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DRAFT SPEFICIATION FOR ELECTRIC LIFTING BARRIER WITH

HAND GENERATOR BACKUP

Specification No. RDSO/SPN/180/2005 with Amd. 1

Version 1.0

Number of pages 18

Government of India

Ministry of Railways

Research Designs & Standards Organisation

Manak Nagar, Lucknow - 226011

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DOCUMENT DATA SHEET

Version
Document No.
1.0
RDSO/SPN/180/2005

Title of Document

Draft Specification for Electric Lifting Barrier with

Hand Generator backup

Author

Vipul Goel, Jt.Director/Sig/RDSO

Approved By RDSO

Name: G.D. Bhatia

Desig: Sr.ED/ Signal

Abstract

This Document defines Draft Specification for Electric Lifting Barrier with Hand Generator
backup

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Document Control sheet

Name Organisation Function Level

Vipul Goel RDSO Member Prepare

G.D.Bhatia RDSO Approval

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Amendments

Version Chapter / Annexes Amendments Effective Date

1.0 First issue

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Table of Contents

Para No. Item Page No.

0. Foreword 7
1. Scope 7
2. Terminology 8
3. Sequence of operation 8
4. Operating characteristics 9
5. General Requirements 9-11
6. Mechanism 11
7. Motor 11
8. Hand operated Generator 12
9. Terminal 12
10. Wiring 12
11. Control Panel 12-13
12. Road Signals 13
13. Manufacture 13-14
14. Marking & Identification 14
15. Finish 14
16. Inspection & Testing 14
16.2 Type test 14
16.4 Acceptance test 14
16.7 Routine test 15
16.8 Visual check 15
16.9 Applied High Voltage test 15
16.10 Insulation resistance test on 15
Motor
16.11 Performance test 15-16
16.12 Environmental test on Motor 16
16.13 Life test 16
17. Rejection 16
18. Warranty 16
19. Packing 16
20. Installation & Maintenance Manual 17
21. Sampling Plan 18

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Abbreviations used

IRS Indian Railway Specification (Approved)

RDSO/SPN RDSO Specification (Tentative)
DC Direct Current
IS Indian Standard

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Government of India

Ministry of Railways

(RDSO)

DRAFT SPECIFICATION FOR

ELECTRIC LIFTING BARRIER WITH HAND GENERATOR BACKUP

Specification No. RDSO/SPN/180/2005

0. FOREWORD
0.1 This specification is issued with the fixed Serial No. RDSO/SPN/180/2005 followed by the year of
adoption as standard or in case of revision, the year of latest revision.
0.2 This specification requires reference to the following Indian Railway Standards (IRS) and British
Standards (BS) specifications, which shall also be complied with to the extent applicable:

IRS: S 10 Mechanical signalling and interlocking equipment

IRS: S 23 Electrical Signalling & Interlocking Equipment.

IRS: S 37 Motors for Electric Point machine

B.S: 376 Pt.2 Railway signalling symbols: Pt. 2 – Wiring symbols and written
Circuits

IS: 1271 Classification of insulating materials for machinery and apparatus on

the basis of thermal stability in service.

0.3 Wherever, in this specification, any of the above mentioned specifications is referred by number only
without mentioning the year of issue, the latest issue of that specification is implied.

0.4 This specification is intended chiefly to cover the technical provisions and does not include all the
necessary provisions of a contract.

1. SCOPE

1.1 This specification covers electrically operated hand generator type lifting barrier extending across the full
width of the road at level crossings.

1.2 This specification lays down the sequence of operation and the operating characteristics. It gives the
requirement of the motor, hand generator, wiring, terminals and general construction and
performance of the lifting barriers.

1.3 This specification lays down the requirements of road signals 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.

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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 by the IRS specification no. S 23 are
defined below:

2.2.1 Electrically Operated Hand Generator backup Lifting Barrier: An electrically operated device,
for closing the level crossing against road traffic and comprises of an electric motor, operating
mechanism, circuit controller, manually operated hand generator, 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 Hand Generator: The generator unit along with very low maintenance gear drive unit capable of
delivering power to operate Electric Lifting Barrier.

2.2.4 Operating Mechanism: Consisting of clutch, reduction gear, boom shaft and suitable locking
device.

2.2.5 Boom: That part of the lifting barrier which in horizontal position prevents passage of road vehicles
across the level crossing.

2.2.6 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.

2.2.7 Time of operation: The time required to operate the barrier from horizontal to the vertical position
and vice versa; but does not include the warning time.

2.2.8 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.

2.2.9 Direct Crank Handle: An appliance by which electrically operated lifting barrier may be operated
manually by hand at the mechanism.

3 SEQUENCE OF OPERATION

3.1 The operation of the Lifting barrier shall take place in the following sequence:

a) Open the detection contacts and simultaneously unlock the boom.

b) Move the boom.
c) Lock the boom in the full horizontal or vertical position and simultaneously close the detection
contacts.

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4. OPERATING CHARACTERISTICS

4.1 The rated voltage and current of the motor of lifting barrier shall be as follows:

Type Rated Voltage Operating Current / barrier for boom Maximum rated current for each
length upto 10 mtr. (max.) barrier for boom length upto 10
mtr. (max.)
DC 24V 3 Amp (max.) 5 Amp
DC 110V 0.6 Amp (max.) 1 Amp

4.2 Time of operation of the lifting barrier shall be kept minimum possible which shall be approx. 10
seconds at rated voltage and approx. 22 seconds at 75% of rated voltage at the motor terminals.

4.3 The Hand generator should have rating of 2 times the rated current of each barrier motor so that
both barriers of a gate can be powered by 1 hand generator simultaneously.

5. GENERAL REQUIREMENTS

5.1 Lifting barrier boom may be manufactured according to the design approved by the Purchaser.

5.2 Lifting barrier shall be robust in construction and the operating mechanism protected from
unauthorized interference.

5.3 The boom of the barrier shall be light in construction and extend across full width of the road. Its
structure in successive sections of boom shall be such that it does not create any unbalance in the
system and can withstand wind pressure.

5.4 The total length of the boom shall be in maximum 4 sections (depending on total length) joined by
nuts and bolts for easy replacement.

5.5 In horizontal position, the height of the boom from the rail level shall not be more than 1 meter. The
length of the boom of the lifting barrier shall be 16/24/32 fts as specified by the purchaser.

5.6 A support mounted on a base shall be provided for the tip of the boom in the horizontal position.

5.7 The lifting barrier shall be provided with a pedestal suitable for mounting on a base.

5.8 The raised or open position of the lifting barrier shall be within 85-90 degree from the horizontal and
the lowered or closed position shall be within 5 degree from the horizontal.

5.9 At the center of the boom, the lifting barrier shall be provided with a 600 mm dia red disc having red
reflector buttons/ luminous stripes facing the road traffic. The disc shall be marked with “STOP” sign
of 50mm width in white luminous paint/ stripes (or similar signage in language specified by
purchaser).

5.10 The boom shall be painted/ provided with luminous stripes (reflective tape) alternately with 300-mm
bands of black and yellow colour.

5.11 Lifting barrier shall be so designed that it can be stopped, reversed or its movement obstructed at
any point during operation without damage. During operation in reverse direction, a delay of atleast
2 seconds shall be provided to avoid excessive load on motor.

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5.12 The mechanism shall be designed to prevent movement of the lifting barrier due to vibration or any
external force applied to the mechanical connections or boom.

5.13 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.

5.14 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.

5.15 The movement of the lifting barrier shall be so arranged to prevent any undue shock on the
mechanism. Suitable snubbing device, capable of operating efficiently in such a way that boom falls
gradually under all weather conditions, shall be provided.

5.16 Means shall be provided to adjust the counter balance of the lifting barrier.

5.17 The operating mechanism shall include a fail-safe locking arrangement to lock the lifting barrier in
the vertical and horizontal positions.

5.18 Electrical contacts shall be easily accessible and independently adjustable.

5.19 High precision, sturdy limit switch having expected life of atleast 10x106 operations shall be used.

5.20 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 purchaser.

5.21 Bearings shall be of adequate dimensions to ensure durability and conform to IRS specification
number S 23 and shall be so constructed as to prevent entry of water.

5.22 Provision shall be made for proper lubrication at convenient locations of the bearing surfaces and
moving parts of the machine wherever necessary.

5.23 Exposed oil holes, cups or grease nipples shall be provided with weather proof spring loaded
covers.

5.24 Lifting barrier shall have two booms, one across the road on either side of the level crossing,
operated by independent mechanism.

5.25 The lifting barrier shall have three modes of operation as given below -

a) With push button switch in case of 24V/110V DC power supply is available

b) With hand generator
c) With direct crank handle on one boom at a time in case of power supply failure. The insertion of
this crank handle shall disconnect the power supply to the motor and it shall not be possible to
reconnect the power supply to the motor until the hand crank is withdrawn.

5.26 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. In case of a
mighty hit, it shall allow for the break of the segment without endangering mechanism itself. The first
section of boom acts as fracture segment.

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5.27 The boom locking proving contact shall be made effective within 0-30mm displacement between the
magnet actuator plate and boom solenoid proving switch. It should be suitably protected from rain
water. This proving contact should make only after boom hook has fallen into the boom lock
arrangement & the locking lever moves into locked position. There shall be no accumulation of
water in the boom lock assembly.

6 MECHANISM

6.1 Mechanism case shall be of metal sheet of sufficient strength, weather proof and of adequate 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 weatherproof cable entrance shall be provided with a flexible conduit of appropriate size.

6.6 Ducts or channels for internal wiring shall be of adequate size and form an integral part of the
mechanism.

7. MOTOR

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 10 minute rating suitable for rotation in both directions. The
rated voltage of the motor shall be 24V DC / 110V DC as specified by the purchaser.

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 cannot reach the brushes, commutator or
windings.

7.5 The cable entry shall be of adequate size, conveniently located for access to the terminals and
arranged to protect the cable from mechanical injury.

7.6 Motor, when connected to electric lifting barrier, shall comply with the operating requirements given
under clause 4.0 of the specification.

7.7 The motors of the barriers shall be compatible with the hand-operated generator provided

7.8 Motor shall be protected against overload. Special motor protection type MCBs having built in
bimetallic overload protection shall be used.

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8.0 HAND OPERATED GENERATOR

8.1 The Hand operated generator of adequate capacity shall provide power simultaneously to both the
motors of one set of barriers. The generator shall be coupled to a sealed type very low maintenance
gear unit to multiply slow rate of approx. 50-70 rpm rotation of crank handle to approx. 1500 rpm to
run the electrical motor.

8.2 The rotational speed of 1500 r.p.m of motor shall be translated into displacement for closing /
opening of the barrier.

8.3 Rotating the crank handle of generator clockwise should close both barriers while anti-clockwise
rotation should open the barriers. If cranking is stopped, the movement of barriers should also stop.

8.4 The generator unit should be of floor mounting type.

9. TERMINAL

9.1 Terminals shall be cage - clamp type of PHOENIX /WAGO make and of suitable capacity.

9.2 Terminals shall be marked for identification purposes in accordance with the diagram of connections.

9.3 Terminals for external connections shall, as far as practicable, be located near the cable entry.

10 WIRING

10.1 Internal wiring shall be neatly arranged and shall conform to IRS specification No. S 23.

10.2 The conductors for the internal wiring shall be insulated, stranded and be of copper 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.

10.3 Common connections shall be capable of being disconnected readily for test purposes.

10.4 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.

11. CONTROL PANEL

11.1 The control panel shall consist of:-

SN Description Nomenclature
1 A selector switch to select hand generator operation / auto push MANUAL / AUTO
button operation.
2 Two push button switches having thermal rated current of 10A for CLOSE, OPEN
closing / opening of the barrier (in case 24V/110V supply is
available). The barrier shall operate as long as corresponding
button is pressed and shall stop when button is released.
3 Two selector switches which can facilitate to operate the two BARRIER 1 ON/OFF,
booms individually as well as simultaneously. BARRIER 2 ON/OFF
4 A selector switch of 10A rating to control feed to motor MOTOR ON/OFF

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11.2 Suitable circuit should be provided to cut off supply to concerned barrier motor when operated
barrier reaches fully open or closed positions.
11.3 Suitable protective devices shall be provided to disconnect the circuit in the case of over-loading of
the motor.

11.4 Push button switches, selector switches having expected electrical & mechanical life of atleast one
million operations shall be used.

11.5 The control panel and hand generator shall be integrated into one unit for ease of operation and
maintenance.

12. ROAD SIGNALS

12.1 Where required by the purchaser, audible and/or visual warning arrangements for the road traffic
shall be provided along with the lifting barrier.

12.2 The audio- visual warning equipment shall be installed on the left side of the road on the top of a
post, on either side of the level crossing, or at a location specified by the purchaser.

12.3 The Audio-Visual unit for road traffic shall consist of red and yellow aspects of LED signal / Signal
lamp from RDSO approved sources and Ding-Dong bell fitted in three aspect signal units as per
RDSO drawing number SA 23002A/M. The red aspect, yellow aspect and Ding-Dong bell shall be
fixable in the three slots available in the three Aspect CLS unit. The operation of Ding-Dong bell and
signal aspects shall be on the same voltage (24V/110V DC) as of the barrier operation

12.4 The traffic signals on each side of the railway line shall be positioned /provided so as to face
outwards from the crossing towards approaching road traffic and shall give 400 m continuous
visibility except curves, where it is not possible to achieve specified visibility due to geographical
conditions.
12.5 Audio and visual warning arrangements for the road traffic shall start operating when the barrier
moves from its vertical or open position and shall continue till both the booms reach within 10 degree
of the horizontal position.
12.6 A steady red light 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 yellow light shall be
exhibited to the road traffic.

12.7 Audio warning shall operate with a clear DING-DONG sound and shall be audible for a distance of
not less than 30 meters in a direction that the sound waves are not obstructed on a clear day, with
the wind velocity and the extraneous noises negligible.

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
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- Workmanship
- Limits and Fits
- Interchangeability
- Other general requirements not covered by this specification.
- Protection against corrosion
- Heat treatment
- Vitreous enamelling
- Welding
- Packing

14. MARKING & IDENTIFICATION

14.1 Marking and identification shall be in accordance with IRS specification no. S: 23. The nameplate of
the lifting barrier shall also bear the following information pertaining to motor-
a) Manufacturers name
b) Serial number
c) Year of manufacture
d) Rated DC voltage and current
e) H.P of the motor

15. FINISH
15.1 Finish of various parts shall be in accordance with IRS specification no. S:10 and S: 23.

15.2 Suitable protective coating to prevent corrosion shall be provided on detector contacts, crank handle
contacts and motor.
16. INSPECTION & TESTING

16.1 Inspection and tests shall be carried out to ensure that all requirements of IRS:S 10, S: 23, S:37,
S:41 and any other specification referred to are complied with to the extent applicable.
16.2 Type Test
The following shall constitute type test and shall be conducted in the sequence given below: -

(a) Visual check (Cl.16.8)

(b) Applied high voltage test ( Cl.16.9 )
(c) Insulation resistance test (Cl.16.10)
(d) Performance test (Cl.16.11)
(e) Environmental test on motor (Cl.16.12)
(f) Life test (Cl.16.13)
16.3 One barrier shall be tested for this purpose. The barrier system shall pass all the type tests for
proving conformity with the relevant specifications. In case of any failure, in any of the tests, the
inspecting authority, at his discretion, may call for another barrier system of the same type and rating
and subject the same to all the type tests. No failure shall be permitted in the repeat test.

16.4 Acceptance Test

The following test constitutes the acceptance test and shall be conducted in the sequence given
below: -

(a) Visual check (Cl 16.8)

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(b) Applied high voltage test ( Cl.16.9 )

(c) Insulation resistance test (Cl.16.10)
(d) Performance test (Cl.16.11)

16.5 The samples for acceptance test shall be selected as per Appendix ‘B’.

16.6 For acceptance of the lot no sample shall fail in the acceptance test.

16.7 Routine Test

The following shall constitute routine test and it shall be conducted by the manufacturer on
every lifting barrier system offered and the test result shall be submitted to the inspecting
authority during inspection.

(a) Applied high voltage test ( Cl.16.9 )

(b) Insulation resistance test (Cl.16.10)
(c) Performance test (Cl.16.11)

16.8 Visual Check

16.8.1 The visual checks shall be carried out as laid down in IRS: S 23 in compliance to the
relevant clauses of the specification. In addition, the detailed dimensional check and
surface finish of all the parts shall be conducted.

16.9 Applied High Voltage Test

16.9.1 The insulation of an assembled barrier system shall withstand for one minute test voltage of 2000 V
rms between all parts of electric circuits and other metallic parts insulated there from.

16.9.2 HV test for motor shall be carried out as follows:

SN Description Test Voltage Duration

1 Between field winding and 2000V AC (rms) at 50 Hz 1 minute for type test and
body with armature isolated between 5-10 secs for
Acceptance & Routine test
2 Between armature and 1000V AC (rms) at 50 Hz 1 minute for type test and
body with field isolated between 5-10 secs for
Acceptance & Routine test

Note: In case of series wound motor, high voltage test shall be conducted between field winding and
body only.

16.10 Insulation Resistance Test on Motor

16.10.1 This test shall be made before and after high voltage test at a potential of not less than 500 V DC
and value obtain shall not be less than 10 Meg ohm.

16.10.2 For series wound motors, the terminals of field and armature winding shall be connected together
and the insulation resistance measured between the common terminal and body. In case of
permanent magnet DC motors, the insulation resistance shall be measured only between the
terminals of armature winding and the body.

16.11 Performance test

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Performance test shall be conducted to verify the following:

16.11.1 Lifting barrier shall be capable of operating satisfactorily between the limits of 75% and 125% of the
rated voltage applied at its terminals as referred in Clause 4.

16.11.2 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.

16.11.3 Performance test of DC motor i.e. momentary overload and temperature rise shall be carried out as
per IRS: S 37 /82 with latest amendment.

16.12 Environmental test on motor

The environmental test shall be carried out on DC motor as per IRS:S 37 in the following sequence.

a) Dry heat test (85 deg. C ± 3 deg.C) as per IS: 9000 Pt.III/Sec.1 to 5 for 16 hours.
b) Cold test (-10 deg.C ± 3 deg.C) as per IS: 9000 Pt.II/Sec.1 to 4 for 16 hours.
c) Damp heat test (cycling) as per IS: 9000 Pt.V/Sec.1 & 2 for one cycle of 24 hours.
d) Salt mist test as per IS: 2106 Part XVIII
e) Water spray test as per IS: 2106 Part XI.

Note: 1. After each of the tests mentioned above, it should be checked up that the motor rotates
freely when connected electrically. In the cast of cold, damp heat, salt mist and water spray
tests a recovery period of two hours should be allowed. The voltage should be increased
gradually from Zero till the rotation sets in. The voltage should under no case exceed 40% of
the rated voltage.

2. Insulation resistance values shall be measured after dry heat, cold and damp heat tests as
per procedure given in clause 16.10. The value of the insulation resistance after the climatic
test shall not be less than 5 Meg ohms.

16.13 Life Test

16.13.1 The system shall be installed and it shall be operated continuously for one-lakh cycles i.e. opening
and closing at the rate of 1 or 2 cycles per minute. The motor shall be tested in integrated manner
alongwith barrier at nominal operating load of the barrier. Hand generator movement shall be
simulated by using a motor and a gear box. No part of the lifting barrier shall show any sign of
erratic behaviour and at the end of test, lifting barrier shall pass the test of operating characteristics
as laid down in Clause 4. Also, no damage shall occur to the motor at the end of the test.

(During the test, for barrier normal maintenance of tightening of bolts, periodic lubrication,
adjustments etc and the motor, normal maintenance of replacing carbon brushes, periodic
lubrication, adjustment etc may be undertaken).

17. REJECTION

The system or any part thereof that does not comply with any of the requirements of this
specification and / or of any other specification and / or of drawings as approved by the
purchaser may be rejected.

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18. WARRANTY

18.1 Warranty shall be as per IRS specification no S-23.

19. PACKING

The packing shall be done in accordance with IRS: S 23. The system shall be packed in a suitable
wooden crate to protect it from any damage during transit etc.

20. INSTALLATION AND MAINTENANCE MANUAL

2 copies of Installation and Maintenance manual shall be supplied along with each system.

The manual shall include the following information:

a) General information about the system.

b) Power supply requirement
c) Installation procedure.
d) Testing and adjustment procedure.
e) Maintenance and lubrication procedures and their periodicity. Grade of oil and grease to be
used.
f) Procedure for replacement of parts and periodicity of routine replacement of parts.
g) Tools required.

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APPENDIX ‘A’

INFORMATION TO BE SUPPLIED BY THE PURCHASER

a) Length of the boom

b) Rating
c) Requirement of number of contacts

APPENDIX ‘B’

SAMPLING PLAN

1. Lot :

All the lifting barrier of the same type manufactured by the same factory during the same period shall
constitute a lot.

2. Sample Size :

The number of lifting barriers selected at random for acceptance test shall constitute sample size.

3. The lot size and sample size shall be as per the following table:

TABLE

S.No. Lot Size Sample Size

1 1-4 25 % (min 1)
2. 5-20 20 % (min 2)
3. 21-50 10 % (min 4)

Note: If a lot consists of more than 50 lifting barriers, the lot shall be divided into smaller lots
consisting of the above lot sizes.

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