GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(Railway Board)
INDIAN RAILWAY
STANDARD SPECIFICATION
FOR
ELECTRIC LIFTING BARRIER
(Tentative)
Serial No.S: 41/70
0.
FOREWORD
0.1
This specification is issued under the fixed serial No.S-41/70 the final number
indicates the year of original adoption as standard or in the event of revision, the
year of latest revision.
0.2
This specification requires reference to the following Indian Railway Standards
(IRS) and British Standard (BS) which shall also be complied with the extent
applicable.
IRS: 10
Mechanical signalling and Interlocking equipment
IRS:S 23
Electrical Signalling & Interlocking Equipment.
BS 170
Electrical performance of fractional horse power electric
motors and generators
BS 376 Pt. II
Railway signalling symbols: Pt. 2- Wiring symbols and
written circuits.
0.3
Whenever in this specification, any of the above mentioned specifications is
referred to by number only, without mentioning the year of issue, the latest issue of
that specification is implied, otherwise the particular issue referred to is meant.
0.4
This specification is intended chiefly to cover the technical provisions and the
provisions relating to supply of the equipment and so does not include all the
necessary provisions of a contract.
1.
SCOPE
1.1
This specification covers electrically operated manually controlled lifing barriers
extending across the full width of the road at level crossings.
1.2
This specification lay down the sequence of operation and the operating
characteristics. It gives the requirement of the motor, wiring, terminals and general
construction and performance of the lifting barriers.
1.3
This specification lays down the requirements of road signals and control panel
where these are also required by the purchaser.
1.4
This specification does not cover the details of external circuits, protective devices
used in conjunction with electric lifting barriers in their installation and railway
signals.
2.
TERMINOLOGY
2.1
The terminology referred to in this specification is covered by the definitions given
in IRS specification No. S 23*.
2.2
The terms referred to in this specification, but not covered BS the IRS specification
No. S 23* are defined below.
2.2.1
Electric Lifting Barrier: An electrically operated device, for closing the level
crossing against road traffic and comprises an electric motor, operating
mechanism, circuit controller, road signals, audible device, boom etc.
2.2.2
Level Crossing: That section of a road where the railway track crosses it at the
same level.
2.2.3
Operating Mechanism: Consisting of clutch, reduction gear, boom shaft and
suitable locking device.
2.2.4
Boom: That part of the barrier which in horizontal position prevents passage
across the level crossing.
2.2.5
Snubbing Device: A device employed, apart from the clutch, to minimise the
physical shock due to stopping the mechanism, at the end of its stroke.
2.2.6
Time of Operating: The time required to operate the barrier from horizontal to the
vertical position and vice versa but does not include the warning time.
2.2.7
Short time rating: A rating which specifies the load at which the motor, starting at
the ambient temperature may be operated for the period and under the conditions
specified on the rating plate, while complying with the requirements of this
specification.
2.2.8
Crank Handle: An appliance by which electrically operated lifting barrier may be
manually operated at the mechanism.
3.
SEQUENCE OF OPERATION
3.1
The operation of the Lifting Barrier shall take place in the following sequence:
a)
b)
c)
d)
e)
Open the detection contacts
Unlock the boom
Move the boom
Lock the boom in the full horizontal or vertical position.
Close the detection contacts.
*Electrical signalling and Interlocking equipment (Tentative)
4.
OPERATING CHARACTERISTICS
4.1
The type, rated voltage and current of the lifting barrier shall be as follows
Type
Rated Voltage
Rated current
Low Voltage
24V dc
High voltage 110V ac 50 hz single phase.
6-8 amps for boom lengths up to 8 m
8-12 amps for boom lengths above 8 m.
2 amps.
4.2
Time of operation of the lifting barrier shall not exceed 10 seconds at rated voltage and 20
seconds at 75% of rated voltage at the motor terminals.
5.
General Requirements
5.1
Lifting barrier shall be manufactured according to the design approved by the Purchaser.
5.2
Lifting barrier shall be robust in construction and the operating mechanism shall be
protected from unauthorized interference.
5.3
The boom of the barrier shall be light in construction and shall extend across the full width
of the road.
5.4
The height of the boom from the rail level shall be 1m. The length of the boom of the lifting
barrier shall be as specified by the purchaser. (See Appendix ‘A’ for preferred lengths of
the boom).
5.5
A support mounted on a base shall be provided for the tip of the boom in the horizontal
position.
5.6
The lifting barrier shall be provided with a pedestal suitable for mounting on a base.
5.7
Fringes of suitable design shall be provided with the lifting barrier, unless specified
otherwise by the purchaser.
5.8
Fringes, if provided, shall be clear of road surface by not more than 15 cm when the boom
is in the horizontal position.
5.9
The raised or open position of the lifting barrier shall be within 85-90 from the horizontal
and the lowered or closed position shall be within 5 deg. From the horizontal.
5.10
At the centre of the boom, the lifting barrier shall be provided with a 600 mm dia red disc
having red reflector buttons facing the road traffic.
5.11
The boom shall be painted alternately with 300 mm bands of black and yellow. The
fringes, if provided, shall also be painted similarly.
5.12
Lifting barrier shall be so designed that it can be stopped, reversed or its movement
obstructed at any point during operation without damage.
5.13
The mechanism shall be designed to prevent movement of the lifting barrier due to
vibration or any external forced applied to the mechanical connections or boom.
5.14
The design of mechanism shall be such and the boom so balanced that in case of failure
of power supply, the barrier shall remain in the position last assumed.
5.15
The mechanism shall be so designed that if the boom is obstructed during operation it
shall stop and on removal of the obstruction shall assume the position corresponding to
the control apparatus, unless protective devices have operated.
5.16
The movement of the lifting barrier shall be arranged to prevent any undue shock on the
mechanism. Suitable snubbing device capable of operating efficiently under all weather
conditions, shall be provided.
5.17
Means shall be provided to adjust the counter balance of the lifting barrier.
5.18
The operating mechanism shall include a suitable device to lock the lifting barrier in the
vertical and horizontal positions.
5.19
Electrical contacts shall be easily accessible and independently adjustable.
5.20
Electrical contacts shall be of low resistance, quick acting, self-aligning and wiping type
and shall conform to IRS specification No. S 23.
5.21
In addition to regular contacts for controlling the lifting barrier, a minimum of 4-additional
contacts shall be provided for controlling the external circuits, unless otherwise specified
by the purchase.
5.22
Bearings shall be of ample dimensions to ensure durability and conform to IRS
specification No.S 23 and shall be so constructed as to prevent entry of water.
5.23
Provision shall be made for proper lubrication at convenient locations of the bearing
surfaces and moving parts of the machine wherever necessary.
5.24
Exposed oil holes, cups or grease nipples shall be provided with weather proof spring
loaded covers.
5.25
Lifting barrier shall have two booms, one across the road on either side of the level
crossing, operated by independent mechanism.
5.26
Means shall be provided for manual operation of the lifting barrier by a hand-crank shall
disconnect the power supply to the motor and it shall not be possible to reconnect the
power supply until the hand-crank is withdrawn, and a switch is operated.
5.27
A separate fracture segment shall connect the boom with the mechanism near the pivot.
Fracture segment mounting shall be of such a design that it can be replaced easily and
quickly and in case of a mighty hit shall allow for the break or the segment without
endangering mechanism itself.
6
MECHANISM
6.1
Mechanism case shall be of metal strong, weather proof and of ample size to properly
house without crowding the apparatus and wiring therein, suitably arranged for convenient
and ready access.
6.2
A suitable gasket shall be provided on the mechanism case between the case and its door
to protect it from the water and dust.
6.3
Arrangement shall be provided for rigidly securing and padlocking the door of the
mechanism case.
6.4
The door or cover when open shall permit easy access to all parts..
6.5
Suitable weather proof cable entrance shall be provided with a flexible conduit of
appropriate size.
6.6
Ducts or channels for internal wiring shall be of ample size and form an integral part of the
mechanism.
7.
MOTOR
7.1
Motor shall be of totally enclosed type and shall comply with BS 170- ‘Electrical
performance of Fractional horse power electric motors and generators’ with class A
insulation for short time ratting (30 minute) motors, suitable for rotation in both the
directions.
7.2
Motor enclosure shall be a strong metallic weather proof case, the cover of which shall be
equipped with suitable fastenings and when open shall permit access to terminals,
commutator and brushes.
7.3
Motor shall be attached to, and form an integral part of the mechanism and shall be
readily removable therefrom.
7.4
Motor bearing shall be so designed that lubricants used can not reach the brushes,
commutator or windings.
7.5
The cable entry shall be of ample size, conveniently located for access to the terminals,
and arranged to protect the cable from mechanical injury.
8
TERMINAL
8.1
Terminals shall conform to IRS specification No. S 23 and be of size M-5.
8.2
Terminals shall be marked for identification purposes in accordance with the diagram of
connections.
9.
WIRING
9.1
Internal wiring shall be neatly arranged and shall conform to IRS specification No. S 23.
9.2
The conductors for the internal wiring shall be insulated and shall be of copper, stranded
having a cross sectional area or not less than 2.5 Sq.. mm and not less than three
strands. Both ends of each separate conductor shall be labeled and provided with an
eyelet of suitable type..
9.3
Common connections shall be capable of being disconnected readily for test purposes.
9.4
Wiring diagram with symbols of BS 376 Part 2 and explanations, if any, in English shall be
securely attached to the inner face of the cover of the mechanism case.
10.
CONTROL PANEL
10.1
When a control panel is specified to be provided by the purchaser, it shall incorporate
facilities to operate the two booms individually as well as simultaneously.
10.2
The control panel may be either of the miniature lever type or provided with push buttons
as specified by the purchaser. In either case, suitable arrangements shall be incorporated
to stop the barrier in any position.
10.3
In case of power failure during the operation of the barrier, it shall not be possible to revert
to normal working on resumption of power supply, unless and additional switch or lever
provided for this purpose is operated
10.4
Contactors of the approved type shall be provided for the operation of the barrier
10.5
Suitable protective devices shall be provided to disconnect the circuit in the case of overloading of the motor
10.6
Where flashing light signals have been specified to be provided for road signals., the
control panel shall incorporate a flasher and a timer unit of approved design. These shall
control the initial delay for warning and the correct flashing rate as specified under Road
signals.
10.7
Details of the control circuits for the barriers shall have the approval of the purchaser.
11.
ROAD SIGNALS
11.1
Where required by the purchaser, audible and/or visual warning arrangements for the
road traffic shall be provided along with the lifting barrier.
11.2
Audible and visual warning arrangements for the road traffic shall start operating 6-8
seconds before operation of the barrier from its vertical or open position and shall
continue till both the booms reach within 10 deg of the horizontal position.
11.3
The audible-visual warning arrangement for road traffic shall consist of an electric bell
operating on the same voltage as of the boom. One bell shall be provided at each side of
the level crossing.
11.4
The bell warning shall operate with a clear ringing sound and shall be audible for a
distance of not less than 300 m in a direction that the sound waves are not obstructed on
a clear day, with the wind velocity and the extraneous noises negligible.
11.5
The visual warning arrangement shall consist of a road signal of the colour light signal
type and the range of visibility shall not be less than 180m burning at 90% of the rated
voltage.
11.6
The colour light signals may display either a steady red light or a pair of horizontally
mounted flashing red lights as specified by the purchaser
11.7
Where a steady red light is specified to be provided as per clause 11.6. It shall continue to
be displayed when the boom is horizontal and when the boom is being raised till the boom
assumes the vertical position. Thereafter a steady while light shall be exhibited to the road
traffic.
11.8
Where flashing red lights are specified for warning arrangements as per Clause 11.6, their
arrangement shall be as per Appendix 'B'.
11.9
Flashing red lights, where provided, shall flash alternately at the rate of 45 to 55 per
minute, so phased that one of the pair of red lights is always exhibited to the road traffic
during the flashing period. They shall become steady once the boom reaches within 10
deg of the horizontal or closed position and shall continue to display a steady red
indication when the boom is being raised till it assumes the vertical position. Thereafter, a
steady while light shall be exhibited to the road traffic
11.10 The roundels used for the road signals shall have 30 deg horizontal spread slight with 15
deg downward deflection, unless otherwise specified by the purchaser.
12.
PERFORMANCE
12.1
Lifting barrier shall be capable of operating satisfactorily between the limits of 75% and
125% of the rated voltage applied at its terminals, and where as is used, with a frequency
variation of ±3%.
12.2
The gate mechanism shall operate uniformly and smoothly and complete all movements
without rebounding. It shall be securely held in clear position, until conditions require the
gate to be lowered.
13.
MANUFACTURE
13.1
The manufacturer shall ensure that in addition to all the provisions of this specification, the
requirements of IRS specification No. S-10* and S-23** tot he extent applicable and any
other specifications and drawings referred to by the purchase are fully complied with.
13.2
The following shall be in accordance with IRS Specification No. s-10* AND s-23** and the
extent applicable:
-
Material
Electro-magnet coils
Workmanship
Limits and Fits
Interchangeability
Other general requirements not covered by this specification.
Protection against corrosion
Heat treatment
Vitreous enamelling
Welding
Packing
14.
MARMING AND IDENTIFICATION
14.1
Marking and identification shall be in accordance with IRS Specification No. S23.
14.2
The name plate of the lifting shall also bear the following information pertaining to motor:
-
Manufacturer's name
Serial number
Year of manufacture
Rated voltage and current
Whether dc or ac
Frequency, if ac
H.P
* Mechanical signalling and Interlocking equipment
** Electrical signalling and Interlocking equipment (Tentative)
15.
FINISH
15.1
Finish of various parts shall be in accordance with IRS specification no. S-10 and S 23.
16
INSPECTION AND TESTING
16.1
Inspection and tests shall be carried out to ensure that all requirements of this
specification, IRS specification S1-0 and S-23 and any other specification referred to are
complied with.
17.
REJECTION
17.1
The lifting barrier or any part thereof that does not comply with any of the requirements of
this specification and / or any other specification and / or any of drawings as approved by
the purchaser, shall be rejected.
18.
WARRANTY
18.1
Warranty shall be as per IRS specification No. S-23.
Appendix 'A'
Information to be supplied by the purchaser
A.1
Type - High voltage or low voltage (Cl.4.1)
A.2
Length of boom (Cl. 5.4) preferred lengths of the boom
-
14 mtrs
12 "
10 "
8 "
6 "
4 "
A.3
Provision of fringe (Cl. 5.7)
A.4
Requirements of additional contacts, if required (Cl. 5.21)
A.5
Type of control panel, if required (Cl. 10.2)
A.6
Whether road signals are required (cl. 11.1)
A.7
Whether steady or flashing red lights shall be used for warning, if road signals are
required (Cl. 11.6)
Amendment No. 1
To
Indian Railway Standard Specification
Electric Lifting Barrier
S.No. S 41/70
Clause 0.2
Substitute 'IRS:S 37 Motors for Electric Point machine 'for' BS: 170 Electrical performance of
fractional horsepower electric motors and generators'.
Add the following at the end of Clause 0.2
"IS:1271 classification of insulting materials for machinery and apparatus on the basis of thermal
stability in service.
Clause 7.1
Substitute the following for the existing clause "7.1 Motor shall be of totally enclosed type and
shall comply with IRS:S 37 except in respect of scope, rated voltage, operating requirements and
dimensions and shall be with class B insulation in accordance with IS: 1271 and short time 30
minute rating suitable for rotation in both directions. The rated voltage of the motor shall be 24V
DC or 110V AC 50Hz as specified by the purchaser".
Add the following after clause 7.5.
"7.6 The motor when connected to Electric Lifting Barrier shall comply with the operating
requirements given under clause 4 of this specification".
Clause 16.1
Inspection and tests shall be carried out on the assembled unit of lifting barrier to ensure that all
the requirements of IRS:S 10, S 23, S 41 and any other specn referred to are complied with to the
extent applicable.
Add the following new clauses after Clause 16.1
Clause 16.2
Routine tests:- These tests shall be carried out on every Electric Lifting Barrier manufactured and
shall comprise
a)
b)
c)
d)
Visual inspection as per Clause 14.2 of IRS:S 23 as applicable.
Tests to ascertain the operating requirements as per Clause 4 of this specification.
High voltage test as per Clause 14.3.2.1 of IRS:S 23.
Insulation resistance test as per Clause 14.3.2.2 of IRS:S 23.
Clause 16.3
Acceptance Tests:- These tests shall be conducted on 10% of a batch subject to a minimum of
one Electric Lifting Barrier and shall comprise the following.
a) Visual inspection as per Clause 14.2 of IRS:S 23.
b) Operating requirements as per Clause 4 of IRS:S 41.
c) High voltage test as per Clause 14.5.2.1 of IRS:S 23.
d) Insulation resistance test as per Clause 14.3.2.2 of IRS:S 23.
Clause 16.4
Type test on Lifting Barrier:- Electric Lifting Barrier shall be operated continuously for 25000
cycles at the rate of 1 or 2 cycles per minute. No part of the lifting barrier shall show any sign of
erratic behaviour and at the end of the test, lifting barrier shall pass the test of operating
characteristics as laid down in Clause 4. This test shall be carried out on 2% of a batch subject to
minimum of one number of Electric lifting barrier.
Clause 16.5 - Tests on Motor
16.5.1 Routine Test: - This test on motor shall be conducted in accordance with Clause 17.2 of
IRS:S 37.
16.5.2 Acceptance Test:- This test on motor shall be conducted on 2% of a batch subject to
minimum of one motor at the rated voltage and shall comprise the following.
a)
b)
c)
d)
e)
f)
Visual inspection as per Clause 14.2 of IRS:S 23.
Operating requirements as per Clause 4 of IRS:S 41.
Temperature rise as per Clause 12 of IRS:S 37 and clause 4 of IRS:S 41.
Momentary over load as per clause 11 of IRS:S 37 and Clause 4 of IRS:S 41.
High voltage test as per Clause 19 of IRS:S 37.
Insulation resistance test as per Clause 18 of IRS:S 37.
16.5.3 Type test: This test on motor shall be conducted in accordance with Clause 17.1 of IRS:S
37.
Amendment No. 2
To
Indian Railway Standard Specification
Electric Lifting Barrier
S.No. S 41/70
Based on the experience gained on the performance of Lifting barrier motors of different
manufacturers, the following amendment to the above specification is being carried out.
Clause 7.1
The existing Clause may be amended as under:
"Motor shall be of totally enclosed type and shall comply with IRS:S 37 except in respect off
……., rated voltage, operating requirements and dimensions and shall be with class B insulation
in accordance with IS: 1271 and short time, 10 minute rating, suitable for rotation in both
directions. The rated voltage of the motor shall be 24V DC or 110V AC 50Hz as specified by the
purchaser".