GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

lR;eso t;rs

FUNCTIONAL REQUIREMENT SPECIFICATION

FOR
MANUFACTURE & SUPPLY OF MODULAR AND FLEXIBLE
ELECTRICAL PANELS

RESEARCH DESIGNS & STANDARDS ORGANIZATION

MANAK NAGAR, LUCKNOW - 226 011

Page 2 of 20

FUNCTIONAL REQUIREMENT SPECIFICATION FOR

MANUFACTURE & SUPPLY OF MODULAR AND FLEXIBLE ELECTRICAL
PANELS
0.0

FORWORD:

This Specification defines the objective guidelines and requirement for the design
manufacture and supply of modular and flexible electrical panels & enclosures.
1.0

GENERAL:

1.0.1 The tenderer shall furnish the following information:1.0.2 Name of manufacturer & country of manufacture.
1.0.3 Credentials of firm as manufacturer of panels.
1.0.4 Description of electrical panels installed during the last five years with the
name of the parties/buyers to whom supplies was made, date of installation and
performance certificate thereafter.
1.0.5 Details of testing facilities at manufacturers works.
1.0.6 Whether manufacturer has technical collaboration with another firm, if so
provide details regarding the same.
1.2 The tenderer shall bring out clearly any additional feature which he deems fit
to include to give a complete and comprehensive offer. He shall, however, explain
reasons for offering such additional features/items in his proposal.
2.0

SCOPE:

The scope of supply & services shall include the design manufacturing, testing &
supply of panels as per enclosed list.
3.0

CLIMATIC CONDITIONS:

3.1 The Panels should be manufactured accordance to covered all the following
mentioned conditions.
3.2 The climatic condition specified in this clause are average conditions, any
specific conditions specified in the tender documents shall override these.

Atmospheric
temperature
Humidity
Reference
site
conditions

(a) Short term peak : +50C

(b) Maximum on a 24Hours avg. : +35C
to 40C
(c) Minimum temp. : -10C
100% saturation during rainy season.
i)
Ambient Temp. : 50 C
ii)
Relative Humidity : 50% at 40C
iii)
Altitude: 1000m above sea level

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Rain fall
Atmosphere
during hot
weather

Pollution
level

Wind speed

4.0

Very heavy in certain areas.

Extremely dusty and desert terrain in
certain areas. The dust concentration in
air may reach a high value of 1.6 mg/m.
In many iron ore and coalmine areas, the
dust concentration is very high affecting
the filter and air ventilation system.
Humid and salt laden atmosphere with
maximum. pH value of 8.5, sulphate of
7mg per liter, max. concentration of
chlorine 6 mg per liter and maximum
conductivity of 130 micro siemens/cm.
High wind speed in certain areas, with
wind pressure reaching 150kg/m

STANDARDS

The Panel shall conform to the following Indian / international Standards as

amended /revised till date unless stated otherwise, as applicable:
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Specification No.
IEC60051/ IS - 1248

Description
For Direct acting indicating analogues
electrical measuring instrument
IEC60947/IS-13947
For Low-voltage switchgears & control
gear
IEC 60439-1
For Low voltage switchgear & control
gear assemblies.
IEC 60529 / IS For Degree of protection provided by
13947 part 1
enclosures ( IP Codes )
EN 61641
For accidental arc conditions
DIN - 43671
For Bus-bar Current rating.
DIN - 3168
For climate control unit for distribution
box / concept testing marking.
DIN VDE 0100
For Outdoor panels painting.
DIN 50961-2000 and
For mounting plates.
IS 1573-1986
DIN 43668
For cam lock with double-bit insert
IS : 5138
For quality of sheet steel
IS : 3072
For installation of switchgear
IS : 1554
For control wiring
IS : 2516
For Air-circuit breaker
IS : 7098 (part-1)
For LT Cables
IS : 2705 part-III 1964 For CTs
IS: 3043
For earthling
IS: 2384-1964
For capacitors
DIN EN ISO 1520,
For Anodic dip coat priming.
2815 & 2409
DIN EN ISO 1520,
For Textured powder coating

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21
22
23

24
25
26
27
28
29
30
31
32
33
34
35

36
37

2815 & 2409 &

9227NSS
DIN 53 577

For Testing elastic foamed material.

Determination of the compress strength
DIN 53 504
For Testing of rubber. Tensile test
DIN EN ISO 1798
For Flexible cellular polymeric materialsdetermination of the tensile strength and
elongation strength ( ISO 1798 : 1997);
German version EN ISO 1798 : 1999
DIN 53 508
For Testing of rubber. Accelerated ageing
DIN75200
For Determination of burning behavior of
interior materials in motor vehicles
EN ISO 1856
For Flexible cellular polymeric materials.
Determination of the compression set
IEC 60255
For Electrical Relays
IEC 60255 / IS - 3231 For Electrical Relays
IEC 609473 / IS - For On load isolators
13947
IEC 60629 2 / IS For Low voltage fuses
13705
IEC 60439-1 / IS - For Low voltage switchgear & control
8623
gear assemblies.
IEC 60947-2/IS13947 For MCCB,
-part 2.
IEC 60898/IS 888281995
IEC 60947-4-1

UL 489/ IEC 609472/ IS13947 -part 4.

For MCB
For Contactors
For MPCB

For material of copper Bus-Bars

DIN EN 13601
IEC 60439-1: 1999, For guidelines for the different
separation types
Annex D,

Other standards shall be applicable provided the stipulation of such a

standard is at least equal to the requirement of the specified standards.
5.0

PANEL SPECIFICATION:

5.1

General :

Frequency
Voltage Variations
Frequency Variations
5.2

50Hz.
+10%.
+3%.

33 kV.
11 kV.

System :

High Voltage Level

Medium Voltage Level

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Low Voltage Level

Design Form

5.3

415V.
3 Phase, 4-wire ( TPN )

Construction

5.3.1. Enclosure:
Enclosure should be of Single sheet sturdy frame section construction of sheet
steel as per IS: 5138, consisting of folded rolled hollow frame section punching in
25mm DIN pitch pattern. All profile edges are radiuses. The corners are stiffened
with welded zinc die-cast corner connectors with load bearing capacity of 1.5 Tons
of static load.
5.3.2 Rear wall:
Rear Panel /Rear Wall should be made with 1.5mm thick cold rolled sheet steel,
with foamed-on seal which should be removable.
5.3.3 Roof panel:
Roof panel should be made with 1.5 mm thick sheet steel with foamed-on seal and
should be removable.
5.3.4 Side panels:
Side panel should be made with 1.5mm thick sheet steel, with a foamed-on seal
and fixing screws. All parts should have been prepared for the attachment of earth
straps.
5.3.5 Surface finish:
Sheets should be cleaned and Nano ceramic coated, electro-dip coat primed and
powder coated with textured polyester RAL 7035.
5.3.6 Doors:
Doors should be made with 2 mm sheet steel, flush-mounted, with foamed-in seal,
vertical perforated mounting strips fitted on both sides (door stiffeners) and screwfastened hinges. Hinges can be fitted on the left or right for single-door enclosures,
130 opening angle as per VDI (retrofittable to 180), cam lock with double-bit
insert as per DIN 43668
5.3.7 Mounting plate:
The mounting plate should be as per DIN 50961 2000 and IS: 1573 1986, 2 - 3
mm sheet steel with system punchings, depth-adjustable stud mountings, without
spangles, zinc-plated @ 120 GSM (Gram per Square Meter).

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5.4

Busbar System

5.4.1 Bus bar & associated connections shall be constructed from 99.98% E-Cu
(Electrolytic Grade of Copper) with tinning thickness of 4 to 5 microns as per DIN
EN13601 with bus-bar rating according to DIN 43 761 standard. Tiniing is done to
avoid oxidation of copper.
5.4.4 The bus-bar support shall be of Polymide fiberglass reinforced with fire
protection corresponding to UL 94 V0.
5.4.5 The bus-bar system shall be capable of withstand stress due to fault current
of up to.
35kA for one second below 800A.
50kA for one second 800 1600A.
75kA for one second 1600 3200A
110 kA for one second for 4000A.
The bus-bar cover shall be complied with UL 94 V0. Tested under IEC60439.
5.4.6 Heat shrinkable sleeves should be provided for identification and protection.
5.4.7 Hardware used in bus-bar system should be of high tensile strength of grade
8.8 or better.
5.5

Painting / Surface treatment

5.5.1 The manufacturer should have RoHS compliance for painting process &
painting should comply with DIN EN ISO 1520, 2815 2409. Anodic dip coat
painting & textured powder coating performance shall be as per DIN EN ISO 9227
NSS. Alternatively, Painting process should comply with IS 3618- class -c for
phosphating (Tri catena zinc - phospahte)& Powder coating as per IS 101 & IS
13871 and Coating weight to confirm the requirement of IS 2618. In order to
ensure optimum corrosion protection in all climatic zones, Aluminum or
Galvanized/zinc plated metal with subsequent Nano-ceramic/zinc-phosphate &
powder coating should be used with the materials that are specified to be intended
for outdoor application.
5.5.2 The thickness of paint should be 70 135 micron.
5.5.3 Properties of Powder Paint
5.5.3.1 External Applications
The Polyester powder paint should be cured polyester powder paint; Triglycidyl
Isocyanurate (TGIC) should provide a wide range of desirable properties.
5.5.3.2 Indoor Applications

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For indoor applications, Epoxy painting should be used. Epoxy has excellent
property for corrosion resistance but inferior in case of UV.
5.5.3.3 Other Properties
The powder paint should resist any corrosion resulting from scratches, and nicks.
Even without a primer coat, powder paint should provide excellent resistance to
corrosion. The paint should also offers excellent protection at sharp edges on metal
fabricated items. Powder painting is stated to be the most flexible coating on the
market. The paint should not crack or lose adhesion when exposed to a bend with
a radius of 1/8 inch or impact of 160 inch pounds. TGIC should have flexibility
properties of the E-coating as well as withstand long-term exposure to heat up to
300F. Corrosion resistance properly should be confirmed as per ASTM B-117.
5.6

Gasket

The gasket should be of tri functional (functioning as a sealant, elastic in nature

and non- water absorbant), CFC free Polyurethane Gasket to provide maximum IP
protection & can withstand a temperature range of -40C to +90C.
It should comply with burning behavior According to DIN755200; also flexible
cellular polymeric materials should be used according to EN ISO 1856 and DIN EN
ISO 1798. Gasket should with stand Compress strength of 5 kPa to 200 kPa (at
25% compression) according to DIN 53 577. Gasket should with stand tensile
strength up to 2 MPa [N/cm] according to DIN53 504. Gasket should be long
lasting according to DIN 53 508. Gasket should be with stand high temperature
according to DIN 75200.
5.6.1
It should Capacity to withstand high temperature: PU gasket should
withstand 180 C/15 minutes.
5.6.2 High Adhesiveness:
Gasket should be with good quality of Adhesive or mixture of liquid Polyurethane
and Isocyanide (Resin & Hardener) & should be poured on the door/covers by a
CNC machine. Upon drying the mixture should solidifies and gets bonded to the
surface of the part permanently.
5.6.3 It should have Hygroscopic feature that is Polyurethane gasket should be non
hygroscopic.
5.7 Control wiring
All control wiring, indication etc. shall be carried out using 650V grade 1.5 sqmm
copper conductor cables PVC insulated conforming to IS 1554 Part-I. CT wiring
shall be with 4/2.5 sqmm copper conductor with suitable CT shorting links. Wiring
shall be suitably protected within the switchboard. Runs of wires shall be neatly
bunched and suitably supported and clamped. Means shall be provided for easy
identification of the wires. Identification ferrules shall be used at both the ends of
the conductors.
5.8

Earthing

Page 8 of 20

The panel shall be provided with copper earth bus running throughout its length as
per IS: 3043. Suitable earthing eyes/bolts shall be provided on the main earthing
bus to connect the same to the earth grid at site. Sufficient no. of star washers
shall be provided at joints to achieve earth continuity between panels and sheet
metal parts.
5.9

LT Cables

All cables shall be of suitable size copper & Aluminium Conductor, armoured,
XLPE insulated and rated for 1.1kV grade as per IS 7098 (part-1) 1998.
5.10 Terminals
All the control, instrumentation and protection wiring shall be provided with
COMPUTERISED Printed PVC ferrules at both ends for long life.
5.11 Name Plate
The panel as well as the feeder compartments door shall be provided with the name
plates giving the feeder description as required.
5.12 Basic Design Parameter
5.12.1 The enclosure should be provided with a degree of protection as per IEC
60529 / IS: 13947 part 1, of not less than IP-54 for indoor and IP-55 with Rain
Canopy and Fan-Filter /outlet filter with Hood for all outdoor mounted panels.
5.12.2 The enclosure should be provided with bus-bar cover (UL 94 V0) made of
Polymide (PA6.6) running all along the length of the switchgear in a separate
enclosure & also It should compliance for any accidental arc conditions as per EN 61641.
5.12.3 Vertical Bus bars shall run at the middle of two adjacent panels to take off
for individual feeders. The Bus bars shall be fully shrouded with bus-bar cover (UL
94 V0) heat shrinkable PVC sleeve to ensure safety of operation when rear doors
are opened.
5.12.14 The switchgear and distribution panels with ACBs & MCCB`s shall be
front operated with Breaker operating knobs clearly indicating position of Breaker
ON / OFF / TRIP.
5.12.15 The switchgear and distribution panels shall be interlocked from door
such that only after tripping of the ACB`s or MCCBs the front door can be opened.
5.12.16 Even with the door closed,
shall be achieved. Rack in / Rack
position can be done with the door
facility to lock the Breakers in service

the test / service position of Breaker (ACB)

out of Breaker from above test to isolated
closed from outside. It shall have a locking
& test positions.

5.12.17 The enclosure should be with insertion of an extended arm the Breaker
can be fully drawn out from the compartment but remains mechanically attached

Page 9 of 20

to the panel so that routine inspection and maintenance checks can be easily
carried out.
5.12.18 The Panel should be Form 1 for LT distribution Panels below 800A as per

IEC 60439-1: 1999, Annex D

5.12.19. The Panel should be Form 4a for LT distribution Panels above 800A as per
IEC 60439-1: 1999, Annex D,

5.12.21 Incomer shall have facility to receive emergency stop push button from
field. These buttons through relay contacts shall be wired to incomer shunt trip in
a way that it trips the breaker whenever emergency push button pressed in field.
Incomer all have operating handle at the outside of that door and an emergency
stop push button.
5.12.22 Incomer shall have RYB lamp indication, On Off & Trip indication, &
Digital ammeter shall be operated through CT and suitably rated PT shall be
provided for Digital Voltmeter
5.12.23 All bus-bar shall be made with Electrolytic Grade of Copper E-Cu 99.98%
purity as per DIN EN 13601with current rating acc. to DIN 43 761.
5.12.24 All cable shall be FRP type with copper conductor.
5.12.25 CTs wherever used shall be resin cast type.
5.12.26 The selection of components shall be made in accordance with feeder
rating keeping 20% extra.
5.12.27 There shall be suitable provision for termination of cable Cu. / Al. from
field.
5.12.28 There shall be separate bus-bar chamber at the top for horizontal busbar.
5.12.29 Minimum 300mm clearance shall be maintained between floor & last
terminal row.
5.12.30 MCC shall have 3 phase 4 wire 50 Hz system i.e. TPN.
5.12.31 In future MCC should have provision to get expended at both ends.
5.12.32 The Panels shall be of single front, double access type having feeder
controls located in the front and vertical Bus bars and cable chamber located in the
rear. Control and selector switches, Push Buttons, indicating instruments, lamps
protective relays, single phasing relays shall be mounted on the front doors of the
respective compartments. Current Transformers and Circuit Breaker control
circuits shall be mounted on the fixed portion of the compartment; CTs shall not be
directly mounted on the Buses.
5.12.33 Suitable liberally designed barriers shall be placed between Circuit
Breakers and all control protective and indication circuits, equipment including
Instrument Transformers. External cable connections shall be carried out in a

Page 10 of 20

separate cable compartment. Separate cable chambers shall be provided for Power
& Control cables.
5.12.34 After isolation of the power and control connections of a circuit, it shall be
possible to safely carry out maintenance in a compartment with the Bus bars and
adjacent circuit in `live' condition.
5.12.36 All the assembly or installation for Low-voltage switchgears & control
gears assemblies should be as per IEC 60947 or IEC 60439 1, & IS : 3072.
5.12.37 All the enclosure climate control unit, like panel AC, etc, if required
should be as per DIN 3168.

5.13 Cable Entry

5.13.1.1 Cable entries in the Cabinets/ SCADAs, /Power/Control cubicles &
other equipments shall be sealed with EPDM Modular based Cable sealing
system with technology based on Multidiameter.
5.13.1.2 The EPDM Modules should be "Low Smoke Index, Halogen free crosslinkable rubber compound based on EPDM (Ethylene - Propylene Diene
Terpolymer).
5.13.1.3 One single module should seal a cable of several different diameters.
5.13.1.4 The system should ensure foolproof protection against hazards induced
by" Water, Dust, Humidity, & Rodents. The sealing system must have built in
spare capacity i.e. option for adding more cables in to the same system.
5.14 Switchgear
The typical requirements of switchgear required to be housed in the electrical
panels are given as under:
5.14.1 ACB
5.14.1.1 Air circuit breaker shall be suitable for a continuous current rating as
specified for each type of panels. Air circuit breakers shall be with microprocessor
release of O/L, S/C, E/F conforming to IS2516. The typical requirements for a
1600 A ACB are as follows:Rated service voltage:
Rated insulation voltage:
Rated impulse withstand voltage:
Continuous rated current:
Capacity of the neutral pole:
Short circuit breaking capacity:
Short circuit making capacity:
Operating temperature:
Frequency:
Version:
Protection:

600 VAC
1000 VAC
12 kV
1600 A
1600 A
42 kA min
80 kA min
[C] -25+70
f [Hz] 50 - 60
Electrically operated drawout type.
O/L, S/C & E/F

5.14.1.2 Necessary isolating plugs and sockets.

Page 11 of 20

5.14.1.3 Necessary independent manual spring closing mechanism with

mechanical ON/OFF indicator as well as electrical ON/OFF indication to be
provided at front panel.
5.14.1.4 Necessary set of auxiliary switches and indication, metering requirements
such as ON/OFF indication, selector switches fuses.
5.14.1.5 ACB shall have motor operated charging system and suitable under
voltage relay.
5.14.1.6 Whenever two or more supplies are available /ACB's shall be electrically
& mechanically interlocked by providing suitable control circuit& devices.
5.14.2 MCCB
5.14.2.1 All the MCCBs shall be rated for at least 35 kA and from the approved
makes.
5.14.2.2 Operating mechanism shall be Quick-make, quick-break, trip free.
5.14.2.3 This shall be independent of manual speed of operation. Contacts shall
not be teased into position, nor can the breaker be held closed under fault
conditions.
5.14.2.4 Shall have Clear indication of ON, OFF and TRIP position.
5.14.2.5 All MCCBs shall be provided with operating handles to be fixed on the
panel door.
5.14.2.6 Facility to push to trip to verify healthiness of mechanism shall be in
built.
5.14.2.7 All parts of circuit breaker shall be enclosed in heat resistance insulating
material housing
5.14.2.8 Silver alloy contacts should have long electrical life and there should be
no arcing on the current carrying part of the contact
5.14.2.9 Terminals shall have large dimensions to accept links or cable lugs are
separated by insulated barriers with adequate clearances.
5.14.2.10 The MCCBs shall comply with the requirements of IEC 609472/IS13947 -part 2.
5.14.3 Capacitors
5.14.3.1 The capacitor shall be of heavy duty suitable for 3ph, 440V, 50Hz as per
IS 13340/1993
and shall be available in 5, 10, 15, 20 and 25 KVAR capacities. . The capacitors
above 15 KVAR Module shall be hermetically sealed and assembled easily in sheet
steel containers with Stud type Terminals. Capacitors shall be suitable for Indoor
use up to ambient temp. of 55 degree C. Sealed in strudy corrosion proof, sheet
steel Containers and impregnated with non-inflammable Synthetic liquid. The
capacitors above 15 KVAR Module shall be hermatically sealed and assembled
easily in sheet steel containers with Stud type Terminals.
5.14.4.2 Capacitors shall be hermitically sealed in sturdy corrosion proof, sheet
steel containers and impregnated with non-inflammable synthetic liquid. The
capacitors shall withstand voltage of 2500V (power frequency test voltage). The
insulation resistance shall not be less than 50 megohm when tested with 500V
megger.
5.14.4 MPCB

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5.14.4.1 There should be manual and local control, when the motor circuitbreaker is used on its own, and automatic and remote control when combined with
a contactor
5.14.4.2 Motor protection should provided by thermal-magnetic devices built into
the circuit-breaker
5.14.4.3 No live parts should be accessible to direct finger contact
5.14.4.4 The addition of an undervoltage trip enables the motor circuit-breaker to
be tripped if voltage is lost
5.14.4.5 The addition of a shunt trip should enable remote control of tripping
5.14.4.6 The control for the open or enclosed motor circuit-breaker should be
locked in the N/C" position using 3 padlocks
5.14.4.7 The MPCB should comply with the requirements UL 489/ IEC 60947-2/
IS13947 -part 4.
5.14.5 MCB
5.14.5.1 The fault current of MCBs shall not be less than 10KA at 230 V. The
MCBs shall be flush mounted and shall be provided with trip free manual operating
mechanism.
5.14.5.2 The circuit breaker dollies shall be of the trip free pattern to prevent
closing the breaker on a faulty circuit.
5.14.5.3 The MCB contacts shall be silver nickel and silver graphite alloy and tip
coated with silver. Proper arc chutes shall be provided to quench the arc
immediately.
5.14.5.4 MCBs shall be provided with magnetic fluid plunger release for over
current and short circuit protection. The overload or short circuit device shall have
a common trip bar in the case of DP and TPN miniature circuit breakers. All the
MCBs shall be tested and certified as per Indian Standards, prior to installation.
5.14.5.5 The MCB should comply with the requirements IEC 60898/IS 888281995
5.14.6 Contactors
5.14.6.1 The contactors shall have minimum making and breaking capacity in
accordance with utilization category AC3 and shall be suitable for minimum Class
II intermittent duty.
5.14.6.2 If the contactor forms part of a distribution board then a separate
enclosure is not required, but the installation of the contactor shall be such that it
is not possible to make an accidental contact with live parts.
5.14.6.3 The Contactor should comply with the requirements IEC 60947-4-1.
5.14.7 Current Transformer
CT s should be cast resin type. They shall be of accuracy class 10 P 10/5 P 10 ( as
per requirement) of IS 2705 part-III 1964, Where ammeters are called for C.T.s
shall be provided for current measuring. Each phase shall be provided with
separate current transformer of accuracy Class I and suitable VA burden for
operation of associated metering and controls.

Page 13 of 20

5.14.8 Push Buttons

The push button unit shall comprise of the contact element, a fixing holder, and a
push button actuator. The push button shall be momentary contact type. The
contacts shall be of silver alloy and rated at 10 Amps. continuous current rating.
The actuator shall of standard type and colour as per its usage for ON, OFF and
TRIP. Wiring for Remote ON, OFF push button is to be required.
5.14.9 Indicating Lamps
Indicating lamps assembly shall be screw type with built in resistor having non
fading color lens. LED type lamps are required. Wiring for Remote ON, OFF, TRIP
indicating lamp is required.
5.14.10 Indicating Instrument & Metering
5.14.10.1 All electrical indicating instruments shall be of digital type with 25mm,
3 digital display as per IS : 1248 or IEC - 60051. The size of the meter shall be 96
Sq.mm and shall be suitable for flush mounting with only flanges projecting on
vertical panels. Instruments shall conform to latest IS and shall have accuracy
class of 1.0. All meters of reputed make and approved by the Corporation shall be
supplied.
5.14.10.2 Wattmeter shall be of static type with accuracy Class of 1.0 type.
5.14.10.3 Voltage and Current circuits shall be arranged in such a way that they
do not appear in adjacent terminal blocks.
b. Care shall be taken to see that no block shall have more than two wires in a
terminal.
5.14.10.4 KWH meter shall be of 3 Phase microprocessor based of accuracy class
0.5, suitable for measurement of unbalanced loads in 3 Phase, 4 wire circuits.
Ammeter, voltmeter and wattmeter shall be of reputed make and approved by
Corporation.
5.14.11Terminals
5.14.11.1 Terminal blocks (both for power and control circuits) shall be of the
650V grade stud type, links between each pair of studs, washers, nuts & lock
nuts. The studs shall be securely locked within the mounting base to prevent their
turning. Insulated barriers shall be provided between adjacent terminals.
5.14.11.2 Terminal blocks shall be adequately rated to carry the current of the
associated circuit.
5.14.11.3 Terminal blocks shall be arranged with at least 50mm Clearance
between two sets of terminal blocks,
5.14.11.4 Control terminals for external connection shall be suitable for
terminating at least conductors each of 2.5Sq.mm size.

5.14.12 Space Heaters & Lighting Outlets

Page 14 of 20

Space heaters of capacity 60W suitable for connection to the single phase A.C
supply shall be provided inside all Cubicles, Panels and Switch boards at the
bottom to prevent condensation of moisture. Wiring connected to the space heaters
in the cubicle shall have porcelain beaded insulation over a safe length from the
heater terminals. All switchboards, cubicles etc., shall be provided with suitably
located lighting outlets and 15A, 3 pin powers plugs with sockets. The lighting
switch shall be provided inside each entrance door at the back of the panels.
5.14.13 Name & Identity Plates
5.14.13.1 Name & identity plate should be 25mm wide white/black Aluminium
plates.
5.14.13.2 All components (i.e. MCCBs, MCBs, Fuses, Contactors, auxiliary
contactors, relays, switches etc.,) inside the panel and out side the panel shall be
labeled with the above mentioned plastic plates and fixed permanently on the panel
beneath each component.
5.14.13.3 All labels shall comprise of black letters on white background. Labels
shall be made of 3ply lamicoid. They shall be properly fixed, with provision to
prevent distortion due to expansion.
Size of labels and lettering are subject to
Corporations approval.
5.14.14Ventilation
The rear enclosing sheets, and all front covers for the Breakers of heavy capacity if
considered necessary, shall be provided with Fan-Filter and outlet filter unit
combination to prevent entry of dust and vermin into the panel and giving IP
54 protection.
5.15 Make of Components
The make of the components to be used in the Electrical panel should be from the
CEEs approved list of the concerned zonal railway. In case, the item doesnt feature
in the list then it should procured from sources having proven design in similar
applications
6.0

SCHEDULE OF TESTS

6.1.0

GENERAL
6.1.1 Only after all the designs and drawings have been approved and
clearance given to this effect by RDSO, the manufacturer shall take
up manufacture of the prototype unit.
6.1.2 The contractor shall submit a detailed test plan, for approval of
RDSO, consisting of test procedures, schematic/circuit diagrams,
items/parameters to be checked and values required as per
specification for each of the tests and the number of days required to

Page 15 of 20

complete all the tests at one stretch. The schedule shall also indicate
the venue of each of the tests.
6.1.3 The routine/acceptance/type tests to be carried out on the panels, as
part of above inspection, are given in para 6.2.0 below.
6.1.4 Prototype inspection shall be witnessed by RDSO as per the approved
test plan. RDSO reserve the right to witness the complete or part of
the tests at their discretion.
6.1.5 During the process of type testing or even later, the DG/EM/RDSO,
Lucknow, reserves the right to conduct any additional test(s), besides
those specified in the test plan herein, on any equipment/item so as
to test the equipment/item to his satisfaction.
6.1.6 The tests shall be conducted on the prototype Panel at the works of
the manufacturer or at any NABL/Government approved test house
or laboratory in the presence of authorized representative of
DG/EM/RDSO. Contractor shall submit the complete test report
consisting of full details of the tests and test parameters.
6.1.7 On successful completion of the tests prototype approval certificate
shall be issued.
6.1.8 Series manufacture shall start only after issue of prototype approval
by RDSO. Acceptance tests, as per the approved test plan, on the
balance quantity shall be done by the authorized representative of the
Indian Railways as per purchase order.
6.1.9 Six copies of the following test certificates shall be submitted to
the
Purchaser for record:6.1.9.1 Type test certificate as issued by RDSO for the panels.
6.1.9.2 Acceptance test certificate for complete lot of the panels.
6.1.9.3 Routine test certificates for each panels.
6.1.10 Test certificates shall be completed with all the results. Purchasers
approval shall be obtained before dispatch of electrical panels.
6.1.11 Manufacturer shall advise the purchaser one month in advance when
the panels shall be ready for inspection and tests, so that the latters
representatives may be deputed to witness the test(s).
6.1.12 No material shall be shipped or dispatched until inspection and tests,
upto the satisfaction of the purchaser, have been completed.
6.1.13 Notwithstanding the successful completion of the tests as above, the
contractor shall be fully responsible for the satisfactory performance
of the panel as per the specification, without any prejudice to any
claim, right or privilege of the purchaser arising out of use of defective
design, material or manufacturing by the contractor.
6.2.0 TESTS:
The test plan, including the sampling plan for various rating of panels, shall be got
approved by RDSO before carrying out the test. Following tests shall be carried out
on the panel as a minimum:

S.
No

General Test Conditions

Performance Tests
Temperature-rise

1.1

Type
Test

Routine
Test

Acceptance
Test

Test
Procedure
Sub Clause (
As per IEC
60947-2 )

8.3.2.5

Page 16 of 20

8.3.3.1

8.3.3.2
8.3.3.3

8.3.3.4

Short-circuit
breaking
capacities
Short-time withstand current
(where applicable)

8.3.4
8.3.5
8.3.6

1.9

Performance
of
integrally
fused circuit-breakers

8.3.7

1.1

Mechanical operation
Tripping
limits
and
characteristics
Dielectric properties
HV test on power & control
circuits ( 2.0kV for one
minute )
Earth continuity test with a
low voltage tester

8.4.1
8.4.2

8.4.3

Insulation test with 500V

megger before & after H.V.
test

Gasket test ( as per details

given below

5.1

Shore 00 hardness for type

(Soft) enclosure 40 + 5
Shore 00 hardness for type
(Hard) enclosure 55 + 5
Shore 00 hardness for type
(Outdoor) enclosure 55 + 5
Shore 00 hardness for type
(Silicon) enclosure 55 + 5

1.2
1.3
1.4
1.5
1.6
1.8

1.8
2
3

5.2
5.3
5.4
5.5

5.6

5.7
5.8

Tripping
limits
and
characteristics
Dielectric properties
Operational
performance
capability
Overload performance (where
applicable)

2
3
S

Compression hardness
[N/mm]
at 25% compression 0.02
0.01 /0.03 0.01
at
40%
compression
0.04 0.01 / 0.08 0.01
Min.
tensile
strength
(approximation)0.150.2
N/mm
Min. elongation at break
75%
Max. water absorption 1-

and

ASTM
97
ASTM
97
ASTM
97
ASTM
97

D2240D2240D2240D2240-

DIN 53504
DIN EN
1798

ISO

Page 17 of 20

5.9
5.10
5.11
5.12

5%
Water penetration >2-4 h

Temperature
resistance
30 minutes 180-300C
Max. change of Shore A(00
hardness +/- 20%
Max. change of tensile strength
+/- 20% after heat ageing

5.13

Heat ageing (168 hrs @ 100200deg C)

5.14

Compression set [%]

Measurement after 24h and
50%
compression,
at
corresponding temperature
at T @ 70C = 10
at T @ -40C = 10
Confirmed
continuous
temperature [C]
@ - 40 to 80C

5.15

6
6.1
6.2
6.3
6.4
6.5
7

7.1
7.2
7.3

ASTM D224097
DIN53504

DIN EN ISO
1798

DIN 53572
AA-TL03-A 4

Bus-Bar Support and Main

Bus-Bar Test ( as per details
given below)
Temperature rise limits ace.
chapter
Dielectric
properties
ace.
Chapter
Short-circuit
withstand
strength ace. chapter
Effectiveness
of protective
circuit ace. chapter
Clearances
and
creepage
distances ace. chapter

Sub Clause (
As per IEC
60439-1 )
8.2. 1

8.2.2

8.2.3

8.2.4

Paint Test ( as per details

given below)
Flexibility(Mandrel
5/8mm dia.

bend)

Cupping test 4mm

Adhesion test (Scratch hatch)

test

Impact resistance TEX

7.4
7.5

Impact resistance Glossy/SG

Din EN ISO
1519/
IS
13871
Din EN ISO
1520
DIN EN ISO
2409
(ASTM
D
2794-69)/ IS
13871
(ASTM
D
2794-69)

Page 18 of 20

7.6
7.7
7.8

Corrosion resistance
Thickness
Tests on Primer

ASTM B-117,
Annex C of IS
2075,DIN
50961
IS 13871
IS 2075

6.2.2 Tests on Cable Entry Sealing System6.2.2.1 Following shall constitute the type tests
1. Water Ingress Test
2. Pull Test
1
Water Ingress Test
i) OBJECTIVE: To determine the water tightness of the Cable Transit System
when subjected to spray of water.
ii) TEST EQUIPMENT: A holding arrangement / fixture of sufficient dimension
to house the Cable Transit System.
iii) INITIAL EXAMINATION: The Cable Transit System shall be assembled with
all its components like modules, stay plates, wedge etc. and a continuous
cable passing through its any module.
iv) CONDITIONING: The cable transit system in its assembled condition shall be
secured at holding arrangement / fixture. The water shall be sprayed with a
pressure of 12.5 l/min and the distance between nozzle & test item shall be
2.5m to 3.0 m. at a normal room temperature. This test shall meet the
requirement as per IEC 60529.
v) DURATION: The test to be done for a 3 min in all direction.
vi) FINAL EXAMINATION: The Cable Transit System shall be examined
externally for any abnormality. The Cable Transit System shall be visually
examined at other side of system for any ingress of water.
vii) ACCEPTANCE: The Cable Transit System will be declared to have passed the
water ingress test in case there is no water vapour presents other side of the
transit system.
2

i)

Pull Test
OBJECTIVE: To check the strength and holding of the cable by module
inside the Cable Transit System.

ii) TEST EQUIPMENT: A holding arrangement / fixture of sufficient dimension

to house the Cable Transit System.
iii) METHOD: The Cable Transit System
should be assembled with a long
length of cable so that it can be pulled to the required force of 80N to check
the strength of module inside the Transit System.

Page 19 of 20

iv) ACCEPTANCE: The cable transit system will be declared to have passed the
pull test in case there is no movement of cables or modules.
6.2.2.2 Following test shall be done to carryout the acceptance of the product.
1) Visual Examination- The Cable Sealing System shall be examined
physically for the workmanship and the design
technology employed. It
shall be checked for any
flaws defects, cracks visible to naked eye
2) Manufacturers Identity & Dimensional Range- Cable Sealing System shall
be examined visually to check the manufacturers trademark. The location
of the trademark on the system shall be matched with the concerned
drawing of system. Each module shall be visually checked for the range of
diameters of cables it can hold & shall be verified by printed dimensional
range mention on each module.
3) Compression of System - The Cable Sealing System shall be examined
visually to check the proper compression of modules. The rays of light
shall not be come through system/ modules.
4) System Configuration - The Cable Sealing System shall be examined
visually to check configuration of modules with frame/system.
Configuration shall be verified with concerned drawing and BOM of
system.
5) Dimensional Test - Each Module is printed with dimensional range
showing the minimum & maximum cable diameters it can hold. The
Module
shall be verified by placing the cables falls under that
dimensional range.
6.3.0 OTHER REQUIREMENTS
Only after approval of the original drawings incorporating changes, if any, as a
result of the prototype tests and clear written approval of the results of the tests on
the prototype is communicated by the Purchaser/DG (EM), RDSO, Lucknow, to the
successful tenderer/manufacturer, shall he take up bulk manufacture of the
panels. In no circumstances shall materials other than those approved in the
design/drawings and/or during the prototype testing be used for bulk manufacture
on the plea that they had been obtained prior to the approval of the prototype.

7.0

DRAWINGS:

Drawing in triplicate incorporating the detailed dimensional cross-sectional

drawing of the panels following particulars shall be submitted with the tender for
the purpose of preliminary study. After award of the contract the successful
tenderer shall be required to submit reproducible copies of final drawings for the
panels ordered.
8.0 IDENTIFICATION AND MARKING
One name plate giving description of the MCC shall be affixed prominently on the
top of the MCC. Details will be furnished latter. The nameplates for individual
feeders shall carry the general information as mentioned below.

Page 20 of 20

Feeder No.
Equipment ref. no. & description
Rating
For spares feeder blank labels shall be provided.
9.0 WARRANTY:
The panels must be guaranteed for satisfactory operation for a period of 12 months
from the date of commissioning.
10.0 INFRINGEMENT OF PATENT RIGHTS
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.
11.0 SCHEDULE OF GUARANTEED PARAMETERS
The following information shall be given by the tenderer in addition to any other
relevant data:S. No.
1
2
3
4
5
6
7

Description
IP Tests
Surface preparation & treatment test
Short circuit test
Bus-bar rating
Factory Acceptance
Third Party Inspection
Main Bus-Bar and Bus-Bar Support

Certificate
Yes
Yes
Yes
Yes
No
Yes
Yes

Test
Yes
No
No
No
Yes
Yes
Yes