_ EDTSOS SPECIFICATION FOR 1 KVA TRANSFORMER 3 1 SCOPE 1.1 This specification covers the construction, performance and test requirements for a 1 KVA ,three phase ,dry type air cooled transformer suitable for floor mounting for feeding halogen reading lights in Railway passenger coaches. TERMINOLOGY:- For the purpose of this standard the definitions as given in specification [Link] (Pt- XXXVIII)-1977 (Electrotechnical vocabulary for transformer) shall apply. 3. SERVICE CONDITIONS The equipment shall be sturdy and suitable for the following service conditions normally to be met in service -Ambient -5 to +55 deg celcius “Train speed 160 Kmph -Humidity upto 98% during rainy season -Altitude Max 1200 meter above sea level -Atmosphere Extremely dusty and desert terrain in certain areas . The dust concentration in air may reach at high value of 1.6 mg/cubic meter. Very dusty atmosphere with fog,cast iron dust of brake block shoe, flying ballast etc. Rainfall Very heavy in certain areas. -coastal area The equipment shall be designed to work in humid salt laden and corrosive atmosphere .The maximum values of the condition shall be as under maximum Ph value 8.5. Sulphate 7 ng/litre Max concentration 6 mg/litre of chlorine Max. conductivity 130 micro siemens/cm -vibration The equipment, system and their mounting arrangement shall be designed to withstand satisfactorily the vibration and shocks encountered in service as specified below. | “&& | 012 of 08] | Eprsos2 | SPEC. NO. | Rev. | Date | Prpd | Chkd | Appd | Sheet |Sinusoidal form of vibrations,the frequency ‘f’ lies between 1 Hz and 100 Hz and their amplitude ‘a’ expressed in mm is given as a function of ‘f’ by the equation a=25/f for values of £ between 1 Hz and 10 Hz 2 a=250/f for values of f between 10 Hz and 100 Hz 4. GENERAL REQUIREMENTS: 4.1 ELECTRICAL REQUIREMENTS: +1.1 The windings,core, terminals shall be robust and of reliable design ' capable of withstanding continous vibrations and jerks during train movement 4.1.2 The transformer primary winding shall be connected in delta and be suitable for three phase,415V (nominal) ,50Hz input. Input supply will be either sinusoidal from DG’set or PWM type from static inverter .The supply frequency variation shall not vary by more than +/- 3%.The secondary winding shall be connected in star with neutral brought out suitable for three phase 18V line voltage to feed a load of 1KVA (phase voltages 10V ). The winding shall be connected in vector group Dy1l of IS:2026 (Pt-IV)-1977. 4.1.3 The value of impedence voltage of the transformer shall not exceed 4 % of the rated voltage. 4.1.4 The overall efficiency of the transformer shall not be less than 92% at one fourth of full load and 95% at full load. +1.5 Primary and secondary studs be provided on a fibre glass SMC terminal board with adequate creepage and clearance distance conforming to 1S:13947-93 Pt-I. The terminal studs shall be metric steel hexagonal as shown in drg. no CC72117 The hexagonal studs shall not rotate while tightening the cable connections. All the studs shall be suitably locked to prevent [Link] securing cables crimping sockets, nuts with plain and spring washers shall be provided. 4.1.6 Primary and secondary terminal arrangement marking shall conform to 18:2026 (Pt-IV)-1977. EDTS052 i | SPEC. NO | 0 | 29.04.98 | | 02 of 08 | | Rev.| Date | Prpd | Chkd | Appd | Sheet |4.1.7 The incoming and outgoing terminals and crimping sockets shall be suitable for : 1) Primary side 41sv 2.5sqmm copper cable 2) Secondary side sv 6:0sqmm copper cable 4.1.8 Earthing terminals shall be provided for earthing the neutral to Coach body. 4.1.9 Mounting holes suitable for M10 sizes to be provided. 4.1.10 The winding shall be done with super enamelled copper winding wire conforming to IS:4800 (Pt-V) of 1968. 4.1.11 Degree of protection of the transformer shall be IP23 as per IS:2147. 4.2 MECHANICAL REQUIREMENTS. 4.2.1 The overall dimensions of the transformer shall be in accordance with drg-no. CC72117. 4.2.2 Transformer shall be provided with suitable mounting angle as shown in the drawing. 4.2.3 All steel work shall be powder coated to grey shade after giving seven tank treatment for anti rust and anti corrosion. Paint used should be fire retardant. 5. RATING 5.1 The transformer shall give the rated out put as specified below at maximum ambient of 55 Deg.C out-put = 1 KVA Primary = 415V +/-5%_, sinusoidal or PWM voltage 3 phase delta connected Secondary = 18 Volt,3 phase star connected Voltage Frequency 50Hz +/-3% Vector group Dy1l of IS:2026 (Pt-IV)-1977 6. Temperature Rise - 6.1 Temperature of winding should not exceed 80 deg.c and class of insulation shall be ’F’. | EpTsos2 | 0 | 29.04.98 | PM) x 03 of o8 | SPEC. NO. | Rev.| Date | Prpd | Chkd | Appd | Sheet |762 Tests Prototype tests The prototype test shall be carried out at the works of the manufacturer to establish the conformity of the product with the specification. The following shall constitute the prototype tests: a) Visual examination, dimensional check & weighment b) Measurement of winding resistance. c) Measurement of voltage ratio & check of voltage vector relationship. a) Measurement of impedance voltage/short circuit impedance and load loss at 75 deg. C. Measurement of NO load loss and current at 75 deg. Cc. Efficiency at one half of the full load and at full load at 75 deg. Cc. Measurement of insulation resistance. Dielectric test. Temperature-rise test with PWM input supply. Measurement of zero-sequence impedance Fire retardant test for terminal board. mo rue Routine Tests Routine tests shall be carried out on all the transformers by the manufacturer at his works to ensure compliance with the specification and the drawings etc. approved by RCF. A proper records to this effect shallbe maintained. Following shall be routine tests: a) Visual examination, dimensional check & weighment b) Measurement of winding resistance. ¢) Measurement of voltage ratio. @) Measurement of impedance voltage/short circuit impedance and load loss at 75 deg. C. e) Measurement of NO load loss and current at 75 deg. c. f) Efficiency at one half of the full load and at fuil load at 75 deg. Cc. g) Measurement of insulation resistance. IDM | 2K Coke | 04 of 08 | SPEC. NO. | Rev.| Date | Prpd | Chkd | Appd | Sheet | EDTSO52 | 0 | 29.04.98 |7.3 Acceptance Tests: These tests are to be carried out by an inspecting authority nominated by the purchaser at the works of the manufacturer, on the sample picked at random as per cl.8.0 Following tests shall be acceptance test. a) Visual examination, dimensional check & weighment b) Measurement of winding resistance. c) Measurement of voltage ratio & check of voltage vector relationship. d) Measurement of impedance _voltage/short circuit impedance and load loss at 75 deg. C. e) Measurement of NO load loss and current at 75 deg. Cc. £) Efficiency at one half of the full load and at full load at 75 deg. Cc. g) Measurement of insulation resistance. h) Dielectric test. Sampling and Rejection Type and acceptance tests shall be carried out on minimum two transformers or maximum two percent picked up at random from the lot offered for inspection. In case any of the samples fails to comply with the requirement of acceptance tests as laid down in clause 6.3 of this standard, the inspecting authority/officer may pick up double the number of samples and repeat all the tests mentioned in the related clause. The lot shall be rejected if any fresh samples fails to meet the tests as laid down in clause 6.3 during the retesting. Prototype Approval The tenderer shall submit two sets of detailed drawings and material specification to RCF for approval. The prototype unit ‘complete in all respects shall be offered for prototype tests by RCF/purchaser. Bulk manufacture shall commence only on approval of the prototype by RCF. “(he 08 of 08 | EDTSO52 | 0 | 29.04.98 | ayo | an SPEC. NO. | Rev.| Date | Prpd | Chkd | Appd | Sheet10.0 11.0 12.0 12.1 12.1. ze I I Testing Facilities The venue for all the tests shall be the manufacturer's works or any reputed testing laboratory. When the testing is done at the firms works, the manufacturer shall provide personnel, equipments and other testing facilities for conducting the test free of charge. The manufacturer shall also supply a copy of the type and routine tests carried out by him to the inspecting officer nominated by the purchaser for his scrutiny and approval. Measuring Instruments The measuring instruments employed for measuring various electrical quantities shall conform to 1$:1248 (latest) and the class of accuracy shall be 0.5. All such instruments used should have been calibrated by a Government authorised laboratory within 12 months prior to the date of the tests. The calibration certificates should be produced for referance at the time of testing on demand by the inspecting authority. Detail of Tests General requirements for tests: 1 Dielectric tests shall be done on the transformer at the ambient temperature. 2 All external components and fittings that are likely to affect the performance of the transformer during each test shall be in place. Sz a | Che | 06 of 08 | SPEC. NO. | Rev.| Date =| Prpd | Chkd | Appd | Sheet | EDTs052 | 0 | 29.04.98 | Jo” |Ale ae 13.0 13.1 14.0 14.1 15.0 15.1 3 The test basis for all characteristics other than insulation is the rated condition, unless the test clause states otherwise. 4 Because of inevitable difference in basic material and variations in ,manufacture, as well as measurement errors, the values obtained on tests may differ from the calculated values and tolerances on guaranteed values are necessary. Table-7 of 1S:2026 Pt-I gives tolerances to be applied to certain rated quantities and other quantities, when they are the subject of manufacturer’s guarantees referring to this standard. Where a tolerance in one direction is omitted there is no restriction on the value in that direction. A transformer is considered as complying with this standard when the quantities subject to tolerances are not out side the tolerances. SCHEDULES The tenderer shall submit along with his tender the particulars of the equipment in a proforma as per appendix ‘A}. He shall supply along with each transformer the test certificates confirming that the transformer has passed the routine tests at makers works. GUARANTEE, Each transformer shall be guaranteed against manufacturing defects for its satisfactory performance for period of 12 months from the date of supply or 18 months from the date of commissioning which ever is earlier. MARKING Following data shall remarked on the name plate a) Manufacturer's name b) Serial number c) Year and quarter of manufacturer a) Rated capacity KVA e) Primary voltage £) Secondary voltage g) Connection diagram Primary Secondary h) Vector symbol i) Frequency EpTS052 | 0 | 29.04.98 | @Y | ae (Cae | 07 of 08 | Date | Prpd | Chkd | Appd | Sheet | SPEC. NO. | Rev.APPENDTX-A (CLAUSE-B) A.1 Name of manufacturer A.2 Service A.3 Rating Rated KVA + «KVA Rated primary voltage uv Rated secondary voltage I ..V Frequency +H Temperature Rise a) Winding by eC] resistance method b) Core by thermometer —..C method -4 Number of phases A.5 Connections High voltage Low voltage Vector group A.6 No load loss at rated W voltage and frequency A.7 Load loss at rated current at 75 C..W A.8 Efficiencies at 75c at unity power factor At full load At a/4 load At a/2 load A.10 No load current at rated W voltage and frequency 4.11 Overall dimensions Length +m Brendth +m Height + +m Weight + kg ENCL:[Link]. aeysenicsteeiot | SPEC. No. | Rev.| Date | Prpd | chkd | Appd | Sheet | |__Eprsos2 | 0 | 29.04.98 | AO” | 9= OFA 1 ETT WOI SGU Te SMa ST ro rt rr 29 9% 30H veg