 54 cell system 94 5V Dos ie NO Ole 10 11 Installation and Maintenance Instructions Installation Unload and store the batteries in covered area on receipt of shipment Read Instruction and operating instruction manual prior to installation of the batteries Clean the batteries as and when dust accumulates The batteries if placed in cubicle provide sufficient ventilation The terminal bolt connections to be torqued to 10Nm 100 Ib inch Retorque the connections once every six months Always use suitable washers where ever bolt connections are provided Keep the batteries away from heat source sparks fire etc Charge the batteries once every six months if stored for long periods After discharge recharge the batteries immediately Note down individual cell voltage readings once every three months Charge the batteries only at 2 25V per cell Page 35 of 41 IRS S 93 96 with Amd 1 Don ts 1 Do not locate the batteries in places exposed to direct sun light rain dust storm etc Do not add water or ac
46. t be used for this purpose The climatic tests shall be carried out by setting the chargers in boost charge mode of operation by means of the selector switch mentioned in Clause 4 5 2 During the period of exposure in each test the chargers shall be connected to supply mains of nominal input voltage and shall deliver the rated output current at output voltage of 2 3V cell to a resistive load Immediately after the damp heat test the insulation resistance of the main transformer shall not go below 100 Mega ohms and for complete charger not below 5 Mega ohms which shall improve to 500 Mega ohms and a Mega ohms respectively after complete recovery During the last half hour of exposure under dry heat test insulation resistance shall not go below 5 Mega ohms The charger shall not show signs of any apparent damage or deterioration The charger shall then satisfy the requirement of Cl 8 7 and no load current shall not vary more than 5 of the initial value before test Requirement of Cl 6 1 will also be ensured Vibration test The charger shall be subjected to vibration test as _ per RDSO SPN 144 2004 Description Upto amp including 75Kg weight Over 75Kg weight Freq Range 05 350 Hz 5 150 Hz Amplitude 6 mm constant 6 mm constant displacement or 15m Sec displacement or 15m Sec constant acceleration constant acceleration No of axes 3 3 No of sweep 20 10 cycle Total duration 105 min
47. ter of IS 1248 The minimum scale length of the meters shall be 60mm for chargers of nominal output voltage up to 24V and rated output current up to 20 Amps For chargers where either the voltage or the current exceeds these limits the scale length shall be minimum 90mm for both meters Switches and Terminals Each charger shall be provided with a ON OFF Rotary switch as per IS 4064 Pt 1 The charger shall be in Float mode immediately after being switched ON In order to change it to Boost mode a two position rotary switch a per IS 4064 Pt I will be provided under a cover so that the charger is not brought in boost mode inadvertently Two potentiometers designated as Total current and Battery path current be provided at suitable location inside the front panel They will be provided with lock nuts Page 18 of 41 B 4 5 4 B 4 5 5 B 4 5 6 B 4 5 8 B 4 5 9 B 4 6 B 4 6 1 B 4 6 2 B 4 6 3 B 4 6 4 B 4 6 5 B 4 6 6 B 4 6 7 B 4 6 8 B 4 6 9 IRS S 93 96 with Amd 1 A potentiometer control designated Voltage control shall be provided to adjust the output voltage over a range of 2 0 to 2 30 volts per cell under float mode of working This shall be provided inside the cubicle accessible only after removal of cover The initial setting will be at 2 25V Current output terminals shall be externally terminated These shall be provided with red and black insulating ends of adequate
48. ticles like metal clips and filings Accidental short circuit by dropped tools fasteners etc Abrasion damage and Vibration and shock to a certain extent QI229T8 The solder masks shall be applied on the solder side and component side of the card Following description shall be engraved on the component side of the PCB a Component outline in the proximity of the component b Manufacturer s name c PCB name d Equipment name e Part Number Following description shall be engraved marked with permanent marker on the PCB a The manufacturers name b Month and year of manufacture Printed circuit cards shall be fitted with gold plated Euro D type plug in connectors with locking arrangement Mechanical arrangement e g a clip or a screw to hold the PCB in inserted position shall be provided Screws should be countersunk and held on PCB when it is plugged out The PCB shall be mechanically polarized so that if is not possible to insert the PCB into wrong slot Suitable mechanical arrangement shall be provided against wrong insertion of connectors Heat Dissipating Components All components dissipating 3W or more power shall be mounted so that its body is not in contact with the board unless a clamp heat sink or other means are used for proper heat dissipation Page 17 of 41 B4 3 14 B 4 3 15 B 4 4 B 4 4 1 B 4 4 2 B 4 4 3 B 4 4 4 B 4 4 5 B 4 5 B 4 5 1 B 4 5 2 B 4 5 3 IRS S 93 96 with
49. ty R is given by The loss in capacity R shall not exceed 15 Endurance test The endurance charge discharge cycles test shall be carried out on a minimum of tw cells of which capacities have been determined as per Cl 10 4 and no other tests have been carried out The cells shall be charged continuously at a constant voltage of 2 25V cell or as specified by the manufacturer with a maximum current of 20 of the rated capacity in amperes for total period of 2000 hours as given below a 2 cycles of 300 h charging followed by test discharge b 3 cycles of 200 h charging followed by test discharge amp c 8 cycles of 100 h charging followed by test discharge Through out these periods of charge the cell shall be immersed in a tank of water the temperature of which shall be maintained t 40 3 deg C The cell shall be so immersed that the top of the cell is 25 mm above the water level in the tank If several cells are placed in the tank a distance of 25mm shall be maintained between them The distance between a cell and the side of the tank shall also be at least 25mm At the end of each period of charging as specified above the cell shall be subjected without recharging to a test discharge at Cio rate to an end voltage of 1 75 At the end of the last discharge cycle i e after 2000 hours shall not be less than 90 of the original capacity of the battery Page 9 of 41 A 10 7 A 10 7 1 A 10 8 A 10 8 1 A 10 9 A 10 9 1
50. urer whichever is less 3 Electric Junctions 15 deg C terminals switches etc 4 Resistors 50 deg C During the test the charger shall be protected from droughts and radiations from warmer object After completion of test and retaining ambient temperature charger shall meet the requirements as given in Cl 8 7 and 8 8 Performance test The charger shall be tested for its output performance watt efficiency regulation no load current power factor and ripple content by connecting a variable resistive load across the output terminals The test shall be carried out at AC input voltages of 160 and 270V Test connections for measurement shall be same as in Cl 8 11 of IRS SX 86 92 Note For chargers of output current higher than 20 Amps If resistive load are not available use of a water load is recommended The capacity of the water load should be sufficient so that the temperature does not rise more than 35 deg Above ambient during the test Float working Set the charger to float mode of working by means of the selector switch mentioned in Cl 4 5 2 Check the working of voltage control pot to ascertain whether variations from 2 0V cell to 2 3V cell is possible at rated output current Then adjust the output voltage at 2 25V cell at rated output current and at nominal input voltage Vary the resistive load and record readings without disturbing the voltage control pot settings Reading shall be taken at a
51. wer components such as diodes SCRs etc shall be rated more than twice the maximum current flowing through them The manufacturer shall declare the peak reverse voltage of the rectifier elements under the ambient conditions the number of elements used and manner of their connection The peak reverse voltage rating should not be less than two times the expected reverse voltage across the rectifier elements All resistors used shall be atleast double the power capacity which is supposed to be dissipated in them The voltage rating of capacitor shall be atleast 50 above peak value The resistors and capacitors used in control cards firing cards and comparator cards etc shall be of tolerances not more than 5 amp 10 The resistors and capacitors used elsewhere in the charger shall be of tolerance not more than 10 amp 20 respectively Potentiometer used for current and voltage control should be wire wound type conforming to JSS 50502 obtained through RDSO approved suppliers The potentiometers shall have high quality phenolic body mould specially selected contact material and the spindle but and back cap should be of brass with nickel plating Printed circuit cards and Components PCB Material Material for the printed circuit board shall be copper clad glass epoxy of grade FR 4 or equivalent PCB shall normally be of standard size e g 3 4 6U Outline Dimensions PCB s shall be of standard size Board Thickness The thickness o
52. ycles 4 days Condition Fully functional during test vi Dust test as per IS 9000 Part XII Duration 1 hour Condition After this test electrical parameters shall be monitored in addition to physical checks vii Bump test as per IS 9000 Part VII Sec ll No of bumps 1000 Peak acceleration 400m Sec Sq Pulse duration 6mS No of axes 03 Condition After this test parameters shall be monitored in addition to physical checks viii Thermal cycling test a The PCB shall be subjected to thermal cycling as per the procedure given below The assembled boards are to be subjected to rapid temperature cycling as mentioned below in the power off condition b This temperature cycling from O deg C to 70 deg C 1 2 hours at each temperature for 9 cycles and 1 hour at each temperature for the 10 cycle Dwell time of 1 hour is provided for the last cycle in order to oxidize defective solder joints exposed through thermal stress c The rate of rise fall of temperature shall be min 10 deg C per minute d In addition to physical checks the electrical parameters are also to be monitored after this test Page 30 of 41 IRS S 93 96 with Amd 1 e Power cycling The power supply modules shall be subjected to 60 ON OFF B 8 13 2 B 8 13 3 B 8 13 4 B 8 14 B 9 B 9 1 B 9 2 cycles for 1 hour The ON OFF switch usually provided in the modules may no
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