Government Of India Ministry Of Railways (iwcce

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Page 1 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 GOVERNMENT OF INDIA MINISTRY OF RAILWAYS DRAFT SPECIFICATION FOR INTEGRATED WAYSTATION CONTROL COMMUNICATION EQUIPMENT (IWCCE) SPECIFICATION NO. RDSO/SPN/TC/70/2007 Revision 0.0 TELECOM DIRECTORATE RESEARCH DESIGNS & STANDARDS ORGANISATION LUCKNOW-226011 Page 2 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 1.0 FOREWORD: 1.1 This draft specification no. RDSO/SPN/TC/70/2007 has been prepared based on the recommendation of the 34th TCSC approved by Railway board vide letter no.2004/Tele/TCM/1 dated 01.06.2007. 1.2 As suggested by members of TCSC, this draft specification is being circulated for comments and suggestions to all the railways/users. On receipt of the same, it will be incorporated in the final draft specification for implementation in the railways. 1.3 In the absence of IRS specification, the procurement may be made as per draft specification. 1.4 This specification requires references to the following standards specifications: SN Specification No. 1. 2. 3. IRS: S-23 IRS: TC-38 IRS: TC-60 4. 5. 6. 7. Description Electrical Signaling and Interlocking Equipment 4-Wire Control Telephone with Way Station Equipment 4W/2W Train Traffic Control Equipment with DTMF Signalling. IS-9000 (Series) Basic Environment Testing Procedure for Electronic and Electrical items. TEC GR/TEL-02/04 Electronic Tone/Pulse Switchable Telephone Instruments. Sept02 IRS: TC-59 Radio Patching Device RDSO/SPN/TL/23/99 48V DC SMPS power plant for Indian Railway Telecom Equipment. Ver. 3 Amendment 1 Wherever reference to any of the above specification appears in this document, it shall be taken as a reference to the latest version of the specification unless the year of issue of the specification is specifically stated. 2.0 SCOPE: 2.1 This specification covers the requirements of Integrated Way Station Control Communication Equipment(IWCCE) which will replace all the 4-W Way Station Equipments(like for Section Control, Deputy Control, Traction Power Control, Engineering control etc.) at a station and will additionally facilitate Intercom Facility amongst Control Telephone Subscribers. 2.2 The system does not cover requirements of external underground cables like PIJF, quad for connection between IWCCE with the telephones. 3.0 OPERATIONAL REQUIREMENTS Page 3 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 3.1 IWCCE shall use the basic protocol of Train Traffic Control Communication intact as defined in IRS : TC 60. General Architecture of IWCCE is at Annexure-I. 3.2 The equipment shall be designed to work with the Control Office Equipment as per IRS : TC 60-93. 3.3 Provision should exists in the IWCCE to connect up to 8(eight) 4-wire Omnibus Control Channels. 3.4 Provision should exists in the IWCCE to connect up to 30 Way Station Control Telephone(Subscribers). Provision should exists to connect upto 6(six) Subscribers each to first two Control Channels and upto 3(three) Subscribers each to remaining six Control Channels. 3.5 Provision should also exists to increase the number of subscribers in a particular Control Channel by utilizing the resources of other unused Control Channels. 3.6 The system should decode both two digit and three digit DTMF code coming from head quarter equipment and generate ring to the desired subscriber. 3.7 The IWCCE shall have a facility to generate ring back tone whenever a ring comes from the Control office. 3.8 For selective calling from Control Office Equipment as per IRS : TC 60-93, a ring back tone should be forwarded towards controller if the desired handset is in on-hook. If the desired subscriber already in off- hook, an acknowledgement tone will be forwarded. For group or general call from control equipment, there should not be any ring back tone towards control equipment, which will make control channel totally noisy. 3.9 The Way Station Control Telephones connected to the IWCCE shall be normal Pulse or Tone switchable Telephone as per TEC Spec. No. TEC GR/TEL-02/04 Sept 02. 3.10 The Telephone shall have a ringing facility with volume control, whenever the controller or any other subscriber dials the code of a telephone. 3.11 The control ring at the telephone shall continue for the period of 15 seconds whenever called and shall get terminated as soon as handset is taken OFF hook. The cadence should be of type 4 sec. ON and 1 sec. OFF. 3.12 A visual indication shall be provided through LED to indicate the incoming ring from control channel. The LED shall glow whenever the ring is received and the same should continue to glow even after the ring terminates and till the subscriber lifts the handset for responding the call. The facility may be provided in a small external box to be placed beside the handset. If the telephone is already in off-hook condition at the time of incoming control call, LED shall start glowing to give indication of incoming call. As soon as the handset is lifted, the control telephone should get connected to the control circuit with the Rx path through but keeping the Tx path disconnected. The Tx of the handset will be enabled either by tapping the cradle switch or by pressing anyone of the key switches on the telephone handset , except # and * switch. 3.13 Page 4 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 3.14 Control call can be diverted, if programmed likewise, to any other telephone under same or different control in case of unattained call or telephone instrument faulty. 3.15 To eliminate the chances of injection of noise from way station control telephones to the control channel, the trans output of the telephone should have ‘Cut-off’ or ‘Enable when Desired’ facility. It can be programmed either through software or through Hardware as per design of the system. 3.16 The system shall have the provision for gain adjustment of 4-Wire Control circuit in both Tx & Rx directions. To get desired level & quality of speech, MUX gain should also be required. 3.17 The IWCCE should support the intercom as well as exchange access facility. The same way station telephone should be used for this purpose when it is free. However, if a control call comes during a local conversation, then the local call should be disconnected and the control call will be extended to the selected subscriber. Local conversation should not use or disturb the omnibus control channel. 3.18 The equipment should have facility to extend standard communication tones like ringing tone, dial tones, ring back tone, number busy tone etc. 3.19 The equipment shall also have the facility to interface at least two analog tie lines like Railway Telephone, BSNL Telephone etc. Subscriber/User connected with this equipment shall have facility to access any of the tie lines as per requirement, in addition to communicate with the controller of the connected 4-W Omnibus Channel. 3.20 In case of Railway or BSNL exchange tie lines (telephone line) to be interfaced by the equipment, the exchange should have tone detection facility. 3.21 If any exchange subscriber wants to dial IWCCE subscriber, it has to first dial exchange number of the particular line connected to the IWCCE to get IWCCS dial tone and then dial subscriber code XY as long as dial tone persists (15 sec.). After this interval, the incoming exchange call should get landed to a particular subscriber if programmed as operator. 3.22 IWCCE should forward a busy tone for about 10 sec. when IWCCE subscriber gets an access to exchange tie line and keeps its handset thereafter. During this interval the tie line remains seized. 3.23 Intercom Facility: The equipment shall have intercom facility. as described in clause no. 3.17. It shall be possible to bar the Intercom & Tie line access facility on a particular telephone through software. Call overriding facility for Controller: Controller shall have overriding priority to call a particular Way Station Telephone even if the subscriber is busy in conversation on intercom or Tie lines. 3.24 3.25 Tie line terminating facility: Page 5 of 12 (i) (ii) Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 It shall be possible to terminate one Railway and one BSNL telephone circuit at all the Way Station equipment having intercom facility for communication of Way Station subscribers to Divisional/other subscribers on Railway/BSNL Network and vice-versa. Provision for tie line bypass directly to the telephone instrument provide on the SM’s table should also be available, in case of equipment shutdown. 3.26 The intercom ring at the telephone shall continue for a period of 40 sec. whenever called and shall get terminated as soon as the handset is taken off-hook. The cadence should be of type 400ms ON, 200ms OFF, 400ms ON and 2 sec. OFF. The visual indication already described in clause no. 4.19 should not glow, in case of unattained local call either in on-hook or off-hook condition. 3.27 Way station subscriber should have programmable exchange priority feature. A priority subscriber can get access to exchange tie line, if the line is engaged by some other low priority subscriber. 3.28 Voice calling from way station telephone to the controller should be available in the system. 3.29 The system shall be compatible to work on any communication media like OFC or Microwave. 3.30 The IWCCE shall be capable of working with -48V± 20% DC Power Supply. Existing -48V DC supply for OFC / Microwave equipments shall be utilized wherever available. 3.31 All the Way Station Control Telephones shall work in tandem with IWCCE and shall not require separate power supply. 3.32 The way station telephone should work on 1200 Ohms. 4.0 TECHNICAL REQUIREMENTS 4.1 System should be housed in a 19” rack mountable and 4U high cabinet made of aluminum of minimum thickness 2 mm should be used for housing the PCBs. The cabinet should be powder coated. 4.2 System Design should be based on high performance 16 bit microcontroller or higher configuration. 4.3 The system should be designed with modular construction with backplane and plug in card with locking facility. External signals may be extended from the backplane through wire-wrap terminal or through any standard connector. Glass expoxy PCB having minimum 1.6mm thickness shall only be used. The PCB shall be coated with epoxy base antifungal varnish to provide protection against dust, humidity, fungal infection and mechanical abuses. The copper cladding thickness shall not be less than 35 microns and shall be suitably tinned. The dimension of PCB shall have a tolerance ±10% of specified value. The PCBs should be coated with anti-fungal conformal coating before dispatch. 4.4 twisted pair cable having a loop resistance of less than Page 6 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 4.5 All ICs should be of industrial grade. Other discrete components should be rated more than 2 times the desired design requirement. Tuning capacitors should be within ±10% tolerance limit. Metal film resistances should have tolerance better than 1%. Components should be procured from reputed and approved sources of the manufacturers and the list should be submitted to RDSO for verification & counter approval. 4.6 The wiring shall be by means of coloured wire, with standard switch board or multistrand PVC insulated wire and shall be capable of carrying the maximum required current of the telephone instrument. The wiring to the components shall be provided with sufficient slack to permit the components to be swung clear of the assembly without any disconnection. 4.7 The driving impedance of each subscriber/way station telephone should be typically 600 ohms. The subscriber interface should be able to handle a maximum loop resistance of 600 ohms without degradation in voice level. 4.8 The design of the system should be such that frequency response shall be within ±3dB in the frequency range of 300Hz to 3400Hz with reference to 1 KHz with output of 0dB across 600Ω load. 4.9 The total harmonic with output 0dBm. 4.10 For faithful decoding of DTMF codes from control channel as well as exchange tie line, the channel should have signal to noise ratio better than 10db. 4.11 For uninterrupted control communication, the two PSU (DC-DC converters) cards shall be provided in the equipment in hot stand by mode and if any one of the PSU card fails, then the Hot Stand By PSU should take over and system should generate an alarm. One PSU card in normal condition shall be able to take care of the full load requirement of the system. 4.12 To minimize downtime of the system, the system should use multiple processor architecture or hot stand by processor architecture. 4.13 The IWCCE shall work on - 48V DC, having working voltage range of -48 V DC +20%. IWCCE at “-48V Power Line” shall be protected with pluggable Surge Protection Devices(SPDs) which consists of combination of varistors/suprressor diodes and GD tube with voltage & current limiting facilities. These SPDs shall have an indication function to indicate the prospective life and failure mode to facilitate the replacement of failed SPDs. This protection at “-48V Power Line” shall be in compliance to IEC 61643-1 and having Nominal Discharge Current of >700 Amp of 8/20 µS, Maximum Discharge Current of >2K Amp of 8/20 µS and Voltage Protection Level of <350V. 4.14 At a terminal station, where both head quarter control equipment and IWCCE are required to be connected on the same control channel, a bridge circuit is required which is generally available in the MUX equipment. distortion shall not exceed 3% at 1KHz across 600Ω Page 7 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 4.15 IWCCE as well as external protection module should be properly earthed. Earthing provided by the Railway having earth resistance less than 1 ohms. 4.16 All the outgoing subscriber lines from integrated way station unit shall have protection module to protect against lightning, surge & transient. 4.17 System shall have a unique station address, which will be hardwired in the system. This will be used during remote access. 4.18 System shall have local RS 232 port through which IWCCE configuration can be downloaded from a laptop. Provision shall also be there to download the configuration from a remote location through a separate 4W omnibus channel dedicated for this purpose for all the IWCCEs in the network. 4.19 Each IWCCE subscriber should be programmed for control number to get an access to its corresponding controller. Intercom and exchange feature to be programmed as well if it is to be enabled. If no program at all for a particular subscriber, it will remain deactivated as a safety measure. 4.20 Flexible way station number programming facility should be available in the system through PC based application software either locally or remotely. To have the facility of remote programming from control test room, separate 4W omnibus control channel will have to be provided by the Railways and a line converter module will have to be procured. However the system software will be provided by the manufacturer including any update. The separate channel provided for this purpose shall have to terminated at each station in the integrated way station unit. 4.21 System shall have two potential free contact outputs, one for service alarm extension and another for equipment shutdown. It can be extended to SM’s room for informing the test room. 4.22 All parameters for the calls should be stored in non-erasable memory of the system, which can be time to time modified locally or remotely as required. 4.23 System should be able to interface with standard 2W DTMF telephone handset (POTS) for giving ring, talk current and hook detection. 4.34 4.25 Subscriber dialing should be based on DTMF signaling. Intercom and Tie lines dial tone shall be available by pressing ‘#’ on DTMF keypad of handset. 4.26 No code should go into the control circuit except the first code dialed from control telephone during control conversation to minimize control noise. 4.27 In case of earth fault to any of the outgoing subscriber line, the subscriber interface shall be temporarily made out of service as a safety measure. Page 8 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 4.28 The system shall be capable of working in non air-conditioned environment having ambient temperature ranging from 0ºC to 50º C and relative humidity up to 95% at 40ºC and storage temperature from -10ºC to +70º C 5.0 TESTS AND PERFORMANCE REQUIREMENT 5.1 Unless otherwise specified, all the tests shall be carried out under prevalent ambient atmospheric conditions. 5.2 5.2.1 Type Test The following shall constitute Type Test: A minimum of two samples of IWCCE are required for type test. These samples shall not form part of supply. a) Visual Inspection (Clause 5.4) b) Applied high voltage test (Clause 5.5) c) Insulation resistance test (Clause 5.6) d) Operation test (Clause 5.7) e) Performance test (Clause 5.8) f) Climatic severity test (Clause 5.9) g) Vibration test (Clause 5.10) 5.3 5.3.1 Acceptance Test. The following shall constitute the acceptance test on IWCCE and shall be carried out as per sampling plan specified in Clause No. 10. a) Visual Inspection (Clause 5.4) b) Applied high voltage test (Clause 5.5) c) Insulation resistance test (Clause 5.6) d) Operation test (Clause 5.7) e) Performance test (Clause 5.8) 5.3.2 Any other tests as required by the inspecting authority to ensure that equipment is in conformity with the requirement of the specification shall also be done. 5.3.3 5.3.4 ROUTINE TEST The manufacturer shall certify that all the tests given in para 5.3.1 have been successfully carried out on all the equipments offered for inspection. He shall produce those tests results at the time of inspection. The manufacturer shall under take auditing of the components/devices for ensuring the reliability. Audit record shall be shown to the inspection authority. 5.4 Visual Inspection Visual inspection shall be carried out as per clause 14.2 of IRS:S-23 to the extent applicable. 5.5 Applied High Voltage Test. The equipment shall with stand without any damage a test voltage of 1KV, applied for a period of one minute, between the body and all the current carrying terminals looped together. Page 9 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 5.6 Insulation Resistance Test The insulation resistance measured with 100V DC between the body and the current carrying terminals looped together shall not be less that 20 mega ohms. 5.7 Operation Test The control office equipment shall be connected to IWCCE and it shall be tested for: (i) Control Call (ii) Local Call (iii) Exchange Call The Operation Test shall be conducted Operation Test Procedure proposed by manufacturer duly reviewed and approved by RDSO/Lucknow. 5.8 5.8.1 Performance Test The Performance Test shall be conducted as per Performance Test Procedure proposed by manufacturer duly reviewed and approved by RDSO/Lucknow. The Performance Test shall be conducted preferably at RDSO/Lucknow, however in case of any difficulty of infrastructure or any other facility at RDSO/Lucknow, the Performance Test may be conducted at Manufacturer’s Premises or in any other mutually agreed Test Laboratory. 5.9 Climatic Test-degree of severity 5.9.1 Dry Heat Test shall be done in two phases-operational and storage. Operational Test shall be done at 55ºC + 3ºC for 16 hrs. and the operation of the equipment shall be tested after completion of the test as per clause no. 5.7. The Storage Test shall be conducted at 70ºC + 2ºC for 16 hrs with a recovery time of 8 hrs. The test shall be conducted as per IS:9000 Part III. Operation of the equipment shall be tested after completion of the test as per Clause 5.7. Damp Heat(study state) : The equipment shall be subjected to 40ºC + 2ºC with RH not less than 93% + -2% for 24 hrs. On completion of the duration of the test the equipment shall be taken out and shall be wiped with dry cloth to remove the condensed water if any from the surface. The equipment shall then be kept in a recovery chamber at 27ºC + 5% RH for 6 hrs and the insulation resistance shall be measured as per clause 5.6. The IR value shall not be less than 10M ohms. The operation of the equipment test shall be done as per clause 5.7. Cold Storage Test shall be done at -10ºC to + 3ºC for 16 Hours with the recovery time of 8 hrs. The test shall be conducted as per IS:9000 Part-II. The operation of the equipment shall be tested as per clause 5.7 after recovery period. 5.9.2 5.9.3 5.10 Vibration Test 5.10.1 The equipment shall be subjected to vibration test as per IS:9000 (Part VIII) (i) Freq. Range : 10Hz to 55 Hz. (ii) Vibration amplitude : 0.35mm iii) Duration of endurance for sweep : 20 sweeps cycles( 10Hz-55Hz-10Hz) iv) No. of axes : 3 coordinate axes. v) Duration at resonant frequency : 30 minutes+/- 1 minutes. 5.11 After completion of climatic and vibration tests the equipment shall be visually inspected to check for any damaged or cracked parts and performance test shall be carried out as per Clause 5.7 Page 10 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 6.0 MANUFACTURE 6.1 The manufacturer shall ensure that it addition to all the provisions of this specification the requirements of other specifications referred to in this specification as far as they are applicable and any specification prescribed by purchaser are fully complied with. 6.2 Workmanship limits and fits insulating materials, electro-magnetic coils, electrical contacts, terminals, wiring, rejection, marking and identification, packing and warranty shall be in accordance with the requirements in IRS: S-23. 6.3 The manufacturer shall have suitable inspection facilities and testing equipment at their works. 6.4 The manufacturer shall provide training to 2 No. Railway Staff per IWCCE, free of cost for one week at his works. 7.0 MANUFACTURER’S IDENTIFICATION 7.1 A metal plate containing the following information shall be firmly secured to the equipment: a) b) c) d) Manufacturer’s Name and Address. Year of manufacture and serial number. IRS Specification No. Indian Railways. 8.0 PACKING 8.1 The equipment shall be so packed as to permit convenient handling and to protect against loss or damage during transit and storage. The following information shall be given on the packing case: a) Name of manufacturer b) Year of manufacture c) Arrow indicating top side. d) Fragile e) Address of consignee. 9.0 INSTRUCTION BOOKS, MEASURING INSTRUMENTS AND WARRANTY. 9.1 The following documents in booklet forms shall be supplied with each equipment:a) Operating instruction manual b) Maintenance instruction and maintenance preventive schedule to be carried out. c) Technical instruction manual giving details of circuit and connection diagrams, values of rating of all components, PCBs wiring etc. 9.2 complete details of the measuring equipment required for servicing shall be provided. 9.3 List of the recommended lifetime spares shall also be provided with the equipment. Page 11 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 9.4 Unless and otherwise agreed between purchaser and manufacturer, the equipment shall have warranty for satisfactory working for a period of one year after installation or two years from the date of purchase, whichever is earlier. 9.5 All the components used in the equipment shall be of high grade quality from reputed manufacturer. 9.6 Data sheet for switches microphone loudspeaker shall be submitted by the manufacturer. 10.0 SAMPLING 10.1 Unless otherwise agreed to by the purchaser and the supplier the double sample plan given below shall be adopted. Lot consisting IWCCE 1 Under 25 25 to 50 51 to 100 101 to 200 201 to 300 301 to 500 of 1st Sample size 2(N1) 3 7 10 13 20 25 2nd Sample Combined size Sample Size 3(N2) 4(N1+N2) 6 9 14 21 20 30 26 39 40 60 50 75 Acceptance number 5(C1) 0 0 0 0 1 1 Rejection Number. 6(C2) 2 3 3 5 5 6 10.2 The number of IWCCE as given in col.2 shall first be selected and subjected to the acceptance test. If in the first sample, the number of defective IWCCE that is those falling in one or more acceptance tests is less than/equal to the corresponding number (C1) given in Col 5. The lot shall be considered as conforming to the requirements of the acceptance test If the number of defective IWCCE in the first sample is greater than or equal to the rejection number given in Col 6, the lot shall be considered as not conforming to the requirement of the acceptance test. If number of defective IWCCE in the first sample lies between (C1) and (C2) a second sample of size (N2) as given in Col 3 shall be selected and subjected to acceptance test. If in the combined sample, the number of defective IWCCE is less than (C2) the lot shall be considered as conforming to the requirements of acceptance test. 10.3 The sample shall be selected at random from at least 10% of the packages for random selection of packages, all the packages in the lot shall be managed in a serial order and every ‘t’ the package shall be selected until the requisite number of packages is obtained. ‘t’ being the integral part of (Total number of packages in the list/Total number of packages to be selected). Page 12 of 12 Effective from RDSO/SPN/TC/ 70 /2007 Revision 0.0 ANNEXURE-I GENERAL ARCHITECTURE FOR IWCCE REPEATER STN1 REPEATER STN2 EQUIPMENT ROOM EQUIPMENT ROOM OFC OPTI MUX DI MUX OPTI MUX 4W CONTROL 4W VOICE CHANNEL LINE DRIVER RS232 LOCAL EXCHANGE (OPTIONAL) RAILWAY EXCHANGE DI MUX 2W EXNG OPTI MUX NMS - 48 V 2W IWCCE DI MUX OPTI MUX 4W CONTROL LOCAL EXCHANGE (OPTIONAL) TERMINAL STN 2W EXNG OPTI MUX NMS - 48 V 2W IWCCE PC HEAD QUARTER EQUIPMENT 2W CABLE IWCCE MANAGEMENT SOFTWARE 2W TELEPHONE 1 2 3 …30… 30… 41 42 1 2 3 …30… 30…41 42