Overview
On-Board Solar Power System for Railway Coaches & Rolling Stock
The Systellar RailGuard is an on-board solar power system for railway coaches — a complete, self-contained power source that sits inside the coach and works with solar panels mounted on the bogie roof and an on-board 110V battery system. Through the day the rooftop solar array charges the battery bank; round the clock the unit delivers a regulated 110V DC supply to run the coach’s own lights, fans and control systems — with no power drawn from the locomotive and no dependence on the railway power grid.
It was designed first for the guard and service-personnel coaches of goods trains, where the crew often had no light or fan at all. RailGuard gives that coach a power source of its own — lights, fans, mobile-charging points and working equipment that keep running on remote, non-electrified sections and even when the train is parked or off-duty. By generating and storing its own solar energy, each coach cuts its reliance on the railway grid and on diesel-charged batteries.
We design, manufacture and supply these custom solar power systems for Indian Railways rolling stock, developed strictly to RDSO specifications and approved drawings. Our flagship build was engineered for the tender:
“Supply, installation and commissioning of solar system including light & fan along with other electrical works in BVCM wagon as per RDSO drawing no. WD-24050-S-07 / Sheet II.”
Backed by years of experience in railway solar power systems, we support Indian Railways, PSUs, Metro corporations, rolling-stock manufacturers and authorized contractors with robust, vibration-resistant, low-maintenance solar systems built for harsh railway operating conditions — from brake vans (BVCM) and guard coaches to inspection cars, Metro coaches and special-purpose wagons.
Where the RailGuard Helps
Typical situations where an on-board solar power unit makes an immediate difference:
- Goods-train guard & brake vans: gives the guard reliable light, a fan and mobile-charging points in a brake van that had no power before.
- Coaches parked or off-duty: keeps a parked or detached coach powered without any mains connection or a running locomotive.
- Remote & non-electrified sections: supplies on-board power on routes with no overhead line, cutting diesel and grid dependence.
- Crew & amenity loads: runs lights, DC fans, mobile-charging points and control systems, day and night.
Planning a new railway solar project? Use these as a starting point — we can adapt the RailGuard to your exact coach, load and RDSO requirement.
RDSO & IEC Compliant Solar System for BVCM Coaches
Designed Under RDSO Guidance
The Systellar RailGuard Solar Power Unit has been developed under the technical guidance and compliance norms of RDSO, ensuring:
- Compatibility with existing railway electrical architecture
- Safe integration with on-board lighting and fan loads
- Long operational life under continuous vibration, dust, and temperature variation
- Ease of maintenance for depot and workshop staff
All components are selected and assembled to meet Indian Railways’ operational, safety, and durability expectations.
IEC Certifications
The Systellar RailGuard Solar Power Unit comes with the following IEC certifications:
- IEC60068-2-1 Cold test
- IEC60068-2-2 Dry heat test
- IEC60068-2-14 Temperature change test
- IEC60068-2-30 Damp heat cyclic test
Key System Components
Solar PV Modules
- High-efficiency solar panels designed for coach rooftop mounting
- Rugged construction suitable for continuous outdoor exposure
- Secure mounting to withstand vibration and wind loads during train movement
Battery Bank & Energy Storage
- Optimized battery configuration for reliable backup
- Ensures uninterrupted power supply for lights and fans
- Designed for long charge–discharge cycles
MPPT Charge Controller & Protection System
- Intelligent MPPT Solar charge controller for LiFePO4 battery health
- 110V DC load output for running DC appliances in railway coaches
- Large LCD display to show all system parameters
- Overcharge, short-circuit, and reverse polarity protection
- Designed for safe railway operation
LED Lighting & DC Fans
- Energy-efficient lighting fixtures for BVCM interiors
- Low-power DC fans optimized for solar operation
- Uniform illumination and reliable air circulation
Why Solar Power for Railway Coaches?
Operational & Strategic Benefits
- Gives each coach a standalone, grid-independent power source for its lights, fans and control systems
- Keeps guard and service-personnel coaches powered even when the train is off-duty or parked
- Reduces dependency on the railway power grid and on diesel-charged batteries
- Lowers operational and maintenance costs over the life of the coach
- Supports Indian Railways’ sustainability and green-energy goals and cuts diesel consumption
- Reliable, low-maintenance operation in remote sections and under continuous vibration
On-board solar power for rolling stock is no longer optional — it is a strategic necessity.
Custom Solar Product Development for Railways & Metro
New Product Development & Tailor-Made Engineering
RailGuard is just one example of what our in-house engineering team can build. If you are a railway vendor, supplier, OEM or contractor looking for a solar solution for railways — standard or entirely new — we can develop it with you. We specialize in:
- New product development of solar power systems for any railway application
- Customized solar product development for railway tenders and RDSO drawings
- Design modification as per tender-specific technical clauses
- Prototype development, testing and technical documentation support
- Adaptation for Metro coaches, inspection cars, EMUs and special-purpose wagons
If your project needs a non-standard solar configuration — a different voltage, load, battery chemistry or form factor — our engineers can design and manufacture it from the ground up. Bring us the requirement; we will build the unit.
Why Choose Us for Railway Solar Systems?
- Proven experience in solar solutions for rail applications
- Deep understanding of RDSO norms and railway tender requirements
- End-to-end capability: design, manufacturing and supply
- High-quality components with railway-grade reliability
- ISO 9001:2015 certified — Designed and Made in India in Meerut since 2012
- Strong after-sales and technical support
We don’t just supply products — we deliver compliant, field-ready railway solar systems.
Looking for a Railway Solar System Partner?
Whether you are:
- An Indian Railways department
- A PSU or Metro authority
- A rolling stock manufacturer or contractor
- A tender participant requiring technical support
You can reach out to us for RDSO-compliant solar solutions and customized development for railway projects.
👉 Contact us today to discuss your BVCM wagon or rolling stock solar requirement.
Technical Specifications
| Parameter | Specification |
|---|---|
| Technology | Solar charger: Two inter-leaved synchronous buck-converter channels. DC-DC converter: Transformer-based forward converter. |
| Microcontroller | ARM Cortex-M4 core, 32-bit advanced microcontroller |
| Charge controller efficiency | >95% |
| DC-DC converter efficiency | >90% |
| Maximum battery charging current | 50A |
| Battery | 12.8V 120Ah LiFePO4 (recommended connection wire: 10 mm²) |
| Max solar panel Voc | 85V (open-circuit voltage) |
| Max solar panel capacity | 750 Wp (recommended connection wire: 4 mm²) |
| Load output | 110V DC, 1.5A (recommended connection wire: 1.5 mm²) |
| Display | 128×64-pixel back-lit graphic LCD (8 rows × ~22 characters) showing live running parameters and energy-meter values |
| Keyboard | Single key — single press: LCD backlight; double press: show energy-meter values; triple press: reset energy meter; long press: system restart |
| Charging | 2-stage for maximum battery care — Bulk charging up to ~14.5V, then Trickle at 13.6V (reverts to Bulk if battery drops below 13.0V) |
| Temperature handling | Battery temperature sensor with on-LCD readout. Per the cell manufacturer, no temperature compensation is applied for LiFePO4; a reading above 50 °C indicates a battery fault that should be attended to. |
| Status indicators | Three on-board status LEDs — Green (charger), Blue (DC-DC converter) and Red (charge controller) — with multi-blink diagnostic codes (see the LED status-indicator chart below) |
| Protections | Battery reverse polarity, solar-panel reverse polarity, output overload, output short circuit, charge-controller overheat, DC-DC converter overheat |
| Idle power | Battery charger: max 1.3W · DC-DC converter: max 12W |
| Warranty | 2-year manufacturer warranty |
LED Status Indicators
The three front-panel LEDs show the live status of the charger, DC-DC converter and charge controller using blink patterns. Use the chart below to interpret them at a glance.
| LED | Pattern | Meaning |
|---|---|---|
| Green — Charger | Off | Not charging |
| Green — Charger | 1 blink every 2 sec | Low charging (< 5A) |
| Green — Charger | 2 blinks every 2 sec | High charging (≥ 5A) |
| Green — Charger | Solid on | Battery fully charged |
| Blue — DC-DC converter | Solid on | Normal output |
| Blue — DC-DC converter | 1 blink every 2 sec | Output overload |
| Blue — DC-DC converter | 2 blinks every 2 sec | Heat-sink temperature high (above 70 °C) or temperature sensor disconnected |
| Blue — DC-DC converter | 3 blinks every 2 sec | Output voltage too high — shutoff |
| Red — Charge controller | Off | Normal operation |
| Red — Charge controller | 1 blink every 2 sec | Battery discharged (below 12.0V) — charging continues, load is off; output resumes once the battery rises above 12.8V |
| Red — Charge controller | 2 blinks every 2 sec | Solar charger heat-sink temperature high (above 70 °C) or temperature sensor disconnected — charging stops |
| Red — Charge controller | 3 blinks every 2 sec | Solar panel voltage too high — charging stops |
| Red — Charge controller | Solid on | Battery voltage too high |
The DC-DC converter shuts off for any of the above faults and restarts automatically once the fault is cleared.
Frequently Asked Questions (FAQ)
What is the RailGuard MPPT Solar Power Unit?
It is a custom solar-based electrical system designed and manufactured by Systellar for Indian Railways Brake Van Cum Material (BVCM) coaches, providing solar-powered lighting and fans developed strictly to RDSO specifications and approved drawings.
Is the system RDSO compliant?
Yes. It is developed under RDSO technical guidance and built to tender drawing WD-24050-S-07 / Sheet II, ensuring safe integration with existing on-board lighting and fan loads.
What IEC certifications does it carry?
The unit is tested to IEC60068-2-1 (cold), IEC60068-2-2 (dry heat), IEC60068-2-14 (temperature change) and IEC60068-2-30 (damp heat cyclic), confirming durability under harsh railway operating conditions.
Is it built to withstand railway vibration and dust?
Yes. Every component is selected and assembled for long operational life under continuous vibration, dust and wide temperature variation, with easy maintenance for depot and workshop staff.
Who can buy this system?
Systellar supplies to Indian Railways, PSUs, Metro corporations and authorized railway contractors. We can also design and manufacture custom railway solar systems to specific RDSO drawings.
Can it power lights and fans in a railway coach without mains electricity?
Yes. The RailGuard is a self-contained, off-grid solar power system for railway coaches. A roof-mounted 550 Wp solar panel (up to 750 Wp) charges a 12.8V 120Ah LiFePO4 battery, and the built-in DC-DC converter delivers a regulated 110V DC supply to run on-board LED lights and DC fans — with no connection to mains AC power and no dependence on train movement.
What solar panel and battery does the railway solar power unit use?
It is built around a 550 Wp solar panel (maximum 750 Wp, open-circuit voltage up to 85V), a 12.8V 120Ah LiFePO4 battery, and a smart MPPT solar charge controller rated for up to 50A charging current with a 110V DC, 1.5A regulated load output.
Can Systellar supply solar power systems for Metro coaches and other rolling stock?
Yes. Beyond BVCM brake and guard vans, Systellar designs and manufactures custom railway solar power systems for Metro coaches, inspection cars and other rolling stock, adapted to specific RDSO drawings and tender-specific technical clauses.
What warranty does the Rail Guard MPPT Solar Power Unit carry?
The Rail Guard MPPT Solar Power Unit comes with a 2-year manufacturer warranty, backed by Systellar's in-house engineering and service team. Custom railway solar systems built to specific RDSO drawings carry the same standard warranty unless a different term is agreed in the supply contract.
Note: product specifications are subject to change for continuous product enhancement. Please contact Systellar for the latest specifications.