VRIOGS 012.7.34 RevA - Public Transport Victoria

Victorian Rail Industry Operators Group StandardsVRIOGS 012.7.34Signal Power Supply Transformers2200V/110V Single Phase 10kVA 50HzRevision:AIssue Date: 06/11/2009

iiVRIOGS 012.7.34 Revision AVRIOGS 012.7.34 Signal Power Supply Transformers 2200V/100V Single Phase 10kVA50 HzRevision AIssue Date: 06/11/2009APPROVAL STATUSAPPROVER STATUS DATE QUALIFICATIONSDocument DeveloperVRIOG SteeringCommitteeApprovedAll SectionsAccredited Rail OperatorMetropolitan Train(Metro TrainsMelbourne)Intrastate Train(V/Line)Interstate Train(ARTC)Tram(Yarra Trams)For any queries please contact vriogs@transport.vic.gov.au.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision AiiiPURPOSE OF THE STANDARDThe Standard has been created through the collaboration of members of theVictorian Rail Industry Operators’ Group (VRIOG) for the purpose of establishingstandards which, if implemented throughout the Victorian Rail Network, will facilitatethe interoperability of infrastructure.The use of the Standard is not prescribed by law but, if adopted, conformity with theprovisions of the Standard is mandatory in order that the purpose of the Standard beachieved.DISCLAIMERThe Standard is published by the Director of Public Transport for informationpurposes only and does not amount to any kind of advice.Each person is responsible for making his or her own assessment of all suchinformation and for verifying such information. The content of this publication is not asubstitute for professional advice.The Director of Public Transport and VRIOG accept no liability for any loss ordamage to any person, howsoever caused, for information contained in thispublication, or any purported reliance thereon.COPYRIGHT STATEMENT© Director of Public Transport 2005.This publication is copyright. No part may be reproduced by any processexcept in accordance with the provisions of the Copyright Act.Where information or material is so used, it should be used accurately and theStandard should be acknowledged as the source of the information.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

ivVRIOGS 012.7.34 Revision ATABLE OF CONTENTSSECTION 1.0 CONVENTIONS...................................................................... 1SECTION 2.0 DEFINITIONS ......................................................................... 2SECTION 3.0 SCOPE AND GENERAL......................................................... 33.1 Scope.................................................................................... 33.2 Application ............................................................................ 33.3 Quality Assurance................................................................. 33.4 Quality Assurance Documentation........................................ 33.5 Maintenance Manual ............................................................ 33.6 Advisory Bulletins ................................................................. 33.7 Occupational Health and Safety ........................................... 3SECTION 4.0 OPERATING ENVIRONMENT ............................................... 44.1 Environmental Conditions..................................................... 44.2 Lightning and Surge Protection............................................. 4SECTION 5.0 TRANSFORMERS GENERAL................................................ 5SECTION 6.0 TRANSFORMERS WINDINGS .............................................. 6SECTION 7.0 TRANSFORMERS PERFORMANCE DETAILS..................... 7SECTION 8.0 MECHANICAL CONSTRUCTION .......................................... 8SECTION 9.0 TERMINALS ........................................................................... 9SECTION 10.0 CASE .................................................................................... 10SECTION 11.0 LABELLING .......................................................................... 11SECTION 12.0 DELIVERABLE REQUIREMENTS ....................................... 1212.1 Inspection and Tests........................................................... 1212.2 Certificates.......................................................................... 12SECTION 13.0 WARRANTY ......................................................................... 13SECTION 14.0 MAINTAINABILITY ............................................................... 14SECTION 15.0 GUARANTEED PERFORMANCE ........................................ 15SECTION 16.0 PACKAGING AND DELIVERY ............................................. 16SECTION 17.0 GENERAL PARTICULARS TO BE SUPPLIED BYMANUFACTURER.............................................................. 17SECTION 18.0 REFERENCES ..................................................................... 18SECTION 19.0 APPENDICES....................................................................... 1919.1 Terminal Voltage................................................................. 1919.2 Nameplate Details............................................................... 1919.3 Technical Details and Guaranteed Performance................ 20NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 1SECTION 1.0CONVENTIONS1) Words or phrases that appear capitalised out of context are defined within theDefinitions section of this VRIOG Standard.2) The word “Shall” is to be understood as mandatory.3) The word “Should” is to be understood as non-mandatory i.e. advisory orrecommended.4) Uncontrolled Standards may not be referenced within the VRIOG Standards.These include former PTC Standards, Franchisee Standards, FranchiseeSubcontractor Standards and Infrastructure Lessee Standards.5) Controlled Standards, including Australian Standards and other VRIOGStandards, may be referenced but only if:• The referenced item can not be adequately explained with an amountof text that could not reasonably be inserted into the body of theStandard.• The reader is not referenced to another Controlled Standardnecessary for the item to be adequately explained i.e. one documentlink only.• The referenced document is a Figure or table and could notreasonably be included in the appendices of the Standard.6) The format employed in the VRIOG Standards is compatible with AustralianStandards, and will be used from this point on.7) The numbering system for the VRIOG Standards is chronologicallysequential from the point of introduction, and is not based on any form ofinterpretive system.8) The VRIOG Standards contain engineering information necessary to operatea safe Railway. VRIOG Standards will not contain any information that can beconstrued as a work instruction, procedure, process or protocol. Thisinformation forms the basis of each individual entity’s Safety AccreditationCertification, and, as such, is outside the scope of VRIOG Standards.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

2 VRIOGS 012.7.34 Revision ASECTION 2.0DEFINITIONSTerminology used and/or applied in this Standard is defined as follows:-TerminologyAccredited RailOperator (ARO)Application forVariation ofAccreditationASPurchaserType ApprovalVRIOGVRIOGSDefinitionA Rail Infrastructure Manager or Rolling Stock Operatorwho is accredited under Part 5 of the Rail Safety Act 2006.An application to the Safety Director by an Accredited RailOperator for variation of its accreditation due to theAccredited Rail Operator proposing to make change to orto the manner of carrying out, accredited rail operationsthat may reasonably be expected:-• To change the nature, character and scope of theaccredited rail operations; or• To not be within the competence and capacity forwhich the Accredited Rail Operator is accredited.Australian StandardPerson or organisation to which the transformers aresupplied or being supplied.Note: They may not be a direct representative of the ARO.Consideration of form, fit and function under specifiedconditions to approve equipment suitability for use withinVRIOG infrastructure. (Refer to VRIOG “Standard forSignalling Design and Documentation” VRIOGS 012.1,Clause 4.2).The Victorian Rail Industry Operators’ Group comprisingthe following members:-• VicTrack• V/Line Passenger• Metro Trains Melbourne• Yarra Trams• Australian Rail Track Corporation (ARTC)• Public Transport Division of the Department ofTransport (PTD)Victoria Rail Industry Operators Group StandardsTable 1 – TerminologyNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 3SECTION 3.0SCOPE AND GENERAL3.1 ScopeThe objective of this Standard is to detail the minimum acceptance criteria for2200V/110V 50Hz 10kVA single phase signal power supply transformers.3.2 ApplicationThe transformers shall be suitable for enclosure in either a totally enclosed steelapparatus case or a power supply cubicle associated with a signal equipment room.3.3 Quality AssuranceThe manufacturer shall be accredited to the appropriate Australian Quality Standardsor recognised international equivalent if the manufacturer is based overseas.It is considered that the following are appropriate Australian Quality Standards:-- AS/ISO 9001 - Quality Management Systems – Requirements- AS/ISO 9004 - Quality Management Systems – Guidelines for Performances3.4 Quality Assurance DocumentationQuality assurance documentation shall be in accordance with the requirements ofAustralian Quality Standard “Quality Management and Quality Assurance Standards”AS/ISO 9000.2 or recognised international equivalent if the manufacturer is basedoverseas.3.5 Maintenance ManualThe maintenance manual shall be in accordance with the requirements of VRIOGStandard “Specification of Signalling Supply, Construction and Installation” VRIOGS012.2, Section 25.3.6 Advisory BulletinsThe Purchaser shall check and act upon any related manufacturer and ARO issuedproduct bulletins in order to ensure that they are aware of and action any safetyrelated concerns regarding the transformers.3.7 Occupational Health and SafetyThe manufacturer shall comply with the Victorian “Rail Safety Act 2006”, the“Occupational Health and Safety Act 2004” and the “Occupational Health and SafetyRegulations 2007”.The weight of the equipment shall be considered with regards to the current“Occupational Health and Safety Regulations 2007 & Codes of Practice” with regardsto safe handling by persons and with respect to the installation and maintenancerequirements.The manufacturer shall comply with a recognised international equivalent if themanufacturer is based overseas.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

4 VRIOGS 012.7.34 Revision ASECTION 4.0OPERATING ENVIRONMENT4.1 Environmental Conditionsa) All transformers shall comply with the condition specified in VRIOG Standard“Environmental Conditions” VRIOGS 012.7.25.b) All transformers shall be subject to the condition specified for Category B4equipment if housed in steel apparatus case.c) All transformers shall be subject to the condition specified for Category A3equipment if housed in a power supply cubicle associated with a signalequipment room.4.2 Lightning and Surge Protectiona) Any application of the transformers shall comply with VRIOG Standard‘Lightning and Surge Protection – General Requirements” VRIOGS 012.7.9.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 5SECTION 5.0TRANSFORMERS GENERALa) All transformers shall comply with the requirements of Australian Standards“Power Transformers” AS 2374 in as far as they applyb) All transformers shall be of single phase double wound type, air cooled bynatural radiation from the case, with rated output specified to operate from asingle phase 50 cycle supply voltage with a temperature rise not exceeding55ºC.c) All apparatus included in the specification shall be the best of its kind both ingeneral design and workmanship.d) Corresponding parts of all apparatus shall be made to gauge and shall beinterchangeable.e) All screws, bolts and nuts shall be locked in position so as to not work loose inservice.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

6 VRIOGS 012.7.34 Revision ASECTION 6.0TRANSFORMERS WINDINGSa) All transformers shall be provided with one primary winding and onesecondary winding with tappings to comply with the combination shown inSection 19 of this specification.b) All insulation used in the transformers shall be non-hygroscopic and designedto withstand continuously a temperature of one hundred degrees centigrade.c) After winding, the completed coils shall be thoroughly impregnated with aninsulating compound under the vacuum process in accordance with AustralianStandard “Power Transformers” AS 2374.d) The composition of the insulating compound shall be such that it will not soften orooze out under the continued action of hot oil.e) None of the materials used shall disintegrate under the continued action ofheat and oil and shall not carbonise, become brittle or lose their flexibility, withthe maximum working temperatures.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 7SECTION 7.0TRANSFORMERS PERFORMANCE DETAILSa) The voltage regulation, efficiency, non-load losses with full voltage applied tothe primary winding, high tension magnetising currents at normal voltage, etc. asshown in Section 17 of this specification, shall be provided by manufacturers.b) A fully descriptive rating plate in accordance with Australian Standard “PowerTransformers – Dry-Type Transformers” AS 60076.11 together with adiagram of input and output voltage tappings shown in Section 19.2 of thisspecification shall be securely fixed to the top of the case.Figure 1 – Transformer EnclosureNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 9SECTION 9.0TERMINALSa) All connections and tappings from the windings of the transformers shall bebrought to approve terminals at the top of the transformers.b) The terminals for the primary connection shall be fixed to the inside of the caseallowing for the connection of the VRIOG Standard “2200V High Voltage SignalPower Distribution cable: 7/1.7mm, 2 core copper cable with steel wire armour”VRIOGS 012.6.11.c) Terminals shall be provided at the front of the transformer case to accommodateall secondary connections. The secondary terminals shall accommodate theconnections leading away from the transformers.d) The secondary terminals shall have a removable transparent protective covermade from polycarbonate or equivalent approved material.The terminal studs shall be of suitable size to accommodate crimp lugs forthe largest cable size, (Cable size 19/1.78mm - 50mm², Minimum stud sizeM8)e) The transformers core shall be electrically connected to the case and a suitableterminal provided on the outside of the case for earthing.f) Terminals shall be legibly and durably marked as shown in Section 19.1 of thisspecification using characters at least 10mm high.g) The terminals +P4 and +S4 shall have the same instantaneous polarity and shall bemarked with a red disc.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

10 VRIOGS 012.7.34 Revision ASECTION 10.0CASEa) The case of the transformers shall be of uncorrugated welded sheet steel notless than 3mm thick.b) It shall be oil tight, and arranged to stand on 50 x 30mm (min) “C” channeliron.c) The transformer case shall have a top cover so arranged that it can easilybe removed when the transformer is in position connected ready for working,but will prevent the ingress of oil or foreign substanced) Collared lifting eyebolts to Australian Standard “Collared Eyebolts” AS 2317shall be fitted to the top of the transformer enclosure.e) Provision shall be made in the case for drainage.f) In order to fit in the Authorities enclosure the overall dimensions of theTransformers shall not exceed:-(i) Depth:(ii) Width:(iii) Height:450mm400mm400mmg) All metal surfaces shall be prepared in accordance with Australian Standard“Metal Finishing – Preparation and Pre-Treatment of Surfaces” AS 1627 priorto the application of protective primer to Australian Standard “Paints for SteelStructures – Epoxy Primer (two packs)” AS 3750.13.h) The exterior of the transformer enclosure shall be painted in accordance withAustralian Standard “Paints for Steel Structures – Full Gloss Epoxy (twopacks)” AS 3750.10 and colour Y13 (vivid yellow) in accordance withAustralian Standard “Colour Standards for General Purposes” AS 2700S.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 11SECTION 11.0LABELLINGa) Labelling shall conform to VRIOG Standard “General Requirements for Labellingof Signalling Equipment” VRIOGS 012.7.30.b) A weatherproof label (nameplate) shall be affixed to the top of eachtransformer and in such a manner that it cannot become dislodged during theoperation life of the transformer.c) The label shall include but not be limited to the following information:-• Manufacturer’s name• Unique serial number assigned by the manufacturer• Date of manufacture• Diagram of input and output voltage tappings including kVA ratingNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

12 VRIOGS 012.7.34 Revision ASECTION 12.0DELIVERABLE REQUIREMENTS12.1 Inspection and Testsa) Each signal power supply transformer shall be subjected to a series ofinspections and tests to ensure that it conforms to the requirements stated inthis specification.b) The transformers shall be tested in accordance with the Routine tests AS2374 in as far as it applies.c) The manufacturer shall carry out all electrical or/and mechanical inspectionsand tests to verify that the transformer conforms fully to this specification priorto delivery.d) All these tests shall be carried out at the manufacturer’s premises at theircost. The Purchaser reserves the right to witness these tests.e) All apparatus and instrumentation required for the tests shall be provided bythe manufacturer.f) The inspection and test records shall be retained by the manufacturer for aperiod not less than the nominated storage life and warranty period of theequipment.12.2 Certificatesa) The results of the inspections and tests are to be submitted in the form of asigned certificate on the manufacturer’s company letterhead.b) The manufacturer shall provide the completed Certificate of Compliance tothe Purchaser with the delivery of the transformers.c) The certificate shall include but not be limited to the following information:-• Certification number and Date of certification• Customer’s Name and Contract number• Purchase order number• Date of manufacture• Quantity of delivery• Unique serial number for individual product or batch code assigned bythe manufacturer• Date of the inspection and testing• Inspection and test results• Statement of compliance to certificate that the product meets all therequirements of this specification• Name and Signature of the manufacturer’s managementrepresentatived) The Purchaser shall have the right to request supporting Quality Assurancedocumentation to accompany the manufacturer‘s Certificate of Compliance.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 13SECTION 13.0WARRANTYa) The manufacturer shall provide warranty to the Purchaser on all items ofequipment supplied.b) All goods supplied by the manufacturer shall be guaranteed against faultyworkmanship and/or materials for a period of 12 months from the date ofcommissioning of the equipment or 24 months from the date of delivery,whichever is the later.c) The manufacturer shall replace without expense to the Purchaser any part (orparts) of the equipment found to be not in accordance with this specificationthroughout this warranty period.d) The manufacturer shall warrant components bought-in from external suppliersa warranty period no less than that specified in Section 13(b) of thisspecification.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

14 VRIOGS 012.7.34 Revision ASECTION 14.0MAINTAINABILITYa) The manufacturer shall provide a recommended maintenance plan for routinepreventative maintenance tasks, task frequencies and fault finding of theequipment to the Purchaser.b) These shall include but not be limited to the following information:-• Installation and maintenance instructions• Maintenance periodicities• Test equipment and specialist tools required to install, adjust, fault find andmaintain of the equipment.• Detailed drawings showing wiring diagrams and complete assembly details• Operational test plan• A troubleshooting guide (fault indications, their likely cause and suggestedsolutions)• Details on equipment repair and replacement procedures• Spare parts listNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 15SECTION 15.0GUARANTEED PERFORMANCEa) The manufacturer shall provide the technical details and guaranteedperformance listed in the Section 19.3 of this specification.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

16 VRIOGS 012.7.34 Revision ASECTION 16.0PACKAGING AND DELIVERYa) The transformer shall be individually and securely packed to avoidmechanical damage.b) All transformers shall be packaged and delivered in a manner such that theirsubsequent in-service performance remains unaffected.c) The packaging shall be labelled in accordance to VRIOG Standard “GeneralRequirements for Labelling of Signalling Equipment” VRIOGS 012.7.30,Section 5.4.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 17SECTION 17.0 GENERAL PARTICULARS TO BE SUPPLIEDBY MANUFACTURERa) The manufacturers shall supply the following information with regard to theequipment to be supplied:Efficiency of normal continuousoutput. (%)Efficiency at half continuousoutput. (%)H.T. Magnetising current.(Ampere)%%AmpInherent voltage regulation. (%) %No-Load losses. (Watt)Copper losses. (Wattage fullload)Weight (kg)Approximate overall dimensions.(mm)WattWatt F/Lkgmm (Depth)mm (Width)mm (Height)Table 2 – General Particularsb) The manufacturers shall forward all electrical and physical details of theirproposed transformers with quotes.c) The specification non-conformances shall be clearly specified so concessionscan be considered.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

18 VRIOGS 012.7.34 Revision ASECTION 18.0REFERENCESThe following documents have been used and referenced for the preparation of thisStandard:-No. Ref No. Title1. AS/ISO 9001 Quality Management Systems – Requirements2. AS/ISO 9004 Quality Management Systems – Guidelines forPerformances3. AS/ISO 9000.2 Quality Management and Quality AssuranceStandards4. AS 2374 Power Transformers5. AS 2317 Collared Eyebolts6. AS 1627 Metal Finishing – Preparation and Pre-Treatment ofSurfaces7. AS 3750.13 Paints for Steel Structures – Epoxy Primer (twopacks)8. AS 3750.10 Paints for Steel Structures – Full Gloss Epoxy (twopacks)9. AS 60076.11 Power Transformers – Dry-Type Transformers10. AS 2700S Colour Standards for General Purposes11. VRIOGS 012.1 Standard for Signalling Design and Documentation12. VRIOGS 012.2 Specification of Signalling Supply, Construction andInstallation13. VRIOGS 012.7.9 Lightning and Surge Protection – GeneralRequirements14. VRIOGS 012.7.25 Environmental Conditions15. VRIOGS 012.7.30 General Requirements for Labelling of SignallingEquipment16. - Rail Safety Act 2006 (Victoria)17. - Occupational Health and Safety Act 2004 (Victoria)18. - Occupational Health and Safety Regulation 2007(Victoria)Table 3 – ReferencesNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.34 Revision A 19SECTION 19.0APPENDICES19.1 Terminal VoltageThe following Terminal Voltage and Marking shall be provided:-+P1-P2 P3 P4200 20001005 11010+S1S2S3-S4Figure 2 – Terminal Voltage marking19.2 Nameplate DetailsThe following name plate and details shall be provided:-VRIOGSIGNALS No.10KVA 4.7 AMPSVOLTAGETYPE1 PHASE 50HZVOLTAGEP2-P1P3 +P4 S3 +S42000 21002200 2300S3-S1110 120115 125Figure 3 – Nameplate detailsNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

20 VRIOGS 012.7.34 Revision A19.3 Technical Details and Guaranteed PerformanceVictorian Rail Industry Operators’ GroupStandards Infrastructure Services GroupInformation & Guaranteed Performance of Transformer Serial No…………….Rated power:Rated voltage:Rated current:Magnetising current:Iron losses (at rated voltage):Copper losses (at rated current):kVA RMSkV RMSAmp RMSAmp RMSWattWattInsulation level:-Clearance in air:-Leading overalldimensions:-Lightning impulse withstand voltage:Power frequency withstand voltage:Phase to Earth:Phase to Phase:Height:Width:Depth:kV PeakkV rmsmmmmmmmmmmMass of core and windings:Mass of enclosure and fittings:Total mass:Enclosure thickness:Is the transformer encapsulated?kgkgkgmmYES / NOTable 4 – Technical details and Guaranteed PerformanceNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.