Page 1 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF ANNEXURE H (Revised in December, 2002) with amendment No.1 DEVIATIONS TO IS: 6680-1992 (FIRST REVISION) SPECIFICATION FOR RAILWAY CARRIAGE FANS Details of deviations: 1. Page 2, Clause 8.2 The clause 8.2 shall be read as under Stampings Laminated core shall be used in the construction of fan motors. The stampings used for laminated yoke and armature core shall be made from electrical steel sheets (See IS: 648-1980, IS: 649-1963) and IS: 3024-1965). 2. Page 2, fig.1a, Page No.3, Fig.1B Grease catcher for 400mm, 300mm and 225mm fan. Grease catcher outer dia shall be read as under: In 400mm, 300mm and 225 mm sweep, RC fan grease catcher outer dia shall be 46 mm. 3. Fig.3, Page 4 The following note shall be added as Note 4 after the existing note 3 under figure 3 for fixed type fan. Note 4: The body can be alternatively fabricated from MS sheet as per ICF s Drg. No. ICF/SK-7-6-095 (Alt. D ), against Railway/Production Units specific requirements. 4. Page 5 Heading for fig.4 shall be read as under: Dimensions for fixed type motor of 400 mm, 300 mm and 225 mm sweep bracket type fan. 1. Page 5, Clause 8.6, Bearings Delete words of approved make in the first line of clause 8.6 and add the followings after first sentence. The ball bearings of the following make shall be used for all types of fans. i) SKF
Page 2 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF NBC iii) FAG Any other indigenous make of bearing of good quality proposed to be used for trial by manufacturers can be used with the prior approval of RDSO. 6. Page 8. Fig. 9 Presently, 7 holes are made in the base of swivelling type fan for mounting. Four additional holes drilled so far are not required. Hence, only 3 holes similar to those of fixed type of fans shall be drilled for mounting of the swivelling type of the fans. 7. Page 8, Clause 8.8 Brushes and brush holders Substitute the following for the existing last sentence of clause 8.8: The following grades of carbon brushed as approved by RDSO shall be used for 110 V dc and 24 V dc carriage fans. Grades of the carbon brushed EG3 L16 (I) E55 (I) Firm s name Assam Carbon Electro Carbonium, Bangalore 8. Page 9. Clause 8.10 Connector, Connecting lead and insulating Bushes. Substitute the following in lieu of the existing clause 8.10:1-8.10.1 : A connector of Fibre Glass Reinforced Plastic manufactured from sheet moulding compound (SMC) of 25% Fibre glass content, self extinguishing grade conforming to RDSO s Drawing s No. SKEL-4296 shall be provided. The connector shall be mounted in the ceiling of the coach and shall be supplied separately with the fan for fixed type fans only. However for swiveling type fans, connector will continue to be supplied with the fans. 9. Page 9. Clause 8.11 Field coil Substitute the existing clause by sub-clauses 8.11.1, 8.11.2 & 8.11.3 8.11.1 24V DC Fans shall be supplied with Aluminium field coils and in that case an anodized plate marked Aluminium shall be provided. 8.11.2 : 110V DC fans shall be supplied with copper field coils. 8.11.3 The copper polysterimide enamelled round winding wires. Class 180 used for field and armature coils shall conform to IS specification No.: 13730 (Part 8)-1996. 10. Page 11. Clause 10 The following shall be added after sub clause 10.2: 10.3: Insulating Materials All the insulating materials used for armature and field coils shall be of ISI quality conforming to the relevant specifications and test conditions specified for class 155 insulating materials. 10.4: Insulating varnish:
The fan s motor shall be well treated with the insulating varnish of Class 155 conforming to relevant IS preferably in vacuum impregnation plant to achieve an insulating value of 20 mega-ohm. The baking of varnish shall be done in an air-circulating oven. 11. Page 11. Clause 11 Speed regulators Clause 11.1, 11.2, 11.3, 11.4 and 11.5 shall be substituted as follows: Page 3 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF IS :6680 FOR RAILWA Y CARRIAGE FANS 11.1 All fans shall be supplied without speed regulators 12. Page 11. Clause 9 The following sub-clause as sub-clause 9.2 shall be added after sub-clause 9.1: Sub-clause 9.2 a) Colour scheme: (i) 24V, dc Black fans (ii) 110V, ac/dc fans Smoke-Grey (iii) 140V, ac fans Smoke-Grey b) The fan base, gimble rings, motors, body and regulator box of 110 V ac dc fans shall be finished with Smoke-Grey color to Color Code No. 692 of IS: 5-1978 and enamel paints conforming to IS: 151-1985. c) The other parts of the fan viz. blade, guard and regulator faceplate including handle shall have no change in finish i.e. they shall be finished with oxidized copper conforming to IS: 1378-1987 and a coating of lacquer shall be applied on the oxidized copper surface conforming to IS: 349-1981. 13 Page 12, Fig.14 (225 mm sweep bracket type fan) dimensions shall be read as under : Screw length 28 mm in place of 18 mm 14. Page 14. Fig.16 Brush Holder for Carriage Fan Following note as Note 3 for fig. 16 may be added as under: Note 3-A 15 mm. long PVC sleeve be provided on the brush holder box (part 2) for 110V dc fans. 15. The dimensions mentioned in enclosed drg. No. RDSO/PE/SK/TL/0026-2002 (Rev 0 ) will supersede the respective dimensions mentioned in Page no. 13 figure no. 15 for Bracket for Bracket type fan and page no. 12 figure no 14 for Base for bracket type fan. 16. Page 17, Fig-19- The spring washer outer dia shall be 9.6 mm and inner dia 6.4 m. 17. Page 19. Table 1: Performance Data (Clause 16.1) Replace existing data under Table-I by the followings; S. No. Parameter dc fans ac fans 400mm 300mm 225mm 400mm 300mm 225 mm
1. Minimum air 50 37 20 65 30 14 delivery in cubic meter per minute 2. Maximum electrical 32 25 19 60 40 28 power input in Watts Page 4 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF 3. Maximum Weight in Kg. 15 14.5 13 15 14.5 13 4. Minimum service value 2.0* 1.80* 1.35* 1.1 0.75 0.6 in cubic meter per 1.8** 1.65** 1.20** minute per watt. * for prototype tests ** for acceptance tests. 18. Page 19. Clause 17.2 Clause 17.2 shall be deleted from the specification 19. Page 19, Clause 18.3 Existing clause may be replaced by the followings: Additional information that the manufacturer may be requested to supply in Annexure B for AC and DC fans separately. Page 20. Clause 19.1.2 for Acceptance tests The following acceptance test shall be added: h) Service value test 20. Page 20. Clause 19.1.2 A sub clause 19.1.2.2 shall be added as under after sub clause 19.1.2.1:- However for Air delivery and Service value test, 2 fans for lot size up to 100, 4 fans for lot size above 100 and up to 200 and 6 fans for lot size above 200 will be selected at random from the lot 21. Page 20. clause 19.1.4-limits of error in electrical instruments: Substitute the following for the existing first sentence of the clause: The measuring instruments like ammeter, voltmeter, and wattmeter shall be of accuracy class 0.5 and calibrated upto date for both type and acceptance test. 22. Page 22 -.Add sub-clause 19.2.6 after clause 19.2.5. 19.2.6 Service value test: The service value will be calculated. This value is the ratio of air delivery in cubic meter per minute obtained in air delivery test to power input in watt obtained in electrical input test for fans sampled as per sub-clause 19.1.2.2. 23. Page 23. Clause 19.11.2-Insulation Resistance test (Routine Test) Substitute 20 mega-ohms in place of 2 mega-ohms in the third line. 24. Page 25. Annexure-B i) Existing description against item (g) of sub-clause B-1 to be replaced by the following: Class and details of winding wire and insulating material. ii) The following two sub-clauses as (s) & (t) shall be added after the Sub-clause (r)
(s) Addresses of the suppliers of raw materials used. (t) Details of quality control measures being exercised for purchase of raw materials and fan components including in-house testing arrangement, details of the tests being conducted in any Government recognized labs, test certificates, visual checking and rejection records of the raw materials and fan components. Page 5 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF 25. In Annexure D of Clause 19.1.2.1 criteria for conformity in third line D3 after the word tests following line may be added. except air delivery test and service value test. 26. Type test shall be repeated for all type of sweep ac/dc fans every two years for revalidation of design. In case, failure rate is high of any particular firm, the type test can be repeated earlier. 27. Infrastructure (Essential facilities, required for manufacturing quality Railway Carriage Fans) enclosed at (Appendix-1) 28. The following additional clause will be added after clause 19.11.2 20.0 Optional Clauses The following optional clauses are being added for placement orders for carriage fans with improved design features. 20.1 The Blade shall be made of fire retardant Polypropylene material with injection moulding process. It shall have adequate mechanical strength. The blade material shall have the following properties. Grade : FRPP HOMO Polymer chlorinated Deflection temperature under load at 18.5 kg/sq.cm deg.c 60 Flammability UL 94-V0 Tensile strength ASTM D638 mpa 34 Flexural strength ASTM D790 mpa 44 Elongation at break ASTM D 658 28 20.2 Powder coating shall be done on fan body (outside and inside) guard and Blade. The thickness of coating shall be not less than 60 microns. The powder is not required for fan blades made of fire retardant poly propylene material. 20.3 The deep drawn design for fan body made from M S Sheet as per RDSO Drg. RDSO/PE/SK/TL/0025 2002 (Rev.0), Alt.2 against Railway Production Units/Railways specific requirements.
*********** Page 6 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF Infrastructure (Essential facilities required for manufacturing quality Raillway Carriage Fans.) Machinery and Plants: 1. Capstan / Turret lathe equivalent to HERBERT 4 for accurate machining of i) Motor body and frame ii) Positioning and centering of shaft. 2. Centre Lathe machine 6 ft for machining CI (Cast Iron) yoke 3. Centre Lathe machine 4 ft for skimming and polishiing the commutator in finished Armature. 4. Milling machine 5. Shaping machine Appendix 1 6. Cylindrical grinding machine suitable for grinding the journal of the Shaft and OD of rotor/armature. 7. Surface grinding machine. 8. Tool and cutter centre grinding machine (for sharpening of the milling / grinding cutters etc.) 9. Hydraulic press for pressing of armature and stator. 10. Tapping machine. 11. Drilling machine-1 inch 12. Drilling machne ¾ inch 13. Vacuum Pressure Impregnation plant of adequate capacity with pre-heating arrangement and necessary control panel, vacuum pump and compressor to maintain required pressure and temperature.
Page 7 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF 14. Coil winding machine with counter. 15. Armature winding machine with counter. 16. Drying / braking oven with the arrangement air circulation. 17. Spray painting machine 18. Stand-by power supply : Diesel-generating set Minimum 5 KVA capacity. 19. Stabilizer for conducting air-delivery test at stabilzed power supply. 20. Various sizes of gauges viz. Slip gauges, dial gauges, vernier calipers, micrometer etc. 21. Go/no-go gauges employed in process and stage inspection of each machined components/sub-assemblies, assemblies. 22. Blade angle adjustment gauge 23. Welding machine. Essential List of Test Equipments 1. Tachometer 2. Voltmeter 0.5% accuracy (d.c.) 3. Ammeter 0.5% accuracy (d.c.) 4. High voltage tester 5. Digital micro-ohms meter of 0.5% accuracy 6. Stop watch 7. Vane types anemometers 100-mm dial. 8. 500 Volt dc meggar 9. stroboscope
Page 7 of 7 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF 10. Rock well hardness tester. 11. The firm should have up to date calibration certificate for measuring instruments. 12. Noise level measuring meter(db meter) 13. Test panel or conducting power-input test. 14. Wattmeter, multimeter, digital thermometer. 15. Air-delivery test chamber and mounting stand for fixing the fan at required height. 16. Frequency meter 17. Power factor meter.
Page 6 of 9 Effective from 20.06.2003 ANNEXURE H WITH AMENDMENT NO.1 OF 27. Infrastructure (Essential facilities, required for manufacturing quality Railway Carriage Fans) enclosed at (Appendix-1) 28. The following additional clause will be added after clause 19.11.2 20.0 Optional Clauses The following optional clauses are being added for placement orders for carriage fans with improved design features. 20.1 The Blade shall be made of fire retardant Polypropylene material with injection moulding process. It shall have adequate mechanical strength. The blade material shall have the following properties. Grade : FRPP HOMO Polymer chlorinated Deflection temperature under load at 18.5 kg/sq.cm deg.c 60 Flammability UL 94-V0 Tensile strength ASTM D638 mpa 34 Flexural strength ASTM D790 mpa 44 Elongation at break ASTM D 658 28 20.2 Powder coating shall be done on fan body (outside and inside) guard and Blade. The thickness of coating shall be not less than 60 microns. The powder coating is not required for fan blades made of fire retardant poly propylene material. 20.3 The deep drawn design for fan body made from M S Sheet as per RDSO Drg. RDSO/PE/SK/TL/0025 2002 (Rev.0), Alt.2 against Railway Production Units/Railways specific requirements. ***********