FuseAutoChangeOver RDSO SPN 209 2012 VER 2
FuseAutoChangeOver RDSO SPN 209 2012 VER 2
FuseAutoChangeOver RDSO SPN 209 2012 VER 2
lR;eso t;rs
TECHNICAL SPECIFICATION
FOR
FUSE AUTO CHANGEOVER SYSTEM (FACS)
FOR USE
IN RAILWAY SIGNALLING
SIGNAL DIRECTORATE
RESEARCH DESIGN & STANDARD ORGNIZATION
LUCKNOW-226011
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
Approved by RDSO
This document specifies technical specification and inspection criteria for Fuse Auto
Changeover System for use in Railway Signalling.
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
REVISIONS/AMENDMENTS
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
TABLE OF CONTENTS
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
0. FOREWORD:
0.1 This specification is issued under the fixed serial number RDSO/SPN/209/2012
0.4 This specification is intended to cover the technical provisions and it does not
include all the necessary provisions of a contract.
1. SCOPE:
1.1 This specification lays down the requirements and tests of Fuse Auto Changeover
System with Alarm facility along with audio and visual indications suitable for
signaling installations of Railways.
1.2 The changeover facility covered in this specification should be suitable for
changing over of circuit operation from main fuse to spare fuse automatically
when main fuse is blown off without affecting the functioning of signaling
circuits. At every change–over, audio/visual indication should appear.
1.3 Equipment shall work either on 24V DC, 60V DC or 110 V AC as specified by
the purchaser. The equipment shall be able to work in tolerance range of +20%, -
30%. The power supply used in the system shall be SMPS type.
Reverse polarity protection and overload protection voltage should also be
provided in the power supply circuit.
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
1.4 The system shall be modular by design and each module of the system shall have
capacity for monitoring either of the following-
TYPE-I: 32 nos. of external Non Deteriorating Type or ‘G’ type fuses from 0.6
Amp to 4 Amp capacities which are in signaling circuits. System shall have 8
cards with monitoring arrangement of 4 fuses in one card.
TYPE II: 24 no. of external Non Deteriorating Type or ‘G’ type fuses from 4 A
to 10 Amp capacities generally used for point operation circuits. Such system
shall have 6 cards with monitoring of 4 fuses in one card.
1.4.1 All fuses being monitored by one card will be of same supply having common
ground. It should be possible to combine more than one such system for
monitoring of more no. of such fuses in the entire installation.
1.5 The system shall be capable of monitoring fuses with system voltage of fuse
circuit as 12V, 24V, 60V or 110V DC/AC.
1.6 Optocoupler shall be used to provide isolation in input circuit for every fuse.
1.7 The standby fuse used in the TYPE I system shall be of 5x20 mm ceramic tube
type with high breaking capacity (1500 Amp) as per IEC 60127-2 standard. The
standby fuse used in TYPE II system shall be of 6.35x 32 mm ceramic tube type
with high breaking capacity (1500 Amp). Standby fuse should be of 250 V rating
& same capacity as that of the main fuse and as specified by the purchaser.
Standby/Spare fuses from internationally reputed manufacturers like Cooper
Bussman, Protectron, Shurter etc. which have internationally approved
accreditations and certification like UL, TUV etc. shall only be used.
1.8 Standby fuse shall come in circuit only after blowing of the main fuse and should
be out of circuit when RESET switch is pressed after replacement of main fuse.
2. ABBREVIATIONS USED:
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
OK: Okay
3 TERMINOLOGY:
3.1 The terminology used in this specification is covered by the definitions given in
IRS: S 23.
4 GENERAL REQUIREMENTS:
4.1 Maximum outline dimensions of each module for TYPE I or TYPE II be such that it
is easily fitted in a standard 19 inch rack. The module shall take not more than 4U
spaces vertically in a standard 19 inch rack. The depth of the module shall be less
than or equal to 165 mm. If the purchaser specifies that the system modules are to be
fitted in standard signaling relay rack instead of standard 19 inch rack, then extender
fixing plates (2 Nos. per modules) of stainless steel of 1.5mm thickness with suitable
fixing holes shall also become part of the system.
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
4.2 The equipment shall be of robust construction. The housing shall be of cold rolled
annealed mild steel sheet of thickness not less than 1 mm. All the modules should be
fixed in housing in such a way that there should not be any space left for entry of
rodents.
4.3 The equipment housing shall be treated with zinc chromate primer followed by
electrostatic epoxy powder coating paint finish. Small metal parts such as nuts, bolts
and washers shall be chrome plated. Other metal parts of the system shall also
generally be corrosion proof. The layout of the components and wiring shall be such
that all parts are easily accessible for inspection, repairs and replacement.
4.4 The cables and wires used shall be neatly secured in position by bunching &
strapping. Only copper wires shall be used inside. The gauge of wires used should be
adequate such that the current density should not exceed 3 Amps/mm². The wires
used shall conform to IRS: S 76/89/ or IS:694 of grading 1100 volts. The colour
scheme used for wiring shall conform to normal conventions and shall be shown in
the Instruction manual.
4.6 The following components shall be provided on the Power Card Module of the
system.
4.7 Following components shall be provided on each monitoring card of the system:
i. Standby Fuses.
ii. LED indications for Main and Standby Fuses monitored by the card.
iii. RESET push button (one for each monitoring card)
4.8 Tapping taken out for monitoring the status of fuse shall load the system to the
minimum possible. In any case, the current drawn for the monitoring purpose
shall not be more than 3 mA for each fuse.
4.9 The system shall be suitable for working on non-electrified, AC electrified and
DC electrified areas and where passenger/freight trains hauled by single phase
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
5. COMPONENTS:
5.1.1 The PCB shall be so designed that it should comply the requirements as laid down
in Clause No. 6.0 of RDSO/SPN/144/2006 (latest).
5.1.2 The components used shall meet the requirement of Clause 5.1 of
RDSO/SPN/144/2006. Compliance of clause 5.2 of RDSO/SPN/144/2006 shall
also be ensured in the design of the equipment.
5.1.3 LEDs used for all indications shall either be of Nichia, Avago, Osram, Cree or
Kwality (India) make. LEDs with 3 mm diameter shall be used for indication
purpose in the system.
5.1.4 The printed circuit cards shall be specifically designed to suit the circuitry used
and no extra wires other than secondary fuse connections shall be used for
interconnection of components on the PC cards. Soldering of components shall be
neatly done.
5.1.5 After mounting and soldering of all the components & testing, the printed circuit
cards shall be coated with transparent epoxy paint or acrylic conformal coating to
provide environmental protection.
5.1.6 All LED indications shall be mounted on PCBs and shall not be loose wired.
5.2.1 The switches and push buttons used shall be of high quality and performance.
These shall be able to withstand >50000 operations. Switches shall be robust in
structure and shall be able to withstand jerks. PCB mounted TACT
switches/buttons may also be accepted.
5.2.2 All wiring from Relay racks to the system cabinet must be terminated on
connectors soldered directly on the cards or motherboard PCB (if used) mounted
inside rear of rack with descriptions.
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5.2.3 All current carrying terminals shall be of copper or brass and shall be plated for
protection against corrosion. Good quality connectors screwless type shall be used
at the rear of the system to facilitate external wiring.
6. DESIGN CRITERIA:
6.1 The system design shall be such that it should be only supervisory / Alarm circuit.
Failure of any component should not interrupt the supply to load by any means.
For monitoring the fuses, wires shall be taken from respective fuses. In each set,
a Green LED shall glow for healthy Main fuse & and a separate one for healthy
Standby fuse. Similarly, separate Red LEDs shall indicate failure of Main fuse &
Standby fuse.
6.2 On the failure of a main fuse, its standby fuse should come in circuit
automatically before dropping of signaling relay. The changeover time shall not
be more than 20 milliseconds at rated voltage of the system.
6.3 When the system starts for the first time, only main fuses should come in circuit
and in no case the standby fuse shall come in circuit if the main fuse is intact.
6.4 The power supply module used inside the equipment should be provided with
natural ventilation.
6.5 TEST push button should be able to test the health of all indications.
6.6 Six no. of potential free contacts shall be provided on rear side for initiation of
remote Common Audio Visual Alarm or any other utility. These contacts should
normally be in MAKE condition.
6.7 On the failure of any main fuse, suitable LED indication should glow and buzzer
of the unit should give audio alarm. Simultaneously two no. of potential free
contacts out of six should also break for initiation of Common Audio Visual
Alarm. If any of the Standby fuses also blows along with its main fuse, the other
pair of potential free contacts shall also break for taking out Audio Visual Alarm
again. The remaining 2 no. of potential free contacts may be used for extending
SMS for main and standby fuse blowing.
6.8 Pressing of the ‘Acknowledge’ button on the unit shall cut off the alarm but the
LED indication shall remain till the fuse is replaced.
6.9 The LED should light up till the fault persists and audible alarm shall only be
reset. The visual indication should disappear when the fuse is replaced and
SSE/Signal ADE/Signal Director/Signal
Prepared By: Checked By: Issued By:
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
RESET button is pressed. However, if another fuse is blown off after resetting /
muting the buzzer, the audible buzzer should come again along with the visible
indication. Standby fuse shall be mounted in a screw type fuse holder of panel
mount type. The fuse holder shall be from reputed UL/UR/CSA/CE approved
manufacturers. The body of the fuse holder shall be UL-94 V-0 Thermoplastic.
The contacts shall be tinned copper with < 5mOhm contact resistance.
6.10 The audible alarm should be given by buzzer having dual tone intermittent
sound with 3-5 KHz frequency.
6.12 The system should operate on N+2 wires where N is the no. of monitored fuses of
same voltage in the system.
6.13 The system should be able to monitor fuses in different voltage circuits of 12V,
24V, 60V, 110V AC/DC in blocks of 4 fuses of each voltage.
6.14.1 Common audio- visual alarm unit shall be hanged in ASM’s room or any other
convenient place and shall have following features:-
ii) Common failure LED indication (RED) in case of any main fuse getting
blown out at the station.
iii) Another LED indication (RED) if any of the standby fuse also is blown
along with its Main fuse. Both the LEDs shall be lit in case of both Main
and Standby getting blown.
iv) Piezoelectric buzzer to give audio alarm for failure conditions mentioned
in Clause- 6.7.
vi) A suitable fuse shall be provided at input of the power supply inside the
unit.
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
6.15 Optional Item- GSM Modem: If the purchaser requires, a GSM modem shall be
supplied and with such modem connected, the system(s) shall send SMSs on
GSM network to upto 5 preselected GSM mobile numbers in case of any of the
fuse blowing. The mobile numbers shall be configurable. SMS shall be generated
within 30 seconds of fuse blowing and if the sending fails, subsequent sending of
SMS shall be tried by the system immediately. Besides this, provision of separate
message indicating blowing of main & standby fuse shall also be there. A
separate message shall again be generated when a fuse is replaced. The SIM
required for the GSM modem shall be provided by the purchaser.
6.16 The GSM modem shall be from reputed make and compatible to Tri-band GSM
850, 900, 1800 and 1900 MHz. It shall support GPRS class 10 and shall be
working on 110V AC with suitable power supply adapter. It shall be able to
withstand operating temperature upto 60º C and humidity upto 95%. When a fuse
blows, it shall generate SMSs as per following details.
Station code: XXXX (to be fed in the system with flexibility of change by user)
EVENT SMS
Main and Standby both fuses blown ATTENTION: BOTH FUSES BLOWN
AT STATION XXXX
7. MARKING:
7.1 All markings/ indications shall be placed in the vicinity of the components to
which they refer and shall not be placed on removable parts.
7.2 All terminals shall be suitably marked to facilitate ease of connection. Supply
voltage shall be indicated nearby the input terminals.
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
7.3 Clauses 12.1 and 12.2 of specification no. RDSO / SPN / 144 / 2006 shall be
complied.
The words ‘Indian Railway Property’ shall be engraved /embossed/ screen printed
on every unit in letters of 5 mm size (minimum) at a conspicuous place.
7.4 Following markings shall be done on every unit either on firmly attached
anodized name plate or using non erasable screen printing on the body.
(a) Name or trademark of the manufacturer
(b) Serial number of the unit
(c) RDSO’s specification number
(d) Operating voltage
(e) Month and year of manufacture
7.5 All markings/indications shall be easily legible and durable. Where the marking is
by use of labels, the labels shall be non ferrous metallic and shall be firmly fixed
and shall not be capable of being removed by hand. Durability of marking shall be
checked by rubbing the marking by hand with a piece of cloth soaked with
petroleum spirit. This requirement shall also be met after completion of climatic
test.
8.1 The Fuse Auto Changeover System (the main module, the common audio visual
alarm unit & the GSM modem) shall be capable of working in non air conditioned
environment in the field. It shall be suitable for installation on AC/ DC electrified
and non-electrified sections. It shall be suitable in all areas including where
locomotives having thyristor controlled single phase or 3-phase induction
motors haul passenger or freight trains and where chopper controlled EMU
stocks are operated. The system shall pass the climatic test as per S. No. 1, 2, 3, 4,
5, 6, 7, 10, 12 & 13 of Clause No. 9.3 Specification RDSO/SPN/144/2006.
8.3 Applied high voltage test for Fuse Auto Changeover System: The equipment shall
withstand for one minute without puncture and arcing when a test voltage of
2000Volts rms is applied between
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
(For testing with part of body, which is used as heat sink, test voltage shall be
1500Volts rms)
8.4 Insulation Resistance Test for Fuse Auto Changeover System: This test shall be
carried out-
(a) Before the high voltage test
(b) After the high voltage test
(c) After completion of the climatic test
The Insulation Resistance shall be measured between the body and the fuse
sensing terminals and supply terminals looped together at a potential of 500 V
DC. There shall not be appreciable change in the values measured before and after
high voltage test and these values shall not be less than 100 Mega ohms. After
completion of climatic test, the insulation resistance shall not be less than 10
Mega ohms for the equipment at a temperature of 40°C and relative humidity
60%.
8.5 Vendor shall submit make, grade and data sheet of all electronic components and
switches alongwith samples. Vendor shall also submit design parameters like
voltages, input current, power consumption etc. along with their tolerances to
achieve specified operating parameters.
8.6 Fail Safety:
The equipment shall be so designed that any short/open or any other defect in any
of the component will not lead to unsafe / undesirable situation.
9 INSPECTION CRITERA
For type test, two samples of Fuse Auto Changeover System shall be subjected to
following tests as applicable:
(i) Visual inspection & dimensional check (Cl. 1.4, 1.4.1, 1.7, 4.1, 4.2, 4.3, 4.4,
4.5, 4.6, 4.7, 5.1.3, 5.1.2, 5.1.4, 5.1.5, 5.1.6, 5.2.1, 5.2.2, 5.2.3,
6.4, 7.1, 7.2, 7.3, 7.4, 7.5).
(ii) Operating Parameters (Cl. 1.2, 1.3, 1.5, 1.6, 1.8, 4.8, 6.1, 6.2, 6.3, 6.5, 6.6,
6.7, 6.8, 6.9, 6.10, 6.11, 6.12, 6.13, 6.14, 6.15, 6.16)
(iii) Climatic tests (sub Clause 1, 2, 3, 4, 5, 6, 7, 10, 12 and 13 of Cl. 9.3 of
RDSO/SPN/ 144/ 2006).
SSE/Signal ADE/Signal Director/Signal
Prepared By: Checked By: Issued By:
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Effective from 01.08.2018 Specification no. RDSO/SPN/209/2012 Ver. 2.0
9.2.1 Out of a lot, 20% of the samples shall be subjected to following tests:
(i) Visual inspection & dimensional check (Cl. 4.7, 5.1.2, 5.1.3, 7.2, 7.3, 7.4, 7.5)
(ii) Operating Parameters (Cl. 6.2, 6.3, 6.5, 6.6, 6.7, 6.8, 6.9 & 6.10)
9.2.2 Minimum five samples from those which have passed tests as per Cl. 9.2.1 shall
be subjected to following tests-
9.2.3 Acceptance tests as per Cl. 9.2.2 shall be conducted before and after ambient
temperature severity test. The equipment shall be kept in energized condition for
1 hour each at -10°C and + 60°C during ambient temperature severity test.
Operating parameters and audio visual alarm tests shall also be conducted after
ambient temperature test.
9.3.1 Following routine tests besides other tests, as deemed fit to ensure quality,
reliability and compliance of this specification, shall be done by the manufacturer
on all the units:
9.4. When one main fuse blows/ unscrewed, then buzzer should come along with main
fuse failure indication.
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10. DOCUMENTATION:
(a) One copy of Installation and maintenance manual. This should also
include following information:
(i) Guaranteed performance data, technical and other particulars.
(ii) Schematic block diagram showing mounting arrangement of various
components & details of each type of assembled PCB.
(iii) Details of Hardware e.g. schematic diagrams of the system circuits/
components, details for each type of assembled PCB and part list
(iv) Mechanical drawings of every unit.
(v) Part no. and manufacturer’s details of components used.
(vi) Trouble shooting procedure alongwith test voltages and waveforms at
various test points in PCBs.
(vii) Details/procedure of trouble shooting of Fuse Auto Changeover System.
(b) Dos & Don’ts (Pocket size laminated cards)
(c) Pre-Commissioning check list
Units shall be packed in suitable boxes / crates, strong enough, with 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.
12. WARRANTEE:
The supplier shall give a warrantee of 24 months from the date of supply for the
equipment supplied under this specification.
(i) The system voltage at which the Fuse Auto Changeover System need to
work (as per clause 1.3).
(ii) TYPE-I or TYPE II system as per clause 1.4.
(iii) No. of fuses with their respective voltage/current ratings as per clause 1.4
(iv) The requirement of GSM modem for connection to the system(s) in
reference to clause 6.14, if any.
(v) Whether the system module is to be mounted in existing relay rack instead
of a standard 19 inch rack.
(vi) Required no. of common audio visual alarm units (as per clause 6.14)
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Indian Railways shall not be responsible for infringement of patent rights due to
similarity in design, manufacturing process, use of components used in design,
development of manufacturing of such equipment and any other factor which may
cause such dispute.
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