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APPX.A TO TENDER DOCUMENTS No.

VRDE/MMG/OTS-22/2011-12

TECHNICAL SPECIFICATION FOR FABRICATION, TESTING, SUPPLY AND


INTEGRATION OF 20 KVA MOBILE POWER SOURCE WITH REMOVABLE
ACCOUSTIC CANOPY

1. INTRODUCTION

1.1. This Specification is for the guidance for fabrication, mounting, integration and supply
of 20 KVA Power Source with removable acoustic canopy and required accessories
etc. The technical offer should be more elaborate and should contain detailed
information on component level. The contractor should submit all the drawings to
VRDE for checking & approval regarding its completeness, accuracy before
commencement of the fabrication.
1.2. VRDE reserves the right to incorporate any changes/ deviation to this specification as
required from time to time until the design is approved. During fabrication, in case any
minor deviations in specification or suggested, the same should be incorporated with
out any additional cost.
1.3. There is a requirement of 2 Nos of 20 KVA Power Source (with air cooled engine) with
removable acoustic canopy. The Gensets will be mounted on the shelter fabricated on
6x6 vehcile chassis. Genset will provide electrical power for operation of Air
conditioners, Computers, Battery chargers, Air filtration system, Lighting etc.
1.4. The system is required to be mounted on the vehicle chassis. Hence, the size of
canopy and total weight of the system are the crucial parameters to avoid over
dimensions & overloading on vehicle axles. The contractor should ensure that the total
weight of the complete systems & components mounted on the vehicle chassis should
be less than 800kg. Any increase in weight above 800 kg is not acceptable. The
estimated weight details of all the systems & components along with overall
dimensions are to be submitted to VRDE by the contractor in the technical bid.

2. BRIEF DESCRIPTION
2.1. The 20 KVA Power Source (at NTP condition) comprise of brush less type alternator
coupled through close type coupling to air-cooled diesel engine mounted on a common
lightweight base frame of high strength steel with suitable anti-vibration mounts.
Gensets shall also include removable diesel tank 70 ltrs capacity inbuilt in base frame,
control panels, cold start device, batteries for engine starting, tools & spares box etc.

2.2. To satisfy the sound levels acceptable as per CPCB norms a removable acoustic
canopy shall be fabricated. The canopy structure should be fabricated with light weight
& high strength material/composite material to withstand the vehicle generated
vibrations & loads. The sound insulation (acoustic) material like mineral wool / foam
etc. of suitable thickness should be provided so that the noise level should be less than
75 dB at 1 m distance from canopy. Acoustic material should be sandwiched between
Aluminum sheet on out side of canopy and perforated Aluminum sheet on inside of the
canopy. The doors will be provided to the removable acoustic canopy. These doors will
be provided with handle and locking arrangement. The removable acoustic canopy
should be 100% rainproof. Detail drawing indicating like dimensions, structural

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members, sheet thickness should be submitted for approval.

3. SCOPE OF WORK :

3.1 Supply of 2 Nos. of 20 KVA Gensets along with accessories and spares.
3.2 Fitment and integration of Gensets on shelter fabricated on Vehicle chassis.
3.3 Fabrication & Fitment of removable acoustic canopy.
3.4 Fabrication and provision of Genset Control Panels (Local & remote).

3.5 Inspection and testing of Gensets along with control panels as per ATP attached at
Appendix ‘A’ & Appendix ‘D’

3.6 All the electrical items (cables, connectors etc.) required for integration should be MIL
grade and to be supplied by the contractor.

4. OPERATING CONDITIONS :
4.1 The Generating Set is required to supply power in the following field conditions : -
a) Operational temperature : - 10°C to + 55 °C
b) Storage temperature : - 20°C to + 70°C
c) Relative humidity : 18 – 95 %
d) Altitude : 3000 m
e) Sound level : Less than 75 dB at 1 m distance from canopy
f) Vibration level : ± 1.5 g to be sustained during transportation.
4.2 The Gensets with accessories will be mounted on the Shelter fabricated on vehicle
chassis. These Gensets are likely to be subjected to the vehicle generated vibrations
during cross country movement. Hence suitable AV mounts are to be provided for its
satisfactory functioning.

5. BRIEF DETAILS AND SPECIFICATIONS FOR CANOPY :

5.1 The removable acoustic canopy should have the following dimensions: -
Length 2000 mm
Width 900mm
Height without silencer 1200mm

5.2 Suitable number of AC exhaust fans / blowers with switch are to be provided to limit
temperature rise (w.r.t. out side temp) inside the acoustic canopy not more than 150C.

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6. GENERATOR SET :
6.1 The Gen set will be supplied with the following configuration :
a) Capacity : 20 KVA at 0.8 Power Factor (P.F.) at NTP
b) Output voltage : 415 V, 3 Phase, 50 Hz, 0.8 Power Factor.

c) Prime Mover : Light weight, compact Air cooled engine with built in cooler,
25 Kw capacity. The engine should be tested & approved for
emission norms as per CPCB & suitable to operate in
adverse Environmental conditions given in Para appendix
‘B’.
d) Alternator : Brushless, self excited, self regulated type 20kVA , single /
double bearing, close coupling with engine, ISI grade.

e) Dimensions : The Genset (Engine + Alternator) dimensions should be


2000 mm (L) x 900 mm (W) x 1200 mm (H) without AV
mounts.

f) Control Panels : Control Panel separate for each Genset – To


be mounted in Genset/non AC compartment.
g) Distribution box : Distribution box should be provided with necessary MCBs,
ELCBs (MIL grade/ ISI make) & Allied make connectors.
h) Battery : 12 V, 180 AH, Low Maintenance. Make : Exide
j) Battery Charger :
i) The diesel engine should be provided with a suitable alternator with built in
regulator and control system for charging the battery.
ii) There should also be a provision to charge the Genset batteries from mains
supply also. Here it is considered that batteries are in completely discharged
condition and 12 V, D.C. Power is not available to make the panel “ON”. Therefore,
suitable Switching Mode Power Supply (SMPS) should be provided which will
operate directly on Mains (AC) to charge the batteries automatically.

k) Mountings: Suitable Anti-Vibration mountings should be provided for complete


Genset, control panels & battery charger.
l) Earthing spike: Two Nos of earthing spikes are to be provided with copper braided
10 meter long 25 mm2, cable. These earthing spikes should be mounted at suitable
accessible location.
m) The cables and wires from removable acoustic canopy to the EMI shielded shelter
are made to pass through conduit without affecting the acoustic chamber design. The
connections of cables in EMI shielded shelter are to be provided with suitable
connectors and gaskets. All the connections going inside the EMI shielded shelter
should be through suitable Fibre optic cables. The supplier should supply fibre optic
cable of reputed make & grade suiting our requirements. All other cables should be
Teflon / Fiberglass based and confirm to MIL grade. The connectors are to be
provided wherever the cables are passing/ entering through the walls.
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6.2 FUEL TANKS & FILLING SYSTEM
70 Ltrs capacity tank (one for each Genset) fabricated through 2 mm thick stainless
steel (SS-304L) sheet should be provided with float switch for cutting ‘OFF’ the fuel
feed pump motor when tank is full. It should be provided with filler neck, drain plug,
mechanical level indicator on tank and digital level indication in control panel. This
fuel tank should be integrated in the base frame of Genset and size to be decided
accordingly. Fuel tanks should be removable from base frame for maintenance and
cleaning purpose.

6.3 SPECIAL DEVICES: Following special devices are to be provided.

i) Hot Air Duct :This is provided in canopy for directing outlet hot air to the
atmosphere.

ii) Inlet Air Duct: This is provided in canopy to avoid mixing of hot outlet air with inlet air.

iii) Cold starting device : Heater glow type electrically operated from 12 V battery is to
be provided to operate the Gen Set at low temperature i.e. up to –100 C

iv) Residential type silencer with cover : To reduce the sound level. These silencers
should be integrated on top of acoustic canopy with covers.

6.4 SAFETY DEVICES


The generator should be provided with the following safety devices:
i) Low lubricating oil pressure
ii) High cylinder head temp
iii) Overload
iv) “V” Belt failure
v) Over speed and under speed protection
vi) High temperature in acoustic canopy
vii) Earth leakage
viii) Earthing spike
Audio Visual alarm system is required for abnormal condition as mentioned in Sr.
No. (i) to (vi) above.

7. DETAILED SPECIFICATION OF MAJOR ITEMS


7.1 PRIME MOVER (ENGINE)
7.1.1 The Prime Mover of the generating sets should be light weight and compact air cooled
diesel engine. The engine should be of ISI grade and should conform to IS: 10000 (Pt-IV)
1980/BS 5514/ISO 3046 IFN.
7.1.2 The engine should be of following specification :
a) Continuous power rating at NTP condition : 25 KW.
c) Speed / RPM : 1500 ± 4%.
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d) Cooling system : Air cooled with built in oil cooler.
e) Speed governing : ± 4% at no load to full load and vice versa with mechanical
governor.

f) Cold starting device: To start the engine at low temperature. For this
heater glow plug operating on 12 V D.C. is to be
provided.
f) Starting system: Electric start, 12 V D.C. system.

h) Shut off device (Through solenoid) for safety of the engine under abnormal operating
conditions.
i) Battery - 12 V, 180 AH, Low Maintenance. Make: EXIDE
j) Inbuilt charging circuit for charging the battery through an alternator.
m) Make: - HATZ GERMANY.
n) Model No. : - 3M41.

7.2 ALTERNATOR
The alternator should be self regulated, brush less, ISI grade and should be in
accordance with IS 4722. The enclosure and class of insulation (class “H”) are to be
provided to satisfy the environmental conditions mentioned in this specification.
The specification of the alternator should be as under:
a) Type : Brushless, 4 Pole, Single/Double bearing with flange
adaptor for mono block close coupling with engine.
b) Rating : 20 kVA, 0.8 power factor lag.
c) Output Voltage : 415/230 V, A.C., 3 phase, 4 wire.
d) Speed : 1500 rpm
e) Voltage regulation : ±1.5 % with electronic voltage regulator.
f) Output Frequency : 50 Hz ± 2 Hz.
g) Overload rating
i) 110% for continuous 1 hour.
OEM Certificate to be provided
ii) 150% for 15 sec at 0.5 P.F. to confirm the overload rating
iii) 200% for 5 sec at 0.4 P.F.
h) Transient voltage drop / rise under all conditions of load - 15%.
j) Transient response time - 0.5 sec.

7.3 CONTROL PANELS FOR GENSET

7.3.2 Control panel should have the following facilities: -


I. There should be a provision in control panels for starting / stopping of the generator

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sets automatically / manually. The solid state control panel will be operatable
between 8-16 Volts from Genset batteries.
II. Provision should be there to bypass the control panel and to start/stop the Genset
manually during manual mode, the important display units like Ammeter, Voltmeter,
Frequency, Engine oil pressure, etc shall be provided.
III. The solid-state controller should have the scrolling facility for various electrical
parameters of different phases. It should have LED display to indicate all the
indications.

IV. Industrial extended grade as per JSS standard/MIL standard components will be
used in the control panel.

V. The solid state control panel will consist of digital electronic display for ease of
inspection and observation of various parameters by the operator as follows : -

a. Engine parameters ( All parameters will be programmable for upper and lower limits)
i) RPM
ii) Oil pressure
iii) Oil temperature
iv) Hour meter
v) Fuel level of individual engine diesel tank as well as spare diesel tank.

b. Electrical parameters
i) Volt meter
ii) Ammeter
iii) Frequency
iv) Power factor
v) KVA
vi) KW

c. Battery charging parameters


i) Voltage 0 – 20 V
ii) Current 0 – 15 A
iii) Starting dip voltage (while crancking)

VI. The solid state control panel will be provided with following scrolling facilities for
respective Genset : -
i) Voltage
ii) Frequency
iii) Current
iv) Power factor
v) KVA
vi) KW

VII. The ruggedised digital temperature indicator (PT-100 thermal sensor) 0-1500 C for
measuring inside temperature of acoustic canopy and setting cut off temperature
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should be provided.

VIII. The circuit diagrams of the control panel, operating procedure along with Do’s &
Don’ts will be provided on the control panel at a convenient position for reference.

IX. The control panel is intelligent & Programmable. Timers and controls will be
adjustable. The data communication to remote place ( master controller ) in UGV
vehicle shall be through Ethernet and data transfer to remote place will be possible
through modem. Genset will be controlled from master controller in UGV using
Labview software. Firm has to make following control signals available over Ethernet
in addition to feedback signals mentioned in para (v)

Operator Controls

(a) Mode selection


(b) Horn reset
(c) Emergency stop push button
(d) Start
(e) Stop
(f) Cranking

System controls

(a) Cool down delay


(b) Pre start delay

X. The control panels should be made of S.S-304L sheet, 1.6 mm thick and are to be
provided with suitable frame and anti vibration mounts.

7.4 ANTI-VIBRATION MOUNTS


Suitable anti-vibration mountings are to be provided to absorb the vibrations of the sets
and to reduce their transmission to other parts. The control panel and the Gen Set are to
be resiliently mounted to reduce transmission of vibration. The level of protection
required is against 1.5 ‘g' (r m s) during transportation.

7.5 DISTRIBUTION BOX : A Distribution box with ELCB, MCB and connectors are to be
provided. Six numbers of 3 phase outputs with MCB (for A/C, B.C. etc.) and six numbers
of single phase outputs with MCB (for Mast, utility etc.) should be provided. This
distribution box is to be embedded in the lower portion of control panel.

7.6 INTEGRATION :
Integration of various control panels with Genset is to be carried out by the
contractor at site (will be communicated later on). The integration work will consists of
following:
i) Mounting of control panels in non AC shelter as per drawing.

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ii) Provision of cables, junction box, ducts, connectors etc is the responsibility of
the contractor.
iii) Connectors of suitable size & capacity should be provided on the panels,
Bulk head panels, wherever the cables are passing through the shelter wall.
Generally two sets of connectors (approx. 14 Nos.) are required to be provided.
However the firm has to estimate the requirement and details to be given in
technical bid.
iv) Fibre optic cables of suitable size should be used for all the connections
(except power connections) from genset to Master controller in UGV
v) Integrated testing / commissioning is to be carried out after completion of
integration.
vi) The connectors should be of MIL grade and of Allied/Amphetronic make.

The connectors shall be type approved.

7.7 GENERAL
Following facilities are to be provided -
a) The Genset control panels should be provided with the loud buzzer in case of
any abnormality during operation e.g. low lubricating oil pressure, high cylinder
head temperature, over load and V belt broken etc.
b) Safety of acoustic canopy :
A digital temperature display should be provided in control panel to monitor the
inside temperature of acoustic canopy. The temperature sensor should be located
in the acoustic canopy.

8. TRAINING :
It is proposed to provide training to the VRDE/user's rep. for operation and maintenance
of Gensets.
,

9. CARRIED SPARES:
The list of carried spares is enclosed at Appendix – ‘B’ to this specification. These spares
are to be provided along with the Genset and cost to be included in the offer itself.

10. TOOLS :
Tools as per Appendix ‘C’ for normal repair & maintenance required are to be provided
along with the Genset and cost to be included in the offer itself.
11. TOOL BOX & SPARES BOX :
One metallic tool box suitable for keeping tools for Normal Repair of Gen Set and another
box for keeping spares are to be provided along with the lock and key. Mounting of these boxes
are to be done at suitable locations

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12. LITERATURES :
20 KVA Genset mounted with removable acoustic canopy is to be supplied with a set of
following documents hard & soft copies ( 3 Nos each ) as per JSS 0251 format : -
a. User Hand Book
b. Repair & Maintenance Manual
c. Complete Equipment Schedule
d. Mechanical drawings(Hard copies as well as soft copies)
e. Electrical diagrams in the form of Table Top Master electrical circuit diagram of
complete system , circuit diagrams at system and subsystem level.(Hard copies as
well as soft copies)
f. List of SMT's (Special Maintenance tools)
g. Illustrated Spare Part List (ISPL) for major component

13. WORKMANSHIP
13.1 The workmanship of the equipment shall be in accordance with the accepted engineering
and production standards of the industry. The set shall be robust to withstand vibrations caused
by transport over high ways, unpaved roads and cross country terrains when mounted on a
vehicle so that no deformation of a permanent nature sets in during transportation.
13.2. Metals having pitted or corroded surfaces are not acceptable. Shearing and chipping shall
be done neatly and accurately. All sharp edges and burrs shall be removed. Burred surfaces
and flame cut materials shall be ground smooth.
11.3 Welding shall be done neatly and efficiently executed and shall be free from all flaws and
defects. Welding should be tested for porosity and cracks etc.
13.4 Bolt holes shall be accurately drilled and shall have the burrs removed. Washers and lock
washers shall be provided on bolts, studs and cap screws having straight threads. All bolts,
Nuts and screws shall be correctly torqued. All bolts should have positive locking i.e. either
nylon lock nuts or spring washer with plain nut should be used.
13.5 All electrical connections shall be made proper and connecting strips shall be used
wherever the connections are tapped. All the wires shall be provided with numbered ferrules for
proper identification. These numbers should be mentioned in the relevant electrical circuit
diagram to be supplied by the contractor.

14. PAINTING AND FINISHING


14.1. The surface treatment and painting of entire body is required to protect the body from
atmospheric corrosion and also to impart aesthetic appearance.
14.2. Wherever mild steel sheets and sections are used for fabrication of canopy, control
panel and Shelter, the red oxide primer coating should immediately be given after proper
finishing of the welded joints. No portion of mild steel structure to be left without red oxide
coating. The red oxide primer should be of standard make like Asian, Apcolite etc. All welded
joints must be cleaned and ground and should be free from fluxes or slag before application of
red oxide.
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14.3. Apply car patch or metal filling putty wherever necessary to fill the minor gaps or joints of
complete fabricated structure and allow the putty to cure or harden sufficiently. Smoothen the
patched up surface with file or emery paper.

14.4. After filling the necessary gap and rough surface, the entire body should be given a
coating of METAL SURFACER with Duco oil primer (thinner) and be left for drying for four
hours. After drying entire surface should be smoothened with fine grain water paper. The
surfacer should be of standard make.

14.5. A second layer coat of Duco surfacer to be given again on the entire surface of body and
thereafter rubbed with fine grain emery water paper to smoothen the surface.

14.6.After second coat of surfacer, if any dents or uneven surface is left, then again the
surfacer to be used and rubbed in such a way that the entire surface is smooth and becomes
ready for painting.

14.7.After good surface preparation with Duco surfacer as described above, two coats of Burger
Luxol. Hi G/s Synenl paints (sand stone colour) be given.

14.8. After coating with above paint the entire body should be polished with car polish wax.

14.9. The underneath of Shelter and flat floor body be painted with conventional method using
black coloured paint.

14.10 All the glass surfaces, plastic components etc. Should be protected from paints by
masking with paper or grease.

15. DESIGN DOCUMENTS :


The contractor shall prepare the detailed dimensional drawings. The contractor shall
also prepare the detailed design report which should include weight of major sub systems, make
& model of major sub systems, total weight of integrated system, Acoustic canopy design,
selection of Engine, Alternator, Anti Vibration Mounts, Ventilation / Cooling system etc. and to
be submitted to VRDE for approval. Only after the approval of design and drawings the
contractor can go ahead with the fabrication and development of the system.

16. WARRANTY
18 months from the date of supply or 12 months from the date of installation /
commissioning, whichever is earlier.

17. INSPECTION &TESTING :


Stage / final inspection & testing will be carried out time to time as per Inspection & Test plan
(provisional ATP) enclosed at Appendix–‘A’ of this specification. Expenditure for the conduct
of testing of genset & road trials to be borne by the contractor. The firm should supply the
necessary instruments and diesel during the inspection and testing free of cost.

18. DELIVERY SCHEDULE :


The system is to be delivered within 06 months from the date of placement of supply

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order. This schedule will be followed strictly. In case of delay the L.D. Clause as given in terms
& conditions of contract shall be applicable.
The contractor shall submit the realistic production plan along with the dates so as to
complete the work within the specified delivery schedule.

-.-.-.-.-

19.0 Block diagram of the tele-operation of the genset

Tele-operation of Genset: Block dia.

UGV PSU

RADIO
LINK RADIO
LINK

PC 104
CONTROLLER HMI
Controller

HMI PANEL
DIO/AI
Modules
DI/DO

GENERATOR AI

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INSPECTION AND TEST PLAN FOR 20 KVA GENSET SYSTEM (PROVISIONAL)

1. The Gensets with removable acoustic canopy will be tested for the following parameters:
a) Damping of sound level as per specifications i.e. less than 75 dB at a distance of 1 m
from all sides of canopy.
b) Rise in temp inside the acoustic canopy during endurance test should not exceed more
than 150C
c) The material test certificate for critical items like mineral wool for acoustic canopy etc. to
be submitted.
2. GEN SET
2.1 The Genset and its accessories shall be first inspected for correctness of major items as
per technical specification/ manufacturer's details. After this, each of the Genset shall be
subjected to the following tests : -
i) Fuel Consumption Test -
The fuel consumption shall be checked at full rated load. During this period,
observations like engine oil temp and pressure shall be recorded hourly. The fuel
consumption of the Genset as per manufacturer's specification is approximately
218 gm/kwh + 5% allowance.
ii) Endurance Test -
The Gen Set should be tested for one cycle of 8 hrs as per details given below :-
Warm up at 25% rated load - 1/2 Hr
100% rated load - 3 Hrs
50% rated load - 1 ½ Hrs
No load - 1/2 Hr
100% rated load - 2 Hrs
50% rated load - 1/2 Hrs

2.2 The electrical load should be such that it should give a power factor of 0.8 through a
suitable induction load. Following data should be recorded during the test at an interval
of ½ Hr
a) Electrical parameters : -
i) Voltage regulation : 415 V ±1.5 % from No load to Full load
ii) Current : Linear variation with load
iii) Frequency range : 50 Hz ± 2 Hz.
iv) Power factor : 0.8, lagging
b) Mechanical parameters : -
i) Lubricating oil temperature : Up to 135° C
ii) Lubricating oil pressure : Min. 1.5 bar (1.8 kg/cm2)
iii) Rise in temp. inside the acoustic canopy : Less than 150C
iv) Indication for functioning of safety devices.

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NOTE : All the Gensets need not to be tested for 8 hr. endurance test. Only one Genset out of
12 sets will be tested for 8 hr cycle & other 11 sets will be tested for 2 hr.(1hr.Full
load + 1 hr 50% load).
2.3 The following test certificate should be produced (issued by the manufacturer) by the firm
i) Diesel engine - For its performance in conformity with IS-10000 / DIN/ISO 3046.
ii) Alternator - For its performance as per IS 4722 or equivalent standard.
iii) Manufacturers test certificate for battery, power cables etc.
2.4 De-rating factor as per manufacturer's specifications may be considered at working temp
more than 270 C. De-rating chart should be provided.

3. CONTROL PANELS : -
All the major items of control panel i.e. cable, connectors etc. will be inspected for their
correctness and proper fittment/assembly. All control panels will be tested for their proper
working during endurance testing of Genset.

4. ENVIRONMENTAL TEST AND EMI/EMC TEST (Qualification Tests) :


Environmental, altitude, vibration and EMI/EMC tests of one Genset with control panels
have to be carried out as per environmental specification. If the Genset is type approved,
then, the contractor should submit all the test certificates for verification.

5. INTEGRATED TESTING :
Integrated testing of Genset will be carried out at site (communicated later on) after
mounting and integration of all the control panels and routing of cables. The connections
should be as per approved layout. Fibre optic cables, connectors etc. will be checked for
proper capacity, quality and desired functionality. During this test all the loads shall be
made “ON”. This
test will be carried out for the duration of 4 hrs. Diesel required for this test shall be
provided by the contractor.

6. Road Trials :
The Vehicle with integrated genset shall be run for 2 Km nearer to
shelter manufacturers premises. The genset should work satisfactorily before and after
road
trials.
-.-x-.-

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LIST OF CARRIED SPARES FOR 20 KVA GENSET SYSTEM

ENGINE SPARES (DEUTZ ENGINE Model BF04L0914)


Sr. Description Qty.
No.
1 Lubricating Oil filter 2 Nos.
2 Fuel filter 2 Nos.
3 V Belt ‘A’ section 2 Nos.
4 Gasket oil sump 1 No.
5 Pressure switch (LOP sensor) 2 Nos.
6 Stop solenoid 1 Nos.
7 Carbon brush for B. C. Alternator 1 Set
8 Carbon brush for starter motor 1 Set
9 Battery terminals +VE and -VE 2 Sets
10 Starter 12 V 1 No.

ALTERNATOR SPARES (STAMFORD)


Sr. Description Qty.
No.
1 Rectifier service kit consists of 2 Sets
a) Set of Diodes forwards = 1 Set
b) Set of Diodes reveres = 1 Set
c) Varistor = 1 No.
2 Automatic voltage regulator 2 Nos.
3 Non drive end bearing 2 Nos.
4 Fuses for Voltage regulator 3 Nos.
5 Fuses for Rectifier assembly 3 Nos.
6 Fuses to GCU 2 Nos.
GENERAL SPARES
Sr.No. Description Qty.
1 Indicating lamp assy. Red 2 Nos.
2 Indicating lamp assy. Yellow 1 No.
3 Indicating lamp assy. Blue 1 No.
4 Bulb 230 V, 50 Watts, AC & 12 V, 21 Watts, DC 2 Each
5 Ignition switch 2 Nos.
6 Fuses 32 Amps 2 Nos.
7 Switch (control panel) 2 Nos.
8 Illuminated Push button Green 2 Nos.
9 Illuminated Push button Yellow 2 Nos.
10 Illuminated Push button Red 2 Nos.

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LIST OF TOOLS

Quantity one each of the following tools shall be provided and be stocked in the tool box:-

1. Plier combination 200 mm insulated.

2. Plier Nose 200 mm insulated

3. Screw driver electrician pattern (tip size 3.2 x 0.5 mm) 125 mm long.

4. Screw driver engineer pattern 6mm blade dia x 200 mm long

5. Screw driver engineer pattern 8mm blade dia x 250 mm long.

6. Spanner set open jaw double end / Ring spanner / Box Spanner required for
loosening / tightening of all the nut-bolts of the Genset.

7. Grease gun

8. Line tester 500 volt

9. Oil can pressure type

10. Soldering gun Pistol type 60 watt, 230 volt, 50 Hz.

11. Tool kit bag of canvas to hold securely the items (1) to (10) above.

12. Digital Multi meter clip on type 100 Amp, 600 volt. Kusam Meco make-2700.

13. Inspection lamp with holder and cable of 5 M, 230 V AC, 60 W

14. Inspection lamp with holder and cable of 5 M 12 V DC 21 W

15. Special tools required for maintenance of control panels.

The tools mentioned above shall be of Gedore / Taparia make. Any tools in
addition to the above list reveled to be necessary shall also be supplied.

-------xxx------

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ENVIRONMENTAL TEST SPECIFICATIONS FOR 20 KVA POWER SOURCE
1) High temperature test : -
a) Pre testing at ambient temp
i) + 55°C + 3°C : for 6 Hrs b) Testing inside the chamber for last 30
ii) + 65°C + 3°C : for 4 Hrs minutes of soaking period.
iii) + 55°C + 3°C : for 6 Hrs c) Post testing at ambient temp
2) Low temperature test : -
a) Pre testing at ambient temp
i) - 10°C + 3°C : for 6 Hrs b) Testing inside the chamber for last 30
ii) - 20°C + 3°C : for 4 Hrs minutes of soaking period.
iii) - 10°C + 3°C : for 6 Hrs c) Post testing at ambient temp
3) Tropical exposure test (for 14 cycles) : -
Each cycle is of 24 Hrs duration:
i) Keep the unit in the chamber at 20 °C ± 5 °C a) Pre testing at ambient
ii) Rise Temperature and RH to 45°C ± 5°C temp
and 95 % respectively in 3 Hrs. b)Testing inside the chamber
iii) Maintain this condition for 12 Hrs. at 7th & 14th Cycle.
iv) Decrease the temp to 20 °C ± 5 °C over a c) Post testing at ambient
period of 3 Hrs. temp
v) Maintain this condition for 6 Hrs.
4) Vibration test ( along single axis) : -
i) Sinusoidal Vibration :
a) 5 - 8 Hz : ± 6 mm constant displacement)
b) 8 – 500 Hz : ± 1.5 g peak.
(OR)
ii) Random Vibration :
a) 5 - 20 Hz : (6 db per octave) desirable.
b) 20 – 50 Hz : 0.02 g2 / Hz, then rolling up to 0.001 g2 / Hz at 500 Hz
Duration: 2 Hrs. cumulative
5) EMI / EMC Test
CE : 0.015 to 50 MHz (BB)
RE : Above 30 MHz, the limit shall be met for
both horizontally and vertically polarized waves.
RS :
(i) Frequency range E – Field (V/m)
UM04 As per MIL-461E
2 – 400 MHz 10
400 MHz to 10 GHz 5
(ii) Above 30 MHz, the limit shall be met for
both horizontally and vertically polarized waves.

Applicability of
Rating Applicability
UM04
For Generators (O/P power rating ≤ 240 kVA CE, RE, RS

SHRI BA LANDGE,Sc-D
FOR DIRECTOR,VRDE

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