0123 led street light

5/24/2018 0123 LED Street Light

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Page 1 of 16 Effective from Draft Specification No. RDSO/PE/SPEC/PS/0123 (Rev. 0)-2009,Amdt -

GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

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

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

Sl.No. Date ofRevision/amendment

Revision/Amendment Remarks

1. 17.09.2010 Amendment 1 Clause nos. 9.0, 10.0, 11.0, 13.0 and 14.0deleted, and typographical errors corrected inclauses 5.9 and 7.0-xii, as per Railway Boardsletter No. 2006/Elect.(G)/150/9/Pt. dated10.09.2010.

2. - Amendment 2 -

vuqeksfnrAPPROVED

dk;Zdkjh funskd@fo|qr tkZizca/k funskky;Executive Director/EEM


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I N D E X

S.N. DESCRIPTION PAGE NO.

1.0 SCOPE 1

2.0 CONSTRUCTION 4

3.0 REFERRED STANDARDS 5

4.0 SERVICE CONDITIONS 5

5.0 TECHNICAL REQUIREMENTS 6

6.0 TESTS 9

7.0 METHOD OF TESTING 10

8.0 MARKING 13

9.0 ISO CERTIFICATION (Deleted) 1310.0 ELIGIBILITY CRITERIA (Deleted) 13

11.0 GUARANTEE (Deleted) 13

12.0 PPROVAL 13

13.0 DETAILS OF ESSENTIAL INFRASTRUCTURE(Deleted)

13

14.0 ESSENTIAL MEASURING INSTRUMENTSFOR TESTING (Deleted)

14

15.0 NNEXURE A 14


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SPECIFICATION FOR ENERGY EFFICIENT LED BASEDLUMINAIREUNIT FOR STREET LIGHT AND PLATFORM LIGHTING

FOREWARD

At present, conventional type luminaire are being provided for the street light and platformlighting. By introduction of white High Power Light Emitting Diode (LED) having more tha50, 000 working hours, it is possible to use LED lamps in place of existing fluorescen,Sodium vapour / Mercury vapour and Metal Halide lamps LED lights are almomaintenance free and as a result, total power saving is expected to be more than 50%Keeping in view of the energy conservation, increased life and recurring savings on accounof maintenance, use of environmental friendly energy efficient LED based luminaire being considered for street light and platform lighting.

1.0 SCOPE

The scope includes design, development, manufacturing, testing and supply of energefficient luminaire complete with all accessories, LED lamps with suitable current contr

driver circuit including mounting arrangement for street light and platform light. Thluminaire shall be suitable for rugged service under the operational and environmentconditions encountered during service as specified in clause 4.0. The following types luminaries are covered in this specification:

TABLE-1 (TYPE OF LUMINAIRE)

Type ofexistingfitting(Street Light)

Wattage ofexistingfitting*

proposed LED fitting MaximumWattage ofLED fitting

Initial LumenOutput

HPSV/HPMV 70W Type A 50W 4000

150W Type B 100W 8000250W Type C 170W 13500

400W Type D 260W 20000

Metal Helide 70W Type E 50W 4000

150W Type F 110W 8800

250W Type G 190W 15000

FTL 1X40W Type H 30W 2400

2X40W Type I 60W 4800

(PlatformLighting)

FTL 1X40W Type J 30W 24002X40W Type K 60W 4800

* At nominal input voltage of 220V AC

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

2.0 CONSTRUCTION


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a. All the luminaire shall be finalised based on the performance requirement. Thdetailed calculation for lux level as per clause no. 5.8 with uniform distributioincluding the lux distribution curve /graph/spatial distribution shall be submittein support of the dimensions selected and variation thereof. Housing shall be madof 1.6 mm thick sheet Steel conforming to IS: 513 (Grade O) or aluminum die cahaving high conductivity preferably to grade 5000 or similar to high conductiviheat sink material. Efforts shall be made to keep the overall outer dimensions aminimum as possible.

All light fittings shall be provided with toughened glass of sufficient strength undthe LED chamber to protect the LED and luminaries.

b. Suitable number of LED lamps shall be used in the luminaire. LED lamps NICHIA/ OSRAM/ SEOUL/ PHILIPS LUMILEDS/ LEDNIUM make shall be used fothe purpose. The manufacturer shall submit the proof of procurement of LEDs froabove OEMs at the time of testing.

c. Suitable reflector / lenses may also be provided to increase the illumination angle.

d. Supplier will be solely responsible for testing and performance of the luminarieafter installation and shall also ensure the specified and uniform illumination ancomfort level on the street/platform.

2.1 High power and high lumen efficient LEDs suitable for following features shall be used:

a. The efficiency of the LED lamps at 1100C junction temperature shall be more tha80%.

b.The working life of the lamp at junction temperature of 1100C for 350mA current shabe more than 50,000 hours of accumulative operation and shall be suitable fo

continuous operation of 24 hours per day .these features shall be supported witdatasheet.

c. Adequate heat sink with proper thermal management shall be provided.

d. Colour temperature of the proposed white colour LED shall be 6500k.

e. Minimum view angle of the LED shall not be less then 1200.

f. The output of LED shall be more than 100 lumen per watt at minimal operatincurrent and shall ensure guaranteed operation life of 50,000 burning hours witcontrolled junction temperature of 1100C.

g. Efficiency of driver electronics shall be more than 85%.

h. Power factor of complete fitting shall be more than 0.95.

i. The driver card shall withstand 440V and shall resume normal working when nominvoltage is applied again.

j. Thermal management shall be in such a way that LED junction temperature shall ngo beyond 80 degree centigrade.


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2.2 INFRINGEMENT OF PATENT RIGHTS

Indian Railways shall not be responsible for infringement of patent rights arising due tsimilarity in design, manufacturing process, use of the components, used in designdevelopment and manufacturing of these light fittings and any other factor which macause such dispute. The responsibility to settle any issue rises with the manufacturer.

3.0 REFERRED STANDARDS

IS: 513 Cold-rolled low carbon steel sheets.

IEC 60529 Classification of degree of protections provided byenclosures.

EN 55015 RFI 30MHz

EN 61000-3-2 Harmonics

EN 61547 Immunity

EN 60929 Performance

IEC 60598-2-1

Fixed general purpose luminaries

IEC 60598-1 General requirement and tests

IEC 61000-3-2 Limits for Harmonic current emission -THD < 10%

IEC 60068-2-38 Specification for Permitted Humidity Test

IS 10322 Specification for the luminaries

IS 4905 Method for random sampling

4.0 SERVICE CONDITIONS:

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

4.1 Environmental conditions

Maximum ambient airtemperature

: 55C

Minimum ambient airtemperature

: -5C

Max. Relative humidity : 100%Atmosphere : Extremely dusty and desert weather and desert

terrain in certain areas. The dust contents in air

may reach as high values as 1.6 mg/m3

Coastal area : The equipment shall be designed to work in coastalarea in humid, salt laden and corrosiveatmosphere.

The maximum value of the condition in the coastal area will be as follows:

Max. pH value : 8.5Sulphate : 7 mg/literMax. concentration of : 6 mg/liter


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chlorineMax. Conductivity : 130 micro sec./cmAnnual rainfall : Ranging between 1750 to 6250 mm with\thunder

stormAltitudes : Not exceeding 1200 m above sea level

4.3 The supplier shall provide In the field service support during guarantee period.

5.0 TECHNICAL REQUIREMENTS

5.1 The luminaire casing/housing shall be made of 1.6 mm thick sheet Steel conforming to I513 (Grade O) or aluminum die cast having high conductivity preferably to grade 5000 osimilar to high conductivity heat sink material.

5.2 The electronic components used shall be as follows:-

a) IC (Integrated circuit) shall be of industrial grade or above.

b) Metallic film / Paper/Polyester Capacitor shall be rated for a maximum temperatu

of 105C.c) The resistors shall be preferably made of metal film of adequate rating. The actu

loading versus rating shall be 3.

d) The junction temperature of the Switching devices such as transistors anMOSFETs etc. shall not exceed 125C (allowing thermal margin of 25 C).

e) The conformal coating used on PCBs should be cleared and transparent and shounot affect colour code of electronic components or the product code of the company

f) The heavy components shall be properly fixed. The solder connection should be witgood finish.

g) The electronics covered for this equipment shall pass all the tests called for in th

specification. The tenderer shall indicate the deviation or compliance otherwise thoffer may not be considered for evaluation.

h) The infrastructure for Quality Assurance facilities as called for in the specificatioshall be available for the manufacturing of this product. The compliance shall bindicated clearly in the tender itself.

5.3 The connecting wires used inside the luminaire, shall be low smoke halogen free, firetardant e-beam /PTFE cable and fuse protection shall be provided in input side.

5.4 Care shall be taken in the design that there is no water stagnation anywhere. The entihousing shall be dust and water proof having IP65 protection as per IEC 60529.

5.5 The control gear shall be designed in such a way so that temperature rise of hesink shall not be more than 450C with respect to ambient temperature.

5.6 For platform lighting, luminaire shall be such that the glare from individual LED restricted and shall not cause inconvenience to the public.

5.7 All the material used in the luminaire shall be halogen free and fire retardan


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confirming to UL94.

5.8 Illumination Level: The fitting shall be so designed that the illumination level shall bevenly distributed and shall be free from glare. Illumination level of different types luminaire shall be as below:

Sl. No. Type ofLuminaries

Vertical Distance offittings from thefloor level (Mtrs)

MinimumIllumination Level (

Lux)at centre

Colour ofillumination

Street Light

1. Type A 5 25 daylight white

2. Type B 7 25 daylight white

3. Type C 7 25 daylight white

4. Type D 7 25 daylight white

5. Type E 5 25 daylight white

6. Type F 7 25 daylight white

7. Type G 7 25 daylight white8. Type H 5 25 daylight white

9. TypeI 7 25 daylight whitePlatform Light

10 Type J 4 50 daylight white

11 TypeK 4 50 daylight white

Note: 1. Variation in illumination level shall be 2% is allowed in input voltage rangfrom 180VAC to 250VAC.

2. The illumination shall not have infra-red and ultra-violet emission. The tecertificate from the NABL approved laboratory shall be submitted.

3. Electronic efficiency shall be more than 85%.

5.8.1 Polar curves:-

Typical distribution of illumination of these luminaries shall be as given below:-

a. Street light


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b. Platform light

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

5.10 Detailed design shall be furnished before manufacturing of prototype. Howeveinformation as per Annexure-A shall be submitted by the manufacturers along with thoffer.

6.0 TESTS:

Tests are classified as:


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Prototype test

Type test

Acceptance test

Routine rest.

6.1 Prototype Test

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

6.2 Type Test

Type tests shall be carried out to prove confirmation with the requirement of specificatioand general quality/design features of the unit. In case of any change in Bill of Material design of unit, complete type test shall be repeated.

If any sample fails in any of the type tests, two fresh samples shall be taken and tested. any sample again fails in that test, the whole lot shall be rejected.

6.3 Acceptance Tests:

These tests are carried out by an inspecting authority at the suppliers premises on samptaken from a lot for the purpose of acceptance of a lot. Acceptance tests shall not bcarried out from particular size from the lot on which type tests have already beeconducted. Recommended sampling plan is given below.

6.3.1 Sample size and criteria for conformity

The luminaries shall be selected from the lot at random. In order to ensure randomness selection, procedures given in IS 4905-1968 (Reaffirmed 2001) may be followed.

6.4 Routine Tests:

These tests shall be performed by the manufacturer on each complete unit of the samtype and the results shall be submitted to the inspecting agency, prior to offering the lofor acceptance test.the firm shall maintain the records with traceability.

6.5 Test Scheme:

Sl.No.

Description of test Clauseno.

PrototypeTest

Type Test AcceptanceTest

RoutineTest

1 Visual and Dimensional check 7 (i) Y Y Y Y

2 Checking of documents ofpurchase of LED

7 (ii) Y Y Y Y

3 Resistance to humidity 7 (iii) Y Y - -

4 Insulation resistance test 7 (iv) Y Y Y Y

5 HV test 7 (v) Y Y Y Y

6 Over voltage protection 7 (vi) Y Y - -

7 Surge protection 7 (vii) Y Y - -

8 Reverse polarity 7 (viii) Y Y Y Y


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9 Temperature rise Test 7 (ix) Y Y - -

10 Ra (Colour Rendering Index)measurement test

7 (x) Y Y - -

11 Lux measurement 7 (xi) Y Y Y Y

12 Fire retardant Test 7 (xii) Y Y

13 Test for IP65protection 7 (xiii) Y Y - -

14 Environmental tests 7 (xv) Y - - -

15 Reliability Test 7 (xvi) Y - - -16 Life Test 7 (xvii) Y Y - -

17 Endurance Test 7 (xviii) Y - - -

7.0 Method of Testing

i) Visual and Dimensional Check:

The unit shall be checked visually for all dimensions as per approved design andrawing. General workmanship should be good; all the components propersecured and sharp edges shall be rounded off. Check the marking and quality of thworkmanship visually. Check the rating and make of electronic / electrical items.

ii) Checking of documents of purchase of LED

Check Document of purchase of LED lamps of approved sources viz. NICHIAOSRAM/ SEOUL/ PHILIPS LUMILEDS / LEDNIUM/AVAGO.

iii) Resistance to humidity test

This is carried out by suspending the painted panels in corrosion chambmaintained at 100% RH and temperature cycle of 42 to 48 deg. C for 7 days anexamining it for any sign of deterioration and corrosion of metal surface.

iv) Insulation resistance test

The insulation resistance of the unit between earth and current carrying par

shorted together shall not be less than 2 Mwhen measured with 500V megger.

v) HV test

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

tripping of supply.

vi) Over voltage protection

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

vii) Surge protection

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


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viii) Reverse polarity

The Luminaire shall withstand polarity reversal. It shall be operated with revervoltage for 5 minutes at maximum value of voltage range. At the end of this periodthe supply shall be made correct polarity and Luminaire shall operate in a normway.

ix) Temperature rise Test:

Temperature rise Test shall be conducted at 180VAC with full load.The temperaturise shall be recorded by temperature detectors mounted at the specified referencpoints on the body of semiconductors, capacitors and other components as agreebetween purchaser and manufacturer. The maximum-recorded temperature undworst conditions shall be corrected to 550C and compared with maximupermissible temperature (for power devices at junction). Under loading conditions aspecified above, the corrected temperature of the power devices shall have a safemargin of minimum 100C.

Temperature at junction shall not exceed 100 0 C when corrected to 550 C. ThLuminaire shall also be subjected for short time rating after continuous loading ensure the temperature rise is within the permissible limit. The maximutemperature rise of the electronics devices on the PCBs shall be in limit foindustrial grade components suitable for 850C environment. In case of exceedinlimit, use of MIL-grade component shall be considered keeping RDSO informed.

x) Ra (Colour Rendering Index) measurement test

The lumen is the unit of luminous flux, which is equal to the flux emitted in a solidangle of one Steradian by a uniform point source of one candela.

The initial reading of the chromaticity co-ordinates x & y shall be within 5 SDC(Standards Deviation for Colour matching) from the standardised rated value as peAnnex. D of IEC 60081 - 1997.The initial reading of the general colour-rendering index (Ra) shall not be less thathe rated value decreased by 3.

The lumen maintenance of the lamp shall not be less than 80% of the initial lumeafter 20000 burning hours and 70% of the initial lumen after 50000 hours . Thinitial lumen will be taken after 100 hours aging.

Photometric test shall be conducted as per annexure B of IEC 60081-97.

The lumen maintenance test shall be done as per annexure C of IEC 60081-97.

xi) Lux measurement

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

xii) Fire retardant Test


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Fire Retardant test shall be conducted as per IEC 332-1 of the wire used in thfittings.

xiii) Test for IP65 protection

This test shall be conducted as per IEC 60529.

xiv) Environmental tests

The Luminaire shall meet the following tests as prescribed in IEC 60571.

a) Dry heat test.b) Damp heat testc) Test in corrosive atmosphered) Combined dust, humidity and heat test

xv) Reliability Test

The reliability can only be determined in actual service. However, the followintests shall be carried out on the prototype to simulate as close as possible, th

service conditions. There shall be no failure during this test.

a)The light unit shall be mounted in an oven maintained at 75C.b)The light will be operated at the specified maximum voltage and at 75C for

period of 100 hours.

xvi) Life Test

The lumen maintenance & life test shall be done as per annexure C of IEC 600897.xvii) Endurance Test

The Luminaire shall be kept ON with input voltage of 250VAC for 200 hours. Aftthis the Luminaire is subjected to 20,000 cycles of ON and OFF, each cycconsisting of 3 seconds ON and 10 seconds OFF period. Luminaire shousurvive this test. Test is to be continued for one lakh cycles, followed bperformance test.

xviii) Safety:

The Luminaire shall comply with the safety requirements as per IEC 61195.

8.0 MARKING:

8.1 The following information shall be distinctly and indelibly marked on the housing:a) Indian Railway Insigniab) Year of manufacture/Batch Number/ Serial Numberc) Name of Manufacturerd) Rated watt and voltage (Input)e) Rated watt- Output


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9.0 ISO CERTIFICATION: (Deleted)

10.0 ELIGIBILITY CRITERIA: (Deleted)

11.0 GUARANTEE: (Deleted)

12.0 APPROVAL

12.1 While seeking approval, the firm shall submit a sample to the RDSO along with test rescircuit diagrams and dimensioned drawing of the Luminaire. The prototype testing shagot done at manufacturers work. However, Environ-mental and surge test shall be conduat any NABL approved laboratories.

12.2 The manufacturer shall also submit details like make, type, reliability grade, rating loading of various electronic components used in the circuit. The temperature rise ofvarious components under the most adverse conditions shall also be declared.

12.3 After completion of the type tests and submission of the sample along-with the techn

details as indicated above, the Luminaire shall be considered for approval.

12.4 WITHDRAWAL OF APPROVAL

Approval granted to the manufacturer is liable to be withdrawn in the event of noticing change at a later date in the design or change from the bill of material as approved eawithout seeking the prototype approving authority i.e. RDSO's approval or using componof inferior specification/quality compromising with the reliability.

13.0 DETAILS OF ESSENTIAL INFRASTRUCTURE (Deleted)

14.0 ESSENTIAL MEASURING INSTRUMENTS FOR TESTING (Deleted)

Annexure-DATA TO BE FURNISHED BY THE TENDERER

(LUMINAIRE WISE)

1.0 CUP SPECIFICATION:

a. Basic Mechanical dimension :b. Electrical and control :

c. Light output :d Cups raw specification with operating characteristics :e. Mechanical characteristics of cup :f. Emission Spectrum :g. Spectral Intensity Distribution :h. Ifvs Luminous Flux :i. Ifvs Correlated Color Temperature :

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


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Sl.No. Parameter Absolute Values

Min. Typical Max.

1 Luminous Flux (lm)

2 Luminous Intensity (cd)

3 Viewing Angle (Degree)

4 Luminous Efficiency(lm/w)

5 Spectral Length (nm)6 Dominant Wavelength (nm)

7 FWHM (nm)

8 Color temperature (K)

9 Purity (%)

10 Colour Rendering Index

11 CIE Coordinates Refer the chromaticity diagram

3.0 ELECTRICAL CHARACTERISTICS:

Sl.No.

Parameter Absolute value

Min. Typical Max.

1 Forward Voltage (V)

2 Pulse forward current (mA)

3 Reverse Leakage current (A)

4 Reverse Voltage (V)

5 Storage Temperature ( 0C)

6 Thermal Resistance ( 0C/W)

(Pulse width 1ms with duty cycle 1/16)

3.1 Forward voltage vs Normalised Vf

3.2 Ifvs Ir

4.0 BIN RANKING : Tj= 250C, If= 350mA

Sl. No. Rank Forward Voltage Vf (Volts) Luminous Flux v,lm

Max Min Max Min

1 Rank WD1

2 Rank WD2

3 Rank WD3

4 Rank WD4

5.0 COLOR RANKING : Tj = 250C, It =350Ma

Sl. No RankWD1,WD2,WD3,WD4

X

y

6.0 LED CUP DEGRADATION CHARACTERISTICS

Flux measurement in lumens from Zero Hours to 1800Hrs at every 100 Hrs.


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7.0 RELIABILITY REPORT:

a. Summary of results for day light cups

Sl.No

Stress DUT Conditions Duration failures

1 Operating life 5 If= 50mA,Tj=800

C 1800 Hrs2 Humidity 8 If=100mA,Tj=1000C,RH=85%

4058 Hrs

3 Temperature cycle 10 T= -400C to 1050C 1000 Cycle

b. Operating life: Tested at If = 350mA, Ta =250C

Sl.No

Condition Luminous flux (lm) Color Temperature

t-0 t-1800 t-0 t-1800

1 Worst

2 Mean

3 Best4

8.0 DRIVER

8.1 Driver weight :8.2 Driver dimension :8.3 Oscillator frequency :

9.0 PROTECTIONS:

- Input polarity :- Open circuit and low voltage conditions :- Short circuit on the output terminals :- Internal short-circuit (Fuse protection) :- Lamp failure :- Overload protection :

10.0 EFFICIENCY:

11.0 MTBF :

12.0 DIELECTRIC (1500V-50HZ FOR ONE MINUTE):

13.0 INSULATION RESISTANCE:

14.0 OPERATING TEMPERATURE:

15.0 GENERAL CHARACTERISTIC


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Type of start :

Internal control :

Nominal input voltage: 220 Volt AC :

Input voltage range 180 Volt AC to 250 VoltAC

:

Power 15 Watt maximum :

Efficiency > 90% : CEC > 70% :

50,000 hours at 350C(16 hours per day at340days/year)

:

Operating temperature: -250C to 80 0C :

Insulation resistance :

High resistance to vibration :

IP :

No Load power losses :

Output Ripple :

Line Regulation :

Load Regulation :

Weight :

Dimmable via wireless and manual control :

Line under voltage and over voltageprotection

:

Accurate Over Temperature and Overloadprotection

:

DONT not Feedback Compensation :

Digital Control :

Auto restart for open protection :

Hysteretic over temperature protection :

Self powered :

Current and voltage feedback providesconstant current output and protectiondisconnected load

:

Operation (kHz) :

U No load specification :

Code of conduct of efficiency of externalpower supply

:

ROHS complaint :

Remote ON & OFF :

Warranty :

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