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Draft Specification No. RDSO/PE/SPEC/PS/0123 (Rev. 0)-2009, Amdt -2

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

lR;eso t;rs

DRAFT SPECIFICATION FOR ENERGY EFFICIENT LED BASED LUMINAIRE UNIT FOR STREET LIGHT AND PLATFORM LIGHTING

Draft Specification No. RDSO/PE/SPEC/PS/0123(Rev 0)-2009, Amdt -2

Sl.No. 1.

Date of Revision/amendment 17.09.2010

Revision/Amendment Amendment 1

Remarks Clause nos. 9.0, 10.0, 11.0, 13.0 and 14.0 deleted, and typographical errors corrected in clauses 5.9 and 7.0-xii, as per Railway Boards letter No. 2006/Elect.(G)/150/9/Pt. dated 10.09.2010. -

2.

Amendment 2

vuqeksfnr APPROVED dk;Zdkjh funskd@fo|qr tkZ izc/k funskky; a Executive Director/EEM

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INDEX

S.N. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0

DESCRIPTION SCOPE CONSTRUCTION REFERRED STANDARDS SERVICE CONDITIONS TECHNICAL REQUIREMENTS TESTS METHOD OF TESTING MARKING ISO CERTIFICATION (Deleted) ELIGIBILITY CRITERIA (Deleted) GUARANTEE (Deleted) APPROVAL DETAILS OF ESSENTIAL INFRASTRUCTURE (Deleted) ESSENTIAL MEASURING INSTRUMENTS FOR TESTING (Deleted) ANNEXURE A

PAGE NO. 1 4 5 5 6 9 10 13 13 13 13 13 13 14 14

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SPECIFICATION FOR ENERGY EFFICIENT LED BASEDLUMINAIRE UNIT FOR STREET LIGHT AND PLATFORM LIGHTING FOREWARD At present, conventional type luminaire are being provided for the street light and platform lighting. By introduction of white High Power Light Emitting Diode (LED) having more than 50, 000 working hours, it is possible to use LED lamps in place of existing fluorescent ,Sodium vapour / Mercury vapour and Metal Halide lamps LED lights are almost maintenance free and as a result, total power saving is expected to be more than 50%. Keeping in view of the energy conservation, increased life and recurring savings on account of maintenance, use of environmental friendly energy efficient LED based luminaire is being considered for street light and platform lighting. 1.0 SCOPE The scope includes design, development, manufacturing, testing and supply of energy efficient luminaire complete with all accessories, LED lamps with suitable current control driver circuit including mounting arrangement for street light and platform light. The luminaire shall be suitable for rugged service under the operational and environmental conditions encountered during service as specified in clause 4.0. The following types of luminaries are covered in this specification: TABLE-1 (TYPE OF LUMINAIRE) Type of existing fitting (Street Light) HPSV/HPMV Wattage of existing fitting* 70W 150W 250W 400W 70W 150W 250W 1X40W 2X40W proposed LED fitting Maximum Wattage of LED fitting Type Type Type Type Type Type Type Type Type A B C D E F G H I 50W 100W 170W 260W 50W 110W 190W 30W 60W Initial Lumen Output

Metal Helide

FTL (Platform Lighting) FTL

4000 8000 13500 20000 4000 8800 15000 2400 4800

1X40W Type J 2X40W Type K * At nominal input voltage of 220V AC

30W 60W

2400 4800

Note: Each type of luminaries shall be supplied with associated driver circuit and required optics.

2.0

CONSTRUCTION

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a.

All the luminaire shall be finalised based on the performance requirement. The detailed calculation for lux level as per clause no. 5.8 with uniform distribution including the lux distribution curve /graph/spatial distribution shall be submitted in support of the dimensions selected and variation thereof. Housing shall be made of 1.6 mm thick sheet Steel conforming to IS: 513 (Grade O) or aluminum die cast having high conductivity preferably to grade 5000 or similar to high conductivity heat sink material. Efforts shall be made to keep the overall outer dimensions as minimum as possible. All light fittings shall be provided with toughened glass of sufficient strength under the LED chamber to protect the LED and luminaries.

b.

Suitable number of LED lamps shall be used in the luminaire. LED lamps of NICHIA/ OSRAM/ SEOUL/ PHILIPS LUMILEDS/ LEDNIUM make shall be used for the purpose. The manufacturer shall submit the proof of procurement of LEDs from above OEMs at the time of testing. Suitable reflector / lenses may also be provided to increase the illumination angle. Supplier will be solely responsible for testing and performance of the luminaries after installation and shall also ensure the specified and uniform illumination and comfort level on the street/platform.

c. d.

2.1

High power and high lumen efficient LEDs suitable for following features shall be used: a. The efficiency of the LED lamps at 1100C junction temperature shall be more than 80%. b. The working life of the lamp at junction temperature of 1100C for 350mA current shall be more than 50,000 hours of accumulative operation and shall be suitable for continuous operation of 24 hours per day .these features shall be supported with datasheet. c. Adequate heat sink with proper thermal management shall be provided. d. Colour temperature of the proposed white colour LED shall be 6500k. e. Minimum view angle of the LED shall not be less then 1200. f. The output of LED shall be more than 100 lumen per watt at minimal operating current and shall ensure guaranteed operation life of 50,000 burning hours with controlled junction temperature of 1100C. g. Efficiency of driver electronics shall be more than 85%. h. Power factor of complete fitting shall be more than 0.95. i. The driver card shall withstand 440V and shall resume normal working when nominal voltage is applied again. j. Thermal management shall be in such a way that LED junction temperature shall not go beyond 80 degree centigrade.

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2.2

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 the components, used in design, development and manufacturing of these light fittings and any other factor which may cause such dispute. The responsibility to settle any issue rises with the manufacturer.

3.0

REFERRED STANDARDS IS: 513 IEC 60529 Cold-rolled low carbon steel sheets. Classification of degree of protections enclosures. EN 55015 RFI <30MHz EN 55022 RFI > 30MHz EN 61000-3-2 Harmonics EN 61547 Immunity EN 60929 Performance IEC 60598-2-1 Fixed general purpose luminaries IEC 60598-1 IEC 61000-3-2 IEC 60068-2-38 IS 10322 IS 4905

provided

by

General requirement and tests Limits for Harmonic current emission -THD < 10% Specification for Permitted Humidity Test Specification for the luminaries Method for random sampling

4.0

SERVICE CONDITIONS: Street light on pipe/Recess mounting type light unit complete with luminaries and mounting accessories shall be suitable for street, office complex ,railway platforms (covered and open) and residential colonies of Indian Railways under the following environmental conditions :-

4.1

Environmental conditions Maximum ambient air temperature Minimum ambient air temperature Max. Relative humidity Atmosphere : : : : 55 C -5 C 100% Extremely dusty and desert weather and desert terrain in certain areas. The dust contents in air may reach as high values as 1.6 mg/m3 The equipment shall be designed to work in coastal area in humid, salt laden and corrosive atmosphere.

Coastal area

The maximum value of the condition in the coastal area will be as follows: Max. pH value Sulphate Max. concentration : : of : 8.5 7 mg/liter 6 mg/liter

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chlorine Max. Conductivity Annual rainfall Altitudes 4.3 5.0 5.1

: : :

130 micro sec./cm Ranging between 1750 to 6250 mm with\thunder storm Not exceeding 1200 m above sea level

The supplier shall provide In the field service support during guarantee period. TECHNICAL REQUIREMENTS The luminaire casing/housing shall be made of 1.6 mm thick sheet Steel conforming to IS: 513 (Grade O) or aluminum die cast having high conductivity preferably to grade 5000 or similar to high conductivity heat sink material. The electronic components used shall be as follows:a) b) c) d) e) f) g) IC (Integrated circuit) shall be of industrial grade or above. Metallic film / Paper/Polyester Capacitor shall be rated for a maximum temperature of 105C. The resistors shall be preferably made of metal film of adequate rating. The actual loading versus rating shall be 3. The junction temperature of the Switching devices such as transistors and MOSFETs etc. shall not exceed 125C (allowing thermal margin of 25 C). The conformal coating used on PCBs should be cleared and transparent and should not affect colour code of electronic components or the product code of the company. The heavy components shall be properly fixed. The solder connection should be with good finish. The electronics covered for this equipment shall pass all the tests called for in the specification. The tenderer shall indicate the deviation or compliance otherwise the offer may not be considered for evaluation. The infrastructure for Quality Assurance facilities as called for in the specification shall be available for the manufacturing of this product. The compliance shall be indicated clearly in the tender itself.

5.2

h)

5.3

The connecting wires used inside the luminaire, shall be low smoke halogen free, fire retardant e-beam /PTFE cable and fuse protection shall be provided in input side. Care shall be taken in the design that there is no water stagnation anywhere. The entire housing shall be dust and water proof having IP65 protection as per IEC 60529.

5.4

5.5

The control gear shall be designed in such a way so that temperature rise of heat sink shall not be more than 450C with respect to ambient temperature. For platform lighting, luminaire shall be such that the glare from individual LED is restricted and shall not cause inconvenience to the public. All the material used in the luminaire shall be halogen free and fire retardant

5.6

5.7

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confirming to UL94 . 5.8 Illumination Level: The fitting shall be so designed that the illumination level shall be evenly distributed and shall be free from glare. Illumination level of different types of luminaire shall be as below: Sl. No. Type of Luminaries Vertical Distance of fittings from the floor level (Mtrs) 5 7 7 7 5 7 7 5 7 4 4 Minimum Illumination Level ( Lux)at centre 25 25 25 25 25 25 25 25 25 50 50 Colour of illumination

Street Light 1. Type A 2. Type B 3. Type C 4. Type D 5. Type E 6. Type F 7. Type G 8. Type H 9. TypeI Platform Light 10 Type J 11 TypeK Note: 1. 2. 3.

daylight daylight daylight daylight daylight daylight daylight daylight daylight

white white white white white white white white white

daylight white daylight white

Variation in illumination level shall be 2% is allowed in input voltage range from 180VAC to 250VAC. The illumination shall not have infra-red and ultra-violet emission. The test certificate from the NABL approved laboratory shall be submitted. Electronic efficiency shall be more than 85%.

5.8.1 Polar curves:Typical distribution of illumination of these luminaries shall be as given below:a. Street light

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b.

Platform light

5.9

After 50,000 burning hours, the luminaire intensity shall be at least 70%. Data sheet showing year wise deterioration in the LED shall also be submitted along with design.

5.10 Detailed design shall be furnished before manufacturing of prototype. However, information as per Annexure-A shall be submitted by the manufacturers along with the offer. 6.0 TESTS: Tests are classified as:

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6.1

Prototype test Type test Acceptance test Routine rest.

Prototype Test Prototype test is conducted on the first unit developed by the firm as per the relevant specification at manufacturers premises.

6.2

Type Test Type tests shall be carried out to prove confirmation with the requirement of specification and general quality/design features of the unit. In case of any change in Bill of Material or design of unit, complete type test shall be repeated. If any sample fails in any of the type tests, two fresh samples shall be taken and tested. If any sample again fails in that test, the whole lot shall be rejected.

6.3

Acceptance Tests: These tests are carried out by an inspecting authority at the suppliers premises on sample taken from a lot for the purpose of acceptance of a lot. Acceptance tests shall not be carried out from particular size from the lot on which type tests have already been conducted. Recommended sampling plan is given below.

6.3.1 Sample size and criteria for conformity The luminaries shall be selected from the lot at random. In order to ensure randomness of selection, procedures given in IS 4905-1968 (Reaffirmed 2001) may be followed. 6.4 Routine Tests: These tests shall be performed by the manufacturer on each complete unit of the same type and the results shall be submitted to the inspecting agency, prior to offering the lot for acceptance test.the firm shall maintain the records with traceability.

6.5
Sl. No. 1 2 3 4 5 6 7 8

Test Scheme:
Description of test Visual and Dimensional check Checking of documents of purchase of LED Resistance to humidity Insulation resistance test HV test Over voltage protection Surge protection Reverse polarity Clause no. 7 (i) 7 (ii) 7 (iii) 7 (iv) 7 (v) 7 (vi) 7 (vii) 7 (viii) Prototype Test Y Y Y Y Y Y Y Y Type Test Y Y Y Y Y Y Y Y Acceptance Test Y Y Y Y Y Routine Test Y Y Y Y Y

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9 10 11 12 13 14 15 16 17

Temperature rise Test Ra (Colour Rendering Index) measurement test Lux measurement Fire retardant Test Test for IP65protection Environmental tests Reliability Test Life Test Endurance Test

7 (ix) 7 (x) 7 (xi) 7 (xii) 7 (xiii) 7 (xv) 7 (xvi) 7 (xvii) 7 (xviii)

Y Y Y Y Y Y Y Y Y

Y Y Y Y Y Y -

Y -

Y -

7.0

Method of Testing i) Visual and Dimensional Check: The unit shall be checked visually for all dimensions as per approved design and drawing. General workmanship should be good; all the components properly secured and sharp edges shall be rounded off. Check the marking and quality of the workmanship visually. Check the rating and make of electronic / electrical items. ii) Checking of documents of purchase of LED Check Document of purchase of LED lamps of approved sources viz. NICHIA/ OSRAM/ SEOUL/ PHILIPS LUMILEDS / LEDNIUM/AVAGO. iii) Resistance to humidity test This is carried out by suspending the painted panels in corrosion chamber maintained at 100% RH and temperature cycle of 42 to 48 deg. C for 7 days and examining it for any sign of deterioration and corrosion of metal surface. iv) Insulation resistance test The insulation resistance of the unit between earth and current carrying parts shorted together shall not be less than 2 M when measured with 500V megger.

v)

HV test Immediately after insulation resistance test, an AC voltage of 1.72 KV rms (1500 + 2 x rated voltage) of sine wave form of 50 Hz shall be applied for one minute between the live parts and frame. There shall not be any kind of break down, flashover or tripping of supply.

vi)

Over voltage protection The Luminaire shall withstand at 300V AC for two minutes.

vii)

Surge protection It shall withstand a surge of 1.5kV 3% for 50 microseconds 20 % at the input terminals for all types. (Tests shall comply with Clause 5.4 of latest IEC 60571-1).

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viii)

Reverse polarity The Luminaire shall withstand polarity reversal. It shall be operated with reverse voltage for 5 minutes at maximum value of voltage range. At the end of this period, the supply shall be made correct polarity and Luminaire shall operate in a normal way.

ix)

Temperature rise Test: Temperature rise Test shall be conducted at 180VAC with full load. The temperature rise shall be recorded by temperature detectors mounted at the specified reference points on the body of semiconductors, capacitors and other components as agreed between purchaser and manufacturer. The maximum-recorded temperature under worst conditions shall be corrected to 550C and compared with maximum permissible temperature (for power devices at junction). Under loading conditions as specified above, the corrected temperature of the power devices shall have a safety margin of minimum 100 C. Temperature at junction shall not exceed 100 0 C when corrected to 550 C. The Luminaire shall also be subjected for short time rating after continuous loading to ensure the temperature rise is within the permissible limit. The maximum temperature rise of the electronics devices on the PCBs shall be in limit for industrial grade components suitable for 850C environment. In case of exceeding limit, use of MIL-grade component shall be considered keeping RDSO informed.

x)

Ra (Colour Rendering Index) measurement test The lumen is the unit of luminous flux, which is equal to the flux emitted in a solid angle of one Steradian by a uniform point source of one candela. The initial reading of the chromaticity co-ordinates x & y shall be within 5 SDCM (Standards Deviation for Colour matching) from the standardised rated value as per Annex. D of IEC 60081 - 1997. The initial reading of the general colour-rendering index (Ra) shall not be less than the rated value decreased by 3. The lumen maintenance of the lamp shall not be less than 80% of the initial lumen after 20000 burning hours and 70% of the initial lumen after 50000 hours . The initial lumen will be taken after 100 hours aging. Photometric test shall be conducted as per annexure B of IEC 60081-97. The lumen maintenance test shall be done as per annexure C of IEC 60081-97.

xi)

Lux measurement Lux measurement with the help of Lux meter shall be done at a distance as shown in para 5.8 above. Value obtained shall not be less than the Lux specified in the table therein. , considering 10% Lumen is absorbed by the reflector.

xii)

Fire retardant Test

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Fire Retardant test shall be conducted as per IEC 332-1 of the wire used in the fittings. xiii) Test for IP65 protection This test shall be conducted as per IEC 60529. xiv) Environmental tests The Luminaire shall meet the following tests as prescribed in IEC 60571. a) b) c) d) xv) Dry heat test. Damp heat test Test in corrosive atmosphere Combined dust, humidity and heat test

Reliability Test

The reliability can only be determined in actual service. However, the following tests shall be carried out on the prototype to simulate as close as possible, the service conditions. There shall be no failure during this test. a) The light unit shall be mounted in an oven maintained at 75C. b) The light will be operated at the specified maximum voltage and at 75C for a period of 100 hours.
xvi) Life Test The lumen maintenance & life test shall be done as per annexure C of IEC 6008197. Endurance Test The Luminaire shall be kept ON with input voltage of 250VAC for 200 hours. After this the Luminaire is subjected to 20,000 cycles of ON and OFF, each cycle consisting of 3 seconds ON and 10 seconds OFF period. Luminaire should survive this test. Test is to be continued for one lakh cycles, followed by performance test. xviii) Safety: The Luminaire shall comply with the safety requirements as per IEC 61195. 8.0 MARKING: information shall be distinctly and indelibly marked on the housing: Indian Railway Insignia Year of manufacture/Batch Number/ Serial Number Name of Manufacturer Rated watt and voltage (Input) Rated watt- Output

xvii)

8.1 The following a) b) c) d) e)

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9.0

ISO CERTIFICATION:

(Deleted) (Deleted)

10.0 ELIGIBILITY CRITERIA: 11.0 GUARANTEE: 12.0 APPROVAL (Deleted)

12.1 While seeking approval, the firm shall submit a sample to the RDSO along with test results, circuit diagrams and dimensioned drawing of the Luminaire. The prototype testing shall be got done at manufacturers work. However, Environ-mental and surge test shall be conducted at any NABL approved laboratories. 12.2 The manufacturer shall also submit details like make, type, reliability grade, rating and loading of various electronic components used in the circuit. The temperature rise of the various components under the most adverse conditions shall also be declared. 12.3 After completion of the type tests and submission of the sample along-with the technical details as indicated above, the Luminaire shall be considered for approval. 12.4 WITHDRAWAL OF APPROVAL Approval granted to the manufacturer is liable to be withdrawn in the event of noticing any change at a later date in the design or change from the bill of material as approved earlier without seeking the prototype approving authority i.e. RDSO's approval or using components of inferior specification/quality compromising with the reliability. 13.0 DETAILS OF ESSENTIAL INFRASTRUCTURE (Deleted)

14.0 ESSENTIAL MEASURING INSTRUMENTS FOR TESTING

(Deleted)

Annexure-A DATA TO BE FURNISHED BY THE TENDERER (LUMINAIRE WISE) 1.0 CUP SPECIFICATION: a. b. c. d e. f. g. h. i. 2.0 Basic Mechanical dimension Electrical and control Light output Cups raw specification with operating Mechanical characteristics of cup Emission Spectrum Spectral Intensity Distribution If vs Luminous Flux If vs Correlated Color Temperature : : : characteristics : : : : : :

ILLUMINATION CHARACTERISTICS: Tj = 250C, It =350mA

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Sl.No. 1 2 3 4 5 6 7 8 9 10 11 3.0 Sl. No. 1 2 3 4 5 6 (Pulse 3.1 3.2 4.0

Parameter Min. Luminous Flux (lm) Luminous Intensity (cd) Viewing Angle (Degree) Luminous Efficiency(lm/w) Spectral Length (nm) Dominant Wavelength (nm) FWHM (nm) Color temperature (K) Purity (%) Colour Rendering Index CIE Coordinates

Absolute Values Typical

Max.

Refer the chromaticity diagram

ELECTRICAL CHARACTERISTICS: Parameter Min. Forward Voltage (V) Pulse forward current (mA) Reverse Leakage current ( A) Reverse Voltage (V) Storage Temperature ( 0C) Thermal Resistance ( 0C/W) width 1ms with duty cycle 1/16) Forward voltage vs Normalised Vf If vs Ir BIN RANKING Rank Rank Rank Rank Rank WD1 WD2 WD3 WD4 : Tj = 250C, It =350Ma Rank WD1, WD2, WD3, WD4 : Tj = 250C, If = 350mA Forward Voltage Vf (Volts) Max Min Luminous Flux v,lm Max Min Absolute value Typical

Max.

Sl. No. 1 2 3 4 5.0

COLOR RANKING

Sl. No X y 6.0

LED CUP DEGRADATION CHARACTERISTICS Flux measurement in lumens from Zero Hours to 1800Hrs at every 100 Hrs.

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7.0 RELIABILITY REPORT : a. Summary of results for day light cups Sl. No 1 2 3 Stress Operating life Humidity Temperature cycle DUT 5 8 10 Conditions If= 50mA,Tj=800C If=100mA,Tj=1000C,RH=85 % T= -400C to 1050C Duration 1800 Hrs 4058 Hrs 1000 Cycle failures

b. Sl. No 1 2 3 4

Operating life: Tested at If = 350mA, Ta =250C Luminous flux (lm) t-0 t-1800 Color Temperature t-0 t-1800

Condition Worst Mean Best

8.0 8.1 8.2 8.3 9.0

DRIVER Driver weight Driver dimension Oscillator frequency PROTECTIONS: Input polarity Open circuit and low voltage conditions Short circuit on the output terminals Internal short-circuit (Fuse protection) Lamp failure Overload protection : : : : : : : : :

10.0 EFFICIENCY: 11.0 MTBF : 12.0 DIELECTRIC (1500V-50HZ FOR ONE MINUTE): 13.0 INSULATION RESISTANCE: 14.0 OPERATING TEMPERATURE: 15.0 GENERAL CHARACTERISTIC

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Type of start Internal control Nominal input voltage: 220 Volt AC Input voltage range 180 Volt AC to 250 Volt AC Power 15 Watt maximum Efficiency > 90% CEC > 70% 50,000 hours at 350C(16 hours per day at 340days/year) Operating temperature: -250C to 80 0C Insulation resistance High resistance to vibration IP No Load power losses Output Ripple Line Regulation Load Regulation Weight Dimmable via wireless and manual control Line under voltage and over voltage protection Accurate Over Temperature and Overload protection DONT not Feedback Compensation Digital Control Auto restart for open protection Hysteretic over temperature protection Self powered Current and voltage feedback provides constant current output and protection disconnected load Operation (kHz) U No load specification Code of conduct of efficiency of external power supply ROHS complaint Remote ON & OFF Warranty

: : : : : : : : : : : : : : : : : : : : : : : : : :

: : : : : :

********