L1-CHE-SPE-298 POWER SUPPLY UNITS FOR SIGNALLING EQUIPMENT - BATTERY CHARGERS

Transcription

1 Engineering Specification Signalling L1-CHE-SPE-298 POWER SUPPLY UNITS FOR SIGNALLING EQUIPMENT - BATTERY CHARGERS Version: 1

2 ENGINEERING SPECIFICATION POWER SUPPLY UNITS FOR SIGNALLING EQUIPMENT - BATTERY CHARGERS L1-CHE-SPE-298 Version: 1 Effective from: 1 st July 2018 Approval Name Position Signature Document Endorser Louisa Waymouth Manager Standards Approving Manager Phil Ellingworth Chief Engineer Amendment Record Approval Date Version Description 20/06/ Rebadge VRIOGS Power Supply Units for Signalling Equipment - Battery Chargers. No change to the technical content. Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 21

3 ENGINEERING SPECIFICATION POWER SUPPLY UNITS FOR SIGNALLING EQUIPMENT - BATTERY CHARGERS L1-CHE-SPE-298 Version: 1 Effective from: 1 st July 2018 PREFACE This Specification replaces VRIOGS Power Supply Units for Signalling Equipment - Battery Chargers. The contents of this Specification were prepared by the Victorian Rail Industry Operators Group (VRIOG). This VRIOG Standard has been rebadged as an MTM document due to the retirement of VRIOG Standards as of 30 th June This Specification will be managed under the Engineering Standards Development Procedure (L1-CHE-PRO-032). As documents are uncontrolled once printed, it is imperative to check the currency of the Document on The Depot or the MTM s Document Portal which is available externally at All MTM Standards and Specifications are periodically reviewed, and new editions are published which incorporate learnings and Technical Notes (formerly known as Design Practice Notes). Technical Notes are issued between editions which correct any errors or ambiguities contained in an MTM Standard/Specifications. Standards and Specifications may also be withdrawn and/or replaced. In the event of conflicts or discrepancies between different types of technical documents, refer to the order of precedence as defined in Chief Engineer s Guideline Engineering Standards Listing (L1-CHE-GDL-005). Note: Any clarification described in a Technical Note or Design Practice Note shall take precedence over the impacted clause or clauses in the associated MTM Standard/Specification. In the event a clause within a Standard/Specification is not achievable a waiver will need to be raised, please refer to the Engineering Waiver Procedure - L1-CHE-PRO-001. Note: MTM does not have the authority to grant waivers on any Standards/Specifications or clauses within a Standard/Specification which relate to Government Regulations or Legislation, e.g. Disability Discrimination Act. Referencing this document Clauses and subclauses of this document should be referenced using the following format style L1-CHE-XXX-YYY Clause Z.Z.Z. Referencing the VRIOGS document number is not required. Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 21

4 ENGINEERING SPECIFICATION POWER SUPPLY UNITS FOR SIGNALLING EQUIPMENT - BATTERY CHARGERS L1-CHE-SPE-298 Version: 1 Effective from: 1 st July 2018 THIS PAGE IS INTENDED TO BE BLANK Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 21

5 Victorian Rail Industry Operators Group Standards VRIOGS Power Supply Units for Signalling Equipment Battery Chargers Revision A Issue Date 6/11/2009

6 ii VRIOGS Revision A VRIOGS Power Supply Units for Signalling Equipment Battery Chargers Revision A Issue Date: 6/11/2009 APPROVAL STATUS APPROVER STATUS DATE QUALIFICATIONS Document Developer VRIOG Steering Committee Approved All Sections Accredited Rail Operator Metropolitan Train (Metro Trains Melbourne) Intrastate Train (V/Line) Interstate Train (ARTC) Tram (Yarra Trams) For any queries please contact vriogs@transport.vic.gov.au. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.

7 VRIOGS Revision A iii PURPOSE OF THE STANDARD The Standard has been created through the collaboration of members of the Victorian Rail Industry Operators Group (VRIOG) for the purpose of establishing standards which, if implemented throughout the Victorian Rail Network, will facilitate the interoperability of infrastructure. The use of the Standard is not prescribed by law but, if adopted, conformity with the provisions of the Standard is mandatory in order that the purpose of the Standard be achieved. DISCLAIMER The Standard is published by the Director of Public Transport for information purposes only and does not amount to any kind of advice. Each person is responsible for making his or her own assessment of all such information and for verifying such information. The content of this publication is not a substitute for professional advice. The Director of Public Transport and VRIOG accept no liability for any loss or damage to any person, howsoever caused, for information contained in this publication, or any purported reliance thereon. COPYRIGHT STATEMENT Director of Public Transport This publication is copyright. No part may be reproduced by any process except in accordance with the provisions of the Copyright Act. Where information or material is so used, it should be used accurately and the Standard should be acknowledged as the source of the information.

8 iv VRIOGS Revision A Table of Contents SECTION 1.0 CONVENTIONS... 1 SECTION 2.0 DEFINITIONS... 2 SECTION 3.0 SCOPE AND APPLICATION Scope Application Quality Assurance Quality Assurance Documentation Maintenance Manual Advisory Bulletins Occupational Health and Safety... 3 SECTION 4.0 OPERATING ENVIRONMENT Environmental Conditions Lightning and Surge Protection... 4 SECTION 5.0 BATTERY CHARGER REQUIREMENTS Electrical Characteristics Assembly and Construction Electrical and Electronic Components Transformers Product Identification Labelling Finish... 8 SECTION 6.0 DELIVERABLE REQUIREMENTS Inspections and Tests Certificates... 9 SECTION 7.0 WARRANTY SECTION 8.0 MAINTAINABILITY SECTION 9.0 PACKAGING AND DELIVERY SECTION 10.0 REFERENCES... 13

9 VRIOGS Revision A 1 SECTION 1.0 CONVENTIONS 1) Words or phrases that appear capitalised out of context are defined within the Definitions section of this VRIOG Standard. 2) The word Shall is to be understood as mandatory. 3) The word Should is to be understood as non-mandatory i.e. advisory or recommended. 4) Uncontrolled Standards may not be referenced within the VRIOG Standards. These include former PTC Standards, Franchisee Standards, Franchisee Subcontractor Standards and Infrastructure Lessee Standards. 5) Controlled Standards, including Australian Standards and other VRIOG Standards, may be referenced but only if: The referenced item can not be adequately explained with an amount of text that could not reasonably be inserted into the body of the Standard. The reader is not referenced to another Controlled Standard necessary for the item to be adequately explained i.e. one document link only. The referenced document is a Figure or table and could not reasonably be included in the appendices of the Standard. 6) The format employed in the VRIOG Standards is compatible with Australian Standards, and will be used from this point on. 7) The numbering system for the VRIOG Standards is chronologically sequential from the point of introduction, and is not based on any form of interpretive system. 8) The VRIOG Standards contain engineering information necessary to operate a safe Railway. VRIOG Standards will not contain any information that can be construed as a work instruction, procedure, process or protocol. This information forms the basis of each individual entity s Safety Accreditation Certification, and, as such, is outside the scope of VRIOG Standards.

10 2 VRIOGS Revision A SECTION 2.0 DEFINITIONS Terminology used and/or applied in this Standard is defined as follows: Terminology Accredited Rail Operator (ARO) Application for Variation of Accreditation AS PCB Purchaser Type Approval VRIOG VRIOGS Definition A Rail Infrastructure Manager or Rolling Stock Operator who is accredited under Part 5 of the Rail Safety Act An application to the Safety Director by an Accredited Rail Operator for variation of its accreditation due to the Accredited Rail Operator proposing to make change to or to the manner of carrying out, accredited rail operations that may reasonably be expected:- To change the nature, character and scope of the accredited rail operations; or To not be within the competence and capacity for which the Accredited Rail Operator is accredited. Australian Standard Printed Circuit Board Person or organisation to which the battery charger is supplied or being supplied. Note: They may not be a direct representative of the ARO. Consideration of form, fit and function under specified conditions to approve equipment suitability for me within VRIOG infrastructure. (Refer to VRIOG Standard for Signalling Design and Documentation VRIOGS 012.1, Clause 4.2) The Victorian Rail Industry Operators Group comprising the following members:- VicTrack V/Line Passenger Metro Trains Melbourne Yarra Trams Australian Rail Track Corporation (ARTC) Public Transport Division of the Department of Transport (PTD) Victorian Rail Industry Operators Group Standards. Table 1 - Terminology

11 VRIOGS Revision A 3 SECTION 3.0 SCOPE AND APPLICATION 3.1 Scope This Standard provides the minimum acceptance criteria for the design, manufacture and supply of battery chargers for use within the Victoria Railway Network. 3.2 Application Unless otherwise specified, all battery chargers shall be Type Approved by the ARO and shall be designed, manufactured and supplied in accordance with this specification. 3.3 Quality Assurance The manufacturer shall be accredited to the appropriate Australian Quality Standards or recognised international equivalent if the manufacturer is based overseas. It is considered that the following are appropriate Australian Quality Standards:- - AS/ISO Quality Management Systems Requirements - AS/ISO Quality Management Systems Guidelines for Performances 3.4 Quality Assurance Documentation Quality assurance documentation shall be in accordance with the requirements of Australian Quality Standard Quality Management and Quality Assurance Standards AS/ISO or recognised international equivalent if the manufacturer is based overseas. 3.5 Maintenance Manual The maintenance manual shall be in accordance with the requirements of VRIOG Standard Specification for Signalling Supply, Construction and Installation VRIOGS 012.2, Section Advisory Bulletins The Purchaser shall check and act upon any related manufacturer and ARO issued product bulletins in order to ensure that they are aware of and action any safety related concerns regarding the battery chargers. 3.7 Occupational Health and Safety The manufacturer shall comply with the Victorian Rail Safety Act 2006, the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations The weight of the equipment shall be considered with regards to the current Occupational Health and Safety Regulations 2007 & Codes of Practice with regards to safe handling by persons and with respect to the installation and maintenance requirements. The manufacturer shall comply with a recognised international equivalent if the manufacturer is based overseas.

12 4 VRIOGS Revision A SECTION 4.0 OPERATING ENVIRONMENT 4.1 Environmental Conditions The battery charger shall be subjected to the conditions specified for Category F equipment in specification VRIOGS Environmental Conditions. 4.2 Lightning and Surge Protection The application of battery charger surge protection shall be in accordance to VRIOG Standard Lightning and Surge Protection General Requirements VRIOGS

13 VRIOGS Revision A 5 SECTION 5.0 BATTERY CHARGER REQUIREMENTS This section of the specification states the minimum requirements to be considered for the design and manufacture of the battery charger. 5.1 Electrical Characteristics a) The battery charger shall be designed to efficiently charge one sealed lead acid (maintenance free) battery. b) The charger shall operate on reduction of battery voltage and automatically cut-off when reaching 13.62V for sealed and 13.50V for lead acid batteries when finally adjusted. c) The voltage change shall be stable to ±1% under ambient temperature conditions between 0ºC to 60ºC with 85% humidity and supply voltage range. d) The unit shall be so designed that it will produce an output of 25A when connected to a flat battery and gradually taper off as the fully charged voltage of the battery is reached. Current limit shall be provided. e) An ammeter of 30A full scale with a robust external shunt to ensure that the charger is not open circuit with overload protection shall be provided. A RED LED shall be provided on the front panel to indicate power (110V AC input) ON. The meter and LED shall be labelled accordingly. f) The unit operation shall be immunised from external electrical and electromagnetic interference. g) The insulation resistance between conducting portions and earth or between parts which are intended to be insulated from each other shall not be less than 5MΩ when tested on a 500V megohmeter. h) The 110V input to the unit shall withstand for one minute an insulation test of 2,000V DC between all parts of such electric circuit and other metallic parts insulated with the surge protection removed. i) The surge protection devices shall be provided across the input and output terminals respectively with the following minimum characteristics:- Peak Current (8/20 µs) Continuous Volts Maximum Voltage (V) Clamping Current (A) Input: 4,500A 130 AC Output: 1,000A 31 DC Table 2 Minimum Characteristics for surge protection devices The manufacturer shall clearly state the devices proposed and submit technical data. j) The unit shall be capable of operating within the specification in a temperature range between 0ºC and 60ºC, with a humidity of 85%. The temperature rise of the unit shall not exceed 30ºC on external surfaces. k) The 110V AC input shall be isolated from the DC output. l) The battery charger units magnetising current shall not exceed 15% of full load current.

14 6 VRIOGS Revision A m) The quiescent current shall be less than 8% of full load current. n) Regulation shall be as close to 0% as possible but must be less than 2%. o) Efficiency shall be greater than 70% at full load. p) The battery charger shall operate on 110V ± 10%, 50Hz. q) The transformers shall be designed for 50Hz operation within the availability of primary taps of 5V, 110V and 10V AC. r) The voltage adjust potentiometer (all to be 10 Turn) shall be of robust construction and in the event of the potentiometer going open circuit the output voltage shall not be less than 13.25V DC. The battery charger shall remain stable when the batteries are removed. s) A suitable HRC fuse shall be provided in such a position to protect the charger in case the current limit fails. 5.2 Assembly and Construction a) The unit shall be enclosed in a metal weatherproof and rigid material to withstand the environmental conditions defined in Section 4.1 of this specification. b) The units shall be completely enclosed, with vents provided in the bottom, front and/or side panels. c) Suitable filtered breather openings or sealing shall be provided to prevent internal damage to wiring or components due to moisture, heat or insects. d) The internal input and output terminations (Klippon type or approved equivalent) shall be of pressure plate design and shall accept cable sizes from 0.5mm² to 16mm². An external cable entry hole shall be provided from the rear. e) Where insulated leads pass through holes in the chassis the holes shall be equipped with grommets with a smooth finish. f) All components fastened to the chassis shall be fastened by machine screws and nuts secured by suitable means which prevent loosening under vibration. Self tapping screws shall not be employed. g) Mechanical pressure for clamping electrical connections to insulating materials shall be made so that the circuit will not be adversely affected by shrinkage of the insulating materials. h) The wire sizes and electrical connections shall be consistent with good engineering practice. i) Wherever a wire is connected to an unthreaded stud, the stud shall be grooved or have a hole drilled through it and wire rounded into the groove or placed through the hole and twisted around the stud before soldering. j) The voltage rating of all insulated wire shall be at least 50% greater than the peak voltage to ground impressed on the conductor in normal operating and shall in no case be less than 500V AC.

15 VRIOGS Revision A Electrical and Electronic Components a) All electrical and electronic components shall be in accordance with the requirements of VRIOG Standard Electrical and Electronic Components (Rating and Construction Requirements) VRIOGS b) The electronic components shall have an in-service life of 20 years (minimum). c) If resistors having ferrule type connections are employed, they shall be mounted in clips equal to those of the positive pressure type. d) The resistors having lug terminals shall be firmly mounted in such a manner as to prevent rotation without relying upon the lugs for support, but shall be easily replaceable in case of failure. e) The variable resistors shall be of multi-turn construction and in the event of failure the output voltage shall not vary by more than 5%. f) Mounting for semi-conductor devices shall be so designed that the device may be removed or installed without damage. Adequate heat sink area must be provided to cover highest operating temperature. g) All components shall operate at below 50% of maximum rating. h) The capacitors shall not be subject to in excess of their working voltage under operating conditions. Use of electrolytic capacitors should be avoided wherever possible. i) The layout of the unit shall allow accessibility to all components, during maintenance and repair of the unit. j) PCB used shall be in accordance with the requirements of VRIOG Standard Electrical and Electronic Components (Rating and Construction Requirements) VRIOGS , Section 5.6. k) The registry pins shall be provided on printed circuits card plug connectors to ensure that only the correct cards can be plugged into socket connections. l) Suitable means shall be provided for locking plug-in cards in position so that they cannot vibrate out of position during service. 5.4 Transformers a) The transformers shall be in accordance with the requirements of VRIOG Standard Electrical and Electronic Components (Rating and Construction Requirements) VRIOGS , Section 5.4. b) The transformer shall be of single phase, double wound, metal clad, natural air cooling type, with rated output specified, to operate from single phase 50Hz supply voltage with a temperature rise not exceeding 55ºC. c) The core, framework, clamping arrangements and structure of the transformer shall be of substantial design so as to form a rigid construction entirely unaffected by ordinary handling during transit and installation. d) The mounting holes shall not be less than 7mm in diameter and provided in an accessible position, clear of core and windings. e) The coils shall be thoroughly vacuum impregnated with a high quality insulating varnish or other suitable insulating compound.

16 8 VRIOGS Revision A f) The terminals shall be of an approved design and shall be legibly marked to permit identification on circuit diagrams. The terminals shall be mounted on a suitable panel and project towards the front of transformer. Full details for any alternative design of terminals shall be submitted with tender. Input terminals are to be shrouded with a cover which is easily accessible. g) All metal parts shall be protected from corrosion by the application of an approved coating. h) The core shall be made of laminated transformer steel sheets complying with BS Specification for Nickel-Iron Transformer and Choke Laminations, so assembled that no humming is perceptible. i) All insulation used in the transformer shall be non-hygroscopic and designed to withstand continuously a temperature of 100ºC, and shall withstand continuously a test of 3,000V RMS for one minute between windings and between windings and core. j) In addition to fully scaled detailed drawings showing general arrangements of the transformer, manufacturers shall supply the following information :- Efficiency at full load Efficiency at half load No load primary current Full load primary current Inherent voltage regulation No load losses Full load losses 5.5 Product Identification a) A metal engraved nameplate shall be affixed in a readily visible position on the unit and such a manner that it cannot become dislodged during the operation life of the battery charger. b) The nameplate shall contain but not be limited to the following information:- Manufacturer s name Manufacturer unique serial number Date of manufacturer Description of the battery charger 5.6 Labelling a) Labelling shall be in accordance with the requirements of VRIOG Standard General Requirements for Labelling of Signalling Equipment VRIOGS Finish a) All parts should be uniform in composition, clean, smooth and free from defects. b) All parts shall be free from sharp corners and burrs which could cause injury to personnel during normal installation and maintenance procedures.

17 VRIOGS Revision A 9 SECTION 6.0 DELIVERABLE REQUIREMENTS 6.1 Inspections and Tests a) Each battery charger shall be subjected to a series of inspections and tests to confirm that it conforms to the requirements stated in this specification. b) The manufacturer shall carry out all electrical and/or mechanical inspections and tests to verify that battery charger supplied conforms fully to this specification prior to delivery. c) All these tests shall be carried out at the manufacturer s premises at their cost. The Purchaser reverses the right to witness these tests. d) All apparatus and instrumentation required for the tests shall be provided by the manufacturer. e) The inspection and test records shall be retained by the manufacturer for a period not less than the nominated storage life and warranty period of the equipment. 6.2 Certificates a) The results of the inspections and tests are to be submitted in the form of a signed certificate on the manufacturer s company letterhead. b) The manufacturer shall provide the completed Certificate of Compliance to the Purchaser with the delivery of the battery charger. c) The certificate shall include but not be limited to the following information:- Certification number and Date of certification Customer s name and Contract number Purchase order number Date of manufacture Quantity of delivery Unique serial number for individual product or batch code assigned by the manufacturer Inspection and test results Date of the inspection and testing Statement of compliance to certificate that the product meets all the requirements of this specification Name and Signature of the manufacturer s management representative d) The Purchaser shall have the right to request supporting Quality Assurance documentation to accompany the manufacturer s Certificate of Compliance.

18 10 VRIOGS Revision A SECTION 7.0 WARRANTY a) The manufacturer shall provide warranty to the Purchaser on all items of equipment supplied. b) All goods supplied by the manufacturer shall be guaranteed against faulty workmanship and/or materials for a period of 12 months from the date of commissioning of the equipment or 24 months from the date of delivery, whichever is the later. c) The manufacturer shall replace without expense to the Purchaser any part (or parts) of the equipment found to be not in accordance with this specification throughout this warranty period. d) The manufacturer shall warrant components bought-in from external suppliers for a warranty period no less than that specified in Section 7(b) of this specification.

19 VRIOGS Revision A 11 SECTION 8.0 MAINTAINABILITY a) The manufacturer shall provide a recommended maintenance plan for routine preventative maintenance tasks, task frequencies and fault finding of the equipment to the Purchaser. b) These shall include but not be limited to the following information:- Installation and maintenance instructions Maintenance periodicities Test equipment and specialist tools required to install, adjust, fault find and maintain the equipment. Detailed drawings showing complete assembly details Operational test plan A troubleshooting guide (fault indications, their likely cause and suggested solutions) Details on equipment repair and replacement procedures Spare parts list

20 12 VRIOGS Revision A SECTION 9.0 PACKAGING AND DELIVERY a) The battery charger shall be individually and securely packed to avoid mechanical damage. b) All battery charger units shall be handled in such a manner that the delivery and storage of the units will not materially influence their subsequent inservice performance. c) The packaging shall be labelled in accordance to VRIOG Standard General Requirements for Labelling of Signalling Equipment VRIOGS , Section 4.4.

21 VRIOGS Revision A 13 SECTION 10.0 REFERENCES The following documents have been used and referenced for the preparation of this standard:- No. Ref No. Title 1. AS/ISO Quality Management Systems Requirements 2. AS/ISO Quality Management Systems Guidelines for Performances 3. AS/ISO Quality Management and Quality Assurance Standards 4. BS 381C Specification for Colours for Identification, Coding and Special Purposes 5. BS Specification for Nickel-Iron Transformer and Choke Laminations 6. VRIOGS Standard for Signalling Design and Documentation 7. VRIOGS Specification for Signalling Supply, Construction and Installation 8. VRIOGS Lightning and Surge Protection General Requirements 9. VRIOGS Environmental Conditions 10. VRIOGS Electrical and Electronic Components (Rating and Construction Requirements) 11. VRIOGS General Requirements for Labelling of Signalling Equipment Rail Safety Act 2006 (Victoria) Occupational Health and Safety Act 2004 (Victoria) Occupational Health and Safety Regulation 2007 (Victoria) Table 3 References