Eoi - SMPS Based Telecom Integrated Power Supply System For Station - 29!03!2014

RB/R&D/08/109
Expression of Interest (EOI)

of
SMPS based TeIecom Integrated Power SuppIy System for Station

Expression of Interest for Empanelment of Indian manufacturer/Design house for Transfer of
Technology for manufacturing of SMPS based Telecom Integrated Power Supply System for
Station as per DRAFT Specification no. RDSO/SPN/TC/102-2013 VERSION 0.0 issued by
RDSO Lucknow.
ITI Ltd, a Public Sector Undertaking under the Department of Telecommunications, Ministry
of Communications & IT, is a leading Telecom equipment manufacturer and turnkey solution
provider in India. The major customers are BSNL, MTNL, Defense, Paramilitary forces and
Railways.
ITI seeks to empanel reputed Indian manufacturer/Design house to provide Transfer of
Technology at CKD level against the requirement of manufacturing of SMPS based TeIecom
Integrated Power SuppIy System for Station as per DRAFT Specification no.
RDSO/SPN/TC/102-2013 VERSION 0.0 issued by RDSO Lucknow (PIease see annex-I).
Further, the Indian manufacturer/Design house has to upgrade/modify the design of the
product as and when the final specification is issued by RDSO lucknow and the TOT for the
same is to be provided to ITI at free of cost
ITI intends to manufacture and supply this equipment at its works i.e. at ITI Limited Raebareli.
Interested Indian manufacturer/Design house are invited to submit their Technical offer in a
sealed envelope. The offers from the manufacturer shall comprise compliance to the
requirement of SMPS based TeIecom Integrated Power SuppIy System for Station as per
DRAFT Specification no. RDSO/SPN/TC/102-2013 VERSION 0.0 issued by RDSO
Lucknow. The offer shall reach ITI on or before 15-04-2014 (4.30 PM). The offer shall be
sent to the following address (super scribe the envelope as "Expression of Interest for
SMPS based TeIecom Integrated Power SuppIy System for Station".
To,
CM(SMPS & Mktg.)
ITI Ltd., Door Bhashnagar
RAEBRELI (UP) 229010
Telephone: (0535) 287335,
Fax 0535-2202589,
Email : krrsingh_rbl@itiltd.co.in
Based on the compliance to General & Technical requirements listed below in Annexure-I, the
manufacturer would be short listed for empanelment.
For any clarifications, you could reach within four days after publication on ITI Ltd., Web Site
at above address and e-mail.
Annexure I
1 GeneraI Requirements & TechnicaI Requirements:
i Name and Address of the manufacturer
ii Contacts / Name and designation of contact person:
Telephones No.:
Fax:
E-mail:
Mobile No:
iii Year of Establishment & Registration number of the Company. Provide
Certificate of Incorporation. ECC No., Sale Tax No.
iv Enclose details on Product Profile of the Company.
v Enclose Technical literature of SMPS based TeIecom Integrated
Power SuppIy System for Station
vi Willingness to furnish clause by clause compliance to
specifications/amendments as and when released by the RDSO
Lucknow for SMPS based TeIecom Integrated Power SuppIy
System for Station
vii Compliance to requirement of SMPS based TeIecom Integrated
Power SuppIy System for Station as per DRAFT Specification no.
RDSO/SPN/TC/102-2013 VERSION 0.0 issued by RDSO Lucknow
(Copy attached at Annex-2) and its updates.
viii The Indian manufacturer/Design house has to upgrade/modify the
design of the product as and when any final Specification is issued by
RDSO Lucknow and TOT for the same is to be provided to ITI at free
of cost.
ix Willingness to Transfer Technology for manufacturing these equipment
to ITI at CKD IeveI.
x Willingness to provide all required assistance to ITI for setting up the
production line for manufacturing and testing of SMPS based
TeIecom Integrated Power SuppIy System for Station.
xi Provide Annual report of the Company, for the last 3 years 2010-11,
2011-12, 2012-13
xii Provide Turn Over and Profit for 2010-11, 2011-12, 2012-13.
xiii Current Net worth of the company.
xiv Past experience

2 Period of Validity of offers: The offer shall remain valid for a period of at least 180 days
from the due date of offer submission. Offers valid for a shorter period shall be
rejected.
3 Offer due Date & Opening: The last date for receiving the offers at ITI is on or before
15-04-2014 (4.30 PM) and the offers would be opened on next working day at 11.30
AM.

4 Late offer: Any offer received after the prescribed timeline shall be rejected and shall
be returned unopened to the vender.

5 Offer Evaluation: The evaluation of the offers will be carried out in two stages: Vendors
who comply with General Conditions and Technical Specifications would be short listed
as part of this empanelment.
6 Language of offers: The offers prepared by the vendor and all the correspondences
and documents relating to the offers exchanged by the vendor, shall be written in the
English language.

7 Award of Contract: After completing evaluation and selection of vendor based on the
offer and further negotiations, if any, ITI shall enter into a Memorandum of
Understanding with the vendor.

8 Authorized Signatory: All certificates and documents received as part of the offer shall
be signed by the Authorized Representative. The power of authorization or any other
document consisting of adequate proof of the ability of the signatory to bind the vendor
shall be submitted if demanded by ITI.
9 ITI reserves the right to suspend or cancel the EOI process at any stage, to accept, or
reject any, or all offers at any stage of the process and / or to modify the process, or
any part thereof, at any time without assigning any reason, without any obligation or
liability whatsoever and the same shall be published in the ITI website or intimated
through email.

10 Cost of EoI: The vendor shall bear all costs associated with the preparation and
submission of its EOI, including cost of presentation for the purposes of clarification of
the offer, if so desired by the ITI. ITI will in no case be responsible or liable for those
costs, regardless of the conduct or outcome of the EOI process.

11 Amendment of EOI: At any time prior to the last date for receipt of offers, ITI, may, for
any reason, whether at its own initiative or in response to a clarification requested by a
prospective vendor, modify the EOI document by an amendment. In order to provide
prospective vendor reasonable time in which to take the amendment into account in
preparing their offers, ITI may, at their discretion, extend the last date for the receipt of
offers and/or make other changes in the requirements set out in the Invitation for EOI.

12 Disclaimer: ITI and/or its officers, employees disclaim all liability from any loss or
damage, whether foreseeable or not, suffered by any person acting on or refraining
from acting because of any information including statements, information, forecasts,
estimates or projections contained in this document or conduct ancillary to it whether or
not the loss or damage arises in connection with any omission, negligence, default,
lack of care or misrepresentation on the part of ITI and/or any of its officers,
employees.

CM(SMPS & Mktg)
ITI Ltd., RaebareIi
Page 1 of 32 Effective from RDSO/SPN/TC/102-2013 Version 0.0

DRAFT SPECIFICATION
OF
SMPS BASED TELECOM INTEGRATED POWER SUPPLY SYSTEM
FOR
STATION

VERSION 0.0

Number of Pages :32

SPECIFICATION NO. RDSO/SPN/TC/102-2013

TELECOM DIRECTORATE
RESEARCH, DESIGNS & STANDARDS ORGANISATION
LUCKNOW - 226011


DOCUMENT DATA SHEET

Specification Number

RDSO/SPN/TC/ 102 -2013

Version

0.0

Title of Document

SMPS based Telecom Integrated Power Supply System for
Station(TIPSS)

Prepared by:
Shri Rakesh Sahariya
Designation: ADE/Tele-I
Shri Rajesh kumar Pandey
Designation: Director / Telecom-IV

Approved by:
Name: Shri S.K.Vyas
Designation: Executive Director/Telecom, RDSO

Abstract
This document defines specification of SMPS based Telecom Integrated Power Supply System
(TIPSS) for Station


DOCUMENT CONTROL SHEET

Designation

Organization Function Level
ADE/Telecom-I RDSO Member Prepare

Director/Telecom

RDSO

Member

Prepare

ED/Telecom

RDSO

-

Approval

TABLE OF CONTENTS
Para No. Item Page No.

Abbreviations used 5
1.0 Foreword 6
2.0 General Requirements 7-11
3.0 Electrical & mechanical Requirements 11-18
4.0 Requirements of DSCA 18-19
5.0 Requirements of DC-DC Converter 19-20
6.0 Requirements of MPPT Charger 20-21
7.0 Source Priortisation 21
8.0 Packing 21
- Schematic of TIPSS 22-23
9.0 Test and Requirements 24-25
10.0 Test Procedure 25-29
11.0 Information to be given by purchaser 29
Annexure-I General Requirements for RFIS 30-31
Annexure-II Schematic diagram of Surge and lightening protection 32


ABBREVIATIONS USED
Abbreviation Detail
AMF Panel Auto Mains Failure Panel
ASM Assistant Station Master
DSA Distribution Switching & Alarm Unit
DG Set Diesel Generator Set
DOD Depth of Discharge
EMI Electromagnetic Interference
FRBC Float Rectifier Cum Boost Charger
IPS Integrated Power Supply
IS/IEC Indian Standard/ International Electrotechnical Commission
LCD Liquid Crystal Diode
LED Light Emitting Diode
MTBF Mean Time Between Failure
MOV Metal Oxide Varistors
OEM Original Equipment Manufacturer
PF Power Factor
PWM Pulse Width Modulation
RE Railway Electrification
RFI Radio Frequency Interference
SMPS Switched Mode Power Supply
SPD Surge Protection Devices
VRLA Valve Regulated Lead Acid
MPPT Maximum Power Point Trecking


GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH, DESIGNS & STANDARDS ORGANISATION (RDSO)

DRAFT SPECIFICATION
OF
"SMPS BASED TELECOM INTEGRATED POWER SUPPLY SYSTEM (TIPSS) FOR STATION"
1.0 FOREWORD
1.1 This Specification Requirement of Switched Mode Power Supply (SMPS) Based "Telecom
Integrated Power Supply System (TIPSS) for Station" has been prepared for the use of various
Telecom equipment provided at station on Indian Railways. This System will consists of 48Volts (V)
SMPS based Power Plant to provide 48V for Control Communication equipments , OFC equipment,
Radio equipments, GSM-R equipment etc provided at station. The System will also provide
galvanically isolated 24V, 12V, and 3-6V DC for other telecom applications with the help of DC-DC
Converter.
1.2 SMPS Based Telecom Integrated Power Supply is intended to be used in Auto Float Rectifier-cum
Float-charger (FR-FC) and/or Float Rectifier cum Boost Charger (FR-BC) mode as a regulated DC
power source, DC-DC Converters are for various DC power supply requirements of Telecom
equipment at Railway Stations. Some of the typical requirements of telecom equipment at the station
are as under:

1.3 This specification requires reference to following specifications:

IRS: S 88/2004
Low Maintenance Lead Acid Battery
IRS:S 93/96(A) Valve Regulated Lead Acid Sealed Maintenance Free
Stationary Battery
IRS: S 63/07 PVC insulated underground unscreened cables for Railway
signalling
RDSO/SPN/144/2006 Safety & reliability requirements of electronic signalling
equipment.
IS:9000 Basic environmental testing procedure for electronic and
electrical item
IEC-61643 Surge Protective Devices connected to low-voltage power
SN Name of Equipment Working Voltage Required Current
1. 25W VHF Set 12V DC 2-3 Amp
2. VF Repeater 12V DC 0.5 Amp
3. Gate Telephone 12V DC 100mA- 500mA
4. Gate Telephone 24 V DC 200 mA-1Amp
5. Way Station Control Telephone 12V DC 100mA
6. Magneto Telephone 3-6 V DC 50mA
7. STM1/4 OFC Equipment 40-60V DC 3 Amp
8. PD MUX 36-72V DC 2 Amp
9. Router 12V DC 3 Amp
10. Switch 12V DC 2 Amp

distribution systems
EN 55022 European Standard for Information Technology Equipment
MIL HBDK 217F Military hand book "Reliability Prediction of Electronic
Equipment"
IEC 61312 Protection against Lightning Electromagnetic Impulse
1.4 Wherever, in this specification, any of the above mentioned specifications is referred by number only
without mentioning the year of issue, the latest issue of that specification is implied
2.0 GENERAL REQUIREMENT
2.1 Telecom Integrated Power Supply System shall consist of a Distribution-Switching-Control- Alarm
Arrangement (DSCA) and Float Rectifier-Cum-chargers (FR-FCs) or Float Rectifier cum Boost
Chargers (FR-BCs) (in N+1 configuration in hot-standby and one module in cold standby), DC-DC
converter (in N+1 configuration in hot-standby) for 24V, 12V, 3-6V, 48V MPPT Battery Charger
(optional) , 48V battery set of adequate capacity.
2.2 The Telecom Integrated Power Supply System shall be capable of meeting the load requirement
(equipment and battery bank) for various telecom equipments. The system shall be expandable at
rack level itself, using the basic modules of the same rating.
2.3 To cater for higher load requirements, (for modules with more than 50 watts) same type of modules
mounted in the same rack shall be capable of working in parallel load sharing arrangement.
2.4 The Telecom Integrated Power Supply System shall be suitable for operation from AC Mains, solar
power supply or from a DG Set.
2.5 The Telecom Integrated Power Supply System shall work satisfactorily either with VRLA
maintenance free Battery as per IRS;S93/96(A) or Low Maintenance Lead Acid Battery as per
IRS;S88/2004 with latest amendment. Battery as per purchaser requirement will be integral part of
system.
2.6 In case purchaser decides to provide solar power as additional source of power supply as indicated in
clause 11.0, Solar Panel Modules of adequate capacity along with suitable Bracket & Bracing Plate as
per IRS:S 84/92 with Latest Amendments shall be supplied alongwith TIPSS. Actual requirement of
number of Solar Panels & its capacity etc. shall be indicated by purchaser based on site requirement.
2.7 One panel consisting of status indications and critical alarms of TIPSS is
room. The monitoring panel shall be of wall mounting type. OEM shall supply 12 core, 1.5 sq.mm
signalling cable as per IRS:S 63/2007 for connecting TIPSS to Status Monitoring Panel in Station
).
2.8 There shall be an automatic arrangement for disconnecting the mains within 500 ms to the rack
whenever the input voltage is beyond the specified operating limits with suitable alarm indication.
The TIPSS shall resume normal working automatically when the input is restored within the working
limits. A self storing type static switch should be provided at the input. It shall be capable to
with-stand 400 volts input continuously without any damage.
2.9 Components
I. Semiconductor and other components used in the equipment shall be of industrial grade with
operating temperature range -25
o
C to + 85
o
C.
II. Semi-conductor power devices and other Solid state components used in TIPSS shall not be operated
at more than 50% of the rated maximum peak voltage and at not more than 50% of the rated
maximum average current under any prevailing conditions. Manufacturer shall submit design details,
components datasheet at the time of type approval.
III. The manufacturer shall declare the peak reverse voltage, current rating and working temperature of
the rectifier element under ambient conditions, the number of elements used and the manner of their
connection. The peak reverse voltage rating should not be less than two times the expected reverse
voltage across the devices.

IV. The recommended list of major components and their makes given in Annexure VI of RDSO/SPN/
165/2012 shall be applicable for this specification also.
V. Printed Circuit Board
Printed Circuit Board shall generally conform to relevant provisions of latest RDSO/SPN/144/2006
for safety & reliability requirement of Electronic signalling equipment.

2.10 Cables & Wiring

a) All the cables and wires used for wiring and inter connections of modules shall conform to
specification No. IRS: S 76-89/IS 694 of grading 1100V. Aluminium wires shall not be used. The
gauge of wiring shall be such that the current density does not exceed 3 amperes/mm square.
b) The colour scheme employed for the rack wiring shall be as below:
I) AC line : Yellow
II) AC neutral : Blue
III) Earthing : Green
IV) DC positive : Red
V) DC negative : Black
VI) Control wiring : Grey
c) All connections shall be made through crimped eyelets and shall be numbered with PVC cable
marker rings/ inkjet printing on cables corresponding to the numbers/letters shown in the schematic
wiring diagram. Soldering shall be used only where use of crimped eyelets is not possible.
d) All non-current carrying metal parts shall be bonded together and adequately earthed.
e) All wiring shall be neatly secured in position by bunching /strapping & adequately supported.
Where wires pass through any part of metal panel or cover, the hole through which they pass shall be
provided with rubber grommets.
f) There shall not be any exposed wiring outside the cabinet.
2.11 Transformers and chokes
Transformers and inductors/ chokes used shall be vacuum impregnated and shall be of natural
air-cooled type conforming IS: 6297 (Category 3 & Grade 2). Class F or higher grade insulating
material as per IS:1271 and polyester enameled copper winding wire conforming to IS 13730(Pt. 3)
shall be used for winding transformers and inductors/chokes. The gauge of winding wires shall be
such that the current density shall not exceed 3A/sq.mm. All exposed metal parts of the transformer
including laminations shall be protected against corrosion.

2.12 Fuses & Connectors
a) All plug- in connectors shall be non-interchangeable. Connectors as per IEC 947 shall be
provided.
b) Fuse holder identification shall include details of fuse rating and type.
c) All power fuses shall confirm to specification IS 13703 / IS 9224.
2.13 Earthing
2.13.1 All non-current carrying metal parts and +ve of 48 V shall be bonded together and earthed. An earth
terminal suitable for taking minimum 4 mm dia wire and with suitable marking shall be provided.
2.13.2 The TIPSS and its individual modules shall have earth terminals and shall be properly earthed to the
cabinet. User shall provide earthing arrangement having earth resistance less than 5 Ohm. The
manufacturer of TIPSS shall clearly provide earthing guidelines/ arrangement required for
satisfactory working of the system. It shall be jointly ensured by Zonal Railways and manufacturer of
TIPSS that earthing has been provided as per system requirement at the time of installation and
commissioning and pre-commissioning check-list in this regard shall be signed jointly.

2.14 Terminations
a. The AC input connection to the FRBC/FRFC module shall be by means of plug and socket
arrangement as per specification No. UL 248 & DIN 41576.
b. The DC output connection should be taken through irreversible plug and socket having power
pins with locking arrangement.
c. The output of each FRBC/FRFC in the Negative lead shall be taken through the HRC fuse of 1.5
times of rated capacity of FRBC/FRFC.
d. In all cases, the male connector shall be mounted in the FRBC/FRFC module and the female
connector shall terminate the cable.
e. To prevent hazards or damaging conditions, all plug-in components shall be
non-interchangeable.
f. All the connections between DSA unit and FRBC/FRFC shall be through proper rated cables
only.
g. Circuit breakers at the input of each FRBC/FRFC shall be easily accessible and rated to 16A for
FRBC/FRFC module.
h. Proper termination for AC at the input of the circuit breakers and its output to the FRBC.

2.15 Labelling And Marking
a. Each electrical/solid state component should be possible to be located by the layout/circuit
drawing. The wiring shall be clearly and permanently identified with a designation or a colour
code, which corresponds to the equipment circuit diagram. Where non-standard colours are
used, cable functions shall be clearly and permanently labelled at both ends.
b. A screen printed cabling / wiring diagram shall be placed on the inside of the front door or any
other convenient place for ready reference of maintenance staff.
c. Screen- ment procedures and operating instructions shall be
provided at convenient place on front panel of the TIPSS cabinet. One laminated block diagram
shall also be provided at convenient place inside the cabinet.
d. The layout of the components and wiring shall be such that all parts are easily accessible for
inspection, repairs and replacement.
e. All markings shall be legible and durable. Where the marking is by use of labels, they shall be
metallic or screen-printed. These shall be firmly struck and shall not be capable of being
removed by hand easily. They shall be placed in the vicinity of the components to which they
refer.
f. All cubicles belonging to one TIPSS shall be identified with a common serial number.
g. Each FRBC, DC-DC converter shall be marked with its name & rating on its front panel. The
placement for particular module in respective rack shall be clearly marked with its application
for the purpose of appropriate replacement.
h. Every SMPS based TIPSS shall be provided with a rating plate fixed outside at a conspicuous
place in TIPSS cubicle. It shall be clearly and indelibly etched, engraved or screen printed and
shall show the following minimum information:
I) Name and trade mark of the manufacturer
II) Specification No.
III) Nominal AC input voltage and frequency
IV) Serial number and year of manufacturing.
V) Version number as per RDSO/SPN/144/2006.

i. All input and output terminals shall be clearly identified by using proper name tags/labels.

2.16 Battery Bank
2.16.1 TIPSS shall be suitable for charging 48V battery bank of 200 AH in case of RE area /300AH in case of
non-RE area Low Maintenance cells as per IRS:S 88/2004 or VRLA Maintenance free cells as per
IRS:S 93/96(A). Battery bank is part of this specification and the same shall be supplied and
commissioned along with TIPSS. If Railway requires higher capacity batteries it should be mentioned
specifically in the Purchase Order.
2.16.2 Battery racks of MS for VRLA batteries or wooden/ FRP rack for low maintenance batteries, along
with its accessories, shall also be supplied with battery bank.
2.16.3 OEM shall supply copper cable of suitable dia as per IS: 694 and grade 1100V for connecting TIPSS to
Battery bank (distance to be given by Railways at the time of indenting) as given below

a) For 200AH battery 16 Sq.mm
b) For 300AH battery 25 sq.mm
2.17 Module replacement time and MTBF
2.17.1 The mean time to replace a faulty module of IPS shall be less than 30 minutes.
2.17.2 The DC fan. provided at rack /module level should have MTBF better than 70,000 hours at 40
o
C. The
fan shall be covered with grill to prevent dust ingress.
2.18 Installation & Commissioning
Installation & commissioning of TIPSS shall be as per guidelines issued by railway board/Zonal
railway.

3.0 ELECTRICAL AND MECHANICAL REQUIREMENT OF FR-FC & FR-BC MODULES
3.1 Mechanical Requirement
3.1.1 The FRBC/FRFC Modules shall be provided with natural/forced cooling. The capacity of
FRBC/FRFC module will be 25 Amp .
3.1.2 The FRBC/FRFC module shall be removable from the front of the rack only. All AC input, DC output
and alarm/control /monitoring cables inter connecting the modules and racks shall be easily
removable/replaceable.
3.1.3 the rack. In the rack
Control panel, FRBC /FRFC Module , DC-DC Converter should be placed from top to bottom
respectively. It shall be also possible to place all the DC-DC Converters in a separate wall mountable
rack of suitable/9U size which may be installed in the ASM Room situated at a maximum distance of
200 Mtr. 48 V supply with class-C SPD Protection (as per Cl. 3.2.12.3 Of this specification) will be
extended to this unit in case this unit is kept in ASM Room. Two core signaling cable of 16 mm
2
as
per IRS:63-07 with latest ammendement is to be supplied by manufacturer and railway/purchaser has
to specify the distance of the ASM Room from TIPSS.
I. Rack Configuration-The cabinet shall be within the overall dimensions of 2000-mm max. Height
750 mm. max. Depth and 750 mm max. Width. Cabinet will have min 10-mm thick
anti-vibrating pad and 75 mm x 5-mm bottom channel .The rack structure and the module frame
shall be made up of rigid framework of steel profiles. The front door, if used, shall be of hinged
type. The rear panel shall be provided with proper ventilation arrangement. Fan shall be
provided at rack level for forced cooling. The operation of such fan shall be continuous.
II. The size of DC-DC Converter/ alarms rack to be provided in the ASM room shall be of 9 U size.
The mounting arrangement of installation in the ASM room shall be approved by In-charge at
the time of installation.

III. The racks and module cabinets shall be of robust construction. They shall be housed in
self-supporting cubicles made of cold rolled closed annealed mild steel sheet of thickness not
less than 1.6mm. The rack shall be adequately ventilated. The ventilating opening shall be less
than 3mm size for protection against entry of lizard s etc. The rack shall conform to IP31 type of
protection as specified in table 1 of specification no. IS 2147-1962.
IV. The racks and the modules shall be treated with zinc chromate primer followed by electrostatic
epoxy powder coating paint finished, passivation shall be done through seven stage process/sand
blasting. Small metal parts such as nuts, bolts and washers shall be chrome plated. All other
metal parts of the rack shall be plated for protection against corrosion.
V. The racks and the module cabinets shall be free from sharp edges & sharp corners.
VI. Provision of doors are optional, the cabinet sides shall have 3mm louvers covered with wire
mesh. However, if the doors are not provided, the sub system shall have proper enclosures so
that any reptile/ insect shall not enter in the TIPSS cabinet. The magnetic latches/handle shall be
provided on the doors.
VII. The racks and the modules shall be designed for easy maintenance and installation.
VIII. Facility shall be provided at the top of the rack to connect external AC power and lightning
arrestors (if provided inside the rack). Where cables pass through metal panels, suitable rubber
grommets shall be provided to protect cable from damage.
IX. The modules shall be of modular type. The module shall be easily mounted or removed from the
front side of the rack. The module shall be designed to slide into the rack on a suitable
mechanical arrangement. Suitable arrangement shall be made for pulling out each module
separately. The associated AC input, DC output connection, control/alarm & interface cable
connecting the module shall be disconnected/installed easily without causing any
interruption/damage to supply & working module.
X. The input and output terminals shall be accessible only when the cover of the cubicle is removed.
All the terminals shall be clearly, neatly and indelibly marked to correspond with the wiring
diagram for easy identification.
XI. Input and output connections of SMR, DC-DC converter, MPPT Charger shall be made using
plug & socket of adequate rating having power pins with locking arrangement. The male
connector shall be mounted on the device and the female connector shall be terminated on the
cable. Use of terminal blocks for input and output connections is not accepted.
XII. The finish of steel and panels shall conform to relevant IS specification. The colour scheme shall
be as follows:
a) Rack & doors Pebble Grey RAL 7032
b) All TIPSS modules shall harmoniously match with rack colour
3.2 Electrical Requirement
FR-FC & FR-BC MODULES shall be based on High Frequency Switch Mode Techniques using
switching frequencies of 20Khz and above.
3.2.1 AC Input supply
The Telecom Integrated Power Supply system using FR-FC or FR-BC shall operate from single
phase AC input supply range from 150-275 V with nominal input frequency of 50Hz which may vary
from 48-52Hz.
3.2.2 DC output Characteristics
DC output Characteristics
(I) Auto Float Mode
a) The Float voltage of each rectifier module shall be continuously adjustable & pre- settable at any
value in the range of 48V to 56V. The prescribed float voltage setting is 54V for VRLA battery.

b) The DC output voltage shall be maintained within 1% of the half load preset voltage in the range
25% load to full load when measured at the output terminals over the full specified input range.
(II) Auto Charge Mode:
In Auto Charge Mode FR-FC shall supply battery & equipment current till terminal voltage reaches
set value, which is normally 2.3V/Cell (55.2V) & shall change over to Auto Float mode after a
n. If
battery voltage falls upto 48 V it will change to Auto Charge mode.
3.2.3 Efficiency
The efficiency of the unit shall be as given below:-
a) At nominal input, output and full rated load better than 90 %
b) For other specified input, output conditions better than 85 % and load between 25% to 100%
3.2.4 Input Power Factor
The input power factor at nominal input, output voltage and load 75% to 100% shall be between 0.95
lagging and 0.98 leading but it shall remain between 0.90 lag and 0.90 lead in any other working
condition and load between 25% to 100%
3.2.5 Total voltage Harmonic Distortion
The total line harmonic voltage distortion shall not be more than 10%.
3.2.6 Total current Harmonic Distortion
The total current harmonic distortion contributed by the unit at the input shall not exceed 10% for
input voltage range 150-275 V for load 50% to 100% of the rated capacity. While input voltage
harmonic Distortion is less than 5%.
3.2.7 Current limiting (Voltage Droop)
(i) The current limiting (Voltage Droop) shall be provided for Float Charge operation. The
Float/Charge current limiting shall be continuously adjustable between 50 to 100% of rated
output current for output voltage range of 44.4V to 56Volts. For test purposes upper limit of
100% + 5% and lower limit of 50% -5% shall be acceptable.
(ii) The float and charge current limit adjustment shall be provided on the front panel of the rectifier
module or through the DSCA controller.
(iii) The FR-FC modules shall be fully protected against short-circuits. It shall be ensured that short
circuit does not lead to any fire hazard.
3.2.8 Soft Start Feature:
(I) Slow start circuitry shall be employed such that FR-FC module input current and output
voltage shall reach their nominal value within 10seconds.
(II) The maximum instantaneous current during start up shall not exceed the peak value of the
rectifier input current at full load at the lowest input voltage.
3.2.9 Voltage overshoot/undershoot
Following requirements shall be achieved without a battery connected to the output of FR- FC
module.
(a) The FRBC/FRFC modules shall be designed to minimize output voltage overshoot/undershoot
such that when they are switched on the DC output voltage shall be limited to 5% of the set
voltage & return to their steady state within 20ms for any load of 25% to 100%.
(b) DC output voltage overshoot for a step change in AC mains shall not cause shut down of FR-FC
module and the voltage overshoot shall be limited to 5% of its set voltage and return to steady
state within 20ms.

(c) The modules shall be designed such that a step load change of 25 to 100% shall not result in DC
output voltage overshoot/undershoot of not more than 5% return to steady state value within
10ms without resulting the unit to trip.
3.2.10 Electrical Noise
(I) The rectifier (FRBC/FRFC) modules shall be provided with suitable filter on the output side.
A resistor shall be provided to discharge the capacitors after the rectifier modules have
stopped operation and the output is isolated.
(II) The Psophometric Noise (e.m.f. weighted at 800Hz) with a battery of appropriate capacity
connected across the output should be within 2mV while delivering the full rated load at
nominal input of 230V. For test purposes, this shall be taken as equivalent to 4mV when the
battery is not connected and other conditions remaining the same as per ITU-T Rec P53.
(III) The Peak to Peak Ripple: voltage at the output of the rectifier module on full load without
battery connected shall not exceed 300mV at the switching Frequency measured by an
Oscilloscope of 50/60 MHz band-width (typical)
3.2.11 Parallel Operation
FRBC/FRFC operating in parallel with one or more modules of similar type, make and rating, other
output conditions remaining within specified limits. The current sharing shall be within 10% of the
average current per rectifier module and within individual capacity of each rectifier module in the
system when loaded between 50 to 100% of its rated capacity for all other working conditions.
3.2.12 Protection
3.2.12.1DC over voltage protection
Each rectifier module shall be fitted with an internal over-voltage protection circuit. In case output
DC voltage exceeds-57V the over voltage protection circuit shall operate & shut off the faulty
module. A tolerance of 0.25V is permitted in this case. Restoration of the module shall be through a
reset switch/push button. Shutting-Off of faulty FRBC/FRFC module shall not affect the operation of
other FR-FCs operating in the rack. Operation of over- voltage shut down shall be suitably indicated
on the module and also extended to monitoring/control unit.
The circuit design shall ensure protection against the discharge of the battery through the FR- FC
module in any case. The over voltage protection circuit failure shall not cause any safety hazard.
3.2.12.2 Fuse/circuit Breakers
Fuses or circuit breakers shall be provided for each FRBC/FRFC module as follows:
a) Live AC Input line
b) Negative DC output
c) Against failure of Control sensing circuit.
All fuses/circuit breaker used shall be suitably fault rated.
3.2.12.3 Lightning Protection
System shall have modular type I/class. B and Type II/Class C type surge protection in TT
configuration of wiring. Both type I/Class B and Type II/Class C arrestors should be from the same
manufacture and shall be mounted as per the specific installation recommendations of the
manufacturer to achieve perfect coordination.
a)Stage 1 Protection (at the entry point of input 230V AC supply in the power/ equipment room)

The Stage 1 protection shall consist of coordinated Class I/ B & II/ C type SPDs at the entry point of
input 230V AC supply in Power /Equipment room in TT configuration in a separate wall mountable
box. The Class I/B SPD shall be provided between Line to Neutral & Neutral to Earth. They shall be
spark gap type voltage switching device and tested as per IEC 61643 with the following
characteristics and features-

SN Parameters Limits
Between Line & Between

Neutral Neutral & Earth
1 Nominal Voltage (U
0
) 230V 230V
2 Maximum continuous operating voltage
(U
c
)
255V 255V
3 Lightning Impulse current 10/350 s
(I
mp
)
25KA 50KA
4 Response time (T
r
) 100 s 100 s
5 Voltage protection level (U
p
) 2.5KV 2.5KV
6 Short circuit withstand and follow up
current extinguishing capacity without
back up fuse (I
sc
& I
fi
)
3KA 100A
7 Temporary Over Voltage (U
T
) 334V min. for 05
secs.
1200V min. for
200ms
8 Operating temperature / RH - 25
o
C to +80
o
C/
95%
- 25
o
C to +80
o
C/
95%
9 Mounted on din rail din rail
10 Indication Mandatory Optional
11 Pluggability Optional Optional
12 Potential free contact for remote
monitoring
Optional Optional
13 Encapsulation Encapsulated Encapsulated
14 Degree of protection IP20 IP20
15 Housing Fire retardant as
per UL 94
Fire retardant as
per UL 94

(b) The Class I/ B SPD will be followed by Class II/ C SPD adjacent to it and connected between
Line & Neutral. The device shall be a single compact varistor of proper rating and in no case
a number of varistors shall be provided in parallel. It shall be voltage clamping device,
thermal disconnecting type and shall be tested as per IEC 61643 with the following
characteristics and features-

SN Parameters Limits (between Line &
neutral)
0
) 230V
2 Maximum continuous operating voltage (U
c
) 300V
3 Nominal discharge current 8/20 s (I
n
) 10KA
4 Maximum discharge current 8/20 s (I
max
) 40KA
5 Response time (T
r
) 25 s
p
) 1.5 KV
o
C to +80
o
C/ 95%
8 Mounted on Din rail
10 Indication Mandatory
11 Pluggability Mandatory
12 Potential free contact for remote monitoring Mandatory

13 Degree of protection IP20
14 Housing Fire retardant as per UL
94

(c) Class I/B and class II/C SPDs of Stage I shall be so coordinated that the voltage protection
level of the coordinated devices is 1.5 KV. As such, these devices shall be from the same
manufacturer and necessary test certificate in this regard shall be submitted by the
manufacturer/ supplier.

(d) Stage 2 protection (at the output side of 48 V)

The 24V-60V DC supplies at
the output side inside the rack of IPS. These shall be provided for External circuits. The Class
II/C type SPD shall be a single compact varistor of proper rating and in no case a number of
varistors shall be provided in parallel. It shall be voltage clamping device and thermal
disconnecting type. They shall be tested as per IEC 61643 with the following characteristics
and features-

SN Parameters Limits (between L1 & L2, L1 & E
, L2 & E)

0
) 24V-60V DC
2 Maximum continuous operating voltage (U
c
) 100 (DC)
3 Nominal discharge current 8/20 s (I
n
) 10KA
4 Maximum discharge current 8/20 s (I
max
) 40KA
5 Response time (T
r
) 25 s
p
) 0.5 KV
o
C to +80
o
C/ 95%
8 Mounted on Din rail
10 Indication Mandatory
11 Pluggability Mandatory
12 Potential free contact for remote monitoring Mandatory
13 Degree of protection IP20
14 Housing Fire retardant as per UL 94

3.2.12.4 Length of all cable connection from SPDs to earth/ equi-potential busbar shall be kept less
than 0.5mtrs. For this, a sub earth equi-potential busbar shall be installed at approx. 20cm
from the SPD box. The details of connection of SPDs for Stage 1, & 2 of a typical installation
with TIPSS is enclosed as Annexure-II.

3.2.12.5 Batch test report of OEM should be submitted by the manufacturer /supplier of Lightning &
Surge protection devices to the IPS manufacturer at the time of supply of these devices. Copy
of the same shall be submitted by IPS manufacturer to RDSO at the time of acceptance test of
IPS system.

3.2.13 Alarms and Indicating Lamps
Visual indications/display such as LEDs, LCDs or a combination of both shall be provided on each
FR-FC module to indicate.
Functional Indications:
A. Mains available
B. FRBC/FRFC on Auto Float
C. FRBC/FRFC on Auto charge
Alarm Indications
A. AC/DC Rectifier module Over Voltage, Under Voltage or Output Fail
B. FRBC/FRFC over Load (Voltage Droop)
C. Fan fail (due to any reason)
Functional indications shall be extended as status and alarm indications as FRBC/FRFC Fail to
Distribution-Switching-control and Alarm Arrangement.
3.2.14 Radio Frequency Interference Suppression: The module shall be designed to minimize the level
of electromagnetic interference (EMI), both conducted and radiated, detected in its vicinity and
generated by Switch Mode Power conversion Equipment operating within the rack. The radiated &
conducted noise shall be within the limits specified in International specification no. IEC CISPR 22
at the time of type test. Limits and test methods are given in Annexure-I.
3.2.15 Noise & Vibration: The Fully equipped rack at full load shall not contribute more than 15dB
(weighted) to the ambient noise level taken as 45dBA. It shall be measured at a distance of 1 meter
from the unit and 1.25m above the floor level in the Acoustic range. The correction factor for Total
Noise when the ambient noise level is more than 45dBA shall be as given below:
Note: The correction factor shall be added to the limit of 60dBA to arrive at the limit when
the ambient is greater than 45dBA.

3.2.16 Rack Configuration:
Rack shall be composed of following units accommodated in sub racks
a) Float Rectifier cum Float Charger (FR-FC) Modules or Float Rectifier Cum Boost Charger
(FR-BC) Modules, and DC-DC Converters.
b) MPPT Charger modules in N+1 configuration with its Master Control.
c) Distribution-Switching-control-Alarm Arrangement (DSCA).

AMBIENT
NOISE
CORRECTION
FACTOR
AMBIEN
T NOISE
CORRECTION
FACTOR
AMBIEN
T NOISE
CORRECTION
FACTOR
45dBA 0dB 51dBA 1.41dB 57dBA 3.69dB
47dBA 0.18dB 52dBA 1.73dB 58dB 4.17dB
48dBA 0.39dB 53dBA 2.07dB 59dBA 4.68dB
49dBA 0.86dB 55dBA 2.82dB
50dBA 1.12dB 56dBA 3.25dB

d) The number and rating of FR-FC, FR-BC and DC-DC Converters Modules shall be provided as
per purchaser s requirement. The Distribution-Switching-Control- Alarm Arrangement (DSCA)
shall be provided for the Ultimate Expandable Capacity. All factory wirings for the rack shall be
for the Ultimate Expandable Capacity so that only plugging-in of FR-FC or FR-BC module,
DC-DC Converter shall in trance ultimate capacity of Telecom Integrated Power Supply
System.
3.2.17 ADDITIONAL REQUIREMENTS FOR LMLA BATTERIES:
Low Maintenance Lead Acid batteries have special requirement of periodic boost charging @ 2.7V
per cell. To meet this requirement, the Telecom Integrated Power Supply shall be so configured that
in addition to the specification requirements, detailed above, shall also have a provision of a group of
FR-BC (as per battery capacity) for charging the batteries @ 2.7V/cell.From 2.4 volt to 2.55 volts the
current capacity will be half of the rated capacity
Float Rectifier-Float-Charger-Boost Charger (FR-FC): In addition to requirement of FR- FC
Modules, the FR-FC Modules shall meet the following additional requirement.
a) The FR-FC module shall be programmable to work as FR-FC or FR-BC. When programmed as
FR-FC, it shall be capable of working as FR-FC with other FR-FCs and shall comply with all the
requirements of FR-FC.
b) It shall also be programmable as a Boost Charger (BC) under manual control after isolating it from
the float bus.
c) As a Boost Charger, its output voltage shall be continuously adjustable and pre-settable at constant
current up to 100% for voltage range 44.4 to 56V and up to 50% to 70% rated capacity at any value in
the range of 56V to 64.8V as per design of the FR-BC. The firm has to specify the percentage of rated
capacity of FR-BC module when it is working in the boost charging mode (56 to 64.8V)
d) The Boost Voltage shall be maintained with 1% of the set value over the full boost current range as
specified.
e) When programmed in Boost Charging Mode, FR-BC modules shall work in parallel load sharing
arrangement with other FR-BC modules in the same mode, keeping other output conditions within
specified limits.
(I) The current sharing shall be within 10% of the average current per FR-BC module (in Boost
charging Mode) in the system (mounted in the same or different racks) when loaded between
50 to 100% of its rated capacity (as BC) for all other working conditions.
(II) In addition to the Visual indications/display specified for FR-FC the following shall also be
provided in FR-BC Module.
a. Functional Indications : FR-BC on Boost Mode
b. Alarm Indications : Following Alarms shall actuate in BC mode:
FR-BC Over Voltage.
FR-BC Over Load (Voltage Droop)
f) Protection: The module shall also be protected against DC over voltage in BC mode. Shutting-off of
faulty FR-BC module in FR-BC mode shall not affect the operations of other FR-BC & FR-BC in
FR-FC mode.

4.0 REQUIREMENT OF DISTRIBUTION-SWITCHING-CONTROL AND ALARM
ARRANGEMENT (DSCA)General:
Depending on the system requirements system shall be provided with a Distribution-
Switching-control-alarm Arrangement (DSCA) for the Ultimate Expandable Capacity.
The unit shall comprise of the following:
a) Termination for the batteries

b) Termination for the load
c) Interconnecting arrangement for power equipment
d) Battery Switching Arrangement (connection to/Isolation from system)
e) Termination for AC input to the rack
f) Termination for AC and DC to FR-FC modules
g) Circuit Breakers/Fuses etc.
h) Termination for Solar power
i) Termination for DG power
Two numbers of potential free contacts for connecting to network monitoring system for monitoring
DC output fail, DC output over voltage, DC output under voltage and mains fail shall be provided.
4.1 Battery Monitoring
a) Battery Under Voltage Isolation:
Cut-off: 1.85V/cell (44.4V+0.25V) Reconnect: 2V /Cell (48 V)
However on resumption of AC mains this contactor should get reconnected automatically.
b) Battery health Monitoring in Auto Mode:
The system shall change over to Auto charge mode to charge the battery at higher voltage of 55.2V till
the battery is fully recouped.
c) It should also be possible to monitor individual cell (for 24 Cells of 2 V each) of battery bank and
status of all cells shall be made available in a graphical form / Table and strength of week cell can be
detected and alarm should be generated which can be displayed in a Alpha-Numeric display provided
in DSCA.
d) Battery Current Limiting Circuit: In auto mode, to ensure the availability of required load and safety
of the battery, battery path current limit shall be settable as per the battery bank requirements so that
the battery path current is kept to 10% of battery Ah capacity.
e) Temperature Compensation for Battery: There shall be provision for monitoring the temperature of
battery and consequent arrangement for automatic temperature compensation of the FR-FC, FR-BC
output voltage to meet the battery temperature dependent charge characteristics.
f) Battery Reverse Polarity Protection: Protection for battery reverse polarity shall be provided in the
system.
g) DC Contactor: High quality DC contactors, UL approved should be used for battery path
disconnection circuit.
4.2 Requirement of ASM Panel:
Status monitoring panel shall be installed in the room of ASM on duty. The panel shall have
following LED indications and alarms with resetting switch:

Instruction Condition LED
Ind.
Remark
A Run Gen set 50% DOD

RED Audio / visual alarm. Alarm can be
acknowledged for audio cut off.
B Emergency
start generator
60% DOD RED -do-
C System shut
down
70% DOD RED

All DC-DC converters to work.
Audio alarm will continue till
Generator is started.

D Call S & T
staff
Equipment fault RED Failure of any module or in case
battery gets disconnected from
circuit will give the alarm in panel.
Alarm can be acknowledged for
audio cut-off.
E Stop Gen Set FRBC change
over to float
mode
GREEN Audio /Visual alarm

Audio alarm in case of A, B & C shall be of one type of tone and there shall be different tone
for the case of D & E cases.
4.2.1 In A, B & C conditions, the visual LED indication will remain lit until fault is cleared or the
DG set is started and battery is charged upto 110V i.e. 2V/cell as the case may be until reset
push button is pressed. In case of D condition, if fault is not cleared, the LED will continue to
glow, even if reset push button is pressed.
5.0 REQUIREMENTS OF DC-DC CONVERTER
5.1 The DC/DC converter covered under this specification shall work satisfactorily meeting all the
prescribed parameters as long as the DC input voltage is within 44V to 58V ( 66V in case of FRBC).
The output regulation shall be 1% of set value from 10% load to full load for the entire input range.
Typical voltage ratings are 24V, 12V, and 3-6V DC and typical current ratings are 1 Amp and 5 Amp
depending upon load requirement.
5.2 Each converter shall be provided with a proper plug in arrangement for DC input & output. A switch
shall be provided for switching ON/OFF the unit.
5.3 The converter shall be provided with means for protection and visual indication on front panel for the
following:

5.4 The unit shall be provided with over-load protection, over-voltage protection and output short circuit
protection with fold back characteristics. The over-load protection shall be effective at 105% and
output short circuit protection shall be effective at 110% of the rated current.
5.5 The DC over voltage protection shall be auto tracking type. Over voltage trip shall be set at
approximately 110% of the set output voltage.
5.6 Output voltage settability of the converter shall be within the -2% of the minimum rated voltage
and +2% of the maximum rated voltage of the converter.
5.7 Output shall be free from overshoot because of Turn on /Turn off or power failure or when the
battery charger is switched ON/OFF.
5.8 In case of failure of DC-DC converter the output voltage shall not exceed beyond pre-set value. For
this a Fail Safe Feature for the module be explained and demonstrated so as to , a) protect the Load
under all circumstances , b) maintain continuity of the DC circuit even if one of the module has failed
(i.e.to isolate one module only and not the entire group ).
5.9 No load input current shall not be more than 10% of the rated input current at maximum full load for
all setting of output voltage and input voltage variation from 44V to 58V ( 66V ) of nominal input
voltage for DC-DC Converters of 50 VA and above.
Description Nomenclature Indication
i) Input Power ON indication INPUT Amber
ii) DC-DC Converter output OK OUTPUT Green
iii) DC-DC Converter fail FAIL Red

5.10 Overall efficiency of the converter at full load shall not be less than 75% for converters rating from
50VA to less than 150VA at rated load and 80% for converters of 150VA or more rated output at 44V
to 58V ( 66V ) of nominal input voltage. . For converters of rating 10VA - 50VA, overall efficiency
shall be greater than 50%. The efficiency shall be measured at the maximum output voltage of the
specified range.
5.11 Each DC-DC converters shall be of modular type which shall be fitted in main rack. The input and
output connections shall be made using irreversible plug in connectors of appropriate rating.
5.12 Output must be isolated from input. Each DC-DC converter shall have blocking diodes at the output.
The test points shall be provided before the blocking diode.
5.13 Radio Frequency Interference Suppression: The DC-DC Converter shall be designed to minimise the
level of Electromagnetic interference (EMI/RFI), both conducted & radiated in the vicinity of
DC-DC Converter. The radiated & conducted noise shall be within the limits specified in
International Specification No.EN-55022. The firm shall submit certificate to this effect.
5.14 The converter shall have self-resetting type protection from over load/ short circuit of DC output. The
converters shall be adequately protected against surges/ lightning at the input.
5.15 The output ripple (peak to peak) of the converter shall not be more than 50mV at full load.
5.16 Provision shall be made for measuring voltage of DC-DC Converter modules with the help of
common meter.
5.17 Parallel Operation:
DC-DC Converter ( more than 50 Watts) operating in parallel with one or more modules of similar
type, make and rating, other output conditions remaining within specified limits. The current sharing
shall be within 10% of the average current per converter module and within individual capacity of
each converter module in the system when loaded between 50 to 100% of its rated capacity for all
other working conditions.

6.0 REQUIREMENTS OF MPPT CHARGER (OPTIONAL)
MPPT( Maximum Power Point Trecking)Charger Module : The MPPT charger module shall be
designed to take DC power form the SPV panels and convert it into suitable DC power so as to
supply 48V DC bus demand. It should be used in N+1 configuration and should have following
features:
(a) It should be using MPPT Algorithm.Giving algorithm efficiency of 98% or higher. Efficiency
at rated output voltage and full load should not be less than 93%. Even at less than full load,
efficiency should not drop to less than 90% at 30% full load.
(b) It should work over higher DC ( SPV ) voltage and should cover 70V to 200V DC
(c) Suitable DC filter with protection be provided at its output.
(d) It should have protection against Lightening and Surges at its input.
(e) It should have facility to be connected with the Mains ( AC ) based SMPS charger modules and
should also work in stand-alone mode when AC mains is not available.
(f) It should work as priority over SMPS charger module so as to save the mains consumptions
when PV is available
(g) It should have protection against DC overvoltage and should isolate itself in case of any such
eventuality . It is Fail Safe feature of the module.
(h) It should have Auto Float/Boost Changeover , Battery path current limiting features.
(i) The module ratings should be 25A/Module.
(j) Compliant to IEC 62509 with the exception of self consumption and set point accuracy (3%
will be allowed).
(k) Protection against moisture and dust shall be of at least IP 31 level.
(l) Capable of handling

(m) Temperature compensated charging.
(n) Provision of blocking diode, preferably a Schottky diode, to prevent the battery from
discharging itself through the SPV system/ charge controller. The current capacity of the
blocking diode shall be 50% higher than the short circuit current at STC. The peak inverse
voltage (PIV) of the diode shall be at least equal to the open circuit battery voltage. In case any
alternative to Schottky diode is proposed, then technical literature and evidence in support of
successful working of the same should be submitted for the consideration of RDSO/ purchaser.
(o) On the SPV power source side, the charge controller shall be protected against lightning and
surges with the help of SPDs if the distance between charge controller and AJB is more than 10
induced surges Class II as per IEC 61643-1. The voltage rating of the SPDs shall be at least
10V higher than the specified value of the SPV array.
(p) Protection shall also be provided against the following: battery overload, battery overcharge,
short circuit and reverse polarity. Auto resettable reverse polarity protection should be
provided.
(q) Cables of appropriate size shall be used to reduce the voltage drop between SPV and battery;
and battery and the output of the charge controller.
(r) The charge controller shall incorporate the auto, bulk and float charging methods. Though not
mandatory, manufacturers are however encouraged to provide equalization charging facility
also. Battery charging modes shall be selectable as per battery type.

7.0 Source Prioritization:

If all power sources are available and option of Solar Power has been used first priority will be given
to solar energy i.e.. Power supply to DCDC converters, telecom loads and Battery will be supplied
through solar modules and if it is not upto the requirement the available current from Solar will be
used and balance requirement will be taken from AC Power Supply. While solar energy is sufficient
enough to support the load all other sources will be disconnected.
Second priority is AC 220V 50 Hz Power supply.
Third priority is given to battery. When grid supply is not available, the main controller checks the
health of battery. If battery is in charged condition and state of charge is greater that 70%, battery
power will be used to support DCDC converters, and telecom loads. If battery is also discharged and
no other source is available, it will give an indication as well as potential free contact should be
provided which may be utilized for starting the DG.
8.0 Packing
8.1 Complete TIPSS shall be packed in suitable wooden boxes/crate, strong enough, without 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.
8.2 FRBC module, DC-DC converters, shall be separately packed. These shall be wrapped in bubble
sheet and then packed in thermocole boxes and empty space shall be filled with suitable filling
material. All modules shall be finally packed in wooden case of sufficient strength so that it can
withstand bumps and jerks encountered in a road / rail journey.
8.3 Each box shall be legibly marked at one end with code numbers, contents, quantity and name of
manufacturer/ supplier. The upside shall be indicated with an arrow. Boxes should have standard
signages to indicate the correct position and precaution "Handle with Care" with necessary
instructions.




9.0 TEST AND REQUIREMENTS
Inspection & tests shall be carried out to ensure that requirements of this specification are complied.
All tests, unless otherwise specified, shall be carried out at ambient atmospheric conditions on all the
modules. For inspection of material, relevant clauses of IRS: S 23 and RDSO/SPN/144/2006 shall
apply unless otherwise specified. Manufacturer shall provide necessary machinery and plants /
/assistance for testing of the TIPSS.
9.1 Initial type approval
Initial type Approval shall be given with solar option and without solar option. Manufacturer shall
furnish following information at the time of initial type approval of TIPSS system.
I) Details of protection provided and their effectiveness / proposed set values and range and
working principle.
II) Bill of material for racks and modules. Details of semi conductors devices used and its
specification and data sheets.
III) Safety margins in voltage, current, thermal (for junction temperature) along with the limit
value for power devices, inductors and transformer etc.
IV) Installation & commissioning manual, Quality Assurance Plan and Service manual
(consisting of indications and fault diagnostics, Do's & Dont's etc.)
V) Design approach for the TIPSS system and salient features through which required MTBF has
been achieved.
While granting initial type approval, it shall be ensured that the system conforms to all the clauses and
passes all type tests as mentioned in clause 9.3.1and other relevant guidelines of RDSO.
9.2 Maintenance type approval
Before expiry of validity period, manufacturer shall submit prototype samples as per guidelines of
RDSO. The TIPSS must pass all type tests as per Clause 9.3.In case of design changes, RDSO may
call for fresh sample in the intermediate stage. ( Manufacturer shall not carry out any changes in
designe till it is approved by RDSO)In such cases, manufacturers shall submit all the information as
per clause 9.2.
9.3 The following shall comprise the Type Tests:
i. Visual Inspection (Cl. 10.1)
ii. Insulation Resistance (Cl. 10.2)
iii. Applied high voltage test (Cl. 10.3)
iv. Temperature rise test (Cl. 10.4)
v. Performance test (Cl. 10.5)
vi. Test for protective devices (Cl. 10.6)
vii. Environmental & Climatic Test (Cl.10.7)
viii. Functional test (Cl. 10.8)
ix. Vibration test on modules as per RDSO/SPN/144/2006.
x. Static discharge test as per RDSO/SPN/144/2006. Electrostatic discharge test shall be carried
out as per international standard IEC 61000-4-2 or its equivalent with 150 Pico Farad
charged capacitor of 7KV and should be discharged through 330 ohm resistor.
Note:
(i) Test for protective devices and performance test shall be carried out before and after
climatic test. There shall not be any significant deviations in the observations recorded.
(ii) Vibration & Static discharge test shall be conducted on one module of FRBC along with DSA unit,
DC-DC Converter.

9.4 The following shall comprise the Acceptance test:
The acceptance test shall be carried out as per the sampling plan given in Clause in 9.4.1.
a) Visual Inspection (Cl. 10.1)
b) Insulation Resistance (Cl.10.2)
c) Applied high voltage test (Cl. 10.3)
d) Temperature rise test (Cl. 10.4)
e) Performance test (Cl. 10.5)
f) Test for protective devices (Cl. 10.6)
g) Functional test (Cl. 10.8)

9.4.1 Visual inspection shall be carried out on one of the TIPSS unit of each type. The functional
test shall be carried on each TIPSS.The modules shall be tested for insulation resistance, high
voltage test, temperature rise test, performance and protection tests as per the sampling plan
given below:

Test Description Ins.
Res.
HV
test
Temp
rise
Performance
test
Protection
test
SMPS (FRBC) N/2 N/2 N/2 N N
DC-DC Converter (of each
type/ rating)
N/2 N/2 - N N
Battery Bank -10 hrs discharge test for capacity: Sample shall be taken as per Clause 11.1
of IS: 8320-1982. Cells shall be taken from all banks of TIPSS.

N = Denotes the no. of modules offered for inspection. N/2 shall be rounded off to the next
number. In case of any failure during acceptance test, the lot shall be rejected.
For acceptance of the lot there shall be no failure in any of the test as mentioned under clause
9.4 above.

9.5 The following shall comprise the Routine test:
The routine test shall be carried out on every module of the TIPSS system and the results will
be submitted by the manufacturer to the inspecting authority at the time of inspection.
a) Visual Inspection (Cl. 10.1)
b) Insulation Resistance (Cl.10.2)
c) Applied high voltage test (Cl.10.3)
d) Performance test (Cl. 10.5)
e) Test for protective devices (Cl. 10.6)
f) Functional test (Cl. 10.8)

10.0 TEST PROCEDURE
10.1 Visual Inspection
Test for visual inspection shall be carried out as per relevant clauses of this specification and
RDSO/SPN/144/2006.
10.2 Insulation Resistance
Insulation resistance (I.R) test shall be carried out:
1) before the high voltage test
2) after the high voltage test
3) after climatic test

The measurement shall be made at a potential of not less than 500 V DC. The insulation resistance
shall be measured at module level / rack as follows:
i) Input line terminals and the body of the equipment
ii) Output line terminals and the body of the equipment
iii) Input line terminals and output line terminals
iv) Between rack and earth
Value of the insulation resistance shall not be less than 10 M.ohm for the rack / equipment when
measured at a temperature of 40C and relative humidity of 60%. There shall not be appreciable
change in the values measured before and after high voltage test and after the temperature rise test.
After completion of climatic test, the values shall not be less than 5 M.ohm for the equipment when
measured at a temperature of 40C and relative humidity of 60%.
Note: - In case, temperature and humidity prevalent at the time of the above measurements of
insulation resistance are different from those specified above, the values of I.R. shall be obtained from
the table given below
R.H

25C 30C 35C 40C
60% 10 M.ohms 10 M.ohms 10 M.ohms 10 M.ohms
65% 10 M.ohms 9.0 M.ohms 8.5 M.ohms 8.0 M.ohms
70% 8 M.Ohms 7.0 M.ohms 6.5 M.ohms 6.0 M.ohms
75% 6 M.ohms 5.3 M.ohms 4.7 M.ohms 4.3 M.ohms
80% 4.2 M.ohms 3.6 M.ohms 3.3 M.ohms 3.0 M.ohms
100% 1.0M.ohms 0.6 M.ohms 0.3 M.ohms 0.1 M.ohms

10.3 Applied High Voltage test
The module shall withstand the application of 2000 V AC rms for one minute without puncture and
arching. The test voltage shall be approximately sine wave and of any frequency between 50 and 100
Hz. The high voltage shall be applied between the following:
(i) Input and earth
(ii) Output and earth
(iii) Input and output
Note:
For FRBC, item(ii) above shall be tested at 1000V AC rms
DC-DC Converter shall be tested for 1, 2 & 3 at 1000V AC rms.
The test shall be carried out after removing surge arrestors /MOVs or any other surge absorbing
components.
In routine test, only one module of each type shall be tested.
10.4 Temperature rise test
Temperature rise test should be logged during functional test of TIPSS after 8 hours, either with the
help of thermo-couple or with resistance method on one module of each type.

While conducting the test with the help of thermo-couple, the temperature of MOSFET/IGBT, diode,
Transformer/ Ferrite Transformer, choke, Internal ambient, Inside cabinet and outside cabinet shall be
recorded at every one hour for first four hours and every half hour for next four hours. During this test,
the temperature compensation probe shall be disconnected.
The temperature rise of heat dissipating components above the ambient measured directly and at heat
sink shall not be more than
(i) Transformer and chokes : 90C
(ii) Thyristor & diodes : 40C
(iii) IGBT/MOSFET : 30C
10.5 Performance test
10.5.1 Performance test for FRBC/FRFC shall include following and other relevant clauses of this
specification.
i) The FRBC shall be tested for its output performance (efficiency, power factor, harmonic distortion,
psophometric noise and ripple voltage) at the AC input voltages 150V, 230V and 275V at different
load currents by connecting a variable resistance load across the output terminals for the auto float
mode and auto boost mode respectively.
ii) In auto float mode, readings shall be taken for float voltage setting of 2.15 V/cell & 2.25V/cell for low
maintenance lead acid batteries & VRLA batteries, respectively at load current in the ranges 25% load
to full load.
iii) In auto boost charger mode, readings shall be taken for boost voltage setting of 2.42V/cell & 2.3
V/cell for conventional lead acid batteries & VRLA batteries respectively at load current in the ranges
25% load to full load.

iv) During the performance test, the system shall fulfil the requirements of efficiency, power factor,
psophometric noise, harmonic distortion, ripple voltage etc. as given under clauses 3.2 of this
specification.
The test report from National /International test house of RFI/EMI shall be submitted by the
manufacturer as per clause 3.2.14.
v) The current sharing of the module working in parallel shall be tested as per clause 3.2.11& 5.17.

10.5.2 Performance test on DSCA unit, DC-DC Converter shall be carried out as per clause no. 4 & 5
respectively.
10.6 Test for protective devices:
10.6.1 Test for protective devices for FRBC shall include following: and other relevant clauses of this
specification.
i) Short circuit: During this test, system shall be connected to AC input voltage of 275V. Output
terminals shall be short-circuited through a suitable arrangement. Steady short circuit current shall be
measured. It should not exceed rated current + 5%. There shall not be any damage to charger.
Working of over load/ short circuit indications/ alarms will also be checked on the FRBC. This shall
be achieved by controlling output current and voltage under short circuit condition and not by
switching off the input/ output voltage under short circuit condition.
ii) Reverse battery connection: A fully charged battery shall be connected in reverse polarity to output
terminals of charger. There shall be no emission of smoke of undue temperature rise of any
component of charger. Working of corresponding indication/ alarm shall also be checked.
iii) Other protection such as over voltage, battery under voltage, battery temperature compensation,
battery current limit, input high & low voltage protection test shall be carried out as detailed as per
clause 4.1.

10.6.2 Test for protective devices for DSA unit, DC-DC Converter shall be carried out as per relevant clause
of the specification.
10.7 Environmental & Climatic test
10.7.1 i) The Environmental & climatic tests shall be conducted on complete TIPSS system in
integrated manner. Not more than 2 chambers shall be used for conducting the tests.
SN Test Reference Severity
1 Change in temperature
test
IS: 9000 Part XIV
Section II
-10 C to
+70 C (as per indoor application of
RDSO/SPN/ 144/2006)
2 Dry Heat Test IS:9000 Part III
Section III
Temp as per indoor application
specification no. RDSO/SPN/
144/2006.
3 Cold test IS: 9000 Part II Section
III
-10 C (as per indoor application of
RDSO/SPN/ 144/2006)
4 Damp Heat test
(Cyclic)
IS: 9000 Part V
Section 1 & 2
Temperature 55C and other
conditions as per
RDSO/SPN/144/2006 for indoor
application.
5 Damp Heat (Storage) IS:9000 Part IV As per Indoor applications of
RDSO/SPN/144/2006
ii) The climatic tests shall be carried out by setting the system in boost charge mode of operation.
During the period of exposure in each test, the system shall be connected to supply mains of
nominal input voltage and shall deliver the rated output voltage of 2.3V/ Cell or 2.4V/cell for
VRLA/LM batteries respectively to a resistive load.
iii) During the exposure, the system shall be loaded and output of the DC-DC Converter shall be
monitored at the end of every cycle.
10.7.2 Following tests shall be conducted on one module of FRBC/FRFC, DSCA unit, DC-DC
Converter,MPPT Charger & ASM unit.
SN Test Reference Severity
1 Salt Mist test IS:9000 Part XI
Procedure 3
As per Indoor applications of
RDSO/SPN/144/2006
2 Dust test IS: 9000 Part XII As per Indoor applications of
RDSO/SPN/144/2006

The performance of modules subjected to above tests shall be observed in TIPSS system.
10.7.3 Vibration test shall be conducted on FRBC, DSA unit, DC-DC Converter,MPPT Charger & ASM unit
as per RDSO/SPN/144/2006. The working of modules subjected for vibration test shall be observed
with the TIPSS.
10.8 OVERALL FUNCTIONING OF TIPSS
After above tests, overall functioning of TIPSS shall be checked as follows:
10.8.1 All sub systems shall be put on full load and with battery bank connected to the TIPSS. The overall
functioning of TIPSS shall be observed for 72 hours during type test, 8 hours during acceptance test &
4 hours during routine test with frequent ON and OFF condition of AC Mains alternately, after every
30 minutes.

10.8.2 All the sub systems of TIPSS shall be connected. The output of all sub systems shall be checked. The
switching over from mains to standby and vice versa of FRBC, and DC-DC converters shall be
checked. Indication of working and faulty condition of FRBC& DC-DC converters shall be checked.
10.8.3 All alarms and indications of ASM status monitoring panel shall be checked for its proper
functioning.
11.0 Information to be given by Purchaser:
1. Type of Battery:LMLA/VRLA and AH capacity.
2. Type of Stand in case LMLA is utilized: Wooden/FRP.
3. Solar (MPTT Charger )(optional) required /Not required.
4. No. of DC-DC Converter, voltage and rating. (1 Amp/5 Amp)
5. Distance of ASM Room from location of TIPSS. (In meters)
6. Distance of Battery Bank from TIPSS. (In meters)

***************************************************************************************


ANNEXURE-I
General Requirements : Radio Frequency Interference Suppression: The system (FR-FC, FR-BC
& DSCA modules) shall be designed to minimize the level of electromagnetic interference (EMI),
both conducted and radiated, detected in its vicinity and generated by the module and shall comply the
following clause.
1. Radiated Emission from power equipment.
Requirement: Any network of conductors and apparatus connected thereto shall not exceed the
level of field strength specified in IEC-CISPR 22 'A' as given below:
Frequency (F) (MHz) Distance (Meters)

Quasi peak limits dB(VV/m)
30-230
230-1000
10M
10 M
40 dB (V /m)
47 dB (V /m)
1. The lower limit shall apply at the transition frequency.
2. Additional provisions may be required for cases where interference occur.

Test Procedure: Test setup, Test procedure & Measurements shall be conducted as per IEC
CISOPR 22.
2. Conducted Emission Limits: All conducted emissions from power equipment or accessories
connected thereto, intended to be connected to the power lines of a public utility shall not
exceed. the limits specified in IEC-CISPR 22'A' as given below :
Frequency (MHz) (F) (MHz) Quasi peak limits dB (V) Average limit dB(V)
0.15 0.5
0.5 30.0

79 dB (V)
73 dB (V)

66 dB (V)
60 dB (V /m)

The lower limit shall apply at the transition frequency.

Test Procedure: Test set up, Test procedure & Measurements shall be conducted as per IECCISPR
22.
3. Conducted Susceptibility Limits : Power equipment used in Telecom Network shall not
malfunction when high voltage surge as specified below is superimposed at the input power
mains to the power equipment, for more than two seconds as per IEC 61000 4-12 9(b). The
equipment shall also not fail or degrade in performance after the surge is withdrawn.

Test levels:
Voltage Rise time (First peak ): 75 nano sec 20%
Oscillation Frequencies : 100 KHz & 1 MHz 10%
Repetition rate : at least 40/s for 100KHz and 400/s for 1 MHz
Decaying : 50% of the peak value between the 3rd & 6th periods.
Burst duration : not less 2 S
Surge amplitude : 250V (-10%) to 2.5 KV (+ 10%)
Wave shape : Damped.
Test Procedure: Test set up, Test procedure & Measurements shall be as per IEC 61000-4-
12. EMI surge of specified levels injected on power leads of test sample shall not cause
degradation of performance or malfunction
4. Electrostatic discharge (ESD) immunity limits: the limits shall be as per IEC 61000 -4-2,
9(1) (Both contact discharge method and Air discharge method) as given below :
Test level:
Contact discharge Air discharge
Level Test voltage KV Level Test voltage KV
4 8 4 15
Test Procedure: This test shall be conducted as per IEC 61000-4-2 for both requirements &
unit shall comply of clause 9(1) of IEC 61000-4-2.
5. Electrical fast transient/Burst immunity limits : The limits shall be as specified in IEC
61000-4-4.
Test level:
Open-circuit output test voltage (20%)

Level On power supply port, Protection Earth
Voltage peak KV4 Repetition rate KHz
4 4 2.5
Rise time of one Pulse -5 ns 30%
Impulse duration - 50 ns 30%

Test Procedure: This test shall be conducted as per IEC 61000-4-4. Test results shall be in
compliance of clause 9(1) of IEC 61000-4-4.
6. Radiated radio-frequency Electromagnetic field immunity limits: The limits as per IEC
610004-3.
Test level:
Frequency range: 80MHz to 1000 MHz

Level Test field strength V/m
3 10

Test Procedure: This test shall be conducted as per IEC 61000-4-3. Test results shall be in
compliance of clause 9(a) of IEC 61000-4-3.
7. Surge Immunity limits: The limits as per IEC 61000-4-5.
Test level:
Level Open circuit test voltage ( 10%) KV

1
2
3
4
0.5
1.0
2.0
4.0
Voltage surge 1.2/50Vs
Amplitude - 2KV (DM)
- 4KV (CM)
- After testing for 4KV, the amplitude shall also be increased to 6KV (1.2/50 Vs Combined
wave form as per EEE C62 41 1991 to cover lightening/Surge protection test also.
Test results shall be in compliance of clause 9(b) of IEC 61000-4-5.

Test Procedure: This test shall be conducted as per IEC 61000-4-5. After testing for 4KV, the
amplitude shall also be increased to 6KV (1.2/50 Vs). Combined wave form as per EEE
C62.41-1991 (to cover Lightening/Surge protection test also.).
Note: The rated voltage of the MOVs issued for the above shall not be less than 320V.
8. Radio Frequency Conducted Susceptibility immunity limits: The limits as per IEC 61000-
4-6.
Test level:
Frequency range: 150 KHz 80 MHz
Level Voltage level ( e.m.f.)
3 10

Test Procedure: This test shall be conducted as per IEC 61000-4-6. Test results shall be
compliance of clause 9(a) of IEC 61000-4-6


ANNEXURE-II

Eoi - SMPS Based Telecom Integrated Power Supply System For Station - 29!03!2014

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