
lR;eso
t;rs
Hkkjr ljdkj] jsy ea=ky;
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SPECIFICATION FOR BATTERY OPERATED LED BASED
FLASHING TAIL LAMP FOR RAILWAY VEHICLES
SPECIFICATION NO. 2002/TR/281/TL (Rev.0)
Issue Date: 30.09.2002
vuqla/kku vfHkdYi vkSj ekud laxBu
y[kuÅ&226011
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW-226011
SPECIFICATION FOR BATTERY OPERATED FLASHING TAIL LAMP FOR
RAILWAY VEHICLES
SPECIFICATION NO: 2002/TR/281/1/TL(Rev.0)
0
FOREWARD
0.1
The purpose of this specification is to develop a lightweight, rugged, maintainable and
user-friendly tail lamp as a last vehicle indicator and warning to train crew of
approaching trains.
0.2
This specification is meant for specifying technical requirements of LED based
flashing tail lamp for railway vehicles for provision on last vehicle of coaches or
wagons. Each train shall be equipped with one LED based flashing tail lamp on the
last vehicle of the train. The specification covers the general and technical
requirements of LED based flashing tail lamp. It also specifies various tests to ensure
consistency of quality of equipment. The tail lamp unit must have the highest
reliability under severe environmental conditions of operations of coaching and
freight trains i.e. dust, humidity, high ambient temperature, shocks and vibrations.
This specification supercedes earlier specifications on tail lamp.
0.3
Other relevant specifications
(a)
(b)
(c)
IS: 6303/1984 for dry cells & batteries.
Specification IEC 86-1/86-2 for alkaline cells.
Standard BS: 1376 for colours of light signals
0.4
Any deviations to this specification considered necessary to improve performance,
reliability of the unit or for any other reason, should be furnished by tenderers with
details and full particulars for consideration of purchaser. Unless such deviations are
accepted in the final contract, the provision of this specification will be binding on the
contractor.
1.0
SCOPE
1.1
The specification covers the general features, performance requirements and test
methods of LED based flashing tail lamp for railway vehicles to be affixed on the last
vehicle of the train.
1.2
The user requirement based specification includes in its ambit all components
required to be assembled into the ultimate product named Battery operated LED based
flashing Tail lamp.
1.3
The customized tail lamp shall be manufactured to principal dimensions in
accordance with sketch (Annexure No. I) designed to be mounted on the ‘L bracket’
of last vehicle of the train (coach or wagon). The tail lamp will be compatible to lock
its fixation such that it cannot be removed from this bracket without unlocking the
lamp.
2
1.4
The tail lamp shall be powered by four commercially available dry cell batteries type
LR-20 HP-2 size D (Duracell or equivalent) and would provide adequate life in terms
of burning hours so as to provide for atleast 3 months interval between battery
changes under normal working conditions on the Indian Railways. The tail lamp
should be compatible to work with R-20 type dry cell batteries also.
2
TECHNICAL REQUIREMENTS:
2.1
Colour Co-ordinates:
Red Aspect: Class ‘C’of BS: 1376
Amber Aspect: Class ‘B’ of BS: 1376
Colour co-ordinates graph as per BS: 1376 is given in Annexure-II.
2.2
OPERATING PARAMETERS:
The L.E.D. type battery operated tail lamp shall meet the under-mentioned working
parameters:
S.
Parameters
No
1
No of flashes per minute
2
3
4
5
Flashing Red
Aspect
Duration of dark period between two successive
flashes.
Rated Voltage (volts)
Average wattage drawn with new batteries at 5565 flashes/minutes and 0.75 secs. off period
Operating Voltage Range (volts)
Flashing Amber
Aspect
Min.55
Max.65
Min.0.67 Secs.
Max.0.75 Secs.
6
6
0.36 max.
1 max.
6 to 2.5
6 to 2.5
6
Illumination measured at 1.5 m.in axial direction
(min.) at low battery indication (LUX)
30
50
7
Individual life (in min. hours) on
L R – 20 cells with intermittent use (continuous
12 hours a day).
Individual life (in min. hours) on
R – 20 cells with intermittent use (Continuous 12
hours a day).
Min. operating battery life between low battery
indicator (LBI) and low battery cut off (LBC)
Min. operating life of AMBER aspect after LBC
of RED aspect
Radiating area (Max.)
Three position Toggle switch [As per clause
2.3.2 (b)]
450 hrs.
100 hrs
150 hrs.
36 hrs.
12 hrs.
3 hrs.
---
4 hrs.
8
9
10
11
12
13
Dispersal angle (As per annexure-III)
3
300 sq. mm
600 sq. mm
The switch shall withstand 7500 operation
at normal current, one operation being
reckoned as one make and one break
50 to 80
2.2.1 VISIBILITY
The visibility of the tail lamp should be 1.6 kms along longitudinal axis and 100 m at
6 degree angular displacement from longitudinal axis, with either of the two aspects:
Amber or Red. This is expected to take care visibility at 800 meters at usual viewing
angles or curves. At any time, there shall be only one possible aspect of the flashing
tail lamp either RED or AMBER.
2.3
DESIGN CRITERIA
2.3.1 The battery operated flashing tail lamp shall be manufactured out of materials of
highest grade and purity, to meet required parameters and be free from defects of
workmanship, material or design. The components, materials used in the manufacture
of the equipment shall be screened and of high quality. The switches, connectors,
PCB and electronic components used shall be of Industrial grade and as per relevant
Indian Standard Specification (IS). The supplier shall indicate specification /
particulars in this regard. The rating of all electronic components used shall be
marked and be readable clearly on components. As the tail lamp is to be used outdoors under all weather conditions, it shall employ minimum ferrous components and
all such ferrous components should be appropriately passivated to withstand
corrosion. Whenever metallic components are to be employed, bronze, copper,
stainless steel or anodized alloy should be used. All metallic electrical contacts shall
be made of brass or copper and the external metallic clamp and wire guard should be
of stainless steel or anodized alloy. Screws, nuts and hinges provided in the
equipment should be of brass. The screws should be of adequate thickness and
ruggedness.
2.3.2 The external appearance of all modules of the tail lamp shall be of Post Office RED
colour. The tail lamp shall be essentially modular in construction and shall comprise
the following three modules:
(a)
The light module encasing electronic circuit elements, with the light-emitting
surface protected by transparent dust & waterproof screen. The body of the
module shall be made from virgin A.B.S., having principal dimensions
indicated in sketch (Appendix-I), provided with suitable number of collecting
strips, to collect power from the battery pack & for memory operation. The
connectors provided between electronic module and power pack shall be
firmly fixed and should not get disconnected because of vibration etc.
(b)
The power pack made out of virgin ABS, designed to accept 4 LR-20 dry
cells (or 4 nos. R-20 leclanche dry cells), each cell internally connected to two
spring loaded terminals to match collecting strips provided in the light module.
The power pack shall be provided with a three position switch to - (i) switch
power off or (ii) switch RED aspect on or (iii) AMBER aspect on, in such
manner that the switch becomes inaccessible after being mounted on the
bracket of last vehicle.
4
(c)
Carrier to be made to accept the two modules described above into itself, so
as to make the assembly complete. The carrier may be made out of virgin ABS
or other metallic components as described in Para 2.3.1, and shall be designed
to mount the unit on the ‘L-bracket’ fixed on the last vehicle of a train. It shall
not be possible to dismantle any of the modules as long as the tail lamp
remains fixed to this bracket. A wire guard should be provided on light
emitting side so as to protect the screen in a way that output of the light is not
affected.
2.3.3 All three modules shall be freely inter-changeable such that it shall be possible,
without any modifications, to re-assemble tail lamp using any assortment of the three
modules without affecting performance.
2.3.4 Light from LED based tail lamps, when projected on a white target at 1.5 m from
LED signal lighting unit, shall illuminate the target uniformly within half power
points and that shall be free from dark circles.
2.3.5 The LED based tail lamps shall be provided with a transparent cover of polycarbonate
material having a minimum thickness of 1.5 mm.
2.3.6 LED module of LED based tail lamps shall be hermetically sealed.
2.3.7 The LED based tail lamps shall have insulation resistance of more than 100-M ohms.
2.3.8 LEDs used in the LED based tail lamps shall be of high performance quality and from
reputed manufacturers. The minimum junction temperature of a LED shall not be less
than 100 deg.
2.3.9 Normally LEDs of the LED based tail lamps shall be driven within average drive
current range recommended by the LED manufacturer and in no circumstances LEDs
shall be driven by current more than the maximum current recommended by the LED
manufacturer.
2.3.10 Reverse polarity protection shall be suitably provided.
2.3.11 The illumination shall be within 5% of normal illumination in the operating voltage
range i.e. normal battery to low battery cut off stage.
2.3.12 On each of the modules shall be printed in indelible ink, or embossed or engraved, the
following alpha numeric legend:
Zonal Rly. e.g. CR, ER, NR, WR
Purchase Order No. & Date
Manufacturer’s Name
e.g. XYZ
For illustration
NR/2002/4605-0056 dt. 5.8.2002/XYZ
5
2.3.13 Weight:
The complete tail lamp shall be designed to weigh less than 650 gms. excluding the
following:


Batteries
Metallic hoop (optional) to fix tail lamp to draw bar hooks.
2.3.14 One pilot amber LED, 3.0 mm size shall be provided at the top surface to indicate that
the tail lamp is in perfect fettle and is working, and shall turn on only when the toggle
power switch is put on.
2.3.15 The pilot amber LED provided as per Clause 2.3.14 above, shall also serve as low
battery indication, and shall begin to flash at the rate of 55-65 per minute, if the
battery has discharged to a level such that less than 12 burning hours life is left (for
RED aspect). Should the lamps be continued in service, beyond this 12 hour period,
the electronic circuit (for red LED only) shall switch itself off completely including
the PILOT LED and the event shall reside in memory, (or by any other means) to be
restored only when battery cells have been replaced. But AMBER flashing aspect will
continue to operate for min. of 4 hours even after this condition sets in.
2.3.16 All LEDs shall be configured in such a way that failure of any LED shall not affect the
working of the unit. LEDs of each circuit will preferably be intermixed so that
radiated area is not affected in case of failure of any LED. The tail lamp be so
designed and constructed that in the event of open circuit of any of the LEDs in the
radiating area, the remaining LEDs shall continue to function. If however the number
of faulty LEDs is more than 25% of that used in the radiation area, the unit shall turn
off. Such failure of LEDs will be indicated through flashing visual indication through
same pilot amber LED provided as per Clause 2.3.14.
2.3.17 The tail lamp shall be designed and constructed so that it is foolproof against
vandalism/miscreants in respect of its operation by providing suitable locking
arrangement once it has been fastened on the bracket of the last vehicle. The locking
arrangement with bracket shall be such that only authorised person can remove the
lamp from the bracket after unlocking it. The tail lamp shall be so designed and
constructed that that change of batteries or replacement of any module is possible
only when the light has been taken off the ‘bracket’ provided on the last vehicle. The
toggle switch provided shall not be accessible for operation after tail lamp has been
fixed on the bracket.
2.3.18 The equipment and its mounting arrangement shall be of robust design and shall
withstand satisfactorily vibrations and shocks normally encountered in service as per
clause 3.5 below. The carrier body shall be so designed that any angular displacement
from the longitudinal axis does not exceed 0.5 degrees, when mounted on a bracket.
3.0
ENVIRONMENT
The tail lamp is normally required to be used as an outdoor last vehicle indicator on
railway passenger coaches & goods wagons operating up to 160 kmph. under all
6
weather conditions ranging from damp coastal to hot arid climate and subject to rain,
dust and vibrations that accompany such service. Environmental parameters that the
proposed unit shall be designed to withstand are as follows.
3.1
Ambient temp
Min 10 degrees c below freezing point
Max. 60 degrees c above freezing point
Test for above will be conducted in energized condition for 2 hours each (i.e. for
minus 100C and 600C.). There should no variation in operating parameters after 1
hour of recovery period.
3.2
Max. operating temp. 70 degrees c for ten hours
3.3
Humidity
100%
3.4
Climate
Dusty, Dry, Arid, as also humid coastal, and heavy rainfall
Accompanied with heavy gale, occasional hail storms,
expected to subject the tail lamp to severe duty.
3.5
Vibrations
Acceleration: 3g in any axis
20 mm at 20Hz.
10 mm at 5 Hz.
For one hour under test conditions.
3.6
Altitude
From mean sea level, up to 1500M above MSL
3.7
Fixation:
The unit shall normally be mounted on a steel bracket in an
upright position. The unit shall however be designed to give its
rated performance in any displaced position, including upsidedown position.
4.0 TESTS :
4.1 Climatic tests : The LED based tail lamps shall be able to withstand following
environmental tests as per IS: 9000:
SN
Name of test
1
Change of temperature test at lower temp. –10 ±
30C and upper temp +70±20C (2 Cycles and
duration of exposure 3 hrs after the stability in
chamber has been reached)
Dry heat test at 85°C ± 2°C , (1 cycle of 16
hours)
Cold test at - 10°C ± 3°C, (1 cycle of 16 hours)
2.
3.
4.
Damp heat cyclic test (one cycle of 12 + 12 = 24
hours), (Upper temperature 55°C)
7
Part & Section of
IS:9000
Part-XIV/Section 2
Recovery
period
2 hours
Part-III/ Section 5
2 hours
Part-II/Section 4
2 hours
Part-V/Section 2
2 hours
5.
Salt Atmosphere test
(4 cycles of 7 days)
Part-XI/ Procedure 2
4 hours
6.
Driving rain test for two hours
4 hours.
7.
Dust Test at 40 ± 3°C for the period of 1 hour.
Part-XVI (Test
condition ‘C’, Clause
7.1.3)
Part-XII
2 hours
Test at S.No.1 shall be conducted in energized condition of the unit. Rest tests shall be
conducted in non-energised condition of the unit. After each of these tests, no LED
shall fail, there should not be any damage in the unit or visual change in colour. Also
illumination will not change by more than ± 5% of original value. Insulation
resistance shall not be less than 100-M.ohms. After completion of all tests colour coordinates shall remain within specified values.
4.2
Dispersion Angle test: This shall be measured as per Annexure III.
4.3
Burning in test: The LED based tail lamps shall be kept continuously ON for
minimum 24 hrs. at 60 °C. at rated voltage for each circuit separately (i.e. RED &
AMBER aspect). There shall not be any difference in operating parameters before and
after burning in test.
4.4
Drop Test: The test lamp shall withstand free drop from a height of 1.5 meters above
an RCC Platform of 75 mm thickness or on a steel plate 12mm thick. For the purpose
of the drop test, the units shall be powered with 4 numbers of alkaline LR-20 cells
each and units shall continue to function effectively, satisfy all parameters after
ensuring two drops. Appearance of cracks on the body may not be deemed as
disqualification as long as units continue to function. The units, however, shall not
disintegrate.
5.0
TEST PLAN
5.1
Type tests
Type test shall be performed on five samples selected from a lot of at least 20
equipments, by Govt approved agencies like NPL etc. All samples shall individually
pass the type tests. Test certificates shall be valid for two years from date of issue.
The unit shall be subjected to the following testsi)
Visual inspection
ii)
Colour co-ordinates (as per clause 2.1)
iii)
Operating Parameters (as per clause 2.2)
iv)
Ambient temperature test (as per clause 3.1)
v)
Climatic tests (as per clause 4.1)
vi)
Visibility test (as per clause 2.2.1)
vii)
Visual Alarm Test (as per clause 2.3.14, 2.3.15 & 2.3.16)
viii) Vibration Test (as per clause 3.5)
ix)
Insulation test (as per clause 2.3.7)
x)
Burning in test (as per clause 4.3)
xi)
Drop test (as per clause 4.4)
8
xiv)
xv)
xvi)
5.2
Durability of the switch to withstand 7500 break/make operations
Reverse polarity protection test (as per clause 2.3.10)
Current drain test (as per clause 2.3.9)
Routine Tests:
Following tests shall be undertaken by manufacturer for every unit offered for
supply:i)
ii)
iii)
iv)
v)
vi)
vii)
vii)
viii)
ix)
5.3
Visual inspection of each unit
Colour co-ordinates (as per clause 2.1)
Operating Parameters (as per clause 2.2)
Visual Alarm Test (as per clause 2.3.14, 2.3.15 & 2.3.16)
Burning-in test (as per clause 4.3)
Current drain test (as per clause 2.3.9)
Verification of marking/embossing in accordance with the specification.
(as per clause 2.3.12)
Weight test (as per clause 2.3.13)
Visibility test (as per clause 2.2.1)
Verification of changeability of modules (as per clause 2.3.2)
Acceptance test:
Acceptance test as per following would be carried out by Railway inspecting officials
while carrying out normal inspection:(a)
(b)
Verify sample plan:
Lot size
Up to 20 Nos
Between 21-50 Nos.
Between 51 –100 Nos.
Sample size
3 Nos.
5 Nos.
8 Nos.
Between 101-150 Nos.
More than 151
12 Nos.
15 Nos.
Following shall constitute acceptance test:
i) Visual inspection
ii) Colour coordinates (as per clause 2.1)
iii) Operating parameters (as per clause 2.2)
iv) Ambient temperature test (as per clause 3.1)
v) Visibility test (as per clause 2.2.1)
vi) Visual alarm test (as per clause 2.3.14, 2.3.15)
Visual alarm test for LED failure should be conducted on one sample for
RED & AMBER LEDs each separately (as per clause 2.3.16)
vii) Insulation test (as per clause 2.3.7)
viii) Burning-in test (as per clause 4.3)
9
ix) Drop test on one sample – performance test to ensure proper functioning
after the drop test (as per clause 4.4)
x) Reverse polarity protection test (as per clause 2.3.10)
xi) Current drain test (as per clause 2.3.9)
xii) Weight test (as per clause 2.3.13)
xiii) Verification of marking//embossing (as per clause 2.3.12)
xiv) Any other test considered necessary by the inspecting agency
6.0
CONDITION OF PACKING AT TIME OF SUPPLY
The tail lamp shall be supplied with 4 nos. of alkaline LR-20 cells, which shall not be
older than 2 months at the time of supply of units.
Each tail lamp shall be packed in an individual carton/packet, to protect it from
foreseeable handling shocks. Packing cases shall not contain more than 100 tail
lamps, each individually packed. The unit shall be so packed as to permit convenient
handling and to protect against loss or damage during transit and storage.
7.0
DETAILS TO BE FURNISHED BY PROSPECTIVE SUPPLIERS
The prospective supplier will be required to include the following details invariably in
the literature/brochure, explain the product and its essential features.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
The principal dimensions of the modules and of the assembled units
Weight (without batteries)
Number of LEDs used and type, and size of window emanate for each
aspect
Operating parameters of the lamp.
Radiating area from which light will emanate.
Thresh hold value of voltage/signal for “low battery” indication to
appear
Dissipation with new batteries
Guaranteed life in burning hours
Warranty offered
Annual maintenance charges after expiry of warranty period/
confirmation that spares modules would be available along with their
cost from the supplier and period thereof so that maintenance plans can
be drawn up.
Credentials regarding past supply to Railways.
Block diagram of circuit clearly indicating the wiring with different
colours and their connections.
Copy of current valid type test results
Above information will be considered while evaluating merits of the tail lamp as
choice has been left to the equipment manufacturer in respect of above items, it is
necessary that these details are furnished.
10
The supplier shall submit four copies of circuit details and connection, technical
data & internal test results conducted for the offered system.
The maintenance/operating manual is to be supplied with each order.
The supplier will submit routine test reports of all units at the time of supply.
8.0
DEVIATIONS:
Any deviation from the above specification shall be brought out by the supplier in
their offer/literature, for specific approval at the time of offering the product for order.
9.0
INFRINGEMENT OF PATENT RIGHTS:
Indian Railway shall not be responsible for infringement of patent rights due to
similarity in design, manufacturing process, use of components used in design,
development of manufacturing of Battery operated LED based flashing Tail lamp and
any other factors which may cause such dispute.
11
ANNEXURE - III
Measurement procedure for Dispersion Angle
1.
2.
3.
Light up the aspect at the nominal voltage on 6 V and place it on the test bench.
The Dispersion Angle shall be calculated by measuring the half intensity points of the
dominant wavelength at 1.5 m from LED signal lighting unit in axial direction on
both the sides and taking average of the distances, d1 & d2 in meters
(d = (d1 + d2) / 2)
The half intensity, point is where half of the normal illumination at rated voltage falls.
The Dispersion Angle shall be calculated using the formula tan-1 d – r = Ø/2
1.5
4.
‘r’ is the distance from center of the unit to the outer most LED provided in the unit.
d1
d2
Ø/2
1.5 m
Face
r
Ø/2
5.
Dispersion Angle = Ø
12