lR;eso Tk;rs

Hkkjr ljdkj
jsy ea=ky;
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

vuqla/kku vfHkdYi ,oa ekud laxBu

jsy ea=ky;
RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANK NAGAR, LUCKNOW-226011

la0 vkj-Mh-,l-vks-@ih-bZ-@,l-ih-bZ-lh-@Vh-,y-@0021&2005 (la’kks- 2)

RDSO Specification No. RDSO/PE/SPEC/TL/0021/2005 (REV ‘2’)

TECHNICAL SPECIFICATION FOR BRUSHLESS DC RAILWAY CARRIAGE FAN

Sl.No Date of No. of Version Reasons for revision

. revision pages
1. 18.12.2000 13 REV ‘0” First issue
2. 30.11.2005 13 1 To incorporate new material for blades in
line with conventional fan, modify various
clauses based on the experience gathered
during prototype testing of various make
BLDC Fans. To include environmental
tests as per IEC-60571 (1998-02) and
vibration tests as per IEC-61373(1999)
3. 00.03.2012 2 To improve the reliability & standardization
of BLDC fan.

vuqeksfnr
APPROVED

dk;Zdkjh funs’kd@ih-,l- ,oa bZ-,e-;w-

Executive Director / PS & EMU
 Page 2 of 2 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

TECHNICAL SPECIFICATION FOR BRUSHLESS DC RAILWAY CARRIAGE FAN

0.0 FORWARD:

Previously, 110Vdc fixed and swiveling type fans of different sweeps having
commutation with the help of carbon brushes were being used in self-generating
coaches and dc EMUs. Maintenance and replacement of carbon brushes & their holders
including maintenance of commutator of these fans had been great concern to Indian
Railways in addition to its low efficiency, reliability and excess noise. In order to reduce
maintenance cost, weight, operational cost and to enhance efficiency, reliability, service
life and aesthetic of these fans implementing the latest state of art technology in this
filed, this specification for brushless DC railway carriage fan has been prepared for
guidance of manufacturers for their design and development.

1.0 REFERENCE TO VARIOUS SPECIFICATIONS

The following publications are applicable to the equipment in general: -

Standards Description
IS:6680 Specification for Railway Carriage Fans
RDSO Spec Reliability of Electronics used in rolling stock application
No.ELRS/SPEC/SI/0015-
Oct-2001
IEC 60571 Electronic Equipment used on Rail vehicles
IEC 60571-1 Electronic equipment used on rail vehicles Part 1: General
requirements and tests for electronics equipment
IS: 616 Safety requirements for mains operated electronics or
related apparatus for household and similar general use
IEC 61373 – 1999 Railway applications –Rolling stock Equipment –Shock &
Vibration tests

Note: Latest version of the above specifications/IEC shall be applicable

2.0 SCOPE :

2.1 This specification covers the requirements of design, manufacture, testing and supply of
400mm sweep BLDC railway carriage fans for rolling stock application complete in all
respect suitable for input voltage of 110V dc system.

2.2 Electronic controller card shall be used as power devices in the inverter. The inverter
shall have control and protections with a single controller board for power supply,
protection; sinusoidal generation etc. and gate driver card shall be provided closer to the
power devices. The detailed specification for power devices used shall be given/
submitted before offering for witnessing the prototype testing.

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 3 of 3 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

2.3 Input to the unit will be fed through battery bank of 110V dc in parallel with alternator,
rectifier cum regulator. The unit shall be suitable for operating voltage available as input
i.e. 90V to 140V DC with 15% ripple. The over voltage trip shall be set between 150 to
155V.

3.0 OPERATING POWER SUPPLY:

The fan shall be suitable for working from the power supply described as under:-
Rated Voltage : 110 V DC
Voltage range : 90- 140V DC

4.0 DESIGN AND GENERAL CONSTRUCTIONAL FEATURES :

4.1 The motor of the fan shall be permanent magnet type, light in weight and small in size
without field winding, brushes and commutator. The stator may be of two or more
windings. The permanent magnet shall be fitted on the rotor in such a manner that it
should not get disengaged. It is desirable that the magnet shall be embedded in slots.
Deep drawn design for fan body made from MS sheet shall conform to RDSO drg. No.
RDSO/PE/SK/TL/0025-2002 (Rev.0) Motor body shall be of aluminum alloy LM-6.
Details of mounting of fan to coach ceiling are as under.

PCD : 108 mm
No. of holes : 3 at equal distance
Hole diameter : 9 mm

For fixing of fan guard, separate provision of collor or extension of fan motor body may
be provided.

4.2 PROPERTIES FOR PERMANENT MAGNET:

The permanent magnet to be used on the fan shall have the following properties:

• Value of coercive force shall be advised after designing the fan

• Hardness of the magnet shall not exceed 700 HV
• It shall have smooth ground surface.
• It shall meet the requirement of clause 8.7 of this specification.
• Rotor magnet shall have 1300-2000 Gauss.

4.3 BLADES:

Fan blades shall conform to RDSO drg. No. RDSO/PE/SK/TL/0108-2008 (ALT ‘1’)
(Rev.0) and shall be easily replaceable / interchangeable.

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 4 of 4 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

4.4 ELECTRONIC CONTROLLER:

Electronic components used in electronic controller or elsewhere in fans shall be as

under:

i. IC (Integrated Circuits) shall be of Industrial Grade.

ii. Electrolytic capacitors shall be rated for maximum temperature of 105°C (Mill grade/
Industrial grade.)
iii. Paper/polyester capacitors shall be rated for maximum temperature of 85°C
iv. Hall Effect sensor (if used) shall be rated for 65°C ambient.
v. The resistors shall be preferably made of metal film of adequate rating.
vi. Switching devices such as transistors, MOSFETs and IGBTs shall have minimum
junction temperature of 150°C.
vii. Devices shall have 20°C thermal margin at the ambient of 55°C
viii. Material for printed circuit board shall be copper clad glass epoxy of grade FR-4 or
superior.
ix. The controller card shall be used with three phase output voltage of 54V±2 volts with
provision of 6 nos. mounting holes as per RDSO drawing no. RDSO/PE/SK/TL/0153-
2011 (Rev ‘0’) - sheet 1 of 4 (or latest).

4.4.1 Assembled printed boards shall be given a conformal coating to enable them for
functioning under adverse environmental conditions. Over and above the conformal
coating, if the firm feels necessary to have potting, they may go for soft potting.
However, hard potting under any circumstances may not be acceptable.

4.4.2 Use of surface mounted devices shall be preferred to the maximum possible extent.

4.4.3 No hand soldering shall be allowed. Only automatic wave soldering / reflow soldering is
acceptable.

4.4.4 The supply cable shall not be connected directly to the PCB. Connector (Wago make
male/female connector part nos. 734-233 and 734-203 for 3-pin and part nos. 237-102
and 237-103 for 2-pin) shall be soldered to PCB for this purpose. Thin walled flexible
elastomeric cables with copper conductors suitable for continuous operation at 120°C
and having halogen free insulation and sheath shall be used.

4.4.5 The connector shall be provided as per RDSO drawing no. RDSO/PE/SK/TL/0153-2011
(Rev ‘0’) - sheet 1 of 4 (or latest) and in such a manner that looking from top of the
connector from left side pin, configuration shall be R, Y, B at the output.

4.5 STAMPINGS:

Laminated core shall be used in the construction of fan motor. The stampings used for
laminated yoke and armature core shall be made from electrical steel sheets (see IS:
648, IS: 649 and IS: 3024 with latest amendments if any).

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 5 of 5 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

4.6 STATOR

Stator used in BLDC fans shall be as under:

No. of phases :3
No. of slots :6
No. of turns : 435-480
Stack length : 11.5 ±o.5
Stack outer dia : 87 mm
Stack inner dia : 56.2 ±0.2

4.7 ROTOR:

4-pole rotor magnet and shaft used in BLDC fan shall be as per RDSO drawing no.
RDSO/PE/SK/ TL/0153-2011 (Rev ‘0’) – sheet 2 of 4 and sheet 3 of 4 (or latest)
respectively. If Hall Effect sensors are used then sensor magnet shall conform to RDSO
drawing no. RDSO/PE/SK/TL/0153-2011 (Rev ‘0’) - sheet 4 of 4 (or latest).

4.8 BEARINGS:

SKF make (6201ZZ) ball bearings or equivalent in NBC/ FAG make bearing shall be
used.

4.9 WINDING WIRE AND INSULATION:

The copper polyestermide enameled round wire of Class 180 conforming to IS

specification NO.13730 (Part 8) shall be used for winding of the motor.

All the insulating materials used in the motor shall be of ISI quality conforming to the
relevant specifications and test conditions specified for class 155 insulating materials.

The fan’s motor shall be well treated with the insulating varnish of Class 155 conforming
to relevant IS in vacuum pressure impregnation plant to achieve minimum IR value of 20
mega Ω. The curing of varnish shall be done in air circulating oven or as per guidelines
issued by varnish manufacturers.

4.10 COLOUR OF FAN BLADE AND BODY:

Complete fan i.e. fan body, motor body, fan guard assembly (of mild steel) etc. shall be
powder coated with minimum thickness of 60 microns to colour silver metallic finish to
HVC 100 of HAWCOPLAST / 95-03014 of MARPOL.

A band of colour of about 20 mm wide over the periphery of the fan body approximately
at its middle portion shall be applied as a colour code for the following :-

• Dark green : BLDC fan without hall sensor

• Dark yellow : BLDC fan with hall sensor

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 6 of 6 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

4.11 GUARD:

Crashworthy design of fan guard shall conform to ICF drg No. ICF/SK-7-6-158 alt. ‘D’
coll-II.

4.12 GENERAL:

Any more information required, if any, for design, construction and test - IS: 6680 shall
be referred to. However, still, if any, clarification is required, RDSO shall be contacted
while development. For any deviation while development, firm shall obtain RDSO’s
approval.

A connector of fiberglass reinforced plastic manufactured from sheet moulding

compound (SMC) of 25% fiberglass contents, self-extinguishing grade conforming to
RDSO’s drawing no. SKEL-4296 shall be provided. The connector shall be mounted in
the ceiling of the coach and shall be supplied separately with the fan.

5.0 PERFORMANCE REQUIREMENTS:

5.1 The fan shall be light weight and energy efficient with maximum air delivery at rated
voltage and shall conform to following parameters:

a. Minimum air delivery in cubic meter per minute : 60

b. Max. input power in watt : 32
c. Maximum weight in Kilograms : 7
d. Min. service value in cub meter /min/watt : 2
e. Noise level (maximum) : 55 dBA

6. 0 MARKING:

6.1 Each fan shall be indelibly marked with the following

(a) Type of fan

(b) Size of fan
(c) Rated voltage and voltage range
(d) Input watts
(e) RPM
(f) Sl.No.
(g) Month & year of manufacture

6.2 An oval shape rectangular plate of size 50 mm x 30 mm fixed by two screws or rivets
shall be provided on the fan motor for marking of Railway Code initials and serial Number
separately.

7.0 TESTS:

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 7 of 7 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

7.1 Type tests shall be carried out by RDSO on five samples of BLDC fans of the same type
selected from the lot available at the premises of the manufacturers. One fan shall used
for endurance tests after carrying out all tests except tests mentioned at clause 8.9.
However temperature of Insulated windings, accessible external surface metallic / non-
metallic, bearings shall be recorded at the end of the endurance test and shall not
exceed the limits given in Table at clause 8.9.

In respect of tests for which testing facility is not available with the manufacturer, the
same may be carried out at NABL accredited test house / lab and test reports shall be
submitted to RDSO.

7.2 The following type, routine and acceptance tests shall be conducted on Brushless DC
Railway Carriage Fans.

S. Test description Type test Routine Acceptanc Remarks/

No test e test Clause ref.
1. 2. 3. 4. 5. 6.
1 Visual inspection and Y Y Y Clause 8.1
verification of dimensions,
materials and finish for
components etc.
2 Running of fan at max voltage Y Y Y Clause 8.2
i.e. 140V.
3 Starting test Y Y Y Clause 8.3
4 Speed test Y Y Y Clause 8.4
5 Electrical In put test Y Y Y Clause 8.5
6 Input overvoltage test Y Y Y Clause 8.6
7. Heating test on permanent Y - - Clause 8.7
magnet
8. Reverse polarity test Y Y Y Clause 8.8
9. Locked rotor test Y - Y Clause 8.9
10. Temperature rise test Y - - Clause 8.10
11. Insulation resistance test Y Y Y Clause 8.11
12. Dielectric test Y - Y Clause 8.12
13. Air delivery test Y Every Y Clause 8.13
500th fan
14. Endurance Test Y - - Clause 8.14
15. Noise level test Y - Y Clause 8.15
16. Test on complete electronic Clause 8.16
devices:
- Voltage surge test Y - -
- Dry heat test Y - -
- Damp heat test Y - -
- Burn-in test Y - -
- Vibration, shock and bump Y - - Cl. 8.17
test.

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 8 of 8 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

NOTE: Y - denotes ‘test to be conducted’.

8.0 METHOD OF TESTS:

8.1 VISUAL INSPECTION:

All components shall be visually examined for finish. Guard, blade and fan motor body
shall be verified for their dimensions and material specification. The manufacturer shall
furnish test report of blade and permanent magnet material as specified in Clause 4.3
and 4.2 respectively.

8.2 RUNNING OF FAN AT MAXIMUM VOLTAGE:

Before starting testing on BLDC fan, the fan shall be run at max. Voltage in voltage
range i.e. at 140V for at least one hour.

8.3 STARTING TEST:

The fan shall be capable of starting from rest at ≤75 volts.

8.4 SPEED TEST:

The fan manufacturer shall furnish the actual speed at specified rated voltage or
voltages specified in various tests such as temperature rise etc. and it is desirable that
constant speed is maintained within the input voltage range i.e. 90V to 110V.

8.5 ELECTRICAL INPUT TEST:

The electrical input in watts to the fan shall be determined by the running the fan at rated
voltage. However input watts at other voltages i.e. 90, 100, 120, 130 and 140 V shall
also be recorded for reference purpose during prototype test.

8.6 INPUT VOLTAGE PROTECTION:

8.6.1 Input over voltage protection shall be provided in the circuit so that whenever input
voltage increased beyond 155V, the fan shall trip and whenever the voltage comes down
to 140V, the fan shall start automatically.

8.6.2 Input under voltage protection shall be provided in the circuit so that whenever input
voltage decreases below 65V, the fan shall trip and whenever the voltage comes to 75V
( 10V Hysteresis), the fan shall start automatically.

Capability to withstand input of 200V DC without any damage to any part of the BLDC
fan for 30 minute shall also be provided. This shall be tested for 30 minutes during type
test and for 2 minutes during routine and acceptance test.

8.7 HEATING TEST ON PERMANENT MAGNET:

Before starting of the test, magnetism of the magnet shall be measured with the help of
flux meter. The shell of the fan motor with magnet fixed shall then be heated up at 1200C
Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 9 of 9 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

for 3 hrs. Continuously. After that, it shall be removed from the oven and cooled to the
room temperature. The flux of the magnet shall be measured again.

The difference in these two-recorded values i.e. before and after heating shall not vary
by more than 5%.

8.8 REVERSE POLARITY TEST:

The fan shall be run with the correct polarity at 110V i.e. rated voltage and then shall be
disconnected from the supply and reconnected with reverse polarity as quickly as
possible. The supply shall be maintained in the reverse direction for duration sufficient to
reach steady speed at rated voltage.
The above test for running the fan with correct and reverse polarity shall be conducted
for twenty-five cycles.

Fan shall run in the same direction irrespective of the supply polarity.

8.9 LOCKED ROTOR TEST:

This test shall be conducted after heating test of the magnet and reverse polarity test.
The fans shall be subjected to the highest value of the voltage range i.e. 140V for one
hour with the armature in the locked conditions providing external means to arrest the
rotation of fan. The fan under this condition shall draw no appreciable current. After the
removal of the lock condition, the fan shall start automatically or switching OFF and ON
the power supply.

Thereafter, the performance test i.e Power input and air delivery tests shall be repeated
in accordance with Clause 8.5 & 8.12 respectively. There shall be no appreciable
variation from initial performance test values.

Note: During acceptance test, air-delivery test shall be conducted on one fan before
locked rotor test and on all the fans (sampled) after locked rotor test.

8.10 TEMPERATURE RISE TEST:

The temperature rise test shall be conduced on four fans at an ambient temperature not
exceeding 55°C and at maximum voltage (i.e. 140 V) for sufficient time to achieve
thermal stabilization of all parts of fan and motor.

The permissible temperature rise when measured shall not exceed the limits given in
Table below:-
TABLE
S.No Item Rise in ° C Method
1 Insulated windings of motor 65 R
2 Accessible external surface, metallic 30 T
3 Bearings 35 T

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 10 of 10 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

R - Resistance method T - Thermometer method

8.11 INSULATION RESISTANCE:

IR shall be measured immediately after temperature rise test on 4 fans and after
endurance test on 5th fan.

The insulation resistance measured with 500 Volt megger between the live parts and the
frame shall not be less than 20 megaΩ. There shall not be an appreciable change in the
IR values obtained before and after dielectric test.

8.12 DI-ELECTRIC TEST:

Immediately after insulation resistance test, an AC voltage of 1.72 KV rms (1500 + 2 x

rated voltage) of sine wave form of 50 Hz shall be applied for one minute between the
live parts and frame. There shall not be any kind of break down, flashover or tripping of
supply.

8.13 AIR DELIVERY TEST:

This test shall be conducted as per Clause No.19.2 of IS: 6680. This test shall be
conducted at 90 volts, 110 volts and at 140 volts during prototype test. In any case, air-
delivery shall not be less than 5% of air-delivery at rated voltage.

8.14 ENDURANCE TEST:

The complete carriage fan with electronic controller shall be tested at rated voltage
i.e.110V DC continuous for 120 hrs. at 55°C temp.. The temperature shall be maintained
with in ± 3°C. The air delivery, temperature rise and power input test shall be carried out
immediately after completion of 120 hrs. The fan shall meet the air delivery, power
consumption, and service value requirements given in Table 1 of the specification.

8.15 NOISE LEVEL MEASUREMENT:

Noise level of the complete fan with guard in position shall be measured at a distance of
3 times of impeller diameter at 4 points on a spherical distribution around the fan as
shown in the following diagram and the average value obtained shall not exceed the
value specified in Table 1 of the specification when measured on A weighting scale. The
measurements shall be done in an reasonably echo free acoustic chamber.

fan
1 4
45° 45°

2 3

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 11 of 11 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

8.16 ENVIRONMENTAL TEST ON COMPLETE ELECTRONIC DEVICES:

These tests shall be conducted on the complete electronic devices such as card,
electronic controllers used for commutation in the Carriage Fans as per the standard
specified against each test.

i) Voltage surge test - Clause5.4 of IEC 571-1

ii) Dry Heat test * - Clause 10.2.4 of IEC 60571
iii) Damp Heat test - Clause 10.2.5 of IEC 60571
iv) Burn-in test - Clause no. 7.7 of RDSO Spec No.ELRS
/ SPEC/SI/0015-Oct-2001
* However, dry heat test shall be conducted at 80°C.

8.17 VIBRATION, SHOCK AND BUMP TEST

The test shall be conducted in accordance with the relevant clauses of IEC 61373 for
category 1- Class A. No mechanical damage or deterioration in performance shall occur
as a result of these tests.

9.0 SAMPLING PLAN FOR ACCEPTANCE TEST:

Method for sampling of fans for conducting acceptance tests shall be as per the table
given below:

SN Lot size (in nos.) Sampling quantity (in Nos.)

1 1-100 5
2 101-500 10
3 501-1000 15
4 Above 1000 20

However, for air delivery, service value and noise level tests, 2 fans for lot size
up to 100, 4 fans for 101 to 200 and 6 nos. for lot size of above 200 will be selected at
random from the lot.

10.0 DEVIATIONS:

Any deviation to this specification proposed by the manufacturer, aimed to improve upon
the performance, utility and reliability/efficiency of the equipment shall be given due
consideration, provided full particulars of the deviations with justification are furnished.

11.0 INFRINGEMENT OF PATENT RIGHT:

Indian Railway shall not be responsible for infringement of patent rights arising due to
similarity in design, manufacturing process, used of components in
design/development/manufacturing of Brushless dc fan and/or any other factor, which

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro

 Page 12 of 12 Effective from RDSO/PE/SPEC/TL/0021/2005
(REV ‘2’)

may cause such dispute. The responsibility to settle any such issue will rest with the
manufacturer.
12.0 TECHNICAL INFORMATION:

The manufacturers shall supply the following technical information in respect of

Brushless dc fan.

v) Rated speed in rev/min.

vi) Air delivery & service value at rated voltage i.e. 110 V DC.
vii) Number of blades and their detailed drawing with material specification along with
the test report.
viii) Class and details of winding insulation & insulating varnish.
ix) Type, make and life etc. of bearings.
x) Instructions for lubrication of bearings.
xi) Details of magnet characteristics.
xii) Weight of fan.
xiii) Drawings showing the overall dimensions of the fan including Motor unit with
mounting dimensions.
xiv) Drawings showing full particulars of the armature/rotor and stator windings
including dimensions, shape, size, section and weight of copper wire used.
xv) Technical details with drg/schematic of electronic controller card.

13.0 INFRASTRUCTURE & ESSENTIAL TESTING EQUIPMENTS

In respect of machinery and plant considered essential for the manufacture of quality
and reliable product, essential testing / measuring equipments and eligibility criteria etc.,
the manufacturer shall fulfill the requirements of latest STR No. RDSO/PE/STR/TL/0016-
2005 (Rev. ‘0’) issued by RDSO for BLDC fan.

*********

Prepared by Checked by Re-Checked by

SSE/PE & Metro ADE/PE & Metro Dir / PE & Metro