0083 Energy saver_Revised 111208

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					Page 1 of 12   Effective from …..          Draft RDSO/PE/SPEC/PS/0083 (REV ‘0’)-2008, , Amdt -2

                               GOVERNMENT OF INDIA
                               MINISTRY OF RAILWAYS

                           DRAFT SPECIFICATION FOR
                        POWER SAVER IN LIGHTING SYSTEM

Draft SPECIFICATION NO. RDSO/PE/SPEC/PS/0083(REV ‘0’)-2008, Amdt -2

S.N.    Amendment               Revision                               Reason
       Number Date           Number      Date
1.     ‘1’      15.10.2010          ‘0’   Dec.2008   Clause No. 15 ( Guarantee) and Clause No.
                                                     16 (After Salves Service) deleted as per Rly.
                                                     Board’s letter no. 2006/Elect.(G)/ 150/9/Pt.
                                                     dated 10.09.2010.
2.     2        -                                    -

Approved by

Executive Director (EM)
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  Sl. No.                           Description                          Page No.
      1.       Foreword                                                        3
      2.       Scope                                                           3
      3.       Reference standards                                             3
      4.       Working Principle                                               4
      5.       Technical Requirements                                          4
      6.       Construction                                                    7
      7.       Meters and indications                                          8
      8.       Protection                                                      8
      9.       Tests                                                           8
     10.       Bill of Material (Deleted)                                     11
     11.       Installation                                                   11
     12.       Instructions / Maintenance Manual                              12
    13.1       Infringement of Patent Right                                   12
    13.2       ISO:9001 Accreditation       (Deleted)                         12
     14.       Training                                                       12
     15.       Guarantee (Deleted)                                            12
     16.       After Sales Service (Deleted)                                  12
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1.0       Foreword

          The need for conservation of electrical energy has been highlighted from time to time in
          the context of reduction in the operating expenses of the railways. Lighting loads form a
          significant part of electrical load effectively contributing large sums in electricity bills.
          This sector has been identified for implementation of energy conservation.

          The voltage required to initiate discharge in gas filled lamps/tubes is higher than the
          voltage required for its continuous operation. These lamps/tubes can be operated at
          lower voltage within its normal operating range therefore consuming less energy. An
          electric device employing this concept to save energy, henceforth, shall be called power

          Power savers may be expected to give significant energy saving if the supply voltage
          exceeds 210 volts.. Therefore, it is advisable to use the energy saver, if the input supply
          voltage available is above 210 volt, for most parts of the day.

2.0       Scope

          The energy saver shall be micro processor based controller employing low-loss
          impedance in the circuit to reduce the running current & voltage to an optimum level in
          the load circuit without affecting the other parameters.

          This specification is intended to cover technical requirements, construction, installation,
          performance & other testing for both single phase & three phase supplies for use in
          Indian Railway Installations. This does not include all the necessary provisions of the

3.0       Reference standards

      •   IS:6297 (Part1)-1971 (reaffirmed 2001):Specification for Transformers & Inductors
          (Power, Audio, pulse & Switching) for Electronic Equipment –Part: 1.
      •   IS:694 :1990: PVC Insulated Cables for working voltages upto & including 1100V
      •   IS;9000, Part 3: Basic environmental testing procedure for electrical & electronic items –
          Dry Heat Test
      •   IS;9000, Part 4: Basic environmental testing procedure for electrical & electronic items –
          Damp Heat Test.
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        •   IS;9000, Part 11: Basic environmental testing procedure for electrical & electronic items
            – Salt mist test
        •   IS:616-1986 (reaffirmed 1998): Safety requirements for mains operated electronics or
            related apparatus for household & similar general use.
        •   IEC 60529:2001 :Degree of protections provided on enclosures (IP Code)

            Note: Latest version of the above specifications shall be referred to.

4.0         Working principle

            At start up, gas discharge lamps/tubes require sufficient voltage to activate the
            phosphorus, mercury and sodium enabling lamps/tubes to emit light. The normal
            working voltage range of different types of discharge lamps, is given below:-

            S. N. Type of discharge Nominal pressure Min supply voltage for stable
                  lamp              ( volts )        operation ( volts )
             1. FTL                       200-240                  200
             2. CFL                       200-240                  200
             3. HPSV                      220-240                  200
             4. HPMV                      200-240                  200
             5. HPMH                      220-240                  220

            The optimal input power shall be achieved by optimization of voltage, current & power
            factor depending upon the load, resulting in substantial power savings. Presently the
            luminaries are connected to a fixed voltage distribution line. Therefore an electrical
            device which provides sufficient voltage to initiate ignition in discharge lamps/tubes and
            lower voltage for its continuous operation is intended to be provided in lighting circuits to
            save energy.

            Power saver shall normally be installed at the sub-distribution board or as near as
            possible to the load point for maximum power saving.

5.0         Technical requirement

5.1         Working conditions

(i)         Incoming voltage from the utility & electricity companies may vary from 180V to 280V
            (single phase). & 380V to 480 V (three phase, four wire) at frequency 50± 3% Hz.
(ii)        Voltage drops during the peak hours and shoots up during the night hours.
(iii)       Surrounding temperature 0º - 55º C.
(iv)        Relative humidity upto 95%
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(v)    Atmosphere: Extremely dusty & desert weather in certain areas, corrosive
       atmosphere in coastal areas.
(vi)   Electrical supply is subjected to surges from time to time resulting in spikes

5.2    The power saver shall be centralized and should of robust design for a useful life of at
       least 15 years and designed for minimum 15% energy saving at operating voltage of
       230 volt (single phase) or 400 volt (three phase) without compromising the performance
       of the system.

5.3    The power saver shall be suitable for all types of discharge lamps such as fluorescent
       tube lights, mercury vapour & sodium vapour lamps, metal halide lamps etc.

5.4    The power saver’s efficiency shall not be less than 98%.

5.5    The power saver shall feature pure sine wave control that ensures no lamp flickering &
       other related problems.

5.6    The power saver shall reduce the distortion of waveform & harmonics shall be well
       within the range / limit of 5%.

5.7    The power saver shall improve the power factor upto 0.95 in most cases but shall not

5.8    Output voltage shall be programmable in the range of 190-240 volt using the software
       provided and fixed as per the requirement of the load.

5.9 The power saver shall be capable to sustain on frequent power supply interruptions.

5.10 The power saver shall be able to withstand 25% overload for duration of 5 minutes.

5.11   The power saver shall safeguard circuits from high voltages.

5.12   No major modification in the present lighting distribution system/re-wiring shall be

5.13   There shall be no discernable loss of lighting quality with fluorescent & other lights.

5.14   The power saver shall have incoming and outgoing protections by MCCB/MCB and
       shall be provided with earth fault & short circuit protection.

5.15   A power factor corrector shall be microprocessor based circuit which will sense the
       power factor from time to time and correct the same by adding          or removing the
       capacitor bank. A suitable static switch / relay / contactor shall be provided for switching
       the capacitor bank.
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5.16   Industrial duty metallized polypropylene self –healing LT capacitors shall be used as per
       IS:10991 .

5.17   Low- loss impedance coil shall be of natural air-cooled type.

5.18   All electronic control cards shall meet the requirements of IS:9000 part 3,4 & 11.

5.19   Material for printed circuit boards shall be copper clad glass epoxy of grade FR-4 or
       better. Thickness of laminates shall not be less than 1.6 mm &    thickness of copper
       cladding shall be 70 Microns.

5.20   All electronic components used on PCBs shall be of industrial grade or superior.

5.21   In case of out sourcing of PCBs, it should be ensured that the PCB manufacturer have
       all the required infrastructure & necessary facilities for assembly /manufacture of PCB
       such as dust free atmosphere, ESD protection and other testing facilities etc.

5.22   Manual/automatic change over switch shall be provided for the by-pass of the        power
       saver in the event of any failure of its components/for its preventive maintenance etc.

5.23   It shall have in-built facility for timer programming so that according to the need, saving
       level can be defined for different time interval on 24hrs real time clock.

5.24 Provision may be made for attachment of data logger with RS232 port for logging
     voltage, current, power factor, KVA, KW & KWH readings. Alternatively USB port shall
     be provided for downloading data in USB flash/pen drive.

5.25 The controller shall function all the above features automatically as mentioned above.

5.26   Markings

5.26.1 All markings/indications shall be placed in the vicinity of the components to which they
       refer & shall not be placed on removable parts.

5.26.2 Each power saver shall be provided with a rating plate of weatherproof material fitted on
       the front panel in a visible position; containing the following information:-

          •    Type of power saver
          •    Specification No.
          •    Name & trade mark of the manufacturer
          •    Equipment serial number
          •    Month & Year of manufacture
          •    No. of phases
          •    Rated KVA
          •    Rated frequency
          •    Input voltage range
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           •   Rated output voltage
           •   Rated output current

        The content of the rating plate shall be indelibly marked by etching or engraving.

 6.0    Construction

 i)     The power saver shall be suitable for indoor and outdoor application with IP54 & IP65
        protections respectively.

 ii)    The power saver for single phase supply shall be wall/floor-mounted type and shall be
        compact in size.

 iii)   The power saver shall be of robust construction. It shall be housed in cubicle fabricated
        with angle iron frame-works fitted with cold rolled annealed mild steel panel of thickness
        not less than 1.6 mm. The cubicle shall be adequately ventilated. Hooks shall be
        provided for lifting purposes.

 iv)    Indoor type cubicle shall be suitably powder coated while outdoor type cubicle shall be
        given a polyurethane coating (such as APCOTHANE CF671 of Asian Paints or
        Shalithane finish of Shalimar or equivalent ) to achieve a minimum coating thickness of
        60 microns.

 v)     The layout of the components & wiring shall be such that all parts are easily accessible
        for inspection, repairs & components replacement.

 vi)    All cables & wires used for wiring shall conform to IS: 694 (1100V). Cables shall be
        neatly secured in position & adequately supported cable termination shall be done after
        proper lugging, crimping & glanding without any gap so as to ensure IP65 protection.
 vii)   The schematic wiring diagram shall be firmly fixed on the inside of the cover of the
        power saver.

 viii) The input & output terminals shall be accessible only when the cover of the cubicle is
       removed. All the terminals shall be neatly, clearly & permanently marked for easy

 ix)    Equipment shall be provided with two separate & distinct terminals for connecting to

7.0     Meters and indications
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       •   A suitable digital meters of class –I accuracy shall be provided to indicate phase
           voltage, current, power factor, active power & energy (KWH).
       •   Green LED on the front panel shall indicate normal working.
       •   Suitable LED lamps shall be provided on the front panel to indicate that:
           - The unit is in “SAVER MODE” or “BY PASS MODE”.
           - The unit is in under voltage, over voltage or over load condition.

8.0    Protections

 8.1   In case of failure of control circuit, the output voltage shall not exceed the upper limit of
       270V & 450V for single phase and 3-Phase systems respectively.

 8.2   To protect the equipment against over voltage and under voltage, facility for automatic
       tripping and disconnecting within 5 seconds shall be provided in case the input goes
       beyond the limits mentioned in clause 5.1.

 8.3   To protect the equipment against over load, facility for automatic tripping and
       disconnecting within 5 seconds shall be provided in case the load current goes beyond
       125% of the rated capacity.

 8.4   MCCBs /MCBs of appropriate ratings shall be provided along with HRC fuses of
       suitable capacity, to isolate internal/external faults.

 8.5   There shall be a provision of thermal protection with cooling fan to protect power saver

8.6    Provision of ELCBs / RCCBs shall be available in power saver.

9.0    Tests

       Type tests shall be carried out at NABL accredited test house/ laboratory and test
results shall be submitted by the supplier along with the supply. The type tests may  be
witnessed by RDSO/Railway’s nominated representatives.

       Acceptance tests shall be carried out at the works of the manufacturer in presence         of
the authorized representative of the purchaser.

        S.N.    Test Description                  Type    Acceptance Routine       Clause
                                                  Test    Test       Test          No.
           1    Visual Inspection                   Y          Y        Y           9.1
           2    No-load Test                        Y           -           -        9.2
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         3     Out put test                       Y          Y           Y        9.3
         4     High Voltage Test                  Y          Y           Y        9.4
         5     Insulation Resistance Test         Y          Y           Y        9.5
         6     Induced High Voltage Test          Y          Y           Y        9.6
         7     Surge test                         Y           -           -       9.7
         8     Test for Protection                Y          Y           Y        9.8
         9     Performance Test                   Y          Y            -       9.9
         10    Temperature         Rise   on      Y          --          ---      9.10
               Impedance coil
         11    Endurance Test                     Y          ---         ---      9.11
         12    Environmental Test on              Y           _          ---      9.12
               - Dry heat test
               - Damp heat test

       Note: ‘Y’ denotes ‘Test to be conducted’.

9.1    Visual inspection

      The power saver shall be visually examined for proper mounting of components, layout,
markings, general workmanship & finish etc.

9.2    No-load test

       At rated voltage the idle current for the equipment shall not exceed 2% of the     rated
output current at rated higher side output voltage.

9.3    Out put test

       The out put voltage at various loads and at various input voltages shall be within ± 1%
       of the set value from no load to full load and efficiency of the equipment shall be

9.4    High voltage test

       After isolating electronic components, the power saver shall withstand a test voltage of
       2 KV of sinusoidal wave form with frequency 50 +/-3% Hz applied between power
       components & earth/body for one minute without any flash over / puncture.
9.5    Insulation resistance test

       Insulation Resistance of the power saver when measured with 500V megger at room
       temperature between all terminals (shorted) & earth/body, shall not be less than 10 M .

9.6    Induced high voltage test
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          Twice the rated voltage shall be applied across the inductor winding output terminals of
          the winding for 60 seconds. Coil shall withstand the test without flash over or any
          insulation damage.

9.7       Surge test

          Surge test shall be conducted as per clause of IEC 60571. During the test, the
          equipment shall be monitored to detect any fault.

9.8       Test for protection

9.8.1 Power saver Unit shall be tested for protection by simulating the                                                                                                                                                                                   appropriate
      conditions mentioned in clause 8.0.

9.8.2 Enclosure of power saver shall be tested for IP protection as per IEC:60529.

9.9       Performance test

          The test shall be carried out to compare the following parameters using a suitable
          lighting load with & without power saver device for mixed load with constant voltage
          source of 230 V, 50 Hz supply for single phase and 400V, 50 Hz. for three phase circuit
          as per the following format:

Type                                                                                                                       Parameters
 of                     Without power saver device                                                                                                             With power saver device
                                                                                       Apparent Power (VA)

                                                                                                                                                                                                                Apparent Power (VA)

                                                                                                                                                                                                                                                           % Energy saving
                                                       Real power (W)

                                                                                                                                                                                Real power (W)
                                                                        Energy (KWH)

                                                                                                                                                                                                 Energy (KWH)
                                        Power Factor

                                                                                                                                                                 Power factor
          Voltage (V)

                                                                                                                                   Voltage (V)
                         Current (A)

                                                                                                                                                 Current (A)
                                                                                                             Lux Level

                                                                                                                                                                                                                                      Lux Level
                                                                                                                           % THD

                                                                                                                                                                                                                                                  % THD

      •   Mixed load, equivalent to 90-100% of rated capacity of energy saver, shall consist of
          50% FL/CFL, 35% HPSV/ HPMV and 15% MH lamps.

      •   Unless otherwise stated, the test shall be conducted at an ambient temperature. The
          test shall run for two hours (one hour without power saver and one hour with power
          saver under similar conditions).
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   •   Energy saving calculated from the above, shall not be less than 15% & lumens drop
       shall not be more than 5% for mixed load defined above at 230V, 50Hz constant voltage

   •   Apparent power (KVA) reduction shall not be less than 12%.
   •   Harmonic level shall remain almost same with & without power saver.
9.10   Temperature rise on impedance coil
       Temperature rise test shall be conducted on impedance coil in accordance
        with IS:6297 Part-I.

9.11   Endurance test
       The power saver shall be tested for minimum 72 hours of continued usage at 50° at
rated load.
9.12   Environmental test on electronics
       All control cards shall be subjected to dry heat, damp heat and salt mist test as per
       IS:9000 part 3, 4 & 11 respectively. Record of test results shall be made available to the
       Inspecting Authority/ Purchaser on demand.

9.13   Climate (Humidity) test
       The equipment shall be kept in a chamber at 27ºC± 2ºC at 95% ± 2% relative humidity
       for 48 hours. After removal of visual drip of water if any, the IR shall not be less than 2
       M .

10.0   Bill of material (BOM) - Deleted

11.0   Installation
       Entire assembly shall be housed in a cabinet with locking facilities. Contractor will be
       fully/wholly responsible for damage/accidents/faults caused to the luminaries, if any,
       during commissioning of Energy saver devices. The installation shall be done by the
       supplier/manufacturer who is responsible for the satisfactory performance of the unit.

12.0   Instruction / Maintenance manual
       Three copies of easy-to-use illustrated installation & operation manual containing the
       following information, shall be supplied along with each power saver;

       •   Instructions for installation.

       •   Working principle.
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       •   Wiring diagram indicating the components.
       •   Drawing showing general mounting arrangement of power saver and its various
       •   Bill of material containing list of components, quantity, their ratings and make.
       •   Clear instruction on regular maintenance, trouble shooting and emergency shut-
           down procedure.
13.0   Infringement of patent rights
13.1   Indian Railways shall not be responsible for infringement of patent rights arising due to
       similarity in design, manufacturing process, use of similar components in the design &
       development of this item and any other factor not mentioned herein which may cause
       such a dispute. The entire responsibility to settle any such disputes/matters lies with the
       manufacturer/ supplier.
13.2   ISO:9000 accreditation: -        Deleted
13.3   No design change shall be undertaken by manufacturer after type test without prior
       approval of RDSO/Railways.

14.0   Training
       Training shall be arranged to railway operating & maintenance staff without              extra
       cost after functionally completion of the unit.
       Training shall include a discussion on equipment design and layout,
       demonstration on routine operation, maintenance & trouble-shooting procedure.
15.0   Guarantee      - Deleted
16.0   After Sales Service - Deleted

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