GOVERNMENT OF INDIA (MINISTRY OF RAILWAYS) RESEARCH ...

Page 1 of 25 RDSO/PE/SPEC/EMU/0065 (Rev. 04) August, 2021

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(ED/PS&EMU)

GOVERNMENT OF INDIA (MINISTRY OF RAILWAYS)

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR LUCKNOW – 226011

SPECIFICATION

FOR LED BASED HEAD CODE, GPS BASED PASSENGER INFORMATION, PUBLIC ADDRESS, DRIVER-GUARD COMMUNICATION

AND EMERGENCY TALK BACK SYSTEM FOR EMUs / MEMUs

S.No. Month / Year of issue Revision / Amendment

Page No.

Reason for Amendment

1 March 2005 Rev 00 -- First Issue

2 Feb 2008 Rev 01 -- Inclusion of AC/DC EMU & MEMU head code and comments of railways

3 April 2010 Rev 02 -- Inclusion of GPS based Passenger Information System (PIS) and title of the specification has been changed

4 June 2010 Amend. 01

10 Correction in viewing angle and lens of LEDs in Clause no. 5.4.7

5 March 2011 Rev 03 Change of communication between coaches through Train line jumper in place of RF communication, inclusion of display of direction of platform and incorporation of comments as per the response of EOI and comments on the draft specification.

6 August 2021 Rev. 04 Technical requirement of Public Address system, driver-guard communication with recording facility and emergency talk back system has been incorporated as per Railway Board guidelines. Title of the specification has been modified accordingly.

SPECIFICATION NO. RDSO/PE/SPEC/EMU/0065 (Rev. 04) – August’ 2021

APPROVED BY

PED (PS & EMU)


Prepared By

(SSE/PS & EMU)

Checked By

(ED/PS&EMU)

CONTENTS

Clause No.

DESCRIPTION Page No.

1.0 OBJECTIVE

2.0 SYSTEM OVERVIEW

3.0 SCOPE OF SUPPLY

4.0 ENVIRONMENTAL CONDITIONS

5.0 TECHNICAL REQUIREMENTS

6.0 SOFTWARE REQUIREMENTS

7.0 HARDWARE REQUREMENTS

8.0 BATCH TESTING OF LED’s

9.0 GENERAL DESIGN REQUIREMENTS

10.0 INSPECTION AND TESTING

11.0 TRAINING

12.0 MARKING


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SPECIFICATION OF LED BASED HEAD CODE, GPS BASED PASSENGER INFORMATION AND PUBLIC ADDRESS SYSTEM (PIS) FOR EMUs / MEMUs:

1.0 OBJECTIVE:

On Indian Railway the suburban services in the metropolitan cities of Kolkata, Mumbai, Delhi, Chennai and Secunderabad are being provided by large number of EMU (Electrical Multiple Units) trains. On mainline sections intercity passenger services are being provided by Mainline EMU (MEMUs). In both EMUs and MEMUs at present the train number and destination are displayed through head codes (Destination boards) provided above the lookout glass in front of the train and are made of tin plates/ cloth scroll, which the motorman replaces or rotates to indicate the destination of the train. These destination boards are not very clear or readable to the passengers from a distance. Also changing of the destination boards is cumbersome and has to be done manually by the motorman. In both EMUs and MEMUs at present an information system to inform the passengers about the next halting station and other passenger related information is not provided. Through this specification, it is proposed to provide a programmed LED based head code to replace the existing head code, as proposed in the 14th EMU MSG meeting and provide GPS based Passenger Information System and in-coach display systems to inform the passengers for the next halting station and other passenger safety related information as decided in the 18th MSG meeting. These will give better visibility and readability to the passengers, as well as allow the destination in the head code to be changed easily by the motorman whenever required through the program. Also provision of Driver-Guard communication with recording facility and provision of ETBs as per Railway Board instructions along with updated passenger address (PA) system has been included. It shall be microprocessor controlled and shall have the facility of programming the destination stations and other important information as per time table based on train number. The complete timetable can be fed in the system and motorman has to only feed the train number to operate head code and Passenger Information System. This specification covers the requirement of design construction, pre-wiring, performance, tests, supply, commissioning and after sales service of LED based Head Code,GPS based passenger Information,Public address System, Driver-Guard Communication and Emergency Talk Back System(ETB) for EMU/MEMU Rolling Stock of Indian Railways These Head code,GPS based Passenger Information, Public address System, Driver-Guard Communication and Emergency Talk Back(ETB) System are proposed to be provided on EMUs/MEMUs which are in operation in the different sections of Indian Railways.

2.0 SYSTEM OVERVIEW


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2.1 The leading and trailing driving coaches shall have GPS antenna, microphone, one set of two Head Code units and a Driver Desk Console (DDC) combined with Train Control Unit (TCU) consisting of CPU and GPS receiver to facilitate change in route/destination of the train by the motorman and necessary power supply for these modules. All the coaches including leading and trailing driving coaches shall have 2 nos. of In-Coach double-sided Display units, Coach control unit(CCU) cum Audio Announcement Unit (AAU), Audio Amplifier Unit along with necessary power supply unit, 4 nos. (Upgradeable to 6) of Loud Speakers and Emergency talkback system(ETB). The head code unit shall have manual override facility to set the display of information in case of failure of DDC/TCU and/or the communication between DDC/TCU and Head code.

2.2 The system shall be designed in such a way that once the route/destination set by the

motorman in the leading/trailing driving coach through Driver Desk Console (DDC), the display units of all coaches shall displays the details of route as given in clause no. 2.5 through Train Control Unit. This communication should be established through wired communication i.e train line jumpers to all the coaches. This will enable the selection of the route for proper display of the destination in the head code units, the selection between fast trains, slow trains and ladies special etc.. System software shall be an embedded part of the CPU fitted in the Train Control Unit which shall also incorporate train route data base of defined route maps.

2.3 To have interchangeability of coaches provided with the passenger information system

of different manufacturers, common train line jumpers and communication protocol shall be used for communication between coaches. The display boards (in - coach and head code) shall be designed in such a way that it is also interchangeable across the different manufacturers. The design of the system shall be such that it does not require more than three train line wires (including one train line wire for establishing common mode reference) for establishing the communication between coaches.

2.4 The entire system shall be designed in such a way that the failure of one equipment of

the system shall not result in to the failure of entire system. The equipments of head code,PIS system, PA system, Driver-Guard communication and ETB system shall be connected through the train line wire in such a way that isolation or removal of any equipment in one coach shall not result into failure of display and announcement in other coaches.

2.5 The display unit provided inside the coach shall display the welcome and farewell

messages, name of station (where the train is presently standing), direction of platform, next halting station, current time, and information related to passenger safety. The system shall be capable of synchronously triggering audio announcement of the above messages through the speakers provided in the coaches.

2.6 The GPS receiver module shall receive the co-ordinates (longitude and latitude)

information of the current location from GPS satellites through roof mounted GPS antenna. The information is transmitted to the DDC/TCU which in turn decodes this position information received and fetches the next station location & name and the direction of platform from the stored data. if positional information is not available from GPS system, messages and announcements shall be triggered based on distance travelled system.


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2.7 The Coach control unit(CCU) cum Audio Announcement Unit (AAU) receives coded short massage from DDC /TCU combined unit and concatenates the required voice segment. Coach control unit(CCU) cum AAU shall have all voice segments stored on it. A voice signal is generated and fed into the amplifier unit and announcement is made on the speakers provided in the coaches. The in-coach display devices shall receive the same coded massage and shall generate the requisite message for display.

2.8 The power source for the Head code,PIS equipment PA system, Driver-Guard

communication and ETB system shall be 110V DC supply derived from Static battery charger/Control Batteries provided in motor coaches. Each battery unit will cater for 3 coach sets/4 coach set (called as one basic unit) consisting of one motor coach and two/three trailer coaches.

2.9 The LED based head code units shall be mounted in the front of the leading and trailing

driving coaches of the EMU/MEMU train with a motorman interface for selection of the route on which the train is to ply.

3.0 SCOPE OF SUPPLY:

The scope of supply covers design, development and commissioning of complete set of LED based head code,GPS based Passenger information,Public address system, Driver-Guard communication and ETB system of EMU/MEMU as per technical requirements laid down in clause 5.0 of this specification.

3.1 MANUFACTURER’S RESPONSIBILITY:

S.No. Description Qty

1 Set consisting two nos. Head Code with one Driver Desk Console (DDC) unit combined with Train Control Unit ( TCU ) consisting of CPU and GPS Receiver,

1 set each for leading and trailing driving coaches.

2 Permanently fixed all weather GPS Antenna along with Antitheft Cover

1 no. each for leading and trailing driving coach.

3 In-Coach Display unit 2 nos. per coach.

4 Loud Speakers 4 nos. per coach.

5 Interconnecting Cables between train line jumper Board to In-Coach Displays , Audio Announcement Unit , Audio Amplifier and speakers

1 set per coach.

6 Coach control unit(CCU) cum Audio Announcement Unit, Audio Amplifier Unit along with Power Supply Unit

1 set per coach

7 All Interconnecting Cables for DDC and TCU combined unit, Head code, GPS antenna and train line jumper board

1 set per leading and trailing driving coach.

8 Microphone 1 set each for leading and trailing driving coaches

9 Emergency talk back unit(ETB) 4 nos. per coach (for designated coaches only)


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The manufacturer’s responsibility will extend to the following:

3.1.1 The manufacturer shall supply detailed instructions for proper installation of the equipment on coaches. For this purpose, the manufacturer shall depute his engineers/supervisors to purchaser site during installation of the equipment in the coaches for first rake installation.

3.1.2 The manufacturer shall be responsible for commissioning, testing and simulated trials of

the equipment in service and depute team of engineers/supervisors for this purpose during developmental stage for first rake installation.

3.1.3 The manufacturer shall arrange required instrumentation and carry out detailed tests,

simulated and commissioning trials jointly with RDSO/Railways for type approval. 3.1.4 The manufacturer will supply the user's manual for maintenance and trouble shooting. 3.1.5 For the purpose of technical decisions on improvements/modifications etc. on

equipment, the final authority from the purchaser’s side will be RDSO. 3.1.6 Consumable such as electrical energy for testing and commissioning of the system will

be provided by the purchaser free of cost. 3.2 INFRINGEMENT OF PATENT RIGHT:

Indian railways shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, components used in design, development and manufacturing equipments and any other factor, which may cause such dispute. The responsibility to settle any issue lies with the manufacturer.

3.3 SIMULATED TEST:

The equipments shall be subjected to simulated test for all the EMU/MEMU train routes of one Zonal Railway as per time table. The manufacturer has to demonstrate the complete working of the system. The test setup for simulated test shall be carried out by the manufacturer.

3.4 COMMISSIONING TRIAL:

The commissioning trials shall be done jointly with railways for the correct working of the entire system. The manufacturer has to demonstrate the complete working of the system during commissioning trial. Commissioning of the equipments for trials shall be carried out by the manufacturer.

3.5 GOVERNING SPECIFICATIONS

Manufacture shall have the following standards and follow in compliance of this specification:


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Standard/ Specification

Description.

IEC 611084

Equipment-Performance standards, Methods of Global Positioning system (GPS)- Receiver

IEC 60571 Electronic equipment used on rail vehicles

RDSO Specification no ELRS/SPEC/ SI/0015 Oct 2001

Reliability of electronics used in rolling stock application

IEC 61373 Shock and Vibration test

IEC 61000 EMC compatibility

IEC 60529 Degree of protection provided by enclosures(IP code)

IEC 60068 Environmental testing

STR No. RDSO / PE / STR / AC / 0032 ( Rev.0) or latest

Schedule of technical requirement (STR) for Passenger Information System for AC and Non AC Coaches of Indian Railways.

4.0 ENVIRONMENTAL CONDITIOINS: 4.1 The equipment shall function satisfactorily under following conditions.

Altitude : Up to an altitude of 2500 meters above Mean Sea level

Ambient temperature : - 4 to +55C (temperature of stationary rake under sun may go as high as high as 70ºC) Relative Humidity : 100%

Ambient Condition : In conditions of dust, dirt, mist, torrential rain, heavy storms with thunder and lightening likely to generate electrical disturbances, presence of oil vapours and radiant heat etc., to which the rolling stock is normally exposed in service on Indian Railways, EMUs / MEMUs also run in saline, salty mist and corrosive atmosphere in coastal areas. The maximum values of related parameters are as under (a) pH value : 8.5 Max. (b) Sulphate : 7 mg/litre (c) Concentration of chlorine : 6 mg/litre Max. (d) Conductivity : 130 micro-siemens/ cm Max. (e) Dust concentration : up to 1.6 mg/m3

4.2 VIBRATION & SHOCK:


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The equipment shall be designed to withstand without damage, vibration and shock as generally encountered in the service as specified below: (i) Max. Vertical acceleration : 3.0 g. (ii) Max. Longitudinal acceleration : 3.0 g. (iii) Max. Transverse acceleration : 3.0 g.

4.3 ELECTROMAGNETIC INTERFERENCE:

i) High degree of electromagnetic interference is expected in the EMU/MEMU motor coaches. The system shall be interference free from electromagnetic interference as well as interference from communication system between motorman-guard, control and public address system. The equipment shall be tested as per IEC–61000 for EMC & EMI compatibility.

ii) Signals generated by the system / equipment shall not cause interference to other

signal and telecommunication system on the EMUs/MEMUs. 5.0 TECHNICAL REQUIREMENTS 5.1 EQUIPMENT VOLTAGE

The entire equipment will be supplied with power from the existing battery set in EMUs / MEMUs. The nominal voltage shall be 110V DC and voltage may vary between 90 V to 135 V DC. The equipment shall perform satisfactorily under this voltage variation. Care should also be taken for the surges in the TCU/DDC. To prevent deep discharge of batteries all systems shall cut off if the DC voltage falls below 85V and reactivate at 100V or any settable parameter greater than 85V.

5.2 COMBINED UNIT OF DDC AND TCU

The combined unit of DDC and TCU is to be mounted on the driver’s desk along with the existing cab equipment. The maximum dimension of combined unit of DDC and TCU shall be 250mm (L) x 120mm (H) x 75mm (D).

5.2.1 DRIVER DESK CONSOLE (DDC) 5.2.1.1 The driver desk console(DDC) mounted inside DDC and TCU combined unit, shall have

a 20x4 backlit alphanumeric (English) LCD display with character height of 5 mm (minimum), a 12(3x4) key alphanumeric push button keypad and 5 key menu surfing feather touch Keypad etc. for user interface and dedicated buttons for selection of PA system, Train radio, Driver-Guard communication, ETB etc.

5.2.1.2 The motorman will enter the train number through the alphanumeric keypad. The DDC

shall refer the stored time table and provide suitable message to the motorman about the status of the system. The DDC shall be configured to the particular route if the route is available in the memory.

5.2.1.3 Upon route selection on the DDC, TCU and the Head Code Units of leading and trailing

driving coaches shall be configured. Provision should be there for entering train number


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in alphanumeric character as per requirement of individual railways. Railways shall be consulted before providing the same.

5.2.1.4 A 20x4 backlit alphanumeric (English) LCD display provided in the combined unit of DDC/TCU shall display the following information to the motorman:

Train No. (alphanumeric 6 Characters)

Originating station code (4 characters)

Destination station code (4 characters)

Next station code (4 characters)

Slow / Fast (1 character)

Real time (HH:MM:SS)

Total nos. of cars in the train (6/8/9/12/16/18/20 – 2 digits)

Status of ETB

5.2.1.5 The DDC shall have backlit type “Left” and “Right” platform selection button, through which the guard shall be able to control the display and announcement of the information regarding the direction of the platform on the halting station. It shall also be possible for the guard to stop the pre fed direction announcement and display through a separate input. This selection shall automatically get reset after each halting station. In case of no selection in DDC by the guard the announcement and display of direction of platform should be according to normal route which will be pre fed for each train no. and for each station along with the time table information. The arrangement shall have to be made for feeding information.

5.2.2 TRAIN CONTROL UNIT (TCU) 5.2.2.1 The train control units shall be mounted inside DDC/TCU combined unit in driving cab of

leading and trailing driving coaches and shall work in tandem so that one becomes master unit and other becomes slave unit. If the master unit fails the slave unit shall take over all the control of the master unit and system shall work normally. The TCU shall consist of Coach Processor Unit (CPU) with GPS receiver

5.2.2.2 COACH PROCESSOR UNIT (CPU) 5.2.2.2.1 CPU shall be a Microprocessor Based system with requisite embedded software and

having the following features:

a. A minimum 16-bit microprocessor based control unit. b. GPS Receiver with following specifications:

L1 frequency, with C/A code with 12 (or higher) independent tracking channels.

NMEA-0183 compatible output.

At least 1Hz update rate

Reacquisition time <250 milli seconds.

Cold start better than 35 seconds.

Hot start better than 5 seconds.

Antenna-external, active with built in antenna bias circuitry.

Antenna short circuit protection.


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Built in Antenna Supervisory Circuit for determination of antenna open/short state.

Permanently fixed all weather GPS Antenna along with Antitheft Cover.

Built-in Non-Volatile RTC with battery backup.

c. At least 8 MB (expandable to 24MB) of non-volatile on-board memory for storing the route related data and for messages to be displayed on the display panel,

d. Adequate RAM (minimum 64 KB) for system functioning. e. USB 2.0(Type ‘A’) compliant port for interfacing with a USB data transfer module

for download and upload of data from the unit. f. Interface for all the coaches through train line jumper wire.

5.2.2.2.2 The CPU fitted in the leading driving coaches shall act as the master and CPU of the trailing coach shall act as a slave and be configured by the leading driving coach’s CPU through train line jumpers.

5.2.2.2.3 It shall store route related data for multiple train routes. CPU shall provide a means to

select the train route on which the coach is to operate with the help of Keypad of DDC/TCU combined unit. The keys shall be provided on the Master Unit’s enclosure. The CPU shall generally provide the following menu options:

Level 1: For route selection, selection of up and down menu etc.

Level 2: For servicing functions.

5.2.2.2.4 It will also be able to store 256 characters x 20 slogans/safety messages for at least 3 languages.

5.2.2.2.5 It shall provide a means to select Up and Down journey, using keypad of DDC/TCU

combined unit or automatically using GPS data. 5.2.2.2.6 The route data pertaining to various routes shall be easily updatable using the Data

Transfer Device or Laptop. 5.2.2.2.7 CPU shall process the GPS data (Latitude, Longitude, Speed and Time) and perform

calculation pertinent to system functioning. The CPU shall detect its presence on the route and automatically indicate the next halting station, direction of platform and periodically transmit them over the RS 485 interface/train line wire to the display devices for display.

5.2.2.2.8 The CPU shall also generate voice messages as per the clause no. 2.5 using the

Coach control unit(CCU) cum Audio Announcement Unit (AAU) and Audio Amplifier provided in the coaches.

5.2.2.2.9 It shall also be capable of controlling up to 4 displays fitted outside the coach in future

with similar interface (physical and communication protocol) as of in-coach display. These displays may need to display different information from that of in-coach display. The information needed to be displayed shall be provided as and when these ports are brought to service.


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5.2.2.2.10 The CPU shall be capable of logging trip related data consisting of station name and date and time of arrival for the last 10 journeys in a FIFO order. The same shall be downloadable using the Data Transfer Device.

5.2.2.3 An active all weather GPS Antenna suitable for the GPS receiver shall be permanently

fixed on the roof of leading and trailing driving coach and shall be provided with an anti-theft cover. It shall be connected to the GPS receiver in the TCU.

Following additional facilities also to be implemented.

5.2.2.4 Driver-Guard Communication: 5.2.2.4.1 Driver-guard or cab–cab communication between two driver’s cabs on the train. The

PIS shall include provision for the announcements to be made remotely by train controllers, however, the purchaser will provide suitable communication facilities. There should be provision of recording the voice of driver & Guard (both) in the flash memory (for a duration of at least 24 hours) and in crash protected memory (for a duration of at least 10 mins). The system shall be designed and constructed to ensure the integrity of the recorded data and the ability to extract data following an incident and it shall be tested in accordance with a recognized international standard such as the UK Railway Group Standard GM/RT 2472. Microphone provided on the driver desk shall be made use of, for this purpose.

5.2.2.4.2 The communication shall be in full duplex mode and multiplexed with suitable

measures to prevent acoustic feedback. 5.2.2.4.3 The communication between Driver and Guard can be initiated by either of the two. 5.2.2.4.4 To initiate communication, the Driver (or guard) shall switch on the call

cabin switch, which shall connect an alert tone for a brief period to the loud speaker provided in the Guard's (or Driver) cabin, at the other end.

5.2.2.4.5 On hearing the tone the Guard (or Driver) shall acknowledge the receipt of the alert

tone by operating his call cabin switch. Now, both can communicate with each other through the directional microphone mounted in the announcing console, after switching the same. The call cabin switch shall be normalized by both after the conversation.

5.2.2.4.6 When the announcement is made by a Driver (Guard) the loud speaker in that cabin

gets muted automatically. But the announcement can be heard by Guard (Driver) in the other cabin.

5.2.2.4.7 The microphone used by the driver shall be common for all voice modes and priority

shall be allocated to various modes. 5.2.2.5 Public Address System: 5.2.2.5.1The Train shall provide a public address (PA) facility so that the Train Driver /Guard

can make announcement to the passengers from driving / non-driving cab. Microphone


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needs to be vandal proof. However, option of overriding facility shall also be made available to crew.

5.2.2.5.2Public Address announcements or playing of taped information by the driver &

connectivity of the public address system of the train with the announcements made by train controller through Train Monitoring System installed by respective user Railways.

5.2.2.5.3 The microphone used by the driver shall be common for all voice modes and priority

shall be allocated to various modes. 5.2.2.5.4 The PA intercom system shall be controlled by the keys in the driver’s dashboard. The

driver shall have the facility of adjusting the volume level from a minimum to maximum level by suitable mode provided in driver’s dashboard.

5.2.2.5.5 The public address system shall be acoustically designed and provided with active

noise control to reduce the unwanted sound. The microphone to be used for public address/announcement shall have high dynamic noise cancellation feature. The Supplier shall submit the details of the system at the design stage. The PA system shall have automatic continuous variable volume control, based on Car background noise level.

5.2.2.5.6 Voice announcements and text messages for the displays shall be pre-recorded and

configured into the system using the “off line” speech and route data base editor. Messages, audio or visual or both shall be in the Hindi, English and regional language. The hardware and dedicated software etc. for editing and modifying the speech and route database shall be supplied.

5.2.2.6 Microphone: 5.2.2.6.1 The microphone shall have a dynamic unidirectional cartridge with following

characteristics:

Output between 2 and 2.5mV/ Pascal sound pressure

Frequency response at least 100Hz - 10,000Hz

Impedance 600 ohm +20% / -20%, at 1 KHz 5.2.2.6.2 The microphone shall have a flexible metal gooseneck mounted securely on an

aluminum die cast base. 5.2.2.6.3 The flexible portion of the gooseneck shall have a length of 150 mm or more. 5.2.2.6.4 The aluminum die cast base of the microphone shall have two holes for mounting the

base to a table or wall. 5.2.2.6.5 The microphone shall be provided with an arrangement for switching it ON and OFF. 5.2.2.6.6 The microphone shall have an audio output through a permanently fixed cable of

minimum length 3000 mm. The cable shall have a 3 pin MXLR connector at one end for connecting it to an amplifier.

5.3 HEAD CODE (FRONT AND REAR END DISPLAY UNIT)


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5.3.1 Two LED display unit each shall be provided at the front end of each driving coach (leading and trailing) above the lookout glass to display the train no. (Alphanumeric 6 character), name of originating station, name of destination station, total no. of cars (8/9/12/15/16/18/20 etc.), slow/fast, handicap symbol along with coach location, Ladies special etc. in English, Hindi and Regional language displayed still type alternatively. The provision should be available to display route along with destination station like (via xyz.) as per the railway requirement and display of “Empty rake to car shed” in EMUs / MEMUs.

5.3.2 The head code after receiving the signal from the DDC/TCU, shall display the

information as per the clause no. 5.3.1. In case of failure of communication with DDC/TCU or failure of DCC/TCU the head code shall work on manual mode whereby it displays the information entered through the keyboard provided on the back of display board.

5.3.3 The colour of LEDs of head code shall not be affected from change in frequency,

current, voltage, sunlight and worst weather conditions and LEDs taken for manufacture of on head code shall be from the same batch so as to avoid the intensity difference in the Head Code.

5.3.4 The head code shall employ solid-state circuit whereby each LED shall be constant

current driven. 5.3.5 The circuit shall also have a controlled in-rush current for the LEDs to ensure their

longevity and prevent premature failure. 5.3.6 LEDs used in the head code shall be of high performance quality. Firm shall use only

Broadcom/Nichia/ Osram/ Seoul Semiconductor/CREE/Everlight Electronics make LED or any other make with prior approval of RDSO. The maximum junction temperature of LED shall not be less than 100ºC and epoxy use in the LED shall have UV inhibitors.

5.3.7 The head code shall meet the following requirements

Overall dimensions 1075mm(L) X 180mm(H) X 90mm(D) (max)- for each display Unit

Enclosure type

1.6 mm Aluminum Sheet with Powder coating and with tinted toughened glass front cover

Powder Coating Black, Texture (Optional colours may be used by Railways). Led Matrix 128(Cols) x 16(Rows) LED Pitch 8 mm Gap between the characters

1 Col.

Communication RS 485 (with the DDC/TCU ) (Protected against surges, wrong connections)

Manual Selection of stations

Through Alpha-numeric Keypad and 2X16 LCD display provided at the back of the display board

Operating Voltage 90 - 135 V DC Intensity Adjustment Automatic (electronic sensor control) Visibility

50 meters (minimum), when head code is facing sun in bright day light.


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5.3.8 The Specification of LED used shall generally be as under:

Colour of LED Amber Type SMD Wavelength (nm) 590+/-10nm Viewing angle 60 deg(minimum) Intensity 1000 mcd (minimum)

5.4 Coach control unit (CCU) cum AUDIO ANNOUNCEMENT UNIT (AAU) AND AUDIO

AMPLIFIER 5.4.1 The Coach control unit (CCU) cum Audio Announcement Unit (AAU) and Audio Amplifier

shall be provided in each coach. 5.4.2 Coach control unit(CCU) cum AAU shall be based on Solid State Technology. 5.4.3 All voice segments shall be compressed prior to transmission / uploading to the Coach

control unit(CCU) cum AAU in a compressed digital format with at least 1:8 data compression to optimize the memory requirements.

5.4.4 General voice segments in Hindi, English and regional language like “Dear

Passengers,”, “This is for your kind attention please” shall be stored on the Coach control unit(CCU) cum AAU itself.

5.4.5 The Coach control unit(CCU) cum AAU shall use non-volatile memory for storing the

voice messages. 5.4.6 The Coach control unit(CCU) cum AAU shall receive announcement triggers from the

DDC and TCU combined unit and generate the requisite voice messages after concatenating various voice segments stored in the Coach control unit(CCU) cum AAU memory.

5.4.7 The audio output port shall be capable of being connected to optimally powered audio

amplifier fitted in the coaches for relaying the messages to the speakers installed inside the coaches. In leading and trailing driving coaches, in addition to the speakers installed in the passenger Area, the amplifier output shall drive the one speaker fitted in the driver cab. The amplifier output shall be automated sound level control.

5.4.8 An auxiliary speaker shall also be provided for testing the functioning of the Coach

control unit(CCU) cum AAU. 5.4.9 The speaker of 6 watt r.m.s. rating of reputed make like Philips, Ahuja or any other make

with prior approval of RDSO shall be used duly fixing it on a base plate. The base plate shall be fixed to the roof panel or the duct with proper size of screw. There shall be an internal short circuit protection at speakers so as to isolate speakers if it is shorted.

5.4.10 The amplifier should be able to drive four 6 watt r.m.s. speakers (upgradeable to 6

speakers) in a coach. The Amplifier shall be suitably designed for automatic volume control. The automatic volume control should be at +10 db compared to the outside


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noise and shall be 94 db (max.). The speakers should be separated into two groups and

each audio line should be supplied by its own amplifier. 5.4.11 Necessary MCB’s / Safety devices for power supply distribution to various equipments

shall be provided in all the coaches. 5.5 IN-COACH DISPLAY UNIT 5.5.1 In-Coach display units shall be mounted in gangway either with coach ceiling or wall

above doorway and shall display visual information to the train passengers. 5.5.2 The LED in-Coach Display Units shall meet the following requirements

16 bit Microprocessor based controlled unit

Data communication via RS-485 data bus/Train line wire

Software controlled multiplexed data for LED driving

Multilingual (Hindi, English and regional language ) alphanumeric display for journey messages

Display size: 16 x 128 SMD type LED at 5 mm pitch.

Display Area 640mm X 80mm and max character - height of 80mm.

Enclosure and fixing to meet vehicle interior requirements

Enclosure Dimensions: 680 mm (L) x135 mm (H) X 80mm (D) (max.)

Tinted toughened glass screen to protect and enhance the contrast ratio.

The visibility shall be 20 meter (minimum) in bright day light.

5.5.3 In case a Display module develops a defect it shall be possible to change it without any need of soldering or de-soldering or change in configuration.

5.5.4 The system shall have SMPS power Supply operating on 90V to 135 DC power supply.

DC supply shall be from 110V DC battery in coaches.

5.5.5 The In-Coach display Units shall display following types of messages in alternately scrolling / fixed mode.

Welcome message

Current time

Current station(when the train is standing on the station)

Next halting station

Slogan for passenger safety

Direction of platform

5.5.6 The In-coach Display units shall have an RS485 Communication/Train line wire for interfacing with the DDC and TCU combined unit through train line wire.

5.5.7 The information on display units shall be displayed in turn in English, Hindi and in

regional language of state (as required by the purchaser). All fonts shall be implemented using True Type Font in the display panel itself.

5.5.8 The display unit shall have a facility for auto-dimming during night hours using GPS time.


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5.5.9 The Specification of the LED used shall generally be as under.

LED Colour Amber

LED type SMD

LED size 3.2mm x 2.8mm or similar

Peak Wavelength 590 ± 10nm

Intensity @ 20mA 63mcd to 100mcd

Viewing Angle 120º(minimum)

Operating Temperature -25ºC to 85ºC

Firm shall use only Broadcom/Nichia/Osram/Seoul Semiconductor/CREE/Everlight

Electronics or any other make with prior approval of RDSO. 5.6 Emergency talk back unit:

5.6.1 Few designated coaches as per latest guidelines of Railway Board in EMUs/MEMUs

shall have the provision of talk back. Emergency buttons and talk back phones shall be located near the doors and gangways. Once pressed/operated , it shall be possible for the passenger to communicate with the Train Driver / Guard. Four ETBs (Two each on physically independent channels) shall be provided per coach. If more than one emergency device has been operated, each demand shall be independently acknowledged, and alarms shall be stored, displayed and answered sequentially. Provision shall be there for voice recording of the conversations with GPS stamping. The CCTV camera of the coach shall focus on the ETB area during the conversation. LED indication (engaged or free) at the passenger end shall communicate the status of ETBs.

5.6.2 TCU panel in the Driver/Guard cab shall have the facility to allow centralized downloading

of the recording (with minimum 30 days audio conversation data) by nominated staff through laptop/exchange of removable media. In case of failure of Master TCU unit, the recording data shall be downloadable from other(slave) TCU unit without the loss of any recording data. Complete Emergency Talk Back system shall provide encrypted and secured audio recording for evidence purposes and user authentication to protect data integrity. Auto Start/Stop functionality of audio recording should be synchronized with

activation of Emergency Talk Back Unit.

5.6.3 There shall be provision of two lamps (one on each side) outside the coaches equipped

with ETB unit to indicate the location of activated ETB. 5.6.4 The communication shall be in full duplex mode. 5.7 All the cables of PIS system shall be conforming to international standards for fire

retardant, fire survival characteristics. Fire survival cables according to EN 50200 shall be used for PA/PIS, ETB circuit, for their continued functioning to the extent possible in the event of fire. Survivable duration classification of PH30 (30 minutes) or higher shall be suitable.

5.8 Audio announcement priority will be as follows:


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1. The first priority will be PA from train radio. 2. The second priority will be Passenger Address system. 3. The third priority will be driver-guard communication. 4. The fourth priority will be Journey information messages

5.9 COMMUNICATION LINE AND INTERFACING 5.9.1 The communication between all the coaches of EMU/MEMU train shall be through Train

line wire (To be decided in consultation with railways). Protection should be provided against heavy electrical surges & line capacitance.

6.0 SOFTWARE REQUIRMENTS 6.1 Software

Setup files and software used in the system on a CD.

Control flow chart and algorithm for the control logic.

Operating manual of the software.

External facility to modify the display program through handheld unit/PC.

External facility to change parameters, if required in future, through handheld terminal/PC.

6.2 The system shall be user friendly to the maximum extent so that addition and alterations

can be done by the Railway Engineer without the help of manufacturer and programmer.

DDC & TCU

Head Code

DDC & TCU

Head Code

In- Coach Display, CCU cum AAU, Audio Amplifier,ETB & Speakers of Coaches

In- Coach Display, CCU cum AAU, Audio Amplifier,ETB & Speakers of Coaches

Coach to Coach Communication Layout.

Train Line Jumper Wire

FIGURE-1 Driver Cab CabCab

Guard Cab

GPS

Antenna

MIC MIC

GPS Antenna


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6.3 The system has to provide selection mechanism for the display, language of display i.e. Hindi, English and Regional or all three.

7.0 HARDWARE REQUIREMENTS 7.1 The manufacturer will submit detailed design manual for the system containing

following details:-

The detail functioning of each card.

Testing procedure of each card.

Circuit diagram & PCB layout.

Gerber files, indexing layout.

Write up on the working of head code with GPS based Passenger Information and public address system.

Operating and maintenance manual

7.2 The power supply cable used should be of Electron-Beam cross-linked cable type or equivalent rated PTFE cables of Size 1.5 mm² of RDSO approved make.

7.3 The wiring shall be with PTFE cable wherever required and bus arrangement for RS 485

ports. The wiring shall be such, that it facilitates easy maintenance and safety of the operator.

7.4 The housing for inside the coach shall be of robust and reliable construction duly made

from 0.8 mm thick CRCA sheet to IS: 513, grade O. 7.5 All the above units in PIS system shall be inter-connected by means of circular

connectors of WAGO/PHOENIX/AMPHENOL/Allied Electronics Corporation or any other make with the prior approval of RDSO.

7.6 The enclosure shall be powder coated. Powder coating thickness shall be minimum 60

microns. 7.7 The components of the panel shall be mounted as approved by RDSO. All operational

controls shall be provided on the panel and shall be accessible to the maintenance personal.

7.8 All the fasteners used shall be of metric size and shall be galvanized. 7.9 All the terminal boards used in the unit shall be of FRP/SMC and properly secured to

rigid members of the panel. 7.10 The power connections to the terminal board for various units shall be terminated

properly taking into consideration the creepage, clearances, safety etc. 7.11 All the control connections, wherever necessary, shall be terminated in a terminal board

with terminal studs and numbered for easy maintenance as per the scheme. The usage of plug in type connectors of any approved make shall be desirable.


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7.12 All the units shall be provided with mounting holes for fixing in the coach. The minimum size of hexagonal head screw for fixing equipment inside the coach shall be M6 hexagonal head screw.

7.13 Earthing lug shall be provided on the units for external coach earthing connection. 7.14 The plug in type connectors shall be accessible by the operator for easy connection and

removal during service. 7.15 The manufacturer shall furnish the following details for all the items. (i) Fixing dimension in mm (ii) Overall dimension in mm (iii) Schematic diagram with components

(iv) Weight in kgs

7.16 CONFORMAL COATINGS: Assembled and tested printed boards should be given a conformal coating to enable them for functioning under adverse environmental conditions. The coating material should be properly chosen to protect the assembly from the following hazards.

Humidity;

Dust and dirt;

Airborne contaminants like smoke and chemical vapors;

Conducting particles like metal clips and filings;

Accidental short circuit by dropped tools, fasteners etc.;

Abrasion damage and

Vibration and shock ( to a certain extent )

7.17 The solder masks shall be applied on the solder side and component side of the card. 7.18 Electronic components used in electronic controller or else where shall be as under:-

(i) IC (Integrated Circuits) shall be of Industrial or Mill Grade. (ii) Capacitors shall be rated for max. temperature of 105 deg.C. (iii) The resistance shall be preferably made of metal film of adequate rating. (iv) Switching devices such as transistors, MOSFETs and IGBTs shall have junction

temperature of 150 deg.C. (v) Devices shall have the adequate (minimum 100C) thermal margin at the ambient

of 55 deg.C. Calculation to be submitted for selection of device. 8.0 BATCH TESTING OF LEDs: 8.1 deleted. 8.2 Manufacturer shall maintain proper account of LEDs being used. The record shall

include various details like source of supply, procurement invoice no. and date, quantity, incoming rejection, lot-wise consumption etc. which may be verified by the inspecting officials.


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8.3 LEDs used in LED display units shall be of high performance quality and from reputed manufacturers as stipulated by RDSO. The maximum junction temperature of a LED shall not be less than 1000 C and epoxy used in the LED shall have UV inhibitors.

8.4 Manufacturer shall advise RDSO if the make and model of LED is changed to another

model/ make approved by RDSO. 8.5 Number of LEDs and their part number shall not be changed without prior approval of

RDSO. 9.0 GENERAL DESIGN REQUIREMENTS 9.1 The unit should be compact and robust. 9.2 The unit shall have protection against open circuit and short circuit of the cable and

circuits used. The design shall ensure interchangeability of Passenger Information system of different makes.

9.3 The unit shall meet the requirement of RDSO Specification no ELRS /SPEC/SI/ 0015

with latest revision for Reliability Requirements for Electronic components used in rolling stock application.

9.4 The rating to loading ratio of various active/passive components to the worst working

conditions shall be more than two. The manufacturer shall submit the rating versus loading chart for the various components used corresponding to the loading at the worst working conditions.

9.5 It will be preferable to have the entire microprocessor based hardware, RAM, EPROM,

Input/output ports and opto isolation etc. so optimized that the component count is kept low without sacrificing the overall system performance and reliability. Necessary interfacing of the hardware and the connectors will be provided on the cards.

10.0 INSPECTION AND TESTING: 10.1 TYPE TEST 10.1.1 Only after the detailed drawings and the design have been approved and the clearance

given to this effect, the manufacturer shall take up the manufacture of the prototype. It is to be clearly understood that any changes, required to be done in the prototype or any additional tests other than specified herein are required to be conducted on the prototype unit or its components, they shall be done expeditiously. During the process of manufacture of the equipment, if the purchaser so desires, he may conduct/repeat any of the routine or additional tests to satisfy himself that the quality of the module being manufactured is of the required standards.

10.1.2 Subject to agreement between user and manufacturer, RDSO/purchaser shall repeat

some or all type tests once in three years on sample basis, so as to confirm the quality of the product to meet the specified requirements.


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10.1.3 The type tests shall be carried out by RDSO representative on prototype unit either totally or in part under the following conditions without any additional cost:

A manufacturer undertakes to manufacture for the first time.

An important change in design details of machines has been introduced.

Specification is modified necessitating re-designing of equipment.

Unsatisfactory performance reported from user Railways.

Resumption of production after an interruption of more than two years. 10.1.4 Investigation tests are intended to obtain additional information regarding the

performance of the product. They shall be specially requested either by the RDSO or by the manufacturer and shall be done at no extra cost.

10.1.5 RDSO may conduct surprise check on manufacturing process and quality control along

with any of the tests to ensure quality of product and its conformance to RDSO specification.

10.1.6 After prototype test, unit shall be put on simulated and commissioning trial, before final

approval is granted. 10.1.7 The tests shall be carried out at the works of the manufacturer or a reputed testing

laboratory in presence of Indian Railway representative on the prototype unit of the PIS unit as per relevant governing specifications modified or amplified. The manufacture shall have all possible necessary arrangement for testing of head code and GPS based Passenger Information system.

10.1.8 The test protocol indicating relevant clause of the test, condition of the test, specified

value and observed value of the parameter for head code and GPS based Passenger Information system shall be submitted by the firm before offering the sample for testing.

10.1.9 The system shall successfully pass all the type tests for proving conformity with this

specification. If any one of the equipment fails in any of the type tests, the type testing agency at his discretion, may call for another equipment/card(s) of the same type and subject it to all tests or the test(s) in which failure occurred. No failure shall be permitted in the repeat test(s). The prototype set shall be used for simulated and commissioning trials. Final clearance shall be given by RDSO after successful completion of above trials.

10.2 ROUTINE TEST 10.2.1 Routine test are to be carried out on each unit to verify that properties & design of the

product of corresponding to those measured during type test. Proper documentation of routine tests results shall be available with the firm and shall be produced before inspecting official on demand. Tests shall be conducted as per test schedule given in clause no. 10.4.

10.3 ACCEPTANCE TEST 10.3.1 Each offered lot of supply shall be subjected to acceptance tests as per RDSO approved

sampling plan or as per sampling plan specified in IS 2500 Part 1, at manufacturer’s


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works. Acceptance test shall be witnessed by inspecting official nominated by purchaser/RDSO. Manufacturer on demand by inspecting official shall produce the internal/routine test report carried out by manufacturer.

10.4 SCHEDULE OF TESTS: schedule of tests to be conducted is as below:

S.No. Description of test

Clause No. Type test Acceptance test

Routine test

1. Visual check

As per clause 10.5.1 of this specification

Yes Yes Yes

2. Performance test

As per clause 10.5.2 of this specification

Yes Yes Yes

3. Reverse Polarity test

As per clause-10.5.3 of this specification

Yes Yes Yes

4. Endurance test

As per clause-10.5.4 of this specification

Yes No No

5. Insulation test As per IEC 60571

Yes Yes Yes

6. Dry heat test

As per IEC 60571

Yes No No

7. Damp heat test

As per IEC 60571

Yes No No

8. Vibration and shock test

As per IEC 61373

Yes No No

9. Testing of enclosure

As per IEC 60529

Yes No No

10. Salt mist test for 96 hours

As per IEC 60571

Yes No No

11. Checking of bill of material of test sample as per design document and QAP

A per clause--10.5.10 of this specification

Yes Yes Yes

12. Software burn in test

A per clause--10.5.5 of this specification

Yes Yes No

13. Burn-in test on populated PCB

A per clause-10.5.6 of this specification

Yes No No

14. Test for electromagnetic

A per clause-10.5.7 of this

Yes No No


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compatibility.

specification

10.5 TEST DESCRIPTIONS: 10.5.1 VISUAL CHECK: During visual check general workmanship, connector, cable and

wiring shall be checked. Dimensions shall be as per approved drawing. Powder coating thickness shall be minimum 60 micron.

10.5.2 PERFORMANCE TEST 10.5.2.1 The input current, visibility of display, power consumption, etc. shall be recorded at

input voltage of 90 to 135 V DC. 10.5.2.2 The test set shall consist of a PC based testing jig for performance testing of TCU. 10.5.2.3 During the performance test conducted as a part of the system shall be connected to

the PC based testing bench and a comprehensive check shall be made during type testing for verifying the functions as per clause 5.0 and its sub-clauses.

10.5.2.4 Data retention of the system including route logs and trip data logged by the TCU

shall be checked by interrupting the power supply and resuming system function. There should be no corruption or loss of data after power interruption.

10.5.2.5 During Routine and Acceptance performance test, the system performance shall be

verified at 90V, 110V, 135 V DC and shall comprise of the following:

Uploading the data by data transfer device,

Performance check using the computer test bench though train route selection, display of characters/slogans on LED devices and data logging features of TCU.

GPS connectivity check by putting the system in open view of the sky to check GPS system performance.

10.5.3 REVERSE POLARITY TEST

The unit shall be functional after applying 200V DC for one minute in the correct polarity as well as in the reverse polarity.

10.5.4 ENDURANCE TEST:

Endurance test shall be conducted on one of the modules for continuous operation which shall be 30 days burning with all LEDs of the module in “on” condition using a test software. The lux level at a distance of 1m normal to the module shall be measured at the center normal position of the module 20 minutes after the beginning of the test. The Lux test shall be repeated at the end of the endurance cycle and reduction in lux level observed shall not be more than 5%. Unit shall be tested with a cycle of 10,000 operations of 2 minute “’on” and 1 minute “off”.

10.5.5 SOFTWARE BURN-IN TEST


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Correct burn-in of embedded software version shall be verified for each unit.

10.5.6 BURN-IN TEST ON POPULATED PCB

Burn-in test shall be done on populated PCB in accordance with RDSO specification ELRS/SPEC/SI/0015.

10.5.7 TEST FOR ELECTROMAGNETIC COMPATIBILITY

The head code,GPS based PIS, PA system, Driver-Guard communication and ETB system unit shall be designed such that there will not be any Electromagnetic Interference and the test shall be conducted for EMI/EMC with relevant clauses of IEC 61000 as under:-

i) Electrical Fast Transient/Burst immunity test The test shall be carried out as per IEC :61000-4-4

Power lines Communication and signal lines

Pulse repetition rate

2.5 KHz 5 KHz

Voltage peak 4 KV 2 KV

ii) Surge Test

The test shall be carried out as per IEC:61000-4-5. Installation class:4. Test level : 4 KV

iii) Electrostatic discharge: The test shall be carried out as per IEC-61000-4-2

a) Enclosure conductive part-contact discharge test at 6 KV b) Enclosure insulated part-air discharge test at 8 KV

iv) Radiated susceptibility test : As per IEC-61000-4-3 v) Earth Potential test:

Body of the master display and slave display units shall be given external voltage of 110V DC performance of units shall not get affected.

10.5.8 TEST FOR ENCLOSURE

This test shall be done as specified in IEC 60529 latest for IP54 class for display unit and IP66 for antenna.

10.5.9 VIBRATION, SHOCK AND SIMULATED LONG LIFE TEST

The Equipment shall be subjected to vibration, shock and simulated long life testing as per IEC 61373-1999 or latest.

Random vibration test as per clause 8 Table 1 , category 1 ,Class B

Simulated long life and random vibration test as per clause 9, Table 2 , category 1, Class B

Shock test as per clause 10, Table 3 , category 1 Class B


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10.5.10 Checking of bill of material of test sample as per design document and QAP. Inspecting authority shall check the bill of material of offered sample with the design document and QAP.

11.0 TRAINING:

The manufacturer shall arrange for training to IR personnel in maintenance and trouble shooting of the system supplied. One day training for three persons per location is to be arranged by the manufacturer in the field of maintenance and trouble shooting to the Railway staff which shall include complete assembly of the system through the use of various modules, integration of hardware, loading of software and complete operation of the system. The manufacturer shall furnish the syllabus and schedule of training programme to RDSO as part of design proposal. Training will be arranged free of cost. Suitable training material will be supplied to the participants.

12.0 MARKING: 12.1 All the individual units shall be provided with a name/rating plate on the enclosure. 12.2 The name/identification plates shall be of bright anodized aluminum with black letters

embossed or etched on white background. These plates shall be fitted by riveting. 12.3 The following information shall be clearly marked at a suitable place on each

equipment: a) Name and Address of the manufacturer. b) Year of the manufacturer. c) Serial number of Equipment d) Specification number e) Software and hardware version f) Schematic diagram of the equipment on the side of the cover.

The first two digits shall indicate the year of manufacture, next two digits month and Next three digits for manufacturing serial number.

12.4 Following description shall be etched / engraved / laser printed etc. on the component

side of the PCB:

Component outline in the proximity of the component;

Manufacturer’s name.

PCB name.

Part number.

The manufacturing serial number.

Month and year of manufacture

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