Rmpu PDF
Rmpu PDF
Rmpu PDF
MINISTRY OF RAILWAYS
SPECIFICATION
FOR
ROOF MOUNTED AC PACKAGE UNIT
FOR
AIR-CONDITIONED COACHES
AUGUST 1999
1.0 SCOPE
The scope of supply for each Roof Mounted A/C Package Unit
shall include the followings unless otherwise stipulated in the
tender.
1.4.1. The Roof Mounted A/C package Unit shall be suitable to work
from 415V, AC, 3 phase, 50 Hz. Sinusoidal/PWM power supply
obtained from DG Sets installed in generator car on EOG type AC
coaches / 25 KVA inverter (110V DC / 415 V – 3 Phase AC) on SG
type AC coaches. The ELPS/Spec. 20/04/Rev. 5 (Aug’ 99). The
control circuit shall be suitable to work on 110 V AC 50 Hz.
Sinusoidal / PWM power supply on EOG/SG type AC coaches
obtained through a step down transformer (415/110 V AC) installed
in control panel.
1.4.2. Din Rail mounted stud type terminal blocks, circular shell type
electrical connectors as per RDSO Drg. No. SKEL 4391 sheet 5/6
(enclosed with RDSO specification No. ELPS/SPEC/AC/04 (Rev.
2) for AC control panel of Roof Mounted A/C Package Units) shall
be used. The insulating material used for terminal blocks shall be
FRP (Fire retardant properties) qualifying the test as per annexure
II (Sheet I & II). Harness numbers shall be strictly as per above
mentioned drawing.
1.4.3. Power cables at 415 V and control cables at 110 V shall run in
separate flexible non-metallic conduits from RMPU to it’s control
panel.
1.4.5. Flexible Elastomeric cables shall be used for power and control
cables in the package unit. The cable shall confirm to composition
clause 6 of RDSO specification No. SPEC/E-14/01 Part 1 (Rev. 2)
Feb’ 1993. Cables shall be procured from RDSO approved supplier.
2.1 The Roof Mounted A/C Package Unit Shall, unless other wise
Specified here in, confirm to the Indian Standards
Specification/ IEC recommendations as indicated below and
the Indian Electricity rules, wherever applicable.
3.2. The Roof Mounted A/C Package Unit shall be suitable for rugged
service normally to be met within Railway Rolling Stock, where
coaches are expected to run upto a maximum speed of 160 kmph in
varying climatic conditions existing throughout India.
3.3 The supplier shall be fully responsible for ensuring that all equipment
forming part of the supply is entirely fit for propose and no part of
this specification shall in any way remove or reduce this obligation
in this respect. In addition, it is the supplier’s responsibility to under
wire the complete air-conditioning system design and ensure that it
is compatible with, and will, in no way, compromise, the design and
performance of RMPU of this supply.
3.4 The supplier shall provide “In the field” service support during the
guarantee period.
3.5 The supplier shall supply any purpose built or special tools or
equipment that may be necessary for the correct operation, servicing,
testing or installation of the air – conditioning equipment (Excluding
normal refrigeration servicing equipment).
3.6 The supplier will provide assistance, both material and technical, in
the development of the system as a whole to ensure that when this
RMPU is installed as part of the integrated vehicle system the
performance of the system meets or exceeds the requirements
specified.
3.6.1 Should the RMPU fail to achieve these requirements, then the
RMPU shall be modified at the supplier’s expense and within a time
scale to be agreed with purchaser/consignee/RDSO.
4.1 The Roof Mounted A/C Package Units shall be able to work
satisfactorily of the “Self Generating” (SG) type/”End-On-
Generation” (EOG) type of A/C Coaches.
4.2. Roof Mounted A/C Package units should give rated capacity to air
condition of coaches under following condition: -
Winter condition
Outside 4 deg. C
Inside 21 deg. C
4.2.2 The RMPU shall be capable to work even with one condenser fan
and cooling capacity so obtained shall not be less than 75% of
rated capacity.
4.2.3 The refrigeration system shall comprise of two circuits i.e. two
sealed/scroll compressors, two condensers & two cooling coils
cum heaters.
4.6 The Roof Mounted A/C Package Unit shall be self-supporting and will
not from part of the vehicle structure. For the RMPU a separate
structural frame shall be employed which will not relay on the
housings of any of the installed components or equipments or
equipment for rigidity and strength. Guards shall not from part of the
structure.
The actual weight of the AC Package unit shall not exceed 750 Kg.
4.8 The RMPU shall be so designed that is interfaces with the vehicles so
as not to allow rain water, washing plant fluid and condensate to enter
in to the vehicle> The connection of supply air opening to the main
duct and return air opening to the coach shall be through bellows with
metallic frame on both ends. The bellows should be despatchable from
the package unit as well as from duct side. The connection of the
coach duct and the package unit to bellows should be through
nuts/bolts/screw. Bellows should be of superior quality preferably of
woven material to IS : 1424-1983 (Third Revision) Amendment No. 2.
4.9 The design and layout of RMPU shall be such as to prevent water traps
even if the vehicle is stopped on the slope or cant. Proper water
drainage arrangement shall also be provided. Each drip tray shall have
drain hole fitted with drain pipe towards condenser’s side. Drain pipe
to drain out condensate water from drip trays to through should be
integral part of the drip tray and with suitable trap at free end, if
required, to prevent the condensate water being sucked in by blower
and thrown in the supply air duct.
4.9.1 Drip trays provided under cooling coils to collect condensate water
should be of stainless steel and should have a depth not less than 60
mm.
4.13 A protective wire mesh guard shall be provided over the package unit
covering entire condenser portion and over condenser fans. Protective
guard shall be made from stainless steel wire of OD not less than 3
mm. The Clearance between the top of the condenser fan and guard
should not be less than 25 mm. The guard shall be in three or more
pieces for ease in handling. The compartment containing cooling
coils/heaters blower fan shall be thermally insulated from all sides, top
and bottom.
4.13.1 The Insulating material used shall be of fire retardant type preferably,
resin bonded fibre glass or fibre retardant polyethylene or combination
of both or any other suitable material. The insulating material shall be
sandwiched and jacketed between two layers of stainless steel sheets
duly sealed on all the sides to avoid peeling/failing of the insulating
material. Manufacturer should obtain prior approval from
RDSO/Purchaser for other type of Insulating material proposed to be
used
4.18 It shall be possible for the attendant to effect manual override of the
control system but with the provision that the RMPU shall be prevent
from operating in a condition where damage could occur.
4.20 The design philosophy shall be of no leaks and a sealed system (with
sealed or scroll compressors).
4.21 RMPU shall be installed above the false ceiling under the coach roof
with condenser portion exposed. The condensing temperature should
be minimum possible.
4.23 The rating of Roof mounted A/C Package unit shall not be less then
6.5 TR as per conditions of clause 4.2 of dry summer conditions.
However the refrigerant capacity above 6.5 TR will be preferred
keeping the maximum power consumption of the RMPU and control
panel below 13.0 KW.
4.24 Heat exchange coils of condenser and evaporator shall be made from
copper tubes, copper fins and copper bends.
4.24.1 The heat rejection capacity of refrigerant condenser shall match the
capacity of air-conditioning system.
4.24.2 All copper parts of the coils shall be tinned with minimum local
thickness of 15 microns confirming to classification Sn 15 of IS :
1359-1992.
4.24.3 Single fin construction should be adopted so that one fin is there for
all the rows of the tubes to avoid possibility of misalignment and
accumulation of dust over fins.
4.24.4 The fins should be uniformly distributed throughout the entire the
length of the tubes. Spacers should be used to maintain uniform
distance between the fins during manufacturing before expansion of
the tubes.
4.24.5 There should be adequate grip of the fins over the tubes and the fins
should have flared collers so that during vibrations, the fins do not
come closer and coller of the fin is not able to go inside the hole of
mechanically expanded.
4.24.12 Cleanable dry type fresh/return air filters shall be provided in the
RMPU filters shall be secured by latches and not by nut/bolts so
that it is easy to remove them from their location for cleaning.
Fresh air filter size shall be 230 (H) x 260 (W) x 60 (T) mm.
Thickness of return air filter shall be 50 mm.
4.24.13 The technical requirements of fresh and return air filters shall be as
under:
4.24.15 In full assembled condition the filters should be flame proof and
shall be tested as per Annexure II.
4.24.17 The opening provided for entry of fresh air in RMPU should be
covered by expanded metal (jali) of 5 mm size to prevent entry of
leaves etc.
4.25 Thermostats :
4.25.3 The cut-in shall occur within +/-0.2 deg. C of the set value of
thermostat. The differential between cut-in and cut-out tempreture
shall be 1.0 deg. C minimum and 2 deg. C maximum.
4.27 The RMPU’s frame shall have arrangements for vibration isolation
from the coach. Compressor shall have anti-vibration resilient
mountings.
4.28 Refrigerant copper piping shall be as short as possible. All joints shall
be brazed/welded. The material of the copper piping shall confirm to
soft annealed grade copper to IS : 10773-1983 and dimensional
requirements to IS : 5493-1981 (First Rev.) subject to minimum
thickness of 1.0 mm.
4.29 Manufacturer shall furnish the weight of the package unit and shall
also supply layout sketch showing distribution of weight of
equipments inside the package unit to study the balancing aspect.
Balancing Calculation shall also be furnished by the manufacturers.
4.31 The fan blades of condenser fan and runner of evaporator blower
should be dynamically balance.
4.32 Air shall be drawn (not blown) over cooling coils (i.e. suck-through
arrangement). Arrangement shall be made to prevent sucking of
condensate water by evaporator blower unit.
4.36 The evaporator unit shall contain adequately rated heater units for
heating during winter. These heaters shall be of highest reliability
standard to obviate any fire hazards. Stainless steel tube heaters with
or without fins shall be provided.
4.37 The cover of terminal boxes of all motors should have gasket all
around as well as grommets at cable entry points to prevent any
ingress of moisture.
4.38 A wide differential, self resetting over-heat protector shall fitted to de-
energise the electric heater bank in the RMPU in the event of restricted
air flow over the elements or due to any other causes with could lead
to excessive heater bank temperature resulting in the potential hazards.
4.41 Compressors, all motors and frame of RMPU shall be provided with
suitable flexible braided copper jumpers with crimped sockets on
either end for double earthing
.
4.42 Cable should be so laid frame of RMPU that removal of any defective
cable is easily possible.
4.43 Cables shall be crimped at both ends with suitable terminal copper lugs
Heat shrinkable type PVC sleeve will be provided over lugs & on the
joints so that sleeves do not get dislodged. Interlocked type cable
markers shall be provided to identify a particular cable.
4.44 Clearance and creepage distance shall be maintained as per IS: 4237-
1982.
4.45 Metallic pads of adequate height shall be provided at the bottom of the
package unit as shown in general arrangement drawing to avoid direct
contact with floor when lying on the floor.
4.46 Vane relay shall generally confirm to RDSO drawing No. SKEL 4428
(enclosed at Annexure-VI) and its mountings brackets for holding vane
relay and thermostats shall confirm to RDSO drawing No. SKEL –
4429 (enclosed at Annexure – VII). The holding bracket shall be so
located that the vane relay flapper is nearer to return air entry. The
provision for mounting & holding thermostat (s) shall be made at both
the return air entries.
4.47 MARKING:
The RMPU shall be marked with the following information in the front
:
Type/Make
Serial No.
Month and year of manufacture
Weight
5.0 TESTS
i). A check on the water tightness of openings shall from type test.
It shall be carried out for a period of 30 minutes with all fan
running under artificial rain of an intensity not less than 60 mm per
minute. The angle of rain will be 45 degree towards evaporator
compartment from condenser side.
iii). In each case, the penetration of water shall be slight, and not be
of such nature as to have an adverse effect on cabling and electrical
equipment, or any other equipment necessary for maintaining the
vehicle in proper working order.
60 x Q x (E2 – E1)
C = ---------------------
S
Note :
1. Conditioned test and fresh air quantity test and measurement of
power shall be conducted on 20% of the lot offered subject to
minimum of two, selected at random.
6.1.2 The tenderer shall indicate their compliance or other wise against
each clause and sub-clause of the technical specification and submit
with the offer. The tenderer shall for this purpose. Enclose a
separate statement, if necessary, indicating the Annexure and clause
reference and compliance or otherwise.
6.1.3 The manufacturer shall submit complete design details of
condenser coil and evaporator coil alongwith basis of capacity
selected before prototype RMPU is offered. Necessary calculation
shall also be submitted.
i). Compressor
ii). Air cooled condenser
iii). Evaporator
iv). Filters
v). Heaters
vi). Motors
8.0 Guarantee
The facilities considered essential to be available with the firm for the
manufacture quality and reliable product are indicated in Annexure –
V. Tenderer shall confirm the availability of these facilities along with
their tender offer.
11.0 Training
The contactor shall undertake to train, free of cost the supervisors &
staff of the Indian Railways for operation, maintenance, fault finding,
repair of offered RMPUs under guidance of skilled engineers, during
the first year of the service of the RMPUs. The number of supervisor
to be trained against a contract will be indicated by the accepting
authority. The wages and allowances of each Railway supervisor
nominated for training shall be paid by the purchaser. The purchaser
shall bear the cost of the passage to and for from the place of training
for the Railway supervisor.
13.0 Enclosures
13.6 Outline of Roof Mounted AC Package Unit RCF drg. No. CC 90012
alt. ‘e’ with two compressors.
13.7 Mounting arrangement of Roof Mounted AC Package Unit RCF
Drg. No. CC 44225 & AE 44225
13.8 RDSO drgs No. SKEL 4428 & SKEL 4429 for vane relay and it’s
mounting bracket.
13.9 RDSO drg. No. RDSO/PE/SK/AC/4533/99 (Rec. 0) &
RDSO/PE/SK/AC/4532/99 (Rev.0) for shafts of condenser fan &
evaporator blower fan motor respectively.
Annexure 1 to
ELPS/SPEC/AC/03 (Rev. 1)
(Clause 1.2.24)
Should the specimen get ignited, it shall not continue to burn for more
than 50 seconds after the flame has been finally removed.
Annexure II to
ELPS/SPEC/AC/03 (Rev. 1)
(Clause 6.1.1)
i) Maker’s name
ii) Type model No.
iii) Heat rejection capacity
Kcal/hr.) at condensing
Temperature 60 deg. C
iv) Cooling air temperature
a) Inlet
b) Out let
v) Total nos of tubes
vi) Total nos of tubes per row
vii) Nos of rows
viii) Material and diameter of tubes
ix) Material and size of bends
x) No. of fins per 25 mm
xi) Gap between fins
xii) Material and gauge of fins
xiii) Type of fins
xiv) Total cooling surface area of fins
And tubes together in sq. mm
xv) Nos. & Details of fins
a) Inlet pipe size
b) Outlet pipe size
xvi) Corrosion treatment
xvii) Method of cleaning
xviii) Overall dimensions
xix) Face area in sq. mm
xx) Drawing/sketch including mounting details
xxi) Weight of condenser unit
D) CONDENSER FAN
i) Manufacturer’s name
ii) Type of mountings
iii) Nos. of fans
iv) Air displacement
v) Nos. and material of blades
vi) Type of bearing
vii) Face velocity of air blown
Over the condenser
viii) Material and nos. of fan blades
ix) Drawing sketch No.
x) Weight of the fan
i) Manufacturer’s name
ii) Type of model and make
iii) Nominal voltage
iv) Rated speed
v) Continuous rating (HP/KW)
vi) Rated current
a) At rated voltage
b) At minimum voltage
vii) Frequency
viii) Phase
ix) Type of cooling
x) Type of insulation
xi) Type of enclosures
xii) Efficiency at full load
xiii) Peak current with duration at starting
xiv) Ambient temperature
xv) Weight
xvi) Direction of rotation
xvii) Starting torque/full load torque
xviii) Coupling arrangement of fan and motor
xix) Degree of protection provided for enclosures
xx) Details of anti-vibration mounting provided
xxi) Frame size
xxii) Shaft details
F) ACCUMULATOR
i) Storage capacity
ii) Material
iii) Protection against corrosion
i) Manufacturer’s name
ii) Type model no.
iii) Frequency of replacement
Evaporator
i) Maker’s Name
ii) Type/model no.
iii) Refrigeration effects (cal/hr) at
Evaporation temperature of
5 deg. C
iv) Rated heater capacity
v) Total numbers of tubes of cooling
vi) Number of rows
vii) Number of tubes per row
viii) Material and size of tubes
ix) Number and size of bends
x) Number of fins per 25 mm
xi) Gap between tubes
xii) Material and gauge of fins
xiii) Type of fins
xiv) Total cooling surface area
of tubes and fins together
xv) Face area
xvi) Detail of condensate water drip tray
xvii) Corrosion treatment
xviii) Overall dimensions
xix) Drawing/sketch No.
xx) Weight
xxi) Detail of heater
a) Rating
b) Type
xxii) Detail of distributor type and size
xxiii) Expansion Valve
a) Make and type
b) Rated output for 5 deg. C
SST/60 deg. C/DT
xxiv) Details of capillary
I) BLOWER
i) Manufacturer’s name
ii) Type model no.
iii) Number of fans
iv) Displacement of fans (m-cub/hr.)
v) Number and material of impeller
vi) Type of bearing
vii) Face velocity of air blown over the
Cooling coil
viii) Static heat (WG)
ix) Pressure drop across the coil (WG)
x) Runner
xi) Weight
i) Manufacturer’s name
ii) Type/model and make
iii) Nominal voltage
iv) Rated speed
v) Continuous rating (HP/KW)
vi) Rated current
a) At rated current
b) At minimum voltage
vii) Frequency
viii) Phase
ix) Type of cooling
x) Class of insulation
xi) Type of enclosure
xii) Efficiency at full load
xiii) Peak current with duration of starting
xiv) Ambient temperature
xv) Weight
xvi) Drawing of winding with complete details
xvii) Direction of rotation
xviii) Starting torque/full load torque
xix) Degree of protection provided
xx) Detail of anti-vibration mounting provided
xxi) Frame size
xxii) Shaft details
K) CONTROL
i) Type of Thermostat
ii) Location of thermostat
iii) Temperature setting for cooling and heating
iv) Differential in deg. C for cut-in & cut-out of
Thermostat
v) Detail of HP cutout
vi) Detail of LP cutout
vii) HP setting for cutout
viii) LP setting for cutout
ix) Details of over heat protector
L) FILTERS
i) Liquid line
ii) Discharge line
iii) Suction line
Annexure IV to
ELPS/SPEC/AC/03 (Rev. 1)
(Clause No. 4.40)
Specification for 3 phase AC electric motors for use on Roof Mounted air-
conditioned Package Units.
1.0 FOREWARD
2.3.1 The vibrations are of sine wave form and the frequency of vibration
is between 1 Hz and 50 Hz. The amplitude a, expressed in
millimeters is given as a function of f, by the equations –
a = 25/f for values of f form 1 Hz to 10 Hz.
a = 250/f² For values of f exceeding 10 Hz and upto
50 Hz.
2.3.2 In the direction corresponding to the longitudinal movement of the
vehicle, the equipment is subjected for 2 min. to 50 Hz vibration of
such a value that the maximum acceleration is equal to 3 g
(amplitude a = 0.3 mm)
Note : Form the point of view of withstanding the vibrations and
shocks of levels as indicated above, the manufacturer shall take all
necessary factors in to consideration while designing various parts e.g.
shaft bearings mounting arrangement etc, and other necessary
mechanical features.
The terminal block will have conducting part which should be made
cadmium plated steel as per IS : 226 and IS : 1572 and all the threaded
portions should be mechanically strong, so that even with 1000
operations of tightening and loosening, the threads should not wear out
nor shall there be any loosening of the inserts. The terminal stud
threads shall not wear out even after 1000 operations of tightening and
loosening at the specified torque. The terminal block design shall be as
per RDSO sketch No. SKEL – 2784 A (enclosed).
Bekelite or Hylem terminal boards shall not be used for terminal box.
5.3.1 Terminal leads shall be of fibre glass sleeve covered silicon rubber
flexible copper cable confirming to IS : 9968 Pt. 1 and BS-6007 of
1100 V grade suitable for temperature from 10 deg. C to 200 deg.
C. The minimum sizes are given below.
5.3.2 Silver brazed joints /fused for connecting terminal leads and
winding wire shall only be used. Soldered joints are not acceptable.
Winding wires shall in no case be brought to the terminal block
directly.
5.3.3 The leads shall be tied securely on the stator overhang of the
winding at their exit from motor stator overhang.
5.3.4 Flexible cable shall be well gripped by the Insulated cable lug while
doing crimping.
5.3.5 A compression type (rubber) gland shall be used for securing the
flexible leads at the entry of terminal block and rubber grommet
should also be used.
5.3.6 The crimped socket and joint shall comply with BS : 4579, Part – I.
5.3.7 Terminal sockets used shall be of annealed electrolytic copper. The
minimum radius between palm and tube shall be 2 mm. Thickness
of socket tube shall be atleast 1 mm.
6.3 Shaft
6.4 Bearings
7.1 Winding wires used for winding of motors shall be of following type.
The enamel thickness shall comply with IS : 13730 Pt. 0 Section M (I)
& (ii) mentioned above
8.0 IMPREGNATION
9.0 WINDING
9.1 The star point of the winding shall be formed inside the stator
overhand. The star point shall be adequately brazed and insulated
ensuring best workmanship. On the brazed joint apply general electric
RTV sealant and over tape with two layers of half lap “Fusa Flex”
76593 tape (Supplier (GE) and seal the joint with a heat gun.
9.2 Coil overhangs in the stator winding shall be adequately secured with
glass cord and stagger taped and each coil emerging from the slot shall
be covered with ½ lap impregnated glass tape of size 0.3 x 20 mm.
Alternatively coil separator similar to the phase separators may be
provided between adjacent coil emerging from the slot.
12.0 FINISH
12.1 The motor shall be treated suitably for rust removal and coated with
anti-rust primer and finished with two coats of battleship grey paint.
13.0 MARKINGS
13.1 Name plate – each motor shall have name plate containing the
following in formations.
14.0 TEST
14.1 The motors shall be required to pass all the tests indicated in IS : 325 –
1991. However type test supply voltage shall be form PWM source.
A. Machinaries & Plats capable for processing stainless steel used during
manufacturing
1. Shearing Machines
2. Hydraulic/Pneumatic/Power press
3. Drill Machine
4. Punching machine
5. Bending machine
6. Lathe machine
7. Dynamic balancing machine
8. Grinding machine and portable grinder
9. Jigs & Fixture suitable for welding levelling and mounting.
1. Vaccum pump
2. Leak testing tank
3. Air compressor with reservoir
4. Refrigerant charges arrangement
5. Tool and dies suitable for stainless steel processing
6. Measuring tapes
7. Vernier calliper
8. Standard measuring gauge
9. Screw gauge
10. Hand lamp
11. Other had tools like spanner, pipe bending machine etc.
C. Testing Facilities
D. Transport Facilities
F. R & D FACILITIES
The firm should have R & D facilities to investigate into the various
types of failures and evalve necessary remedial measures to avoid
failures in future.
G. OTHER FACILITEIS
Note :If this facility is not available, the firm has to ensure to
arrange above power supply (i.e. identical to supply
available on SG AC coaches) within one year from the
date of clearance prototype.
Note :The firm should obtain ISO approval within one year
from the date of approval of the prototype if not ISO approved at the
time of placement of development order. However, preference for
registration will be given to ISO approved firm. The new firms will be
considered initially for educational order and will be considered for
regular basis only after successful field trails and after obtaining ISO-
9000 certification.