Ref: CG- WI-4.2.1-1 Page Date of iss Spec RDSO/CG-1800 Ver...

Ref: CG-Ver 1.0

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Ref: CG-WI-4.2.1-1 Ver 1.0

Page 2 of 49 Date of issue: January 2018

Spec. No. RDSO/CG-18001

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INDEX

Clause No.

DESERIPTION Page No.

PART-I: GENERAL 1 Introduction 05

2 Definition & Explanation 05

3 Scope of Supply 06

4 Eligibility Criterion 09

5 Prototype Approval 09

6 Comprehensive Annual Maintenance 09

7 Supplier’s Responsibility 10

8 Infringement of IPR 10

9 Cartel Formation 11

10 On - SITE REPLACEMENT WARRANTY 11

11 Spare Parts, Reserve Apparatus 11

12 Prices 11

13 After Sales Service 12

14 Training 13

15 Packing 13

16 Marking 13

PART-II: FUNCTIONAL & DESIGN REQUIREMENT

17 Functional Requirements 15

18 System Level Block Diagram 16

19 Design Requirements 17

20 Description of Equipment’s 30

21 Communication Protocol 35

22 Data Base 35

23 Inspection & Tests by Manufacturer/Supplier 36

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24 Batch Testing of LEDs. 36

25 Routine tests 36

26 Inspection of Finished Products by Inspecting Authority.

37

Part-III. Infrastructure Requirement 1. Scope 40

2. Requirements 40

3. Manufacturing Facilities 40

4. Testing facilities 41

5. Quality Control Requirements 41

6. Documentation 41

7. Training 41

Annexures

Annexure No.

Description

Annexure-I Drawings for Power Supply Connections 36

Annexure-II Location for Fixing/Mounting of LED Destination Board 40

Annexure-III Parameters to be checked during field Trial. 41

Annexure-IV Undertaking Against Cartel Formation 42

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SCHEDULE OF TECHNICAL REQUIREMENT FOR SUPPLY, INSTALLATION, COMMISSIONING & MAINTENANCE OF GPS

LOCATION BASED PUBLIC ADDRESS SYSTEM, PASSENGER INFORMATION SYSTEM & LED DESTINATION BOARDS IN LHB TYPE AC AND NON- AC

COACHES Foreword: 0.1 This specification covers the general requirement of design construction, pre-

wiring, performance, tests, supply, commissioning and after sales service of GPS (Global Positioning System) based Public Address System (PAS), Passenger Information System (PIS) & LED Destination boards for newly manufactured LHB type AC and Non AC coaches including LHB Pantry car & LHB Power car. Specification also covers the additional functionalities (optional) like CCTV surveillance system, Wi-Fi based infotainment system, Electronic passenger reservation charting system & Wired / Wireless train networking for data interlinking of coaches as per requirement of Indian Railways.

0.2 This specification covers the technical requirements / provision relating to material, tests and does not include all the necessary provisions of contract.

0.3 This schedule draws reference of some specifications & drawings. The latest versions of the relevant specifications shall be taken as reference.

0.4 This specification requires the reference to the following specifications: Specification Description RDSO/SPN/144 The Safety and reliability requirement of electronic

signaling equipment. IS: 9000 Basic environmental testing procedures for electronic

and electrical items. IEC: 60571 Electronic equipment’s used on railway vehicles IS: 60947-1 IP65 protection

0.5 For the purpose of this specification, the terminology given in RDSO/SPN/144 shall apply.

0.6 SCOPE: This specification for “GPS (Global Positioning System) location based PAS (public address system ), PIS (passenger information system) & LED destination boards for LHB type AC and Non AC Coaches” covers three parts. Part-I covers general requirements regarding supply, installation, commissioning and after sales service while Part-II covers the functional & Design requirements and method of quality control of the system. Part –III covers the Minimum M&P and Test Equipment’s for the manufacturing and testing of the system.

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PART-I: GENERAL REQUIREMENTS 1. INTRODUCTION:

This specification GPS LOCATION BASED PUBLIC ADDRESS SYSTEM (PAS), PASSENGER INFORMATION SYSTEM (PIS) & DESTINATION BOARDS FOR LHB TYPE AC AND NON AC COACHES is designed keeping in view to develop a suitable system which shall take care of all future possible up gradation. In first phase Passenger address system along with passenger information system and LED destination board shall be integrated for providing all important information in audio and visual form to the passengers. Key feature and technology of the proposed system will be based on internet services through Quad Band GSM/GPRS or HSDPA/HSUPA modem or through Wi-Fi connectivity to the base station for remote accessibility of the system and monitoring of important parameters. The system is also equipped with GPS technology for activating location based audio visual information and features of the system like speed, locations of the coach and calculating kilometer run by the coach on per day/month/year basis. This specification covers the general, functional design requirements of such system for Indian Railway coaches.

2. DEFINITION & EXPLANATION: 2.1. GPS location based public address system (PAS), Passenger Information

System (PIS) & Destination boards for LHB type AC and Non AC coaches means "complete system including all related equipment’s, such as, main processing unit (MPU), GSM/3G modem, GPS system, LED display unit and LCD display units for outside and inside of the coach, IP65 enclosure for exposed system, suitable power supply unit and all associated sub systems and accessories, wires, fittings etc.

2.2. Following terms are used in specification for their relevant meaning like µP means microprocessor, LCD display unit means LED/LCD display unit, LED display unit means light emitting diode matrix display unit , GPS means global positioning system, GPRS means General Packet Radio Service, and CPU means central processing unit.

2.3. Similarly following words i.e BMU means base monitoring unit, MPU means main processing unit, PAS means passenger address system and PIS means Passenger information system shall be used in the specification for their respective meaning.

2.4. `Supplier' means the firm/company on whom the order for the manufacture, supply, installation and commissioning and maintenance of the GPS location based public address system (PAS), passenger information system (PIS) & destination boards for LHB type AC and Non AC coaches are placed or

Ref: CG-WI-4.2.1-1 Ver 1.0



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will be placed. 2.5. ‘PURCHASER’ means the Indian Railways on behalf of the President of the

Republic of India, who is purchasing the system. 2.6. ‘INSPECTING AUTHORITY’ means the Organisation or its representative

nominated by the Purchaser to inspect the system on his behalf. 2.7. RDSO means Research Designs and Standards Organization, Manak Nagar,

Lucknow-226011. 2.8. Indian Railways is hereafter referred to as I.R. 2.9. In case of any clarification in respect of any clause of this specification or

drawings, the same shall be obtained from purchaser/ DG (Carriage), RDSO. 3. SCOPE OF SUPPLY:

3.1. The scope of supply includes the following systems and subsystems:

Each Coach shall be equipped with following separate units along with required, networking devices, connectors, wiring for communication & power supply. Tentative wiring scheme for Power supply is attached at Annexure 1.

Sl Description of unit Quantity per coach

Type of coach

LHB AC coaches

LHB Non-AC

(Reserved) coaches

LHB Non-AC (Un-

Reserved) coaches)

1 Main Processing Unit Description of Main Processing Unit shall be as per clause no. 20.1 of Part –II of this specification.

01 per coach

2 Slave PIS LCD Display system. Description of Slave Destination Board Display system shall be as per clause no. 20.4 of Part –II of this specification.

AC2T AC3T

02 Nil Nil

AC Ist 01 in each coupe

Chair Car 06

Slave PIS LED Display system.

LHB Sleeper and Nil 02 Nil

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Description of Slave LED Display Unit shall be as per clause no. 20.3 of Part –II of this specification.

Chair car

GS & Pantry car Nil 02

Power Car Nil- 01

3 Slave Destination Board Display system: Description of Slave Destination Board Display system shall be as per clause no. 20.2 of Part –II of this specification.

02 unit per coach

4 Boxed enclosure Power Supply unit Description of Boxed enclosure Power Supply unit shall be as per clause no. 20.5 of Part –II of this specification.

01unit per coach

5 PA system (Passenger address system) Details of PA system including amplifier, speakers, Microphone for manual Goose announcement and its wiring as per existing specification of passenger address system for LHB type coaches

01 set per coach

6 Networking device ,

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Cables & junction box All types of Cables: i.e. power supply, control signals and data transfer cables required for wiring. Networking devices Data and signal Converters, connectors and interconnections between the systems components, Cable junction box etc.

01 set as per requirement

7 Software 1. Set of system and

application software required for smooth operation of the complete system.

2. Set of user manual, operating manual and trouble shooting manual for the systems / sub systems supplied.

02 sets

All the module / units may be mounted in a IP 65 compliant enclosure unit, designed with anti-pilferage features, Enclosure units shall be mounted at suitable location in the coach with mutually identified or allotted locations in the coach.

3.2. Base Monitoring Unit :Optional - Two units at each Depot Description of Base Monitoring Unit shall be as per clause no. 20.6 of Part –II of this specification.

3.3. Centralized Web Server (not in the scope of supply): For hosting of online services and database of all the train routes, rake

formations of trains a web server ( server availability 100 % uptime round the clock ) shall be hired by Indian Railway to serve the entire fleet of coaches as well as prospectus users of the system.

3.4. The scope of the supply includes acceptance testing, installation and commissioning of the complete system on the coaches, On-Site Replacement

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Warranty for two years and commitment to undertake Comprehensive Annual Maintenance Contract after warranty period.

3.5. The purchaser can purchase any or all of the above sub systems based on their requirements.

4. ELIGIBILITY CRITERIA:

4.1 Firm /manufacturer shall have adequate experience of design, development

and manufacturing of similar system like onboard vehicle tracking, monitoring of assets, passenger information display boards or online management of data interchange between control center system and onboard system in rolling stock (rail / road transport) application and shall be capable of developing material to the required quality and standards.

4.2 Firm/ manufacturer should have installed successfully at least 100 such systems in past and have completed minimum two years satisfactory service. The list of supplies made along with contact details of the customers and performance certificate should be submitted as documentary evidence.

4.3 If the firm not complying the clause 4.2 they will provide their credential for development of the system as per the specification. The details will be submitted to RDSO by the firm for examination by RDSO after clearance from RDSO firm will offer a prototype system to RDSO for acceptance as per specification. Thereafter the case will be initiated as per Clause 5.3.

5. PROTOTYPE APPROVAL AND FIELD TRIAL PERFORMANCE MONITORING:

5.1 The prototype approval by RDSO shall be mandatory in case of new vendor and in case of design change of approved vendor, followed by field trial performance monitoring of the system offered and same has been allowed for field trial by RDSO in any Railway. Parameters for the performance field trial are specified at Annexure ‘3’.

5.2 For field trial performance monitoring of the system, Firms covered under clause 4.2 shall initially supply 50 coach sets to the 2 specified railway for field trial of 06 months period as per trial scheme finalized after prototype approval.

5.3 The firm who comes under Para 4.3 above will go for field trial performance monitoring of the system, initially supply 25 coach sets to the 01 specified railway for field trial of 12 Months. After satisfactory trial of mentioned period firm has to follow the decorum of Para 5.2.

6. COMPREHENSIVE ANNUAL MAINTENANCE CONTRACT: The SUPPLIER shall be liable for Comprehensive Annual Maintenance Contract

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for the period of at least 2 years followed by warranty period. Comprehensive annual maintenance shall be requiredfor maintaining the system. The Comprehensive annual maintenance shall include the following items:

A) TRIP Maintenance: a. Checking the entire system for its:

Working reliability. Mechanical fixing thoroughly.

b. Checking the entire system for water-tight sealing arrangement and any visual defect.

c. Monitoring the power supply, voltage, and wiring etc. periodically.

B) Three monthly Maintenance: a. Monitoring the antenna connectors. b. The maintenance shall cover the free replacement of entire

components including MODEM, CPU, SMPS, ANTENNA etc. if found faulty/ defective.

Note: 1. Any fault / defect shall be rectified within period as specified in clause no.

10. 2. The maintenance shall also cover the updating of route data / customized

messages in all coach units installed as per latest time table of I.R. as and when required by the purchaser. After updating route data a soft copy of updated route data shall be submitted to the purchaser.

3. Supp l ie r shall also update / change latest version of the applicable system software as and when required by the purchaser.

4. For checking / fixing of the DISPLAY BOARDS & MPU or Power supply Unit , Railway authorities shall provide necessary assistance to supplier and ensure that the checking is carried out under safe conditions.

5. The Supplier shall ensure that the AC/D.C power supply provided to the systems are working properly, if any problem in the Power source the railways shall ensure that the problem is solved.

7. SUPPLIER’S RESPONSIBILITY

The Supplier shall be responsible for the execution of the contract strictly in accordance with the terms and the conditions of this specification and the conditions of contract made with purchaser.

8. INFRINGEMENT OF IPR

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Undertaking to be signed by firm /company on “INFRINGEMENT OF PATENT RIGHTS”. The undertaking can be as under. “Indian Railways shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, use of similar components in the design & development of this item and any other factor not mentioned herein which may cause such a dispute. The entire responsibility to settle any such disputes/matters lies with the manufacturer/ supplier. Details / design/documents given by them are not infringing any IPR and they are responsible in absolute and full measure instead of railways for any such violations. Data, specifications and other IP as generated out of interaction with railways shall not be unilaterally used without the consent of RDSO and right of Railways / RDSO on such IP is acceptable to them.”

9. CARTEL FORMATION Manufacturer and supplier shall have to submit the affidavit as per Annexure 4 given in specification.

10. ON-SITE REPLACEMENT WARRANTY:

The time period of On-Site replacement warranty shall be two year for complete system from the date of the installation and commissioning. The supplier shall replace all rejected products during installation and commissioning due to their non-compliance with the requirements. The supplier shall also replace those products which show deficiencies during the warranty period by products complying with the requirements within a period of two weeks for the purpose of warranty support. The supplier will provide two e-mail addresses of different domains and time of two weeks will be considered from the date on which an e-mail has been sent. A fax or other mode of communication will also have same sanctity for counting number of days. Adequate penalty clause may be incorporated in the tender document by the purchaser.

11. SPARE PARTS, RESERVE APPARATUS. 11.1 The offer shall include recommended list of spare parts required for day to day

maintenance of the complete system equipments and spares in the form of kit for the various sub-assemblies for the maintenance at the time of POH. The list shall give the batch no. / Part number, quantity and price of each components.

11.2 Tenderer shall ensure availability of all spares for a period of at least 10 years. This shall be irrespective of the fact whether the tenderer or his subcontractor(s) have stopped manufacturing of the equipment to the designs applied to IR.

11.3 In order to ensure the availability and utilization of systems fitted in the coaches, certain number of standby units of principal assemblies is required. In addition, it is proposed to stock sufficient minor components and spares to meet renewal and replacement on account of wear-tear or occasional failure, for a period of 6

Ref: CG-WI-4.2.1-1 Ver 1.0

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years of service. Tenderer shall, therefore, submit a classified list of spares, unit exchange spares & stage / normal maintenance) for each type of equipment used in destination display board, which he recommended for stocking.

12. PRICES 12.1 The Supplier shall give price of complete destination board display system per

coach set and shall also submit the item wise price breakup of all the components of the various items.

12.2 The Purchaser reserves the right to either buy the complete system as offered or any part thereof based on items wise break-up of cost indicated by the Supplier.

13. AFTER SALES SERVICE 13.1 Supplier is required to send his technical staff during the installation and

commissioning of their equipment on coach / coaches. 13.2 Supplier shall arrange for adequate service engineers at his own cost to ensure

that the equipment supplied performs satisfactorily. 13.3 Supplier shall also depute his staff on request by the Purchaser / RDSO, to

investigate and attend to specific problems that may come up during actual operation of destination board display system.

13.4 Supplier shall associate with Indian Railways during the trials of destination board display system. He shall also undertake to modify the equipment supplied, if required as a result of trials.

13.5 The Supplier shall arrange to supply at least 5 hard & soft copies of the Operation & Maintenance Manuals and servicing Instructions for proper maintenance of equipment. The number of manuals to be supplied shall be 5 against first Contract and 2 at every contract and shall be supplied free of cost.

13.6 Manuals shall be illustrated, containing information pertaining to the principle of operation, maintenance schedule of all the items o f equipment being supplied.

13.7 The Manual shall also contain information on the following Details of attention required during IOH / POH or any other schedule.

13.8 Test procedure and standards for all the equipments on test bench as well as single unit / coach /rake testing.

13.9 Details of gauges, jigs &fixture, tools, machinery and plant for maintenance of destination board display system.

13.10 Typical defects and their remedial measures. 13.11 List of spares for day-to-day maintenance and for POH in the form of periodic

overhaul kit. 13.12 Identification code numbers for main equipment and their component parts to

Ref: CG-WI-4.2.1-1 Ver 1.0

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avoid mixing of different applications by mistake. 13.13 Tenderer shall submit the frequency and detailed work content of various

inspection/maintenance schedule necessary for maintenance of the complete system offered by him. Whether these requirements are time based or distance traveled based shall be indicated for each schedule.

13.14 The Supplier shall also arrange to supply along with equipment Wall Charts of all equipment being supplied by them for display in maintenance depots. These shall be supplied @ 5 sets against first contract and thereafter 2 sets against every contract and shall be supplied free of cost. These charts shall be pictorial, showing all components along with their part Nos. for each item of equipment.

13.15 The Supplier shall supply revised Maintenance Manuals and Wall Charts incorporating necessary changes in the Manuals and Wall Charts already supplied by them for earlier contracts. The copies of maintenance manuals and wall charts are meant for wider circulation on Railway and fresh copies shall be furnished as stipulated even if there are no changes in the manuals & wall charts furnished against earlier contract.

14. TRAINING

The Supplier shall undertake to train the following Indian Railway personnel free of cost.

14.1 Railway Technicians Minimum 4 persons per depot for 6 working days training shall be trained on site / in depot to cover maintenance and testing of the complete system.

14.2 Officers and Engineers One officer and 2 Engineers shall be trained at the works of the principles for a minimum period of one week. This training shall cover all the aspects of the complete system like design, manufacture, quality control, maintenance and testing etc.

15. PACKING 15.1 Supplier shall ensure that all outer and exposed portions of the various items of

the system being supplied are covered with suitable protection/packing material to prevent ingress of foreign matter/ damage during handling, storage, transportation and stone throwing on it etc.

16. MARKING 16.1 All the individual units shall be provided with a suitable name plate / electrical

rating plate on the enclosure units. The following information shall be available either by etching process or by engraving or screen-printed.

16.2 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

Ref: CG-WI-4.2.1-1 Ver 1.0

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riveting. The nameplate shall indicate the following usual information. 16.3 The following information shall be clearly marked on above mentioned marking

plate at a suitable place on each equipment: i) Name and Address of the manufacturer. ii) Month and Year of the manufacturing. iii) Serial number of Equipment iv) Specification number v) Software and hardware version vi) Schematic diagram of the equipment on the side of the cover.

16.4 The first two digits shall indicate the year of manufacturing and next two digits shall

indicate month. Further next five digits shall indicate manufacturing serial number.

****************

Ref: CG-WI-4.2.1-1 Ver 1.0

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PART II: FUNCTIONAL & DESIGN REQUIREMENTS

17. FUNCTIONAL REQUIREMENTS: 17.1 Ambient conditions:

The display unit shall perform satisfactorily under the following climatic conditions i) Ambient temperature : -5oC to 55oC ii) Max. Sunlight temperature : 700C ii) Altitude : Sea level to 2500 m iv) Relative humidity : 40% to 90% (non condensing) v) The rainfall is fairly heavy. vi) During dry weather, the atmosphere is likely to be full of dirt & dust. vii) Temperature variation may be quite high in the same journey or short

period of time. viii) Coaches operate in coastal areas with continued exposure to salt laden air. ix) Airborne contaminants like smoke and chemical vapors. x) Conducting particles like metal clips and filings. xi) Accidental short circuit by dropped tools, fasteners etc. xii) Stones may be thrown on the system by the ant-social elements during

procession or strikes etc. xiii) Abrasion damage and xiv) Vibration and shock

17.2 Maintenance Conditions: The coach exteriors are cleaned with mild acidic cleaning agents using brushes with nonmetallic bristles or automatic car washing plants. The system should not be affected by this cleaning either in performance, reliability or aesthetic.

17.3 Power Supply Availability

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110V AC or DC supply is available from coach circuits. This Supply varies from 77V DC to 138 V DC with 2% ripple.

17.4 Car-body dynamics: ±100 mm vertically ±55 mm laterally ±10 mm longitudinally ±4 degree bogie rotation about center pivot

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19. DESIGN REQUIREMENTS: The “GPS location based PAS (public address system), PIS ( passenger information system) & LED destination boards for LHB type AC and Non AC coaches”, including all sub-systems and equipment shall be of proven design. Entire system can be understood by “SYSTEM LEVEL BLOCK DIAGRAM” as shown above which elaborates the system working / requirements.

19.1 MAIN PROCESSING UNIT (MPU) shall have following features:

19.1.1 Main Processing Unit may be compact fanless Panel PC with IP 65 from

front and IP 20 from back or may be compact fanless industrial grade boxed PC with IP65 compliant enclosure unit along with panel mounted IP 65 compliant external touch screen display and comply the requirements as specified in EN50155 (Railway Application). Main processing unit shall have built-in GSM 3G/4G modem, GPS receiver, Audio, LAN and Wi-Fi module along with suitable system software (Windows embedded standard / Linux embedded), and provision of external antenna for GSM modem, GPS receiver. Detailed system configuration of the system shall be as detailed in clause no. 20.1.

19.1.2 The Main Processing unit shall support the all the sub systems fitted or to be integrated through networking devices in future. Data /database files shall be transferred to sub systems by standard file transfer /copying / synchronizing techniques i.e. FTP, SMTP or any other suitable method.

19.1.3 LED Display Units for inside and outside of the coaches shall operate as slave units and consist of LED Matrix Display cards along with LED driver Circuitry and a microprocessor based Control Module for communication with MPU & controlling the LED Display Cards.

19.1.4 The MPU shall be capable of addressing communication with at least 04 LED display units connected over Cat6 Ethernet cable & It shall be possible to add at least 04 more display units in future.

19.1.5 Each slave LED Display unit shall have a Unique Hardware identification number stored within slave unit. Unique HW ID of the LED DISPLAY UNIT shall be a 12-digit code where first three digits shall be vendor code followed by 4 digit of year and month of manufacture (yy/mm format) and the other 5 digits shall be unique serial number assigned by vendor. Vendor code will be assigned after validation of vendor request by RDSO.

19.1.6 Each Main Processing unit shall be identified digitally with an alphanumeric character (up to 12 characters) of the coach number like, "SC00245", "NCR00245" or ECOR00245. Where first two/three/four digits are Zonal

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Railway Code, next two digits are year of manufacture and the next three digits are running serial number of the coach and last three digits are for optional information as displayed on the coaches. Using this digital identification it can be ensured that only the targeted set of coaches or rake receives the command while programming through BMU / Central web server. The Main Processing unit (MPU) shall also have Hardware ID code similar to LED display units in the embedded memory which can be retrieved by the user at any point of time through the BMU or Central server. Alternatively MAC ID of the LAN may be used for this purpose.

19.1.7 The MPU of each coach shall be pre-programmed for the desired train routes in Hindi, English and two Regional languages (originating and terminating stations state languages) for the desired halts/ locations / scheduled stoppage stations along with GPS coordinates and relevant voice segments for PAS, PIS and LED display units using application software provided for this purpose in BMU / web server. This system shall have capability to store and handle the data base of at least 100 up and 100 down train routes with up to 4 language support and capability to display all regional languages in Unicode Bold font (True type fonts for Indian languages available at web site http://www.ildc.in/ shall be used by all manufacturers). The display data along with voice data stored in the MPU can be replaced to any required new train data by transferring fresh data from the BMU /Central server; (the old version of a route or least used route data is overwritten automatically in such a case).

19.1.8 The GSM module of MPU shall be provided with a valid SIM card and a data plan with national data roaming providing pan-India connectivity. The MPU shall remain connected with the Web server over GSM/GPRS service. Connectivity status of the MPU will be updated to the Web Server. The vendor shall provide necessary application Programm interface on the MPU to allow effective communication with BMU/ Web server.

19.1.9 In case connectivity to BMU/ Web server is not available, the service requests shall be queued in BMU/ Web Server for updating, whenever connectivity is available to the MPU, it shall be updated automatically. it shall be possible for a remote user on a internet enabled PC (BMU) to view the state of a configuration service request and whether the same has been acknowledged or not, through web server acknowledgment state.

19.1.10 When the train passes through programmed train route, GPS receiver receives co-ordinates information of the current location from the GPS satellites. After 15 minutes of arrival at the destination station, the MPU shall automatically reset the selected train number and automatically select return train number route / follow-up route which is already queued in MPU or synchronise (select / download) the follow-up route already selected at

Ref: CG-WI-4.2.1-1 Ver 1.0

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server side. 19.1.11 Train route selection on Main Processing Unit shall be done using BMU/ web

server interface normally; in case of failure of this mode due non-availability of internet connectivity, authenticated touch screen interface (level 1 or level 2) available in the system shall be used for selection of train route. GUI based application software of the MPU shall be designed such a way, so that selection of the desired route database can be done manually from the available database. Access Level 1: For route selection, selection of up and down menu etc by

AC mechanic. Access Level 2:For servicing functions like testing of GPS device,

communication links, display of route data, management of system passwords, coach number modification addition / deletion / updation of train route information using a USB pen-drive etc by maintenance supervisor.

19.1.12 When the Main Processing unit is changed/ replaced from one coach to the

other coach, It shall be possible to modify the coach-id stored in the MPU either through the GSM interface (online mode) or manually by touch screen interface provided in MPU, However such modification shall be authenticated password protected. Once updating is done, the coach ID configured on the MPU can be visually verified on the LCD screen of the MPU.

19.1.13 It should be possible to upgrade/ extend the system hardware and software. There shall be provision to add extra display units without any change in electronics.

19.1.14 MPU shall be capable of sending information / recorded messages/ logs / alerts generated on receiving the request from Base monitoring unit / web server as and when required.

19.1.15 The user shall be able to configure the desired rake composition assigning requisite coaches and select train number for the complete rake over GSM network using client application software in BMU. Application software on the server side shall ensure scheduled and unscheduled mid-route removal and addition of coaches to a particular rake/ train accordingly by updating such data. If it is desired to configure any specific train route to a particular coach/set of coach it shall be done in online mode normally through BMU/ web server interface but, it shall be possible to manually configure the MPU with the help of a touch screen keypad in the system, such selection shall be password protected.

19.1.16 In case of failure of GSM communication or non-availability of Internet at BMU site, the user shall be able to compile the information using application

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software of BMU in offline mode and upload the ad-hoc information to the MPU using a USB pen drive such updation shall be authenticated password protected.

19.1.17 Any ad-hoc change in data / configuration of the MPU shall be logged with a date and time stamp as an event and shall be synchronised with BMU/ web server system upon availability of network. Whenever network available latest data /database files shall be down loaded from server and MPU shall be updated accordingly based on time and date stamp.

19.1.18 When the train passes through programmed train route, GPS receiver receives co-ordinates information of the current location from the GPS satellites. After 15 minutes of arrival at the destination station, the MPU shall automatically reset the selected train number and automatically select return train number route / follow-up route which is already queued in MPU or synchronized from Central server or BMU (select / download).

19.1.19 The MPU shall have on-board diagnostics for working status of GPS module, GPS antenna status, on-board system memory, connectivity with the slave systems, working status of the Slave PIS and LED Destination Board, PA system and update the status on the web server upon availability of internet connectivity.

19.1.20 In case a fault is detected, the MPU shall be capable of storing such faults with date and time stamp, Provision for storing minimum 200 such most recent faults on FIFO basis shall be provided in MPU. Faults shall be retrievable either by the online fault retrieval system for generation of reports or through the USB interface of the MPU manually using a standard pen drive. In case of manual retrieval existing faults shall not be reset from memory.

19.1.21 Kilometer-age earned by each coach shall be computed & logged date-wise data of kilometer run for the last 36 months on the basis of GPS information by MPU to assist in creating maintenance schedules.

19.1.22 Distance travelled log shall be prepared based on the available GPS accuracy and cumulative kilometrage earned date wise shall be stored in the MPU and same shall be synchronised to the web server at regular interval say every day. Calculation of the Kilometer-age run by MPU shall be recorded on the basis of every one kilometer as recorded by the GPS co-ordinates.

19.1.23 This information shall be accessible through a BMU for review by the POH staff to assist in the maintenance activity. Kilometers earned shall also be retrievable using the USB interface of the MPU and can be seen on MPU LCD also whenever it is required.

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19.2 Base Monitoring Unit shall have following Design features:

Base Monitoring Unit (BMU) is a standard workstation Personal Computer, which shall work on latest windows® software. The BMU shall be connected to GSM/3G data Modem, and also with wired broad band internet for the connectivity with the web server.

BLOCK DIAGRAM OF BASE MONITORING UNIT (BMU)

(FOR USER RAILWAY)

Normally following tasks shall be done by Base Monitoring Unit: 19.2.1 Train rake composition data shall be entered at originating station by TXR

staff using this Base Monitoring Unit via web server. Using rake composition data it shall be possible to select the train route for entire rake in one command.

19.2.2 Retrieval of recorded messages / alerts / logs/ reports generated of coach health from Main Processing Unit and compilation of final reports for the maintenance staff.

19.2.3 The BMU shall host a local client application software (common to all vendors having similar interface of web server ) which shall enable it to store locally complete divisional / Zonal Railways train route database on it. The client application on the BMU shall allow local compilation of routes to tide over network related issues. It shall be vendor responsibility to ensure latest software (OS and client application software ) and database on BMU that permits Railways to download and work in offline mode at remote locations.

19.2.4 It shall also be possible for the user to add /delete a coach from the rake formation, create and maintain route logs etc. and update the MPU of the coaches with latest train route locally. Such updating shall be done directly

BASE MONITORING UNIT

STANDARD W/S PC

INTERNET NETWORK

GPRS MODEM

UN-INTRUPTED POWER SUPPLY

Wi-Fi Hotspot Network for Complete

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through authenticated access with the help of touch screen interface and USB pen-drive to the MPU’s of the division’s rakes. To ensure interchangeability a standard file format .xls (excel) or .mdb (Access ) or any other file format mutually agreed upon shall be used for the purpose.

19.2.5 The BMU shall have a synchronization module for client software of web server so that latest version of train route and Rake composition database shall be synchronized to it. If the database version on the BMU is older than the version on the Web Server, the synchronization module shall copy the database to the BMU.

19.3 WORKING OF THE SLAVE PIS DISPLAY UNITS

Working of the PIS system & features mentioned hereunder may be part of Main Processing unit which are elaborated as below..

19.3.1 MPU shall process the GPS data (Latitude, Longitude, date and time) on real time basis and detect its presence on the train route automatically and perform calculation for initiation of triggering command for audio / visual data for PAS and PIS LCD display units or PIS LED display units as per pre-recorded digital data and processed digital information of the route selected.

19.3.2 Based on the current location identified by GPS, MPU shall calculate the current time, speed, next halting station, distance from current location to the next halting station, expected time to reach next halting station and late running status to the next scheduled station, only if train is running late by more than thirty (30) minutes. The CPU shall also generate relevant voice messages upon arrival or departure from scheduled station.

19.3.3 It shall be able to compile and transmit welcome and farewell messages on departure and arrival at source and destination stations in Hindi and English.

19.3.4 In case the coach is detached from specified train route and attached to some other train with different route, system should be able to identify such situation by comparing the route selected and real time GPS data and system should stop showing incorrect information in such case it will show the data error message i.e. ”WELCOME TO INDIAN RAILWAYS” and In any case system will not show the wrong route information.

19.3.5 All Slave LED Display Units and Slave LCD display units shall display same audio/video information in all AC and Non AC coaches of the rake.

19.3.6 Slave LED display units & Slave LCD display units will display the following messages in alternately scrolling / fixed mode.

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a) Welcome message. b) Train Route c) Train Speed d) Current time. e) Next halting station & Approximate distance of next halting station with

accuracy of less than 1 km. f) expected time to reach at next halting station g) Slogan for passenger safety. h) Late running status of train on next scheduled stoppage station,

Schedule time .

19.3.7 The information (Current time ,Next halting station , Approximate distance of next halting station with accuracy of less than 1 km , Late running status of train on reaching the train on next scheduled station) on display boards shall be displayed in English, Hindi and in regional languages (originating and terminating station) as mentioned in this specification. All fonts shall be implemented using Unicode font in the display devices /MPU itself.

19.3.8 To reduce inconvenience to the passengers at night hours, the display of the safety slogan and welcome/farewell message should be stopped and prior to 5 km of approaching scheduled station, the train running status should be displayed at the interval of 10 minutes.

19.3.9 Auto dimming function during night hours by Real time clock(RTC) calculation from 10 P.M. to 6 A.M. , whereby display brightness of LED display board ,LCD display panel to be reduced to 20 % of original.

19.4 WORKING OF PAS (PUBLIC ADRESS SYSTEM )

PA System (Public address system) in the coaches shall be based on digital signal processing technology and audio output shall be generated by application software in MPU unit based on the GPS location and selected route data of the train. Initial signals shall be processed in the MPU unit to produce audio output from MPU unit

19.4.1 Audio Messages shall be enabled before 5 km when train is approaching next scheduled station between 6 AM to 10 PM. No audio announcement should be made between 10 P.M. to 6 A.M. and setting of night hours time can be altered. The altered time shall be stored in the memory of MPU, if required.

19.4.2 All voice segments shall be compressed prior to transmission / uploading in system storage of MPU in a compressed digital format with at least 1:8 data compression to optimize the memory requirements.

19.4.3 The application software for audio announcement in the system shall receive

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announcement triggers based on the GPS location and route data and generate the requisite voice messages after concatenating various voice segments stored in the memory of MPU.

19.4.4 System shall be provided with required audio-video Codec for converting digital audio to analogue and pre-amplifier circuit with a rated power output (Mono/BTL) or stereo.

19.4.5 The audio output port shall be capable of being connected to an optimally powered external amplifier fitted in the coach for relaying the messages to the speakers installed inside the coaches.

19.4.6 Main amplifier unit and distribution amplifier unit shall require input voltage signal of 1.8+/- 0.2 volts and input impedance of 10 K Ohm.

19.5 Manual Audio Announcement In case of Emergency/critical condition, PAS unit connected with wired input throughout the train shall be able to provide facility to train superintendant / responsible on duty person for manual announcement of important message to passengers in all coaches through speakers and speech unit in Rajdhani / Shatabdi coaches.

19.5.1 In other trains, manual announcement of important message through speech unit and speakers to passengers shall be provided by firm in individual coach basis by pressing the push to talk button by responsible railway staff on duty.

19.5.2 There shall be provision in audio announcement unit to manually stop the audio of PAS as per the requirement by switching off audio amplifier.

19.6 LED DISPLAY UNITS FOR OUTSIDE COACH

19.6.1 The LED destination display unit shall be wall mounted with 1.2 mm thickness of robust Stainless Steel AISI 304 of 1220mm X 220mm X 75mm size (LED display of 16x128 matrix and 8 mm pitch). Maximum allowed thickness of the enclosure unit is 75 mm, it may be in the range of 50mm to 75 mm. The Display unit SS casing is designed in such a way so that it can be properly secured in the existing destination board brackets available on the coach. Casing shall be designed for the compliance of the requirement of degree of protection IP65 as per latest IS: 60947-1. Additional holding brackets required to be provided duly welded to coach body to support the Display unit from bottom. The mechanical and electrical installation, Complete with wiring shall be done in accordance with the governing specifications for the coaches. There should not be any projection beyond Maximum Moving Dimension after mounting.

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19.6.2 MECHANICAL ENCLOSURE Physical dimensions

1220±1mm X 220±1mm X 75±0.5mm

Mounting Provision

As per location given in the drawing no. CG-K7168 at Annexure ’2’

Color & Finish

Natural Metal Colour, having buff finish.

19.6.3 The Display unit shall be used to display the following information: i) The Train No., Coach commercial abbreviation in left corner on each

display as shown in figure below in fixed mode ii) Train Name - [train name] iii) Destination of the train - [source station] to [destination station] iv) Train route (via) - Via [list of 05 important station in route] v) Welcome Message - Indian Railways welcomes you All above messages except point no.( i) shall be required in four languages i.e. Hindi, English, regional languages of the train originating & Terminating station shall be displayed in timed sequence by scrolling message from Right to Left. The whole LED DESTINATION BOARD DISPLAY shall display only two languages (i.e. Hindi & English) in the region where ‘Hindi’ is recognized as a regional language.

Presentation scheme of the entire display shall be as below: 5 Character 12 Characters

A-11 LUCKNOW TO NEW DELHI Frame 1

12003 NEW DELHI SHATABDI EXPRESS Frame 2

A-11 LUCKNOW TO NEW DELHI Frame 3

12003 VIA KANPUR, ALIGARH, GHAZIABADFrame 4

Note:

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1. Each frame data shall be displayed in horizontal scrolling (crawling text) mode only. Normal scrolling speed shall be 50 columns per second. However Train no. and coach commercial abbreviation shall be shown in alternating fixed mode.

2. For Hindi and regional languages same cycle of presentation shall also be used in same sequential order.

3. Scroll speed shall be adjustable through MPU as and when it is required 19.6.4 Super bright amber colour LED’s of uniform intensity shall be used for longer

visibility in destination display boards. The intensity of the illumination should be such that it shall be possible to read the information clearly from a distance of minimum 21 meters visibility. This should be checked and ensured for that part / spot of indicator which has maximum intensity of ambient light. The LEDs shall be procured from NICHIA /AVAGO /OSRAM / CREE / SEOUL or any other brand approved by RDSO.

19.6.5 The Absolute Maximum Rating of the LEDs is given as below: ELECTRICAL PROPERTIES

PARAMETER SYMBOL LIMIT UNIT Reverse Voltage Vr 5 V DC forward current If 20min - 60 max mA DC Power dissipation Ptot 100 to 150 mW Peak forward Current(1/10 Duty cycle same pulse width) Ifs 120 mA

Operating temperature Top -20 to +85 °C Storage Temperature Tstg -30 to +100 °C Soldering temperature (2 mm from body, Max 5 Sec)

260 max °C

OPTICAL PROPERTIES SNo. Parameters Amber LED 1 Size 5 mm oval leaded /SMD LED 2 LED Type Diffused 3 Color Amber 4 Wave Length 590 +/-10nm 5 Viewing Angle (50% lv in mcd) 600(Min.) horizontal,30o vertical

6 Luminous Intensity @ rated biased current

2200 mcd /1000 mcd for SMD LED (preferably higher intensity LED shall be used if availability in SMD)

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7 Operating Temperature - 300C to +850C

8 Make Avago / Nichia/ OSRAM/ CREE/ SEOUL

19.7 SLAVE PIS LED DISPLAY BOARD UNITS FOR INSIDE OF THE COACHES SLAVE PIS LED DISPLAY BOARD UNITS shall be designed to display all the messages as elaborated in clause no. 19.2 , which shall be synchronized in real time basis from MPU to slave as and when display data is updated from MPU side.

19.7.1 The system should not have crashed display/hung display. The control circuit provided in LED display units shall be equipped with Ethernet port. All slave units shall be connected to MPU through Cat6 Ethernet cable and networking device.

19.7.2 All Slave PIS LED display unit shall take independent power supply through Power supply unit provided in the coach.

19.7.3 All the slave PIS LED display unit shall be mounted in gangway either with coach ceiling or wall above doorway.

19.7.4 Slave PIS LED Display units shall meet the following requirements:- a) 32 bit Microprocessor based controlled unit. b) Data communication via Ethernet port. c) Software controlled multiplexed data for LED driving. d) Multilingual (Hindi & English and regional language) alphanumeric

display for journey messages. e) Display size: 16 Rows x 112 SMD type LED at 5 mm pitch. f) Display Area 560mm X 80mm and max - height of 80 mm. g) Enclosure and fixing to meet vehicle interior requirements. h) IP54 compliant enclosure unit, Dimensions: 600 mm (length) x125 mm

(maximum height) X 90mm (maximum depth). i) Enclosure Fixing Dimensions: 585mm X 105mm with 6mm holes. The

enclosure shall be with anti theft protection/anti vandal protection. j) Tinted toughened glass of thickness of minimum 3 mm shall be provided

to protect Master and slave LED display board unit. 19.7.5 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.

19.7.6 LEDs used in PIS LED units shall be of high performance & to the quality as

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specified hereunder and shall be procured from reputed manufacturers like NICHIA /AVAGO /OSRAM / CREE / SEOUL or any other brand approved by RDSO.

19.7.7 Manufacturer shall obtain prior approval of RDSO before changing the make and model of LED.

19.7.8 Number of LEDs and their part number shall not be changed without prior approval of RDSO.

19.7.9 The Specification of the LED used shall generally be as below.

LED Colour Amber LED type SMD LED size 3.2mm x 2.8mm or similar Peak Wavelength 592 ± 10nm Intensity @ 20mA 63mcd to 100mcd Viewing Angle 120º Operating Temperature -25ºC to 85ºC

19.8 General manufacturing standards for LED display units and other

electronic modules 19.8.1 Complete system must be properly shielded and earthed to overcome the

effect of 25 KV traction line or electromagnetic induction or any other electro-static induction etc.

19.8.2 LEDs with equal fringe and uniform intensity are to be used to ensure that the information to be displayed is with excellent contrast so that no black patches are visible on the display screen and display on the board should be flicker free. Each Display Board should be manufactured by same lot and firm will ensure that displays are free from any visible defect on account of LED.

19.8.3 The construction of the whole unit should be modular, such that any module (i.e. control card, LED Display module, etc.) can be easily removed when defective and a fresh module is fixed to make the system functional again. Wiring between different modules should be done with the help of male / female type of connectors. There should not be any requirement of rewiring, re-soldering / de-soldering or opening and reconnections of wiring etc. during the maintenance, unless there is damage to the wiring.

19.8.4 Material for the printed circuit board (PCB) shall be copper clad glass epoxy of grade FR-4 or equivalent. The display PCB thickness shall be 1.6 mm. Following description shall be etched on the component side of the PCB: a) Component outline in the proximity of the component

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b) Manufacturer’s name. c) PCB name. d) Part number. e) The manufacturing serial number. f) Month and year of manufacture.

19.8.5 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.

a) Humidity; b) Dust and dirt; c) Airborne contaminants like smoke and chemical vapors; d) Conducting particles like metal clips and filings; e) Accidental short circuit by dropped tools, fasteners etc.; f) Abrasion damage and g) Vibration and shock

19.8.6 The solder masks shall be applied on the solder side and component side of the PCB.

19.8.7 The display boards should not display any garbage until the required information is placed on the system. All the embedded boards should have watchdog circuit, which should reset the processor in case the processor goes haywire due to any external disturbance caused by high voltage traction etc.

19.8.8 All the slave units should have facility to work on standby mode in case if it is required to be stopped. Each unit should be provided with a power switch to switch on or switch off the display unit in from the Power Supply Unit.

19.8.9 Complete electronic parts should confirm to RDSO specifications RDSO/SPN/144 for reliability and electronics used in rolling stock application.

19.9 SLAVE LCD DISPLAY PANEL inside the AC coach : Slave LCD displays Panels inside the AC coach having following specification as defined in clause no. 20.4

19.9.1 Power source for LCD display units shall be derived from power supply unit and video input from MPU unit shall be given from HDMI port of the system.

19.9.2 All the Slave PIS LCD unit shall be connected through HDMI cables, booster units and splitter cable may be used to improve the signal quality in all LCD units of the coach. Alternatively all the LCD can be connected through Cat6 Ethernet cable and shall use media streaming port (RTSP Protocol ) of the MPU.

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19.9.3 Dry heat test shall be conducted on complete LCD display unit with enclosure inside the AC coach as per IEC 60571-1 with 55°C temperature in the energized condition.

19.9.4 Damp heat test shall be conducted on complete LCD display unit with enclosure inside the AC coach as per IEC 60571-1 with 90% Relative Humidity.

20. DESCRIPTION OF EQUIPMENTS Each Coach shall be equipped with following separate units along with required connectors and wiring for communication & power supply.

20.1 MAIN PROCESSING UNIT :

Main Processing Unit may be compact fanless Panel PC with IP 65 from front and IP 20 from back or may be compact fanless industrial grade boxed PC with IP65 compliant enclosure unit along with panel mounted IP 65 compliant external touch screen display. Main processing unit shall also comply the requirements as specified in EN50155 (Railway Application). MPU shall have following minimum configuration:

i) 32/64 bit standard CPU of reputed manufacturer like INTEL / AMD or similar having clock speed 1.6 GHz or better.

ii) built-in or external display of 5 to 7 inch capacitive/ resistive / SAW touch screen having minimum 640x480 resolution; Brightness 280 cd/M2 or better ; contrast ratio 350:1 or better; viewing angel 140o or better.

iii) RAM minimum 4 GB soldered on board or better iv) 2 GB flash disk soldered on board or better. v) 1 removable micro SDHC slot with memory support of minimum 64 GB or

better vi) 1 mSATA internal SSD storage slot with memory support minimum 500

GB or better and 128 GB industrial mSATA SSD drive. vii) Built in quad band GSM/HSDPA/HSUPA/UMTS/LTE modem with user

accessible SIM card slot. viii) Built in Wi-Fi module compliant to IEEE: 802.11 a/b/g/n standards ix) Built in 50 channel GPS receiver along with roof mounted external

antenna, associated cable and connectors. x) Standard embedded system software like Microsoft® Windows®

Embedded standard latest version / Linux based OS kernel 2.6 or better operating system.

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xi) Audio ports : Mic / Line Input (stereo); stereo line output ; stereo Headphone

xii) The system shall have following serial interface modules at-least 2USB, 1RS 485 and 1 RS232.

xiii) The system shall have 100/1000 MB/s industrial Ethernet port. Circular M12 (D-coded ) connector or IP67 compliant RJ45 port shall be used.

xiv) Main processing unit shall have provision of external antenna for GSM/3G modem, GPS receiver, Wi-Fi and Maintenance interface for SIM card , Micro SDHC card/SSD, LED indication for Power on /Power good (low or high voltage ) indication in front side of the system, system shall have VGA and HDMI/DVI output, Reset push button.

xv) At least 2 USB interfaces of Main Processing unit, LCD touch screen, SIM slots for GSM / 3G modem, on/off switch, power indicator shall be provided in front side of the enclosure unit for easy accessibility.

xvi) Preferable dimension of the system is 8.5”x6”x 3” maximum along with provisions for DIN Rail mount on wall / rack or mounting of the system to VESA 75 standard.

20.2 Slave LED Destination Board Display System: Slave Destination Board Display system (Outside Coach) shall have following minimum configuration: i.) Display unit of 16X128 LED with auto brightness control Module ii.) LED display Driver and control module iii.) 10/100 MB/s Ethernet port iv.) IP65 protected mechanical enclosure with 3mm polycarbonate sheet

with silicon hard coating having more than 85% light transmission properties similar to RDSO specification C-K404 rev-1

v.) DC-DC Converter Module (12V DC to required voltage adjustable). vi.) 1.5 mm2 multi stand copper wire with Teflon sleeve approx. 10 meters

20.3 Slave PIS LED Display units shall meet the following requirements: i.) Display size: 16 Rows x 112 SMD type LED at 5 mm pitch. ii.) Data communication via Ethernet port. iii.) Display Area 560mm X 80mm and max - height of 80 mm. iv.) IP54 compliant Enclosure Dimensions: 600 mm (length) x125 mm

(maximum height) X 90mm (maximum depth).

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v.) Tinted toughened glass of thickness of minimum 3 mm shall be provided to protect slave LED display board unit.

20.4 Slave PIS LCD Display units shall meet the following requirements:

SN Parameter Description

1. Size 19.0 inch LCD in 16:9 ratio with suitable antitheft and anti vandal protection mounting arrangement.

2. Resolution 1280X1024 Pixel or better. 3. Display Colour 16 M or better. 3 Brightness 350 cd/m² or better. 4 Contrast ratio 1500:1 or better. 5 Viewing angle Horizontal view angle 170 degree or better

Vertical view angle 170 degree or better 6 Input video format Video interface to PIS controller shall be

HDMI port , DVI port, VGA port, RF cable, LAN, Wi-Fi

7 Operating temperature range

0°C to 50°C or more

8 Storage temperature range

-5°C to 60°C or more

9 Relative humidity 80% or more 10 Shock and Vibration

test on LCD display panel with enclosure

As per IEC 61373 & IEC 60571 and as mentioned in clause 5.6.9 of this specification.

20.5 Boxed enclosure Power Supply unit :

Boxed enclosure Power Supply Unit compliant to NEMA 2 or better, consisting of two SMPS of at least 100 W each in redundant mode. In case of failure of one power supply, the other shall take over automatically.

i) The SMPS shall be designed to work 110V AC or DC with capability to take care of wide range input voltage 77 V to 138V AC/DC and will deliver DC output +12 V, +5 V and GND to the all devices of the system. Other voltages required shall be derived from this voltage locally in each unit.

ii) 1.6 mm thickness enclosure unit along with required capacity MCB at Input, terminal board for connection of wires, short circuit protection fuse etc.

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iii) 1.5 sq. mm multi strand copper wire with Teflon sleeve approximate 100 Meters, separate colour for each voltage.

20.6 Base Monitoring Unit - Two units at each Depot Windows based standard workstation of reputed make, connected to internet with fixed IP having following specification shall be deployed in each base depot. i) Intel core i3/i5/i7 series processor or AMD Processor of similar class,

minimum 4GB DDR3 RAM, 1 TB SATA Hard disk, minimum 17” LED colour Monitor. Quad band GSM/HSDPA/UMTS Modem, Front-End client application software of web server application shall be installed and updated time to time so that preparation of new rake configuration and editing rake configuration (ADD/Delete Coaches) can be done locally as and when required. By using Front-End application user can select either one coach or more than one coach (Rake selection) for required data interchange /selection of train route.

ii) The Base Monitoring Unit shall be able to operate from 230 Volts A.C directly. UPS and suitable power back-up shall be ensured for proper working of the system.

20.7 Industrial Ethernet switch 16 port PoE 10/100/1000 Mbps network compliant to IEEE:802.3 at/bt having M12 Connectors.

20.8 GSM /GPRS /3G/4G Modem Specifications GSM/ GPRS Modem (Quad-Band 850/ 900/ 1800/ 1900 /2100 MHz)

General Features i) Antenna Impedance : RF Antenna Interface with 50Ω Impedance ii) Frequency Range : Quad Band (850/ 900 MHz and 1800/ 1900 /2100

MHz) iii) SIM Interface : External SIM 1.8V / 3V iv) SMS : Text mode v) AT Commands : GSM 07.07 ,07.05 latest AT Commands vi) EDGE data rate : Class 12 (237 kbps (downlink))

: Coding schemes CS 1, 2, 3, 4 Compliant to GSM phase 2/2+

vii) Compliant to GSM phase 2/2+ : Class 4 (2 W @850/ 900 MHz) : Class 1 (1 W @ 1800/1900MHz)

Ref: CG-WI-4.2.1-1 Ver 1.0

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viii) Protocol : TCP/IP ix) RF Receive sensitivity : -109dBm (Typical)

: -107dBm (Max) 20.9 Technical Parameters for GPS:

i) L1 frequency, C-A code (SPS) with 50 independent tracking channels.

ii) NMEA-0183 compatible output. iii) Update rate 1Hz iv) Reacquisition time 250 mili Sec to 1 Sec. v) Cold start better than 35 seconds vi) Hot start better than 5 seconds. vii) Antenna- external, active passive with built-in

antenna bias circuitry. viii) Built in Antenna supervisory circuit for determination of active antenna open

or short state. ix) Should be provided with magnetically mounted active antenna powered

directly through GPS receiver. x) Autonomous positional accuracy shall be better than10 meter.

20.10 Connectors:

20.10.1 Circular M12 connector, 4 pin A coded according to IEC 61076-2-101 for

power supply where separate power is required. 20.10.2 Circular M12 connector, 8 pin X coded according IEC 61076-2-109 for all

networking, data and media streaming shall be used. 20.10.3 Systems / devices / Display units shall have panel mounted circular M12

female connector. 20.10.4 Connecting cable for all subsystem shall be provided with male connector. 20.10.5 All the connector shall be of reputed make like WAGO/ Phoenix Germany/

Weidmuller Germany/ Amphenol / Harting etc. 20.11 Power Supply:

110V AC or DC power supply available in the coach shall be used as a power source for the Power supply unit (110V AC or DC to 12V DC Converter) with short circuit protection & properly rated fuse at its input. Output of the power supply unit shall be connected to all units with IS specified cables through

Ref: CG-WI-4.2.1-1 Ver 1.0

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suitable HRC fuses. High voltage protection is to be provided. Connection diagram of power supply unit shall be as per Annexure‘1’

20.12 EMI Filter Assembly:

EMI FILTER ASSEMBLY is to be used to suppress any unwanted spikes and surges generated from the power lines or from the coach battery.

20.13 Wiring Assembly: Wiring assembly shall be neat and clean with suitable cable markers on every wire and proper sleeving. The wiring standard shall be as per RDSO/2006/SPN-144 specification.

21. COMMUNICATION PROTOCOL: Industry standard protocols like http, FTP, SMTP, IMAP etc. shall be used over standard IP network for all types of the communication modes for transfer of data, software files and reports generated. No vendor specific protocol or file or data formats shall be allowed, so that interoperability of the devices selected for the system may be ensured.

22. DATA BASE BMU System will have capability to generate any new Train Number database and to store 100 train routes up and 100 train route down data. However to prepare this data following information shall be provided by coaching depot, conforming to clause no. 19.6.3 of the required train routes in the following format in Hindi, English and regional languages.

Route No.

Train No.

Train Name

Starting Station and Regional Language

List of Scheduled stoppages along with time table.

Destination Station and Regional Language

VIA (List of important station)

Software (as elaborated below) for feeding and editing data in Hindi, English and all Regional language as per 8th schedule of constitution of India and article 344(1) and 351 shall be provided by web server administrator. Supplier will do the necessary training and hand-holding support for making and editing database for first 3 months. Software Requirement i) Setup files of computer software on a CD. ii) Control flow chart and algorithm for the control logic.

Ref: CG-WI-4.2.1-1 Ver 1.0

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iii) Operating manual of the software. iv) Facility to modify the display program through Base Monitoring Unit/PC. v) 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 suppliers and programmer.

23. INSPECTION & TESTS: All the tests will be carried out from para No. 24 to 26 by manufacturer and record will be maintained by them, and will be produced to any authorized official of RDSO/ Railway/ Inspecting authority.

All tests from para No. 24 to 26 will be verified during approval and quality audit of the firm.

Regular acceptance test will be carried out as per Para 26.2, and manufacturer will produce all test record to inspecting authority.

In the event of dispute between the inspecting officer and the firm the decision of the Engineer shall be final and binding.

i) Unless otherwise specified all the tests shall be carried out at ambient

atmospheric conditions. For inspection of material, RDSO/SPN/144 shall apply. Inspection and testing shall be carried out to the effect that all requirements of this specification are complied with.

ii) Inspection shall be carried out for various types of boards, hardware modu les , for all its parameters, and software.

iii) PC based simulation facilities shall be created for demonstration of all the features of the LED destination board and PA, PIS units. System shall have all the necessary hardware and software modules for this purpose along with Un-Interrupted Power Supply Unit. This shall be checked during inspection for the functional and performance requirement of the complete system as per specification.

24. Batch Testing of LEDs. 24.1 At least 0.01% or Min 05 Nos. of the LEDs of every procured lot shall be tested

before use to the dispersion angle test procedure. Lot wise test record shall be maintained which may be verified by the inspecting officials.

24.2 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.

Ref: CG-WI-4.2.1-1 Ver 1.0

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24.3 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 1000C and epoxy used in the PCB shall have UV inhibitors.

24.4 Number of LEDs and their part number shall not be changed without prior approval of RDSO.

25. Routine Tests:

The following shall comprise the routine tests and shall be conducted by manufacturer in-house on every equipment and the test results will be submitted to the inspection authority before inspection. The application software in proper format shall also be submitted to the inspection authority in advance. i) Visual inspection of complete system ii) Insulation Resistance Tests iii) Performance test iv) Card-level functional tests on all the cards v) System level functional tests Any other tests shall be carried out as considered necessary by the purchaser

26. Type Tests For type test, one complete system consisting of all type of display boards shall be subjected to following tests as applicable:

26.1.1 Environmental /Climate Tests: All the Environmental /climate tests shall be conducted as per RDSO/SPN/144.

i) Enclosure Unit Sealing Test

Testing of the specified units for degree of protection IP65 is to be certified by one of the Government accredited testing laboratories.

ii) Shock and vibration testing Shock and Vibration testing of the complete system to be done to the standard of IS 60571/1 by one of the Government accredited testing laboratories.

Above test shall be repeated at 1000 units manufactured.

26.1.2 Endurance Test: i. Endurance test shall be conducted on the LED modules for continuous

operation which shall be 30 days continues burning with all LEDs of the module in “on” condition using a test software. The lux level at a distance of

Ref: CG-WI-4.2.1-1 Ver 1.0

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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%.

ii. Unit shall also be tested with a cycle of 10,000 operations of 2 minute “’on” and 1 minute “off”.

iii. Suitable digital timer device powered with same source which is used for LED modules shall be attached for the recording of total time period. Suitable power backup and UPS shall be provided for un-interrupted testing of the LED modules.

26.2 Acceptance Tests: 26.2.1 Sampling criteria :

Constitute the acceptance tests, which shall be carried out by the inspecting authority for the purpose of acceptance on 20% of the lots (minimum2 each type of system) offered for inspection by the supplier: following test shall be carried out on sample picked for acceptance testing. A. Visual inspection of complete system

i. System level functional tests ii. Card Level Checking iii. Module Level Checking

B. Performance Test C. Insulation Resistance Test D. Applied High Voltage Test

A. Visual Inspection: Each equipment of the system shall be visually inspected to ensure compliance with the requirement of this specification. The visual inspection shall broadly include: a) System Level Checking:

i) Constructional details. ii) Dimensional check. iii) General workmanship. iv) Configuration. v) Mechanical polarization on cards.

b) Card Level Checking: i) General track layout. ii) Quality of soldering and component mounting. iii) Conformal Coating. iv) Legend printing. v) Green /Black masking.

Ref: CG-WI-4.2.1-1 Ver 1.0

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c) Module Level Checking: i) Indications and displays. ii) Mounting and clamping of connectors. iii) Proper housing of cards.

B. Performance test : All the units shall be tested for their functionality as required in service condition as per this specifications design requirements. To simulate such condition in test lab a PC based simulator shall be specially developed for this purpose by the manufacturer.

C. Insulation Resistance Test: Insulation Resistance Test shall be conducted as per RDSO/SPN/144.

D. Applied High Voltage Test:

Applied High voltage test shall be conducted as per RDSO/SPN/144

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Ref: CG-WI-4.2.1-1 Ver 1.0

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Part-III INFRASTRUCTURAL REQUIREMENT

1. Scope: This section covers the infrastructural requirement for manufacturing and testing of the LED Destination board with Coach Diagnostic and Information System.

2. Requirements : All the vendors seeking registration with RDSO shall comply all the requirements mentioned below.

3. Manufacturing Facilities: 3.1. The manufacturer shall have adequate space and covered area with cemented

floor to accommodate the following. a) Damp free place for storage of raw material and finished products. b) Independent Manufacturing area c) Inspection area

3.2. Firm shall have following minimum M&P and Infrastructure at their works: i) Automatic wave soldering machine or automatic SMD pick & place

machine with Reflow oven.(MOU with third party for job work on pick and place machine as per QAP shall be allowed: if not available in-house )

ii) In Circuit Debugger / tester. iii) Ultrasonic PCB Cleaning Machine.

Ref: CG-WI-4.2.1-1 Ver 1.0

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iv) Regulated DC power supplies. v) Temperature controlled soldering and de-soldering work stations. vi) Electro static charge free work and storage area to prevent sensitive

components from damage during manufacturing, testing and storage. vii) LED illumination test fixture along with Dark Enclosure for measurement

of various parameters. viii) Micro computer based CAD work stations and developmental

workstations for hardware and software for PA & PIS. ix) Other regular tools like Measuring tape, Measuring scale, Magnifying

glass, screw drivers, cutting tools, crimping tools etc. used for manufacturing, electronic assembly line, inspection and testing of the LED destination board and PA & PIS.

4. Testing Facilities: 4.1 Firm should have following minimum testing facilities at their works:

i) Burn in test chamber / Dry heat chamber. ii) Insulation tester. iii) Dual Beam Oscilloscope of 20 MHz bandwidth iv) Chromo Meter or Spectrometer v) Digital Millimeters : 3 and 1/2 Digit Display with facility of diode &

transistor testing with 1% accuracy vi) LCR meter. vii) Megger (500 Volt) viii) PC based Simulator ix) Test Jig x) GSM/GPRS modem test setup through Hyper terminal xi) Any other test equipment considered necessary.

4.2 The firm should have arrangement for periodical calibration of all the equipment’s and test instruments.

5 QUALITY CONTROL REQUIREMENTS

5.1 The firm should have acquired ISO: 9001certification from the agency accredited by an accreditation body which is a part of International Accreditation Forum

Ref: CG-WI-4.2.1-1 Ver 1.0

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(IAF), and the product for which the approval is sought should be broadly covered in the scope of the certification for manufacture and supply.

5.2 The Quality manual of the firm for ISO: 9001 should clearly indicate at every stage the control over manufacturing and testing of the said railway product.

5.3 There should be a system to ensure the traceability of the product from raw material stage to finished product stage. The system should also facilitate to identify the raw material composition from the finish product stage.

5.4 It should be ensured that there is a Quality Assurance Plan for the product detailing the following various aspects. • Organisation chart • Process flow chart • Process control chart • Stage inspection details from the raw material stage to finish product stage. • Various Parameters to be checked and level of acceptance of such

parameters indicated and method to ensure control over them. • Disposal system of rejected raw material and components

5.5 There should be at least one full time technologist having a minimum Master’s degree in relevant field with experience of at least 3 years or Bachelor’s degree in relevant field with experience of at least 5 years or a person with Diploma in relevant field with 12 years experience. He should be free from day-to-day production, testing and quality control responsibilities. He should be mainly responsible for development of a product, analysis of products, control over raw material, and corrective action in case of difficulties in achieving the parameters.

5.6 Ensure that the in-charge of the Quality Control Section is having a qualification of minimum Master’s degree in relevant field with experience of at least 3 years or Bachelor’s degree in the relevant field with a minimum of 5 years’ experience or alternatively he should be a Diploma holder with minimum of 12 years’ experience. He should be actively involved in day-to-day activities of quality control / stage inspection / compliance of QAP etc.

5.7 The firm must ensure that proper analysis is being done on monthly basis to examine the rejections at various internal stages and it is documented.

5.8 The firm should ensure that latest version all the relevant specifications, IS Standards are available with the firm.

6. DOCUMENTATION

Firm shall maintain the following documents/records: 6.1 A well-documented Quality Plan.

Ref: CG-WI-4.2.1-1 Ver 1.0

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6.2 Incoming raw material register with Test Certificates references of suppliers and internal test results.

6.3 Stage inspection results including finished products results. 6.4 Records of internal rejection and its analysis vis-à-vis action plan. 6.5 Records of final products inspection by external agencies (like RDSO), Non–

conformity reports and case analysis as well as action taken thereof. 6.6 6.7 Ensure that proper systems are available for dealing with customer complaint. 7 TRAINING

Training needs should be identified for all concerned officials and regular training shall be organised and imparted on maintenance of machines, quality assurance, safety parameters etc.

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Ref: CGVer 1.0

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ANNEXURE,’2’

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Annexure -3 PARAMETERS TO BE CHECKED DURING THE FIELD TRIAL: Sl.No.

Parameter to be recorded in the field trial

Compliance (Complied /semi complied/ not complied)

Adequacy Remarks if any

1 Software for preparation of database of routes in PC/Laptop and interface with web server for data entry.

2 Uploading of route database /Modification/Replacing using Various option provided as well as through web server.

3 Recording coach health messages /alerts /reports of PA & PIS in MPU and synchronization in web server.

4 Train selection through web server, local authenticated SMS and manual selection in MPU directly.

6 Display of the destination board as per Presentation scheme defined in the specification.

7 Failure monitoring of the complete system and logging of the report in the MPU and synchronization of the report to web server.

8 Response time of the vendor for attending the complaints. Date of fitment and details of the firm along with contact address are required to be provided.

9 Downloading the daily log report of the Kms. earned by the coach.

10 Display quality and visibility of the destination board during daylight and other timings.

Ref: CG-WI-4.2.1-1 Ver 1.0

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Data of the train routes shall be provided by the depot conforming to the clause no. 20 of the specification.

ANNEXURE –4

UNDERTAKING AGAINST CARTEL FORMATION

We, ……………………………………. hereby, give an undertaking that as a Registered Vendor for manufacture and supply INSTALLATION, COMMISSIONING & MAINTENANCE OF GPS location based public address system, passenger information system & LED destination boards in LHB type AC and NON- AC coaches will not be a part of a cartel with other vendors and will be quoting competitive rates in the tenders invited by the Indian Railway/PUs.

We …………………………… are aware of the fact that the Registering Authority i.e. RDSO may de-list the name of our firm from the Master List of Approved Vendors if complaint is received about such cartel formation from any of the Railways/Production Units.

We confirm that the information furnished is correct to the best of our knowledge.

Seal and Signature (Authorised signatory of the firm)

Date : Place : Seal :

Date post:	31-Jan-2020
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Ref: CG- WI-4.2.1-1 Page Date of iss Spec RDSO/CG-1800 Ver...

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