1 Scope
This document specifies the requirements for the use, design, manufacture and testing of electronic devices installed on rail rolling stock, as well as the basic requirements for the hardware and software required for the durability and reliability of the devices. If appropriate, additional requirements in other standards or specifications may be added to this document. The mutually agreeable provisions of this document are listed in Appendix A.
This document applies to all control, regulation, protection, diagnostic, power supply and other electronic devices installed on rail vehicles, which may be powered by onboard batteries or generators, or by low-voltage power supplies (transformers, voltage dividers, auxiliary power supplies) connected directly or indirectly to the contact network.
The special requirements required to ensure a functional safety level in practice are defined in GB/T 21562-2008, 4.6.3.1, 4.6.3.2 and Appendix A.
When residual risks remain and are to be performed by a software-driven programmable electronic system, Software Safety Integrity Level 1 or higher is considered, see GB/T 28808-2021.
For the purposes of this document, an electronic device (hereinafter referred to as "device") is a device consisting primarily of semiconductor devices and other common components, usually mounted on a printed circuit board.
Note. This document is also used for sensors (such as current, voltage, speed, etc.) and power electronic devices trigger board, complete trigger device see GB/T 25122.1.
2 Normative references
The contents of the following documents constitute essential provisions of this document through the normative references in the text. Among them, the date of the cited documents, only the date of the corresponding version applicable to this document; do not note the date of the cited documents, the latest version (including all the revision of the list) applicable to this document.
GB/T 1402 Voltage for traction power supply systems for rail vehicles (GB/T 1402-2010, 1EC 60850:2007, MOD)
GB/T 2423.1 Environmental tests for electrical and electronic products ﹑ Part 1: Test methods, Test A: Low temperature (GB/T 2423.1-2008,1EC 60068-2-1:2007,IDT)
GB/T 2423.2 Environmental testing of electrical and electronic products, Part 1: Test methods: Test B: High temperature (GB/T 2423.2-2008, 1EC 60068-2-2:2007, IDT)
3 Terminology and definitions
The following terms and definitions apply to this document.
3.1
Printed boardprinted board
A substrate material that can be divided into various sizes.
Note 1: Includes all holes and has at least one conductive type.
Note 2: Printed boards are usually classified according to their structure (e.g. single, double-sided or multilayer boards) or the nature of the substrate material (e.g. rigid or flexible).
3.2
Printed board assembly
A printed board that contains electrical and mechanical components, ancillary printed boards and has been soldered, coated and other production processes.
3.3
Plug-in unit
Plug-in boxes. Various units supported by rails.
Note: For example, a cassette unit or a printed board assembly in a frame designed for plug-in connection.
4 Environmental conditions
4.1 General conditions of use
4.1.1 Altitude
The altitude should not exceed 1400 m during normal operation.
The altitude correction factor K for frequency withstand voltage shall be determined by negotiation between the supplier and the customer in accordance with the value of 4.2 in GB/T 32347.1-2015.
4.1.2 Ambient temperature
Under the temperature classes selected in accordance with Table 1, the design and manufacture of the device shall meet all the performance requirements specified. The design shall take into account the temperature rise within the cabinet to ensure that the device does not exceed the specified temperature rating. In addition, the device shall comply with the specified thermal conditions for short term start-up by selecting the temperature values specified in column 3 of Table 1.
4.2 Special operating conditions
4.2.1 General requirements
Where the conditions of use differ from 4.1 (e.g. where the device is mounted on a bogie or in a power converter), special measures shall be taken by agreement between the supplier and the customer. In order to verify the effectiveness of these measures, selective test items may be specified and tested in test chambers or on rolling stock according to methods to be determined by both the supplier and the demander.
4.2.2 Atmospheric pollution
The device may be exposed to a variety of pollutants (e.g. oil mist, salt spray, conductive dust, sulphur dioxide) during its lifetime and the type of these pollutants and their concentration shall be determined by agreement between the supplier and the customer.
5 Electrical requirements
5.1 Power supply
5.1.1 Power supply from batteries 5.1.1.1 General requirements
The nominal voltage (U,) of the device shall be selected from the following values; 24 V, 32 V, 36 V, 48 V, 64 V, 74 V, 87 V, 96 V and 110o v.
24 v, 74 V and 110 v are suitable.
The different voltage ranges can be determined by mutual agreement between supply and demand in accordance with GB/T 21413.1.
Note: These nominal voltage values are only used as standard values for the design of the device and are not considered as the no-load voltage of the battery; the no-load voltage of the battery is determined by the battery type, the number of individual batteries and the operating conditions.
5.2 Power supply overvoltage
In the device, all connecting wires connected to the control system power supply shall be able to withstand:
a) 5.1.1.2, 5.1.2 in the provisions of the power supply overvoltage;
b) the supply overvoltage applied in accordance with 12.2.7.
The overvoltage can be considered to be generated by the return electrical energy from the control system power supply. For the control system voltage before and after the occurrence of the overvoltage, the overvoltage is expressed as an increment and the overvoltage of the opposite polarity to the control system power supply is not to be considered.
Overvoltages greater than 1.25 U, with a time of more than 0.1 s can be considered to occur only when the control system power supply fails.
5.3 Installation
The device should be connected as directly as possible to the power supply by a separate conductor, which should only be used to supply the electronic circuits. The device should be installed in such a way as to minimise the effects of external electrical disturbances.
Sources of electrical interference should be suppressed.
5.4 Surge, electrostatic discharge and electrical fast transient pulse group immunity
All devices shall comply with the requirements of GB/T 24338.4-2018 for surge, electrostatic discharge and electrical fast transient pulse group immunity testing.
5.5 Electromagnetic compatibility
The device shall be free from the adverse effects of conducted or radiated interference, in accordance with GB/T 24338.4-2018, and the radio frequency disturbance generated by the device shall not exceed the level specified in GB/T 24338.4-2018.
6 Reliability, serviceability and expected service life
6.1 Reliability of the device
6.1.1 Expected reliability
The user may request the supplier to provide reliability data or to meet the user's reliability index. The supplier and the user shall agree on the method of calculation in accordance with mutually agreed criteria.
6.1.2 Verification of reliability
When the user has specified a reliability level, the following shall be carried out:
a) Careful monitoring of the performance of the device;
b) All operations performed by the device shall be recorded by agreement between the supplier and the user;
c) To verify the reliability level of the device, a defect analysis report shall be provided at the end of a mutually agreed period (mileage or hours of use), indicating the replacement components (e.g. the number of miles or hours of use).
c) To demonstrate the reliability level of the device, at the end of a mutually agreed period (mileage or operating hours), a defect analysis report shall be provided, indicating the components replaced (component code, type, manufacturer, production lot number, mileage and/or operating hours, etc.), the definition and cause of the fault (design weaknesses, software, component problems, etc.); and Software, component problems, etc.);
d) In order to demonstrate that the device meets the specified reliability requirements, a reliability assessment of the device should be carried out, which can be done using GB/T 5080 (all parts) as a guide;
e) The contract should state the specific reliability assessment procedure.
6.2 Service life
The service life of the device shall be determined by agreement between the supplier and the customer.
Where the supplier intends to use components whose life expectancy is shorter than the life expectancy of the device, the use and periodic replacement procedures for these components shall be agreed between the supplier and the customer.
6.3 Serviceability
Unless otherwise agreed, the installation shall normally be designed so as not to require periodic maintenance. Special maintenance requirements, if any, shall be determined by agreement between the supplier and the customer.
It shall be possible to test printed board assemblies and plug-in boxes individually.
In addition, the supplier of the device shall indicate the maintenance procedures that should and should not be followed.
6.4 Maintenance levels
7 Design
8 Components
9 Manufacture
10Safety
11Documentation
12Inspection
13 Product marking and packaging
Appendix A (informative) Terms that can be agreed between supply and demand
Appendix B (informative) Loading and running tests
Bibliography
1 Scope
2 Normative references
3 Terminology and definitions
4 Environmental conditions
5 Electrical requirements
6 Reliability, serviceability and expected service life
7 Design
8 Components
9 Manufacture
10Safety
11Documentation
12Inspection
13 Product marking and packaging
Appendix A (informative) Terms that can be agreed between supply and demand
Appendix B (informative) Loading and running tests
Bibliography
1 Scope
This document specifies the requirements for the use, design, manufacture and testing of electronic devices installed on rail rolling stock, as well as the basic requirements for the hardware and software required for the durability and reliability of the devices. If appropriate, additional requirements in other standards or specifications may be added to this document. The mutually agreeable provisions of this document are listed in Appendix A.
This document applies to all control, regulation, protection, diagnostic, power supply and other electronic devices installed on rail vehicles, which may be powered by onboard batteries or generators, or by low-voltage power supplies (transformers, voltage dividers, auxiliary power supplies) connected directly or indirectly to the contact network.
The special requirements required to ensure a functional safety level in practice are defined in GB/T 21562-2008, 4.6.3.1, 4.6.3.2 and Appendix A.
When residual risks remain and are to be performed by a software-driven programmable electronic system, Software Safety Integrity Level 1 or higher is considered, see GB/T 28808-2021.
For the purposes of this document, an electronic device (hereinafter referred to as "device") is a device consisting primarily of semiconductor devices and other common components, usually mounted on a printed circuit board.
Note. This document is also used for sensors (such as current, voltage, speed, etc.) and power electronic devices trigger board, complete trigger device see GB/T 25122.1.
2 Normative references
The contents of the following documents constitute essential provisions of this document through the normative references in the text. Among them, the date of the cited documents, only the date of the corresponding version applicable to this document; do not note the date of the cited documents, the latest version (including all the revision of the list) applicable to this document.
GB/T 1402 Voltage for traction power supply systems for rail vehicles (GB/T 1402-2010, 1EC 60850:2007, MOD)
GB/T 2423.1 Environmental tests for electrical and electronic products ﹑ Part 1: Test methods, Test A: Low temperature (GB/T 2423.1-2008,1EC 60068-2-1:2007,IDT)
GB/T 2423.2 Environmental testing of electrical and electronic products, Part 1: Test methods: Test B: High temperature (GB/T 2423.2-2008, 1EC 60068-2-2:2007, IDT)
3 Terminology and definitions
The following terms and definitions apply to this document.
3.1
Printed boardprinted board
A substrate material that can be divided into various sizes.
Note 1: Includes all holes and has at least one conductive type.
Note 2: Printed boards are usually classified according to their structure (e.g. single, double-sided or multilayer boards) or the nature of the substrate material (e.g. rigid or flexible).
3.2
Printed board assembly
A printed board that contains electrical and mechanical components, ancillary printed boards and has been soldered, coated and other production processes.
3.3
Plug-in unit
Plug-in boxes. Various units supported by rails.
Note: For example, a cassette unit or a printed board assembly in a frame designed for plug-in connection.
4 Environmental conditions
4.1 General conditions of use
4.1.1 Altitude
The altitude should not exceed 1400 m during normal operation.
The altitude correction factor K for frequency withstand voltage shall be determined by negotiation between the supplier and the customer in accordance with the value of 4.2 in GB/T 32347.1-2015.
4.1.2 Ambient temperature
Under the temperature classes selected in accordance with Table 1, the design and manufacture of the device shall meet all the performance requirements specified. The design shall take into account the temperature rise within the cabinet to ensure that the device does not exceed the specified temperature rating. In addition, the device shall comply with the specified thermal conditions for short term start-up by selecting the temperature values specified in column 3 of Table 1.
4.2 Special operating conditions
4.2.1 General requirements
Where the conditions of use differ from 4.1 (e.g. where the device is mounted on a bogie or in a power converter), special measures shall be taken by agreement between the supplier and the customer. In order to verify the effectiveness of these measures, selective test items may be specified and tested in test chambers or on rolling stock according to methods to be determined by both the supplier and the demander.
4.2.2 Atmospheric pollution
The device may be exposed to a variety of pollutants (e.g. oil mist, salt spray, conductive dust, sulphur dioxide) during its lifetime and the type of these pollutants and their concentration shall be determined by agreement between the supplier and the customer.
5 Electrical requirements
5.1 Power supply
5.1.1 Power supply from batteries 5.1.1.1 General requirements
The nominal voltage (U,) of the device shall be selected from the following values; 24 V, 32 V, 36 V, 48 V, 64 V, 74 V, 87 V, 96 V and 110o v.
24 v, 74 V and 110 v are suitable.
The different voltage ranges can be determined by mutual agreement between supply and demand in accordance with GB/T 21413.1.
Note: These nominal voltage values are only used as standard values for the design of the device and are not considered as the no-load voltage of the battery; the no-load voltage of the battery is determined by the battery type, the number of individual batteries and the operating conditions.
5.2 Power supply overvoltage
In the device, all connecting wires connected to the control system power supply shall be able to withstand:
a) 5.1.1.2, 5.1.2 in the provisions of the power supply overvoltage;
b) the supply overvoltage applied in accordance with 12.2.7.
The overvoltage can be considered to be generated by the return electrical energy from the control system power supply. For the control system voltage before and after the occurrence of the overvoltage, the overvoltage is expressed as an increment and the overvoltage of the opposite polarity to the control system power supply is not to be considered.
Overvoltages greater than 1.25 U, with a time of more than 0.1 s can be considered to occur only when the control system power supply fails.
5.3 Installation
The device should be connected as directly as possible to the power supply by a separate conductor, which should only be used to supply the electronic circuits. The device should be installed in such a way as to minimise the effects of external electrical disturbances.
Sources of electrical interference should be suppressed.
5.4 Surge, electrostatic discharge and electrical fast transient pulse group immunity
All devices shall comply with the requirements of GB/T 24338.4-2018 for surge, electrostatic discharge and electrical fast transient pulse group immunity testing.
5.5 Electromagnetic compatibility
The device shall be free from the adverse effects of conducted or radiated interference, in accordance with GB/T 24338.4-2018, and the radio frequency disturbance generated by the device shall not exceed the level specified in GB/T 24338.4-2018.
6 Reliability, serviceability and expected service life
6.1 Reliability of the device
6.1.1 Expected reliability
The user may request the supplier to provide reliability data or to meet the user's reliability index. The supplier and the user shall agree on the method of calculation in accordance with mutually agreed criteria.
6.1.2 Verification of reliability
When the user has specified a reliability level, the following shall be carried out:
a) Careful monitoring of the performance of the device;
b) All operations performed by the device shall be recorded by agreement between the supplier and the user;
c) To verify the reliability level of the device, a defect analysis report shall be provided at the end of a mutually agreed period (mileage or hours of use), indicating the replacement components (e.g. the number of miles or hours of use).
c) To demonstrate the reliability level of the device, at the end of a mutually agreed period (mileage or operating hours), a defect analysis report shall be provided, indicating the components replaced (component code, type, manufacturer, production lot number, mileage and/or operating hours, etc.), the definition and cause of the fault (design weaknesses, software, component problems, etc.); and Software, component problems, etc.);
d) In order to demonstrate that the device meets the specified reliability requirements, a reliability assessment of the device should be carried out, which can be done using GB/T 5080 (all parts) as a guide;
e) The contract should state the specific reliability assessment procedure.
6.2 Service life
The service life of the device shall be determined by agreement between the supplier and the customer.
Where the supplier intends to use components whose life expectancy is shorter than the life expectancy of the device, the use and periodic replacement procedures for these components shall be agreed between the supplier and the customer.
6.3 Serviceability
Unless otherwise agreed, the installation shall normally be designed so as not to require periodic maintenance. Special maintenance requirements, if any, shall be determined by agreement between the supplier and the customer.
It shall be possible to test printed board assemblies and plug-in boxes individually.
In addition, the supplier of the device shall indicate the maintenance procedures that should and should not be followed.
6.4 Maintenance levels
7 Design
8 Components
9 Manufacture
10Safety
11Documentation
12Inspection
13 Product marking and packaging
Appendix A (informative) Terms that can be agreed between supply and demand
Appendix B (informative) Loading and running tests
Bibliography
Contents of GB/T 25119-2021
1 Scope
2 Normative references
3 Terminology and definitions
4 Environmental conditions
5 Electrical requirements
6 Reliability, serviceability and expected service life
7 Design
8 Components
9 Manufacture
10Safety
11Documentation
12Inspection
13 Product marking and packaging
Appendix A (informative) Terms that can be agreed between supply and demand
Appendix B (informative) Loading and running tests
Bibliography
