SECTION 15 – MATERIALS AND WORKMANSHIP
15.1 GENERAL
15.1.1 QUALITY
North American transit equipment experience indicates that construction must be to a high standard to achieve satisfactory vehicle service under the environmental and operating conditions which prevail. Specific standards with respect to material and workmanship are necessary. This section defines the minimum performance requirements for materials to be used in the construction of the streetcars and establishes minimum guidelines for workmanship. It identifies mandatory government requirements and industry specifications controlling the quality of specific materials and components and the construction methods. Alternatives will be considered.
The Contractor shall ensure that all equipment, materials, manufacturing, assembly, and installation processes and practices are in full conformance with the intent and the requirements of this Specification as well as with proven and recognized industry practices and recommendations.
15.1.2 STANDARDS
All materials shall conform to the appropriate industry standards for use on rail transit equipment. These standards include Federal or Military Specifications or Standards, the Specifications of the Aluminum Association of America, AAR, ANSI, ASME, ASTM, FRA, IEEE, IEC, EN, or other requirements as specified herein. Foreign or international standards are encouraged to be proposed by the Contractor as alternatives. The Contractor shall submit proposed standards in English for review by the City. A service history of equipment built to these standards may be included to demonstrate the applicability of the standard.
15.1.3 STORAGE OF MATERIAL
All equipment and material intended for use in these cars shall be shipped and stored such that damage or reduction in life is prevented. All stored material subject to corrosion shall be protected by waterproof covers or coatings. Materials and equipment shall be stored under cover and off the floor or ground.
All equipment shall be stored with all ports, covers, and all other enclosure openings closed to prevent ingestion of dirt or moisture.
All dated material shall be clearly marked with the expiration date and shall not be used beyond the expiration date. All material with special handling or storage requirements shall be handled or stored according to the manufacturers requirements.
All material shall be clearly marked and/or stored with appropriate nomenclature to prevent misapplication.
Rejected material shall be clearly marked as such and stored in an area specifically designated for that purpose.
15.1.4 PROHIBITED MATERIALS
The following materials are prohibited for use in the construction of these cars, except where specifically permitted:
• PVC
• Asbestos
• Lead in brake shoes
• Urethane Foam
• Aluminum Threaded Fasteners
15.1.5 DISSIMILAR MATERIALS
In this context, dissimilar materials refers to materials that corrode or otherwise become damaged when in contact with other materials.
Connection of dissimilar materials is permitted only at permanent connections and with suitable electrochemical isolation. All such isolation treatments shall be permanent and not require maintenance or replacement for the life of the car.
Dissimilar materials are not permitted at electrical connections or connections requiring disassembly for maintenance or for removal and replacement of equipment.
15.2 JOINING AND FASTENING
15.2.1 FASTENERS
15.2.1.1 GENERAL
All bolts, screws, nuts, washers, and other related fastening devices shall be plated steel, stainless steel, or aluminum. All threaded, 1/4-turn, or otherwise non-permanent fasteners shall have Phillips, tamper proof, hex socket, or hex heads. Slotted-head fasteners shall not be used unless specifically approved by the City for application inside equipment enclosures and for bolts 5 mm diameter or less.
Except for fasteners internal to electrical or electronic components, plastic screws, bolts, nuts, or other plastic fastening components shall not be used unless approved.
Protruding screws, mounting bolts or similar items will not be permitted either on the interior or exterior of the car, except for those appointments which can not be built into the structure in any other manner. Interior or exterior screws, bolts, and nuts exposed to passengers shall be used only if approved.
All fasteners used for access panels, equipment box covers, or other areas requiring frequent operator or maintenance access shall be captive to the cover.
Fasteners shall not be used near heat sources that will exceed the fastener manufacturer's recommended operating temperature or otherwise damage or reduce the life of the fastener.
15.2.1.2 THREADED FASTENERS
Threaded fasteners shall have screw thread conforming to ISO-metric standards. Metric fasteners shall be identified as required by applicable ASTM specifications, abstracted in "Metric Fastener Standards", Industrial Fasteners Institute, latest edition.
Self-tapping screws shall not be used except as approved for a specific application. All fastenings on access panels, plates, covers, of other components accessible by passengers, shall be a tamper-resistant type.
Stainless steel screws or bolts, nuts, flat washers, and lock washers shall be used in mounting, and in making connections at power resistors and other heat-producing apparatus where copper, stainless steel or other high expansion alloys are connected. For carbon steel or other low expansion materials that produce heat, connections shall be made with Grade 5 zinc plated hardware. Cadmium plated fasteners shall not be used to connect heat producing devices.
All structural or load carrying bolts shall be a minimum of Grade 5 and the bolt diameter shall be no less than M10, regardless of design load. Stronger fasteners shall be used if the application requires.
When bolts are used to secure apparatus where the bolt head is inaccessible, a reusable mechanical locking device shall be used to prevent the bolt head from turning when the nut is being removed.
At least 1a screw threads shall project beyond all nuts.
15.2.1.3 WASHERS AND LOCK WASHERS
Washers shall conform to ANSI B18.22M, latest revision, as is appropriate for the application.
Flat washers shall be used on both sides of all electrical connections, that is, under the bolt head and the nut.
Lock washers shall not be used in structural applications or in fatigue applications where the fastener must be torqued and marked. All lock washers shall conform to International Fastener Institute (IFI) 1970 Fastener Standards.
15.2.1.4 NUTS
Predominant type nuts shall be regular-height, nylon-insert, self-locking ESNA stop nuts or approved equal. Self-locking nuts shall be used throughout, where practical. Non-self-locking nuts with lock washers may be used in non-structural applications upon approval by the City or where required by the Specification.
Nylon insert lock nuts shall not be used near heat sources that will exceed the manufacturers recommended operating temperature.
15.2.1.5 TORQUING
All threaded fasteners shall be torqued to a value assigned by the designer or to standard torque values recommended by the fastener manufacture. All safety related fasteners, including truck and brake equipment bolts, shall be "torque-striped" after torquing by paint or equal approved means.
15.2.16 RIVETS
Rivets and lock pins exposed to passengers shall be stainless steel or aluminum as appropriate to the materials being joined.
15.2.2 JOINT FITTING
Joints shall be properly fitted, whether exposed or concealed. Gaps between joints shall be held to a minimum and be uniform in width. The edges of panels shall have a smooth, finished appearance.
15.2.3 METAL-TO-METAL CONNECTIONS
Where metal is riveted or bolted to metal, contact surfaces shall be free of dirt, grease, rust and scale, and shall be coated with a metal base primer.
If aluminum parts are used for any purpose, metal-to-metal connections shall be in accordance with the latest revision of "Specifications Covering Use of Aluminum in Passenger Carrying Rail Vehicles"; Technical Report Number 524 by the Aluminum Company of America.
15.2.4 WOOD-TO-METAL CONNECTIONS
Where wood and ferrous metal surfaces are placed together, the wood shall be coated with aluminum paint conforming to Federal Specification TT-P-38, and the metal, shall be coated with a primer which conforms to Federal Specification TT-P-664
.
All bolts or rods passing through wood shall be coated with aluminum paint conforming to Federal Specification TT-P-38.
If aluminum parts are used for any purpose, wood-to-metal connections shall be in accordance with the latest revision of "Specifications Covering Use of Aluminum in Passenger Carrying Railway Vehicles" per Technical Report Number 524 by the Aluminum Association of America.
15.2.5 WOOD-TO-WOOD CONNECTIONS
Where wood and wood are placed together, both abutting surfaces shall be coated with aluminum paint conforming to Federal Specification TT-P-38.
15.3 STAINLESS STEEL
Structural stainless steel components shall be of AISI type 201L or 301LN and shall conform to the requirements of ASTM A 666 except that the carbon content shall not exceed 0.03 percent and type 301LN may contain up to 0.25 percent nitrogen. Other high strength stainless steels proposed by the Contractor may be used if approved by the City.
Stainless steel used in non-structural applications shall be AISI types 201, 202, 301, 302, 304, 316, 430 or as proposed by the Contractor and approved by the City.
15.4 LOW-ALLOY, HIGH-TENSILE STEEL
Structural shapes, plates and bars shall conform, as a minimum, to the requirements of ASTM A 588. General requirements for delivery of LAHT shapes, plates, and bars shall be as required by ASTM A 6.
Welded LAHT steel shall develop 20 foot-lbs Charpy V Notch impact strength in the CGHAZ (Coarse grain heat affected zone 1mm from fusion area) at 0EF.
Hot rolled or formed structural shapes may be used for non-structural applications including equipment supports, jack pads, and clip angles.
Cold and hot rolled LAHT sheet and strip shall, as a minimum, conform to the requirements of ASTM A 606, Type 4. General requirements for delivery of these products shall be as required by ASTM A 568.
Other low-alloy, high-tensile steels which meet or exceed the above requirements may be used, provided their detailed specifications are submitted and approved as equivalent, or better material, for the proposed applications.
All LAHT steels shall be applied according to their specification properties.
15.5 STEEL CASTINGS
Steel castings used in any location throughout the car shall be selected by the Contractor for composition, heat treatment, and design best suited for the intended service.
All steel castings shall be sound throughout and shall be suitably marked with pattern and serial numbers in a manner that will not impair their strength.
All steel castings used in the truck structure, bolster, and center bearing arrangement shall meet AAR Specification M-201 latest revision, Grade "B", plus 2% nickel, minimum. These castings shall be heat treated to develop a minimum tensile strength of 517 MPa, a minimum yield strength of 331 MPa, elongation of not less than 25% in 50.4 mm, and reduction of area of not less than 50%.
Magnetic particle inspections of all surfaces of all castings shall be conducted in accordance with ASTM E 709, by personnel certified to MIL-STD-410A, latest revision.
Where specified or required, radiographic inspection meeting the requirements of ASTM Standard E 94 and using reference radiographs to ASTM E 446 shall be applied.
Welding of castings is permitted, provided the casting supplier performs all repair welds in accordance with an approved written procedure and uses welders qualified to ASTM A 488.
15.6 ALUMINUM
Aluminum alloy mill products shall be identified by designations prescribed by the Aluminum Association of America and shall conform to specifications contained in the Association's publication "Aluminum Standards and Data". Castings shall conform to ASTM B 26, B 85, and B 108 for sand, die, or permanent mold castings respectively. Aluminum alloy forgings shall conform to ASTM B 247.
Protection shall be provided at the contact surface of all connections to aluminum. The following instructions are provided for general guidance and shall not be construed to supersede conflicting recommendations by the aluminum manufacturer or by the Aluminum Association of America Technical Report No. 524.
The contact surfaces of aluminum alloy with aluminum alloy shall be etched or anodized before securing.
Aluminum alloy surfaces shall not be secured to, nor make direct metal to metal contact with the surfaces of copper, copper bearing aluminum alloy, brass, bronze, silver, nickel and nickel plated parts or alloys thereof, lead, tin, ferrous materials and wood.
The surfaces of aluminum alloy parts secured to steel parts shall be protected as follows:
• With a one-part polysulphide sealant or zinc chromate paste.
• Alternatively, an approved insulation joint material, which completely covers the fayed surfaces, may be used. The material shall be non-hygroscopic and, if fibrous, shall be impregnated with bitumen or some other approved water and moisture-repellant substance. Fasteners shall be primed and painted with red oxide or aluminum paint after installation.
Wood-to-metal connections shall be as specified above. The wood shall be thoroughly dried and then coated with varnish or other comparable sealant, as approved.
Carbon steel fasteners shall be cadmium plated as required above. The entire fastening, including washers and nuts, shall be plated and where possible, the head and unthreaded portion of the shank of the bolt shall be in contact with the aluminum part when secured in place. Suitable bushings may be used.
Rivets driven hot may be considered as covered by a protective oxide coating due to the heating, but the method of riveting shall, if possible, always be with the formed rivet head in contact with the aluminum alloy.
15.7 WELDING AND BRAZING
The Contractor shall control the quality of all welding and brazing, including that of its subcontractors. Prior to performing work under this Contract, all welders shall have been tested to confirm their ability to operate the welding equipment and to make the types of welds required by the design or this document.
15.7.1 STRUCTURAL WELDING
All structural welding practices not specifically covered in other sections of this Specification shall be in accordance with requirements of EN287-1 for steel; EN287-2 for aluminum;; and the AWS Handbook. Resistance welding shall be in accordance with MIL-W-6858. Requirements for dynamically loaded structures shall have precedence over those for statically loaded structures.
Structural welding of stainless steel by the fusion-arc process shall be governed by ASME Section IX and ASME Section VIII, Part UHA. AISI 201L and 301LN stainless steels shall be treated as P-No. 8, Group-No. 3 category for reference to ASME requirements. Weld heat affected-zones (HAZ) and weld metal shall be limited to maximum allowable stress values in ASME Section VIII, Table UHA-23 for UNS S20100 stainless steel and Table UW-12 rating of welds, regardless of strength level of the base metal. Ferrite number for welds shall be between WRC4 and WRC10, or as proposed by the Contractor and approved by the City.
Additional information on definitions, processes or other questions pertaining to welding shall be referred to AWS Welding Handbooks, latest edition.
The Contractor may propose the substitution of other standards as detailed in Section 15.1.2 above.
15.7.2 WELDER QUALIFICATION
Welders shall make only those welds for which they have been qualified in accordance with the requirements of the AWS, ASME Section IX, EN 288, or other approved qualifying procedures. Records of welder qualification tests shall be made available for review upon the City's request.
15.7.3 WELD PENETRATION
Full penetration welds are required for all structural welds unless otherwise approved by the City. Where partial penetration welds are proposed for structural welds, the Contractor shall provide design calculations supporting the penetration required and conduct tests to prove that production welding achieves this required penetration with a margin of safety suited to the design application. Partial penetration welds in structural connections may be made only with approval of the Contractor's formal detailed proposal.
All full penetration welds made from one side without backup shall be considered partial penetration welds. In no case shall partial penetration welds be used where they experience alternating tensile or bending loads at the weld root.
15.7.4 INSPECTION
The Contractor shall inspect all structural welds. In addition to visual inspection requirements specified by the AWS welding code, nondestructive surface inspection (dye penetrant or magnetic particle methods, as appropriate) shall be used to inspect all first production welds. The Contractor shall specify additional nondestructive inspection requirements for subsequent welds.
15.7.5 WELD CLEANING REQUIREMENTS
All welds exposed to passengers or on the surface of truck frames and bolsters shall be completely cleaned of all spatter.
15.7.6 WELDING ROD OR WIRE
All welding rod or wire shall be purchased to AWS Specifications. Where special materials are required that are not covered by these or other applicable AWS welding material specifications, the Contractor shall submit the purchase specifications for approval.
Welding rod and wire shall be purchased in packages of convenient size, which shall be marked with the manufacturer's name and the specification, diameter and net weight of the material.
The material shall be stored in accordance with recommendations to the AWS "Structural Welding Code" to protect it from damage, and so that it can be easily identified. Material shall be issued and handled in such a way as to prevent it from being mixed with that of another specification.
15.7.7 SPECIAL WELDING
Procedures for structural welding of stainless steel to LAHT, or other combinations of metals or conditions not covered by AWS specifications or codes, shall be submitted for approval.
Austenitic stainless steel electrodes or wire shall be used to join carbon or LAHT steels to stainless steels.
15.7.8 RESISTANCE WELDING
Resistance welding of stainless or carbon steels shall be in accordance with MIL-W-6858, Class B for structural applications and Class C for non-structural applications. The Contractor shall control current, time, electrode size, shape, and tip force to produce uniform welds of specified strength which are not subject to intergranular, stress-corrosion cracking. Resistance welds shall be arranged to avoid tension or "peeling" forces on the welds under any anticipated loading condition.
Surface indentation shall not exceed 20 percent of material thickness (t) or 0.01 inch, whichever is greater; however, for exterior resistance-welded areas exposed to passenger view, indentation shall not exceed 10 percent of t or 0.005 inch, whichever is greater. Surface burn and discoloration shall be removed by an approved method.
Any deviation desired by the Contractor from the MIL-W-6858 standards including, but not limited to, weld nugget diameter, tension shear strength, and minimum spacing, shall be submitted and approved prior to inclusion in the design or in production procedures.
15.7.9 PROHIBITIONS
Galvanized steel shall not be welded to stainless steel. Brazing shall not be used to join stainless steel to itself or to other metals unless specifically permitted by the City.
15.7.10 RESISTANCE, SPOT WELD, AND INTERMITTENT WELD SPACING
Spacing of resistance and spot welds shall be appropriate to the design. Spacing shall not exceed 50 mm plus twice the weld nugget diameter for any structural application, including car body side sheets. Intermittent weld spacing shall not exceed 125 mm for 50 mm weld length (40 percent minimum).
15.7.11 TORCH BRAZING
All brazing (above 840EF) shall follow the recommendations contained in the AWS Welding Handbook, Volume 2, latest issue. Procedures and personnel who perform brazing work shall be qualified in accordance with AWS B2.2-85, “Standard for Brazing Procedure and Performance Qualification”.
Brazed joints shall present a workman-like appearance in accordance with AWS quality standards. The inner surfaces of air conditioning tubing shall be protected from oxidizing contaminants during and after brazing operations have been completed.
15.7.12 TORCH SOLDERING
All soldering (below 840EF) shall follow the recommendations contained in the AWS Welding Handbook, Volume 2, latest issue. Procedures and personnel who perform torch soldering shall be qualified through the preparation and testing of test samples, as follows:
• Copper piping into fittings – Each worker designated to perform this work shall prepare 3 copper piping connections in the vertical position. The sample joints shall present a smooth, workman-like appearance, without excess solder reinforcement. Each joint shall be pressure tested using a water or air system to confirm that it is leak-free.
• Stainless Steel Lap Joints (Trim Seams) – One typical trim seam sample, using the same stainless steel materials, finish and thicknesses as used on the actual car, shall be prepared by each person doing this work. The seam for evaluation shall be a minimum of 36 inch in length and shall be setup in the horizontal, flat position during soldering. Specimen width shall be selected, or the test setup arranged, so that premature overheating of the joint does not occur. Finished samples shall be saw-cut into 4 pieces so that 8 cross-sections of the joint may be examined. Exposed solder surfaces shall display a uniform, smooth contour and shall meet or exceed all applicable AWS quality standards.
15.7.13 TOUGHNESS OF WELDED ASSEMBLIES
The Contractor shall prove that all safety related welded structures such as, but not limited to, end underframes, fabricated truck frames and bolsters, and welded coupler components, have adequate toughness for the specified environmental exposure. Specifically, the weld heat affected zone (HAZ) and base metal shall resist service impact loads at the lowest specified operating temperature. Criteria for acceptance shall be shown by the Contractor to be adequate.
In the absence of prior operating history, and if no analysis requires greater toughness, the minimum impact value for Charpy V-notch specimens shall be 20 Joules of absorbed energy at the lowest specified operating temperature.
15.8 ELASTOMERS
All elastomeric parts shall be of neoprene unless otherwise specified or approved. Elastomers shall be compounded and cured to perform as intended in the Portland environment specified in Section 2 of these TECHNICAL SPECIFICATIONS. Elastomers shall have high resistance to ultraviolet and other solar radiation, all vehicle washing fluids, and long life. All elastomeric parts shall be resistant to ozone, oxidation, heat, oil, grease and acid.
All resilient parts shall have a design life no less than ten (10) years.
For all parts made by vulcanizing and elastomer to metal, any premature failure (less than five years) between metal and the elastomer or in the elastomer, occurring when the parts are used in normal service and according to the provisions of this Specification, shall be considered as having been caused by defect of materials or workmanship.
Metal parts to which neoprene or other such material is cured shall be made of SAE 1020 or 1045 hot-rolled steel or approved equal, suitable for brass plating after pickling.
All door mating edges, door and window seals, and glazing strips shall be of neoprene material and shall be free of defects of material and workmanship. The durometer hardness measured with a Shore Type "A" durometer at a temperature between 20EC and 30EC shall be 70 " 5.
15.9 GLAZING MATERIALS
The manufacture of glass panes for use in the vehicles shall insure maximum safety, as well as considering comfort, economic use, and aesthetics. Safety glass shall meet the requirements under Item 1, Table 1 of the latest revision of American National Standard ANSI Z26.1, "Safety code for Safety Glass for Glazing Motor Vehicles Operating on Land Highways" or other approved standards as appropriate for the application.
All safety glass shall be of the laminated sheet type. All windshield material shall be clear.
Corners and burrs shall be ground smooth and all edges shall be seamed.
The bond between the glass and the membrane shall be such that when the glass is broken by twisting or by direct impact, there will be no separation between the laminations.
Safety sheet glass shall produce minimal distortion on a line of 45 degrees to the plane of the glass. Safety plate glass shall meet the requirements under Item 2, Table 1 of the latest revision of American National Standard ANSI Z26.1, "Safety Code for Safety Glass for Glazing Motor Vehicles Operating on Land Highways".
All safety glass shall be marked with proper identification in accordance with ANSI Z26.1, and other appropriate designation.
Plastic glazing is not permitted for use on these cars.
15.10 FLOOR COVERING
The floor covering shall have a static coefficient of friction of at least 0.6 measured in accordance with ASTM D 2047, using leather and rubber shoe materials. Leather shoe material shall be in accordance with Federal Specification KK-L-165C. Rubber shoe material shall be in accordance with ASTM Method D 1630.
Rubber floor covering shall contain 20 percent (nominal, by weight of compound) butadiene styrene rubber, shall be non-staining, non-discoloring, and 100 percent non-oil extended. Only high quality hard clay shall be used as a filler.
No whitening (limestone) shall be used in the compound.
At room temperature, the rubber flooring shall bend around a 20 mm diameter mandrel without breaking, cracking, crazing, or showing any change in color. The rubber flooring material shall be fully homogeneous throughout, and shall meet the requirements of Federal Specification SS-T-312.
Rubber flooring shall conform to the criteria below.
(a) A thin skinned blister is a blister, which when finger-pushed, will collapse upon itself. Thin skin blisters of the indicated sizes are permitted as follows and shall be repaired as indicated:
• Maximum Size - 0.75 mm height, 0.500 mm² area with longest dimension of 50 mm.
• Maximum Population - 3 blisters in a 300 mm² by 300 mm² area, there shall be only one other blister within 1 m of this area.
• Repair Method - using a hypodermic needle, apply just enough Super Bond 420 or Bostik 1685 to bring to a flush surface.
(b) A thick skinned blister is a blister, which when finger-pushed, will collapse and then return to its original condition. Thick skin blisters of the indicated sizes are permitted as follows and shall be repaired as indicated:
• Maximum Size - 0.75 mm height, 0.500 mm² area with longest dimension of 50 mm.
• Maximum Population - 3 blisters in a 300 mm² by 300 mm² area, there shall be only one other blister within 1 m of this area.
• Repair Method - no repair authorized.
(c) A lump is a blister without a void, consisting of solid material. Lumps of the indicated sizes are permitted as follows and shall be repaired as indicated:
• Maximum Size - 0.75 mm height, 0.500 mm² area with longest dimension of 50 mm.
• Maximum Population - 3 lumps in a 300 mm² by 300 mm² area, there shall be only one other lump within 1 m of this area.
• Repair Method - no repair required.
(d) A hole is a defect which is 100% through the material. Holes of any size or population are not permitted nor shall holes be repaired.
(e) A thin area is a defect where the sheet is below thickness locally. Thin areas of the indicated sizes are permitted as follows and shall be repaired as indicated:
• Maximum Size - 0.75 mm deep at the lowest point, 2000 mm² with the longest dimension of 125 mm.
• Maximum Population - one thin area in a 1 m by 1 m area, and there shall not be another thin area within 1 m of this area.
• Repair Method - rub with #00 steel wool to blend this area into the normal thickness material and then buff to a normal surface finish.
15.11 PIPING AND TUBING
15.11.1 GENERAL
All piping, valves, fittings, installation methods and testing shall be in accordance with the latest edition of ANSI B31.1 Pressure Piping. Straight runs of pipe shall be continuous and without fittings unless otherwise approved. All piping systems shall be cleaned after installation by flushing with an approved cleaning solutions. All piping systems shall be pressure tested after installation in accordance with the latest edition of the code for Pressure Piping, ANSI B31.1. All leaks shall be repaired and the system retested until leak free.
Piping shall be rigidly clamped where it passes through holes in fixed members. Clamps shall not be welded, brazed or otherwise permanently fastened to any piping. Piping clamps shall be insulated with an approved elastomeric or woven mineral fabric tape to protect and acoustically insulate the piping from structure. All pipe clamps shall rigidly clamp piping to support structure. Cantilevered or other flimsy piping supports are prohibited.
Piping connections to resiliently mounted or moving equipment shall be via hose or other resilient device, as appropriate. Piping shall be clamped within 50 mm of the resilient connection.
Truck piping shall not be run on the bottom of truck side frames, transom, or bolster.
15.11.2 HYDRAULIC PIPING, TUBING, AND FITTINGS
All hydraulic pipes shall be sized in accordance with the function intended. Tubing shall be seamless cold drawn steel, SAE 1010 or as approved, and designed for hydraulic applications. Wall thickness shall be schedule 80 for truck mounted piping and sufficient to maintain a safety factor of 6 at the maximum system pressure. Wall thickness in other locations shall be sufficient to maintain a safety factor of 6 at the maximum system pressure.
All hydraulic pipe or tube connections shall be via steel or stainless steel fittings. All piping and tubing connections shall utilize the same type of fitting. Fittings may be either JIC 37° flare or flareless.
All hose utilized within the hydraulic system shall be rated to withstand four times the maximum operating pressure without bursting. Hose shall not be used in locations where the temperature may exceed 100° C. All hose fittings shall be permanently fitted to the hose and the hose openings shall be capped immediately after fabrication and cleaning.
Joints shall be kept to a minimum and there shall be no inaccessible joints. Instead of elbows, tubing may be bent utilizing a bending tool designed specifically for bending of the tubing to be used. All piping shall be deburred after cutting. All piping and pipe sub assemblies shall be cleaned and capped on all openings after fabrication. Caps shall remain in place until immediately prior to incorporation into the final assembly.
Connections to manifold ports, valve bodies, and other hydraulic system components shall use straight thread fittings with separate O-ring seals, unless otherwise approved.
Use of tapered pipe threads on any fluid carrying system component is expressly prohibited.
Quick connect couplings shall be double shutoff with valves built into both of the mating parts and conform to the requirements of MIL-C-25427A, latest revision, or City approved commercial couplings that provide equivalent performance.
All cutout cocks shall be designed to automatically depressurize the portion of the system which is being isolated by the cutout cock.
15.11.3 AIR CONDITIONING SYSTEM PIPING AND FITTINGS
Air conditioning refrigerant lines and condensate drain lines shall be type "K", as above, seamless copper tubing with wrought copper sweat type fittings. Joints shall be kept to a minimum and there shall be no inaccessible joints or fittings. Finned tubing in evaporators and condensers need not be type "K". Tubing may be bent with an appropriate tube bending tool.
Suction lines shall be without traps and shall be sized for 20 kPa maximum pressure drop. The liquid line shall be sized adequately to prevent flashing due to pressure drop.
All condensate drain lines and suction line piping shall be insulated with an approved insulation that meets the smoke and flammability requirements of this section. The liquid line shall be insulated in all areas where required to provide additional mechanical or thermal protection. The insulating material shall be applied to the piping with a suitable contact cement. All joints and directional changes in the insulation shall be appropriately mitred and sealed with an approved material.
All piping shall be deburred after cutting and thoroughly cleaned after installation in accordance with this section. All piping and pipe sub assemblies shall be cleaned, dried (if required) and capped on all openings after pre-fabrication. Caps shall remain in place until immediately prior to incorporation into the final assembly.
All inaccessible runs of tubing shall be without joints. Lines subject to sweating shall be insulated. Vibration eliminators shall be used in piping connections to the compressor. Tubing installations shall be designed such that any single length of tubing may be replaced without dismantling or removing surrounding equipment, piping, wiring or other appurtenances.
15.11.4 SOLDERING OF PIPING AND FITTINGS
All refrigerant piping shall be joined using silver solder, Sil-Fos, or approved equal conforming to Federal Specification QQ-B-654-Class 1 or 3. Refrigeration tubing shall be internally swept with a continuous flow of an inert gas such as dry nitrogen during brazing.
Condensate drain tubing and air piping shall be joined using 95-5 solder or silver solder as above. Solder fittings shall be wiped and have flux cleaned from tubing and fittings after soldering. After fabrication, the system shall be cleared of all dirt and foreign matter, evacuated, dried and charged according to an approved procedure.
15.12 PAINTS AND COATINGS
The exterior portion of the car body receiving paint shall be painted as required by the Specification in accordance with the approved color scheme, lettering, and numbering. Any austenitic stainless steel portions of the car body shall not be painted except for City approved cosmetic reasons. Where stainless steel is painted, the painting procedures shall be as recommended by the paint manufacturer for that application.
15.12.1 MATERIALS AND APPLICATION
All painting materials shall be prepared and applied according to the paint supplier's recommendations. All paint materials shall be used at the consistency recommended by the paint supplier. Thinners shall be as approved by the paint manufacturer and shall be used only to the extent recommended.
All painting materials for exterior surfaces visible to passengers and staff shall be a two-part, high solids, low VOC, polyurethane paint system.
Metal portions of the carbody not constructed of austenitic stainless steel shall, after fabricating, be prepared for painting by grit blasting, and immediately thereafter painted with a coat of wash (etch) primer. After application of the wash primer, all metal portions of the vehicle, except the outside skin which will receive the polyurethane paint system, shall be coated with a primer according to Federal Specification TT-P-664. After erection of the framing structure and body sheets, all under car metal except stainless steel shall receive a second primer coat as specified above, plus one coat of charcoal gray enamel, per Federal Specification TT-E-527.
Alternative preparation methods and primers offering equivalent performance may be used with City approval.
15.12.2 EXTERIOR FINISH PAINTING
Before painting any car surface that is exposed to view, all dents, gashes, nicks, roughness, or other surface imperfections or depressions shall be rectified. Recitification shall include removal so far as possible by straightening followed by application of filler material. After straightening, the surface shall be properly prepared to receive the filler material. These surfaces shall be wash primed following straightening. Remaining imperfections shall be filled with an approved epoxy-based filler and sanded smooth. The maximum allowable filler thickness shall not exceed 3 mm.
The finished exterior shall present a high quality appearance free from sags, drips, scratches, variations in gloss, and other imperfections.
15.12.3 APPARATUS AND EQUIPMENT ENCLOSURES
All apparatus and enclosures shall be painted only after all metal working activities are completed.
The exterior and interior surfaces of undercar equipment enclosures and apparatus made from carbon steel shall be prepared, primed and painted.
Parts of undercar equipment enclosures made from plastic or fiberglass shall be painted in accordance with the above requirements for metal portions except that the paint system shall be compatible with the plastic used, and an insulating coating need not be applied to interior surfaces.
All apparatus from suppliers shall be painted by the suppliers, under the Contractor's direction, according to the above requirements and approved color scheme, prior to installation on the vehicle.
15.12.4 MISCELLANEOUS PAINTING AND FINISHING
Exterior stainless steel shall be cleaned with an approved alkaline cleaning solution, which shall not damage any previously painted surfaces. Other than framing structures, all hidden aluminum or ferrous materials, except stainless steel, shall be given 1 coat of a primer and one coat of an approved sealer.
15.12.5 PAINTING RESTRICTIONS
Any equipment or parts of equipment which would be damaged or suffer impaired operation from painting shall not be painted.
The following undercar items shall not be painted:
• Flexible conduit and fittings
• Copper tubing, piping and fittings
• Wire and cable
• Power resistors
• Heat transfer surfaces
• Electrical insulators
• Elastomeric devices
• Grounding pads
The following truck-related items shall not be painted:
• Wheels
• Axles
• Elastomeric parts
• Grease fittings
• Linkages
• Threads used for adjustments
• Electrical equipment
• Current pick-up devices
• Wearing surfaces
15.12.6 INTERIOR PAINTING
All interior surfaces requiring paint shall be coated with an approved thermosetting epoxy powder-coating. Parts which are to be powder-coated shall be cleaned and prepared in accordance with the recommendations of the powder supplier and the substrate material being covered.
15.12.7 CORROSION PROTECTION
Concealed surfaces capable of rusting or oxidation shall be properly cleaned, primed with a rust inhibitor paint and painted with an approved paint. Where arc welding is performed on joints between stainless steel and other materials, the joint shall be de-scaled and cleaned and then painted in accordance with this section.
15.12.8 UNDERCOATING
Undercoating and acoustical insulating materials shall be applied to properly cleaned and primed underframe, sides, ends, roof and floor members, as required in Sections 3 and 13 of these TECHNICAL SPECIFICATIONS. The materials shall be resistant to dilute acids, alcohols, grease, gasolines, aliphatic oils and vermin and shall meet the smoke and flammability requirements of Section 15.13 below.
15.12.9 TRUCKS
Before installation, trucks shall be cleaned by blowing off with compressed air and solvent-wiped to remove all dirt and grease. All truck components shall then be sprayed with one coat of primer and one coat of an approved black truck paint and air dried. Truck paint shall be selected such that structural cracks will not be hidden.
15.12.10 PAINT PROCESS DOCUMENTATION
The Contractor shall prepare a paint coating and application document containing procedures for surface cleaning and preparation, priming, surfacing and painting for all equipment that is painted or powder-coated whether by itself or by its manufacturers and suppliers. A detailed paint schedule showing the equipment painted, paint type and manufacturers, recommended thickness and other pertinent information shall also be included. This document shall be submitted for review and shall be made part of the maintenance manuals.
15.13 FLAMMABILITY AND SMOKE EMISSION REQUIREMENTS
15.13.1 GENERAL
All combustible material used in the construction of the car shall satisfy the flammability and smoke emission requirements cited in this Section.
As a minimum, all materials used in the construction of the car shall meet the requirements of NF F 16-101 Category A2, DIN 5510 Level 1, or the US Department of Transportation's "Recommended Fire Safety Practices for Rail Passenger Car Materials Selection - January 1989" as it appeared in the Federal Register, Volume 54, No. 10 of January 17, 1989, pages 1837 through 1840 inclusive, or the latest issue of that document, subject to the following conditions:
Should a conflict exist between the referenced standards and the detailed requirements in Section 15.13.2 below, the more restrictive requirements shall govern. Independent laboratory certification is required for all materials, including successful compliance with these requirements.
Should the Contractor feel that the quantity of a particular material is such that it would not contribute significantly to a fire, the Contractor may request a waiver from testing for this material. The waiver shall be submitted in writing and shall include the total weight of the material to be used, the location of the material and the distribution in the car, and any previous test reports available.
15.13.2 FLAMMABILITY AND SMOKE EMISSION
Specific materials used on the streetcars for this Contract shall be tested to demonstrate compliance with the requirements set forth in this Section.
• TEST REQUIREMENTS FOR PASSENGER VEHICLE MATERIAL
• FIRE RISK ASSESSMENT
• Function of Test Performance
• Material Procedures Criteria
• Interior Panels ASTM E 162 Is < 35
• ASTM E 662 Ds (1.5) < 100
• ASTM E 662 Ds (4.0) < 200
Materials tested for surface flammability shall not exhibit any flaming running or flaming dripping.
The following information shall be supplied for all materials tested.
• Test
• Test Facility
• Test Result
15.13.3 TOXICITY
Materials and products having high toxic products of combustion shall not be used.
15.14 WOOD AND PANELS
15.14.1 LUMBER
Lumber shall be thoroughly air seasoned or kiln dried before using and shall be dressed on all surfaces to full dimensions. Lumber shall be straight grained, free from dry rot, knots checks, and other defects which may impair its strength and durability or mar its appearance.
The use of wood in the car, except where specified, shall be limited to specifically approved applications.
15.14.2 PLYWOOD
All plywood shall be manufactured to conform with the requirements of Grade - Structural I of the National Bureau of Standards Voluntary Product Standard (American Plywood Association) PS 1-83, and then stored under cover. All plywood panels shall be formed from one piece and shall be sealed with aluminum lacquer on all edges and cutouts as soon as possible after fabrication. All exposed edges of the panels, joints between panels, fastener heads, and openings of panels used in areas accessible to moisture shall be waterproofed and sealed in accordance with MIL-P-8053, paragraph 3.4, prior to installation in the car.
15.14.3 HONEYCOMB PANELS
The term "honeycomb panels" as used in this document refers to honeycomb material bonded to melamine or to metal. Honeycomb material shall conform to Military Specification MIL-C-7438G. Bonding shall be sufficient to develop the full strength of the honeycomb material.
15.14.4 FLATNESS
Surfaces exposed to passengers shall not deviate from the specified contour by more than 2.5 mm in any 1 m distance. The slope of any such deviation shall not exceed 2 mm in 100 mm.
15.15 FIBERGLASS REINFORCED PLASTIC
Fiberglass Reinforced Plastic, (FRP) shall be a polymeric-reinforced, laminated material, composed of a gel-coated surface, fiberglass reinforcement, and a polyester resin. FRP shall withstand, without any physical deformation, structural damage, or reduction in life, the environmental conditions in Section 2 of these TECHNICAL SPECIFICATIONS, and shall be resistant to acids, mild alkaline solutions and those cleaning solutions recommended by the Contractor. The FRP shall meet the relevant smoke and flammability requirements of Section 15.13 above.
FRP shall be manufactured by either open molding, hand lay-up, spray lay-up, or the matched die molding process. Production techniques shall ensure that the glass fiber reinforcement is distributed throughout the final product in such a manner as to avoid resin-rich or resin-starved sections.
Reinforced plastic parts shall have greater thickness at attachment points and edges. Exposed sharp edges are not permitted on any parts.
Additives, fillers, monomers, catalysts, activators, pigments, fire retardants, and smoke inhibitors shall be added to the resin mixes to obtain finished products with the required physical characteristics below and other requirements of this document.
Mineral filler shall not exceed 28 percent of finished weight for any preformed matched die molding process.
15.16 WIRE AND CABLE
All wire sizes and insulations shall be based on the current carrying capacity, voltage drop, mechanical strength, temperature and flexibility requirements indicated in this section or as approved by the City.
Within this document, the term "wire" refers to a single insulated conductor of any size while the term "cable" refers to a group of wires contained within an overall insulating covering. Cable may also be referred to as multi-conductor cable.
All requirements in this document referring to wire also apply to cable, except for requirements that explicitly apply to wire or cable only.
All car wiring shall be designed, rated, and selected to last the life of the car.
15.16.1 CONDUCTORS
Maximum wire ampacities for each circuit shall conform to the lower of the following:
(a) National Electric Code (NFPA 70) Table 310-16, 90°C column for copper conductors, or;
(b) The lowest temperature rating of all devices connected to the circuit, such as wire terminals, circuit breakers, etc.
Where more than three (3) conductors are routed in a raceway or cable, the ampacities shall be derated as detailed by Note 8 to Table 310-16.
All wire conductors shall be of stranded, soft annealed, tinned copper wires in accordance with ASTM B 33. Solid wire is not permitted except for approved wire wrap applications.
Stranding and conductor construction for all wires and cables of No. 18 AWG and larger shall be in accordance with ICEA S-66-524 Table L-7, Class K, or Table L-8, Class M, as appropriate for the application.
Stranding and conductor construction for wires and cables AWG 20 and smaller diameters shall be in accordance with ICEA S-19-81 Table 2-8, Class M, or shall be 19-strand construction as appropriate for the wire size.
15.16.2 INSULATION
15.16.2.1 GENERAL
All general car body wire insulation shall be a flame retardant, low smoke, flexible, cross-linked polyolefin or approved equal material having a continuous temperature rating of 110°C. Halogenated insulation is prohibited.
Insulation shall be rated at 2000 Vdc for circuits of greater than 300 Vac or Vdc and rated at 600 Vdc for circuits of 300 V or less, ac or dc.
Alternative insulation types shall have a service proven history in rail transit applications. Submittals shall include specifications for the following characteristics:
(a) Smoke Density (preferably Test Method, ASTM E 662)
(b) Insulation Resistance (preferably Test Method ASTM Standard D 470)
(c) Heat Distortion
(d) Moisture Absorption
(e) Ozone (preferably Test Method, ICEA S-19-81, Paragraph 6.8)
(f) Tension Set (preferably Test Method ICEA S-66-524, Paragraph 6.4.11.4)
(g) Corrosion (preferably Test Method ASTM Standard D 2671-Copper Mirror)
(h) Abrasion Resistance
15.16.2.2 WIRE INSULATION FOR HIGH TEMPERATURE APPLICATIONS
High temperature insulation shall be in accordance with the following requirements:
(a) For wire sizes AWG 16 and larger: abrasion resistant Teflon Polytetrafluorethylene (PTFE) meeting MIL-W-22759/6B, or silicone rubber meeting AAR Standard S-503(No.59)
(b) For wire sizes AWG 18 and smaller: Kapton film insulated/liquid H aromatic polyamide covered per MIL-W-81381/22 (AS) or abrasion resistant PTFE Teflon meeting MIL-W-22759/6B. When used for interconnecting pieces of apparatus, this type wire shall be in bundles with a protective covering.
High temperature insulated wire shall not be used in conduit or raceways without specific approval.
The Contractor shall submit all applications of high temperature wire insulation for approval.
15.16.2.3 WIRE INSULATION WITHIN EQUIPMENT
Wiring within replacement modular units, electronic apparatus such as cards and card racks, and other equipment, as approved, shall be Tefzel Ethylenetetra-fluoroethylene (ETFE) per ASTM D 3159 and insulation construction per Military Specification MIL-W-22759/16 (AS) except the wall thickness shall be 0.6 mm, cross-linked polyolefin or Teflon Polytetrafluorethylene (PTFE) type EE per Military Specification MIL-W-16878/5.
15.16.2.4 WIRE INSULATION IN CROWDED LOCATIONS
Wire for connections to the control console, or in other locations with similarly crowded low voltage control wiring, may be insulated with ETFE Tefzel per ASTM D 3159 and insulation construction per Military Specification MIL-W-22759/16 (AS) except the wall thickness shall be 0.6 mm.
When used for this application, these type wires shall be bundled with a protective covering of cross-linked modified polyolefin or similar high temperature rated, low smoke generating insulation.
15.16.3 MULTI-CONDUCTOR CABLES
Multi-conductor cables shall be constructed using wiring as described above. For high temperature applications, the cable shall conform to MIL-C-27072, with Type V connectors Style 4 sheaths, Class D jackets, if needed, and shields, if needed.
Materials used in the construction of multi-conductor cables shall meet the requirements below.
All conductors in multi-conductor cables shall be color coded or otherwise permanently identified as approved.
Where required to obtain a circular cross-section, fillers shall be made of non-hygroscopic materials compatible with the wire insulation and jacket and shall be of the same or of a higher temperature rating than the wire insulation.
A binder tape may be employed over the assembly of conductors in multi-conductor cables if needed to assist in cable manufacture, or as required to permit the cable to function as intended in its application. The binder tape material shall be non-hygroscopic and shall be of the same (or better) temperature class as the wire insulation, and shall be of a compatible material.
The shield, if required, shall consist of either copper braid, concentrically served copper, or aluminum/polyester tape with a drain wire, as is appropriate for the application. The shields shall have the following minimum properties:
(a) Copper shield shall be made of either tinned, coated copper strands which conform to ASTM B 33, or silver-coated copper strands which conform to ASTM B 298, as is appropriate for the wire insulation. Shield coverage shall not be less than 85 percent. Shield strand size and application shall be as recommended by the cable manufacturer for the particular application.
(b) Aluminum/polyester tape shields shall consist of a helical wrap of aluminum/polyester tape aluminum on a backing of polyester. The tape shall have a minimum overlap of 10 percent of the tape width to ensure complete coverage. In contact with the aluminum side of the shielding tape shall be a No. 22 AWG 7/30 tinned copper drain wire conforming to ASTM B 33 and B 174.
The overall jacket of multiconductor cables shall be of flame retardant, cross-linked, modified polyolefin; ETFE Tefzel or TFE Teflon to match the wire insulation and application as approved. Low smoke Hypalon shall be used on intercar jumper cables, where increased cable flexibility is necessary. The jacket shall be extruded and vulcanized over the cabled conductors, and shall be well centered, with a smooth appearance without objectionable roughness or irregularities, consistent with good industry practice. The nominal jacket thickness shall be that shown below, with the minimum wall not less than 80% nominal value.
15.17 WIRING INSTALLATION
15.17.1 GENERAL
All car wiring shall be in conformance with Chapter 3 of the National Fire Protection Association's Publication NFPA No. 70, National Electric Code, except where otherwise specified, and except that all wire shall be as specified in this document.
All car wiring shall have circuit protection conforming to Chapter 2 of NFPA publication No. 70, Article 240 or as specified in this document.
15.17.2 WIRING
Wiring shall be sized for the intended load, voltage drop, installation method, and applicable codes.
Regardless of the load, minimum wire sizes shall be as follows:
(a) Wire which is pulled through conduit - 14 AWG
(b) Wire on electronic units, cards, and card racks - 22 AWG
(c) Wiring which is laid in, rather than pulled through, wire ducts - 16 AWG
Wires sizes other than the above shall be as approved.
15.17.3 WIRE HANDLING
All wiring shall be performed by qualified, experienced wiring personnel using appropriate tools for stripping insulation, cutting, tinning, soldering, harness making, attaching terminals, etc. All wiring tools and equipment shall be used as recommended by the tool and equipment manufacturer.
Wire shall be protected from damage during all phases of equipment manufacture. Wire shall not be walked on, dragged across sharp or abrasive objects, kinked or twisted, or otherwise mishandled. The ends of wire shall not be permitted to lay on wet floors or other damp areas where moisture may be absorbed into the conductors.
When removing insulation, wire strands shall not be nicked or broken in excess of the requirements of FAA Specification No. AC 43.13-1A, Chapter 11, Section 449, "Stripping Insulation". Additionally, the following criteria applies:
• Wire Size Nicked or Broken Strands
• Wires smaller than No. 10 None
• No. 10 through 1/0 7.4 - 4.4 percent
• Above 1/0 through 1600/24 4.4 - 2.0 percent
(above on graduated scale)
Definitions:
a) A cutoff strand shall count as two nicked strands.
b) A nick is defined as 25 percent or more of the strand area damaged, or cut more than 1/3 of its diameter.
c) Longitudinal scratches in a copper strand are not considered cause for rejection.
15.17.4 CIRCUIT SEPARATION
Circuits shall be physically separated to reduce the possibility of unsafe conditions, interference, or equipment damage.
The following major circuit groups shall not be harnessed or bundled together, shall not run in the same conduit, and shall be physically separated and secured in enclosures, wire ducts, junction boxes, or other wire routing devices:
• High voltage circuits
• AC circuits
• Communication circuits
• Battery voltage level circuits
• Semiconductor voltage level circuits
Wiring operating at potentials differing by 50 V or more shall not be harnessed or cabled together or be run in conduit together. Wiring of different potential in wire ducts, raceways, junction boxes, or other wire routing devices shall be separated by a rigid physical barrier.
Wiring of different potential within equipment enclosures shall be separated, routed, and secured such that contact between wiring is not possible. All wiring within an enclosure shall be insulated for the highest voltage in the enclosure, unless approved otherwise.
Separation and/or electromagnetic shielding shall be provided between the conductors of high current switching or transient generating equipment and the wiring of semiconductor, logic, or communication circuits such that interference does not occur between circuits.
15.17.5 ROUTING OF WIRING
15.17.5.1 GENERAL
All wiring shall be secured and protected against movement, chafing, and any contact with conductive, sharp, or abrasive objects including the inside surfaces of wire runs.
No wiring shall be secured directly to the car structure, equipment enclosures, or any metallic surface. Wiring securing devices shall be either completely non-metallic or metallic with a resilient, insulating member between the wiring and the metallic portion of the device.
All wiring shall be located and secured such that normal equipment motions, maintenance access, heat sources, and the Portland environment do not damage or reduce the life of the wiring.
Within this document, the term "wire run" refers to all equipment used for routing of wiring except electrical enclosures or electrical apparatus and includes conduits, wire ducts, and associated hardware defined below.
All indicated wire run requirements apply to all wiring types and locations, including undercar wiring, wiring within the car, and truck wiring unless explicitly indicated otherwise.
15.17.5.2 WIRING BETWEEN EQUIPMENT OR ENCLOSURES
All wiring not fully contained within electrical enclosures or electrical apparatus shall be contained within wire runs, as defined below.
All wire runs shall be fully enclosed wire ducts, conduits, junction boxes, or similar hardware. Large wires and cables may be exempt from this requirement, see Section 15.17.5.3 below. For wiring within enclosures, see Section 15.17.5.4 below.
All undercar wire runs shall be waterproof. All entrance and exit points of undercar wire runs, equipment enclosures, or other wiring devices shall be waterproof. Except for conduit, all wire runs shall have removable covers sufficient to gain access to all wiring within the run. All wire run covers shall have reusable resilient waterproof seals.
All wiring to resiliently mounted or moving equipment shall be by flexible conduit or ducting.
All metallic wire runs shall be grounded to the car structure.
Except for within conduit, all wiring within wire runs shall be secured at least every 450 mm. Wiring shall be secured only to the top or sides of wire runs and no wiring shall be secured to, or rest on, the bottom of wire runs.
Wiring within conduit shall not be bundled or secured.
Junction boxes or equipment enclosures shall be used for all wire terminations or circuit branches. Wire splices of any type are not permitted except as approved on a case-by-case basis during construction.
Wiring to electrical apparatus shall be carried within the wire run as close to the apparatus as possible. Wiring between the wire run and the apparatus shall be in rigid conduit, liquidtight flexible conduit or other device. See Section 15.17.5.3 below for exceptions. In areas of likely impact, such as on trucks, flexible conduit shall be without an internal metallic liner and shall include an external abrasion shield.
All entrance and exit points from wire runs or enclosures shall have permanently retained insulating liners. All wiring entering or exiting wire runs or enclosures shall be secured at, or within 150 mm of, the transition point. The securing device and wiring slack shall insure that there is no strain on the wiring at the transition point.
All wiring shall be removable from wire runs and enclosures without removal of wire terminals or connectors.
Wiring shall not pass through or over the battery compartment nor shall they pass over heat generating equipment such as acceleration and braking resistors, even if the wiring is within wire runs.
All truck wiring shall be in rigid conduit to the greatest extent possible except for the connection to electrical apparatus (see above).
All wiring passing through the floor shall be in wire runs.
All wiring shall be replaceable without disassembly of wire runs, except for access cover removal.
15.17.5.3 EXPOSED WIRING
Large sizes of wire, No. 1 AWG or larger, may be cleated in place with no protective wire run. Exposed wiring in areas of likely impact or abrasion shall have additional protection in the form of additional jacketing or armor. Multi-conductor cable shall not be exposed except for wiring to standard small devices, such as speed sensors, that cannot accept conduit fittings.
Cleating shall be by split-block cleats of fire retardant neoprene rubber with a durometer of 50 to 60. The neoprene blocks shall be clamped together with no fewer than two bolts with a rigid stiffener on each side of the cleat. The stiffeners shall insure that clamping pressure is evenly distributed over the full length of the cleat.
Each cleat opening shall be sized only for the intended wire size and shall firmly grip the wire without insulation damage or cold flow. Shimming of oversized openings is not permitted. All cleat openings shall be molded into the material by an experienced manufacturer. Cutting, drilling, or modification of cleat openings during car construction is prohibited.
Cleated wiring shall be routed and supported such that wiring cannot contact each other or any other part of the car under any circumstances. Intervals between adjacent cleats shall not exceed 500 mm.
A drip loop shall be provided on all exposed wiring to prevent fluid runoff into connected equipment.
15.17.5.4 WIRING WITHIN ENCLOSURES
The requirements below apply to all electrical equipment enclosures, including junction boxes.
All wiring within enclosures shall be attached to wire supports rigidly fastened to the enclosure structure. Wiring shall be free from edges, bolt heads, or similar areas, and shall not interfere with nor contact enclosure covers.
Wiring shall be located on the top or sides of the enclosure. All wiring shall be a minimum of 50 mm above the bottom of the box including all wiring that must connect to the bottom of apparatus.
Wiring entering any removable enclosure shall be harnessed and secured to facilitate removal of the box. Wires from different wire runs shall not be harnessed together or with internal wiring.
All wiring shall be secured such that there is no strain on wire terminals, multi-pin connector pins, or other wire termination hardware.
Wire dress shall allow for sufficient slack at terminals to provide for shock and vibration induced movements, equipment shifting, alignment, cover removal and component replacement. Sufficient additional wire length shall be provided for retermination of wires without excess tension or splicing as follows:
No. 10 and smaller - Three reterminations
No. 8 and larger - Two reterminations
Wiring entry into enclosures shall be through the top or upper half of the sides for underfloor equipment. Wiring entry into the bottom of enclosures is prohibited except for wiring entering into interior enclosures through the floor.
15.17.5.5 PRIMARY POWER WIRING
Primary power wiring installed within the car body, including wiring between the roof and underfloor locations, shall be run in conduit or wireways. Conduits or ducts that penetrate the roof shall be terminated in a waterproof entrance box or with a waterproof fitting. Primary power wiring, except for heater wiring, shall not terminate within the car body.
15.17.5.6 ARTICULATION CONNECTIONS
Flexible hoses, wiring and cabling routed across the articulation shall be run in ducting with non-conductive inserts. The routing shall minimize excess length and unnecessary flexing. All primary power wiring shall be run on the vehicle roof. Low voltage wiring may be run below or above the floor line.
Quick disconnects shall be provided for low voltage circuits and terminal connections shall be provided for high voltage circuits on one or both sides of the articulation. If provided on one side of the articulation, all wire and cable shall be readily removable from, and re-installed through, the articulation without damage to the wire, cable, or connectors.
Refer to Section 15.18.4 below for connector requirements.
15.17.6 MARKING
The Contractor shall devise a wire and terminal designation system that will coordinate all electrical circuits in the car into a unified system. The system shall identify all wiring, including circuit return wiring, and terminals according to their respective circuit function(s) and shall accurately correlate with car schematics. Common designations for return circuits are not permitted. Alternative designations may be used with City approval in small standard assemblies such as PA amplifiers.
All wires and terminals shall be clearly identified with white or yellow permanent markers, with black printing or by continuous wire marking printed on the wire. The markers shall be oil and grease resistant and shall withstand all combinations of ambient and equipment temperatures. Printing shall be done by machine with permanent ink that will not rub off. Hand printing is prohibited. Color coded wires are permitted as an alternative in small standard assemblies such as PA amplifiers.
Each wire shall be labeled with both its circuit designation, and if attached to a terminal, its terminal designation. All wires shall be marked within 75 mm of the end of the wire.
15.17.7 SOLDER
Solder shall be in accordance with ASTM B 32, Grade 60B. A non-corrosive flux shall be applied immediately before soldering. An automatic temperature controlled solder pot shall be used.
Corrosive flux may be used only if an adequate deactivation process follows the soldering process.
15.17.8 TAPE
Electrical tape shall be polyvinyl chloride in accordance with AAR Standard S-540 of Section F of the AAR Manual Standards and Recommended Practices, or equivalent approved railway practice. Electrical tape shall meet or exceed the voltage rating of wire where the tape is applied.
15.17.9 WIRE TIES AND CLAMPS
Wire ties, clamps, and anchors shall be nylon formulated for resistance to ozone and ultraviolet light, rated for outdoor service, and shall last the life of the car. Wire ties shall be installed with tools with automatic tensioning devices, as supplied by the wire tie manufacturer. Wire ties shall be installed with sufficient tension to restrain the wiring without indenting the wire insulation.
If used, wire tie anchors shall be riveted or screwed to rigid structure. Adhesive-based wire tie anchors are not permitted.
Wire tie width shall be selected for intended wiring load and minimum insulation indentation.
Wire clamps shall be either nylon or stainless steel covered with neoprene or silicon rubber similar to those manufactured by Adel. Wire clamps shall be sized for each harness such that no less than 90 percent of the harness circumference is securely clamped. Clamps shall be fastened with bolts and elastic stop nuts.
15.18 WIRING CONNECTIONS
All car wiring shall be connected via terminals and terminal boards and/or multi-pin connectors.
15.18.1 TERMINAL BOARDS
As used in this document, the term "terminal board" refers to all devices commonly called terminal blocks, terminal strips, terminal studs, or similar to which wires are connected.
Terminal boards shall be either stud type, compression clamp, or push-on tab (FASTON type), with barriers and of a series service proven in rail transit.
Each terminal board shall have a minimum of 10 percent, but no fewer than one, unused terminals. For terminal boards with more than 100 terminals, the minimum number of unused terminals shall be 10 plus 2 for every 50 additional terminals above 100. Jumpers between adjacent terminals shall be plated brass or copper.
The terminal board insulation shall be a strong, high temperature rated, tracking resistant material that is not brittle. The material shall be either a filled reinforced thermosetting material or a thermoplastic material. General purpose phenolic is prohibited. Jumpers between adjacent terminals shall be plated brass or copper.
On compression clamp terminal boards, a maximum of 2 terminals shall be connected to any one binding terminal. All connected wires shall be terminated with mechanical crimp type terminals as specified in Section 15.18.2 below.
15.18.2 WIRE TERMINATIONS
Wire terminals used throughout the car shall be mechanical crimp type terminals as made by AMP Incorporated or other approved manufacturer with a comprehensive line of terminals, connector pins and application tools available. The Contractor shall submit the proposed product line for approval. Terminal lugs shall be in accordance with Military Standard MS-25036. All terminals shall be plated copper.
Wire terminals shall be AMP PIDG ring-lug type terminals or approved equal. "FASTON" type terminals shall be of a type which permits at least 100 cycles of removal and re-attachment without loosing proper grip and shall be AMP PIDG terminals, S/N 640 903-1 for wire sizes 22-18, S/N 640 905-1 for wire sizes 16-14, or S/N 640 907-1 for wire sizes 12-10, or approved equal. Terminals used with compression clamp terminal blocks shall have insulating collars and shall be of a series approved by the terminal board manufacturer for use with the selected terminal boards. Spade and hook type terminals are not permitted.
Terminals used on conductor sizes No. 10 AWG or smaller shall be insulated and shall have a metal strain relief device under the insulation that is crimped onto and grips the wire insulation simultaneously with the terminal. Other strain relief devices shall be submitted for approval. The insulation material shall be rated for the expected worst case temperature.
All wire terminals and connections shall be attached to the wiring with crimping tools and dies as recommended by the manufacturer and approved by the City. Crimping tools shall be ratcheting types that insure a complete compression. The contractor shall maintain these tools in proper calibration and insure that all personnel using them are properly trained.
A maximum of one (1) wire shall be crimped in any one (1) terminal.
15.18.3 POWER WIRING TERMINATIONS
Power wiring shall be terminated with bolted compression terminals as manufactured by AMP, Thomas & Betts, or approved equal and shall be applied using tools and procedures recommended by the terminal manufacturer. Crimping tools shall be ratcheting types that insure a complete compression.
Double bolted terminals shall be used at all locations where rotation of a single bolted terminal would result in contact or unacceptable clearance with other conductors or the enclosure.
Traction motor wire terminals may be as recommended by the motor manufacturer, subject to approval.
15.18.4 MULTI-PIN CABLE CONNECTORS
15.18.4.1 GENERAL
All cable connectors shall be equipped with removable crimp contacts. Contacts shall be selected for the intended wire size and as recommended by the manufacturer.
Adjacent connectors shall either use different inserts or different insert orientations to prevent erroneous connections.
Cables shall be clamped at the back of the connector by clamping over the cable jacket. Clamping on cable wires is prohibited.
Extension bodies shall be used where necessary to insure that there is sufficient room to terminate cable wires while providing the seal and clamp on the cable jacket.
All cable connector applications shall be approved.
15.18.4.2 WATERPROOF CABLE CONNECTORS
Waterproof cable connectors with the qualities described below shall be used for all under car or exposed locations and may be used at all other locations. Cable connectors shall be equipped with sealing gaskets on the front mating surface and on the back at the cable entry. Unused connector pin positions shall be sealed with either connector contacts or plastic sealing plugs designed for that purpose.
The cable connectors shall be metal shelled, positive locking, one quarter to one third turn, with three bayonet couplings, quick disconnect, environmental watertight connectors. Connectors shall be rated for a minimum life of 2,000 couplings before failure. Connectors shall give audible, visual and tactile indications of full coupling. Connectors shall be type CIR connectors as made by Litton-Veam SPA, or approved equal.
Speed sensor connectors only may be multi-turn, fine thread, metal shelled, waterproof connectors. These connectors shall be Cannon CA06RXA, or approved equal.
15.18.4.3 NON-WATERPROOF CABLE CONNECTORS
In weatherproof interior locations, the use of non-weatherproof connectors is permitted. Connectors shall be Amp Circular Plastic Connectors, Amp Circular Metal Shell, or approved equal.
15.18.5 GROUND CONNECTIONS
Grounding connections to the car body, truck frame, and other car structures shall be made through tinned or silver electro-plated copper pads silver soldered or brazed to both the carbody and the grounded item.
All grounding wires shall be sized to limit voltage rise to less than 50 V under worst case fault currents. The grounding connection method employed shall not produce a DC resistance in excess of 0.0025 ohms, or more than 0.025 ohms at 150 kilohertz for any applied AC voltage.
Grounding wires to resiliently mounted equipment, from the carbody to truck frame, or other locations with relative movement shall be tinned braided copper ground cables fitted with flared terminal barrels designed for strain relief.
Grounding wires to fixed equipment may be standard car wiring. Fixed equipment which is held by screws, bolts or metallic clamps may be considered to be grounded by its mounting hardware.
All ground connections shall utilize bolted terminals. All ground pads shall be through-drilled and the ground wire fastened with a bolt, flat washer and locknut. The flat washer shall bear on the ground wire terminal.
15.18.6 WIRE SPLICING
Wire splicing is not permitted.
15.19 SEMI-CONDUCTOR STANDARDS
15.19.1 GENERAL
Semiconductors shall be selected to withstand all continuous and transient voltage and power demands present in the circuit application without damage or reduction in life. All circuit designs shall provide for the presence of high current switching equipment on the vehicle and the resultant induced voltages and currents in electrical equipment.
Discrete semiconductors shall have the following minimum voltage breakdown ratings:
• Semiconductors, except diodes (see below), operated from the battery supply, or those connected to trainlines, shall have minimum breakdown ratings of 4 times the maximum achievable circuit voltage. Suppression devices shall be provided as necessary to protect the devices and limit the circuit voltage.
• Diodes operated from the battery supply, used as suppression devices, or connected to trainlines shall have a minimum breakdown rating (PIV) of 1000 V. Diodes with less than 1000 V PIV rating may be used if adequate circuit transient protection is also provided.
• All discrete semiconductors operated from inverters or other isolating devices shall have a minimum breakdown rating of 2 times the maximum circuit voltage, except where specifically detailed otherwise. Suppression devices shall be provided as necessary to protect the devices and limit the circuit voltage.
All semiconductor junction temperatures shall be limited to 150°C (or to the maximum rated temperature for the device, whichever is less) or less at maximum ambient temperature and at maximum rated output power.
All semiconductors shall be operated at less than 50 percent of the maximum continuous current rating or 50% of the maximum continuous power rating, whichever is more restrictive. High power/current devices may be exempt from this requirement with prior approval, on a case-by-case basis. The Contractor shall submit complete device information, including all manufacturer's application recommendations, and calculated current and power demands with all waiver requests. If approved, such waivers do not reduce other requirements, including reliability.
Integrated circuits operated from the battery supply through inverters or other isolating devices shall be operated within the voltage and current ratings specified by the manufacturer, derated to less than 50% of the maximum stress level at the maximum operating temperature of the device as specified by the manufacturer.
Where the supplies to integrated circuits are regulated and surge protected, the voltage rating shall be 15% below the manufacturer's recommended maximum. In addition, the maximum power shall be limited to 50% of the manufacturer's specified maximum at the maximum operating temperature.
All Gallium Arsenide and similar optical semi-conductors shall be rated for operation over the temperature range of -40°C to +85°C.
15.19.2 AVAILABILITY AND JEDEC REGISTRATION
Except as approved, all semiconductor devices shall be JEDEC registered and numbered.
JEDEC registered devices with house numbers may be used only if a complete cross reference is provided linking each house numbered device with a JEDEC registered device. House labeled devices shall be clearly labeled with the manufacturer's name or logo.
15.19.3 BURN-IN
All integrated circuits shall be burned-in and screened for defects during a minimum 100 h burn-in for the completed assembly. The burn-in shall be performed with the equipment operational (power on) and with the necessary input signals and loads to simulate the maximum power dissipating condition in the device.
15.19.4 OTHER PROHIBITIONS
Electronic equipment shall utilize stock components and shall function properly with the component manufacturer's full range of tolerances such that after-purchase screening or testing of components shall not be required.
Matching of components is permitted only if the components are normally available from the manufacturer in matched sets.
Germanium semiconductors shall not be used.
15.20 PRINTED CIRCUIT BOARD STANDARDS
Circuit board material shall be per MIL-P-13949, latest revision, with a minimum thickness of 1.5 mm using type GB or GH base material. The copper laminate shall be firmly attached to the board and shall be resistant to blistering and peeling when heated with a soldering iron.
Components with pins shall be mounted only on one side. Connections shall be made to the other side or internal layers via plated through holes. SMT devices may be mounted on both sides if part of an approved existing design.
The footprint for all ICs shall permit the future use of sockets.
All circuit boards shall be inherently stiff or shall be reinforced to prevent damage due to vibration or handling. Circuit boards larger than 50,000 mm2 shall be centrally stiffened unless otherwise approved.
All printed circuits boards with the same function shall be interchangeable between equipment groups without additional adjustment.
15.20.1 MARKING
All circuit boards shall be labeled with a part number and descriptive nomenclature.
All components shall be labeled on the board with component drawing references and such other information as may be required to repair and troubleshoot the board. The component and wiring sides of the board shall each be marked to indicate capacitor and diode polarity, and at least two leads or one lead and a graphic symbol indicating orientation of all transistors and thyristors. Alternative schemes for component identification on circuit boards may be submitted for City approval.
Integrated circuits and other multi-terminal devices shall have an index mark on the component side of the board, visible with the component inserted, to indicate proper keying and insertion; the first pin on all IC packages shall be identified on the wiring side of the board.
15.20.2 COMPONENT MOUNTING
Components shall be fastened to the board in such a manner as to withstand repeated exposure to shock and vibration. Large components shall be supported in addition to the solder connections.
15.20.3 CONFORMAL COATING
Both sides of assembled printed circuit boards shall be coated with a clear insulating and protective coating material conforming to MIL-I-46058 latest revision, or approved equal.
The coating shall be easily removed with a brush-applied solvent or penetrated by a hot soldering iron when a component must be unsoldered. The coating solvent shall not adversely affect board mounted components.
All IC sockets, connectors, and test points shall be masked when the coating is applied.
15.20.4 KEYING AND INTERLOCKS
All circuit boards shall be keyed to prevent insertion into the wrong location.
All circuit boards in safety related control systems including ATS, propulsion, friction brakes, or any other systems which can cause unsafe train operation with a card removed, shall be interlocked through a safety circuit to disable the vehicle if a circuit board is removed.
15.20.5 CIRCUIT BOARD CONNECTORS
Printed circuit board connectors shall be heavy duty, high reliability, 2-part type with a history of successful service in rail applications.
The connector contact area shall be plated with a minimum of 0.75 µm of gold over a minimum of 1.25 µm of low stress nickel.
Card edge connectors are prohibited.
15.20.6 ENCLOSURES AND CIRCUIT BOARD HARDWARE
All circuit boards that are rack mounted shall plug into racks containing the mating half of the circuit board connector (see above). The circuit board rack shall mount in an enclosure conforming to requirements in this document. The rack, circuit board, and circuit board hardware shall be designed as an integrated system.
The rack and enclosure shall provide environmental and EMI shielding as required to meet the requirements of this document.
Printed circuit boards shall be positively retained by means of keeper bars or other approved method. The enclosure or rack cover shall not be used to retain the circuit boards.
Each circuit board shall be fitted with an ejector or hand grip to assist in board removal.
The rack and the edge of each board, or the card ejector, shall be labeled with corresponding numbers to identify board location within the enclosure.
15.20.7 EXTENDERS
Printed circuit board extenders (2 sets of each type) shall be provided by the Contractor for test purposes. At least 2 extenders of each type shall be available for use during acceptance testing.
15.21 MICROPROCESSOR BASED SYSTEMS
15.21.1 GENERAL
The microprocessor based control system shall be based on an established family of microprocessors in wide use in the control system industry. They shall be supported by a full range of software development languages and diagnostic programs similar to that available for the Intel 80XXX family of devices.
Should the Contractor elect to use a multi-processor bus architecture, the architecture shall be based on the Intel Multibus, Motorola VME or similar bus used widely in industrial process control equipment. Alternative bus structures may be submitted for City approval.
Program code and fixed data shall be stored in PROMs or EPROMs. Either static or dynamic RAM or EEPROM may be used for temporary data storage. All EPROM windows shall be covered with labels that are opaque at the UV erasing wavelengths.
Battery-backed RAM may be used only to store fault information (see below). Batteries shall be sized to retain data for at least six months without charging and shall be located such that leakage cannot damage any control system components. Battery life shall be no less than five years, regardless of type.
At least 30% additional memory space shall be installed and available for future modifications to program code, fixed data space, and temporary data space.
15.21.2 SOFTWARE
Software may be written in a high or low level language. The language, and its implementation for the selected microprocessor system, shall be commercially available in English.
All software, whether interrupt based or polled, shall always assign the highest priority to safety related tasks
Software shall perform the following basic functions:
(a) Implement the desired control scheme such that the specified performance is achieved;
(b) Monitor all inputs for unsafe, erroneous, or unknown conditions or combinations of conditions;
(c) Sample all input conditions at rates sufficient to detect and remedy all unsafe or damaging conditions in the shortest possible time. Sampling rates and program execution times shall be such that the control system is not the limiting factor in response to unsafe or damaging conditions;
(d) Limit all output commands to safe levels regardless of any combination of input conditions;
(e) Perform self diagnostic routines and respond promptly, safely, and predictably to detected faults;
(f) Respond safely and predictably when powering up or recovering from power interruptions. All power interruptions likely to have corrupted temporary storage shall be detected and cause the system to re-initialize all affected routines and temporary data. Detection of power interruptions may be by hardware.
(g) Permit thorough interrogation of all input, output, and internal conditions by external diagnostic equipment.
15.21.3 ISOLATION AND INTERFACING
The control system shall be powered by dedicated, transformer isolated, power supplies driven from the vehicle battery circuit.
All control system input and output signals, including power supply voltages, shall be through isolation buffers. The buffers shall:
(a) Protect and isolate the control system from damage due to overvoltage, undervoltage, transients, shorts, and opens.
(b) Perform necessary voltage translations.
(c) Remove noise and undesired signals.
(d) Limit, pre-process, discriminate and format those signals that would otherwise require excessive processor time.
15.21.4 SOFTWARE QUALITY ASSURANCE AND DOCUMENTATION
The Contractor shall submit, for approval, a Software Quality Assurance Plan in accordance with ANSI/IEEE Standard 730-1984. For reference, this Standard has the following minimum software documentation requirements:
• Software Requirements Specification
• Software Design Description
• Software Verification and Validation Plan
• Software Verification and Validation Report
• User Documentation
The Software Design Description (SDD) shall be in accordance with ANSI/IEEE Standard 1016-1987. The final Software Design Description shall include detailed program flow information and an input/output port map.
15.22 CONTACTORS AND RELAYS
All contactors and relays shall meet or exceed the requirements of MIL-R-6106 and MIL-R-5757 respectively, or shall have a documented successful history of operation in rail transit control applications.
The coils of all devices shall be suppressed except where performance may be affected. Unsuppressed coils are permitted only with the explicit approval of the City.
Contact current ratings shall be based on continuous, inrush, or interrupting requirements, whichever is worse and then derated by at least a factor of four. Contact materials shall be selected for the actual loads, and not solely on the device rating. Silver bifurcated contacts and gold alloy bifurcated cross bar contacts shall be used on low level and dry circuits, respectively.
Contacts connected in series shall not be operated in circuits where the voltages and currents exceed the single derated contact ratings. Contacts shall not be connected in parallel.
Contact ratings shall be for the worst condition of reduced surface contact which may result from tip misalignment during normal operation of the device.
All contactors shall be built with series fed arc blowout coils.
All time delay relays shall be of the R-C or solid state type. Mechanical or pneumatic time delay devices are not permitted.
All relays and contactors shall be identified with the appropriate circuit designation. The label shall not be obscured by wiring or other equipment and shall not be mounted on relay covers, arc chutes, or other removable items.
Plug-in relays shall be provided with a retainer that is captive to the relay socket. The retainer shall be arranged such that, when released, contact cannot be made with energized adjacent circuitry.
All contactors shall have a guaranteed mechanical service life of at least 5 million switching operations, except as approved where infrequent operation is expected.
All relays shall have a guaranteed mechanical service life of at least 10 million switching operations. Contact electrical life shall be no less that 500,000 operations, or 10 years, whichever is greater.
There shall be a maximum of two wire terminations on any relay or contactor terminal.
All relays and contactors shall be mounted and oriented as recommended by the supplier.
15.23 SWITCHES
All switches shall be oiltight, industrial grade switches suitable for NEMA type 4 and 13 applications for exterior and interior uses respectively.
Contacts shall not be operated at voltages or currents in excess of the manufacturer's recommendations. Contact current ratings shall be de-rated by at least a factor of four for all applications. Contacts connected in series shall not be operated in circuits where the voltages and currents exceed the single derated contact ratings. Contacts shall not be connected in parallel.
Switches shall not directly control highly inductive or high inrush loads. Switch contacts shall be silver, double break. All switch mechanisms shall provide a wiping motion when contacts make or break.
All switch bodies shall be keyed to prevent rotation. All mounting hardware, including the body portion extending through the panel, shall be metal.
There shall be a maximum of two (2) wires connected to each switch terminal.
15.24 CIRCUIT BREAKERS
15.24.1 GENERAL
All circuit breakers of the same rating shall be of the same manufacture and model throughout the vehicle.
The ON and OFF positions of all circuit breakers shall be permanently marked on the handle or the case of the circuit breaker. The circuit breaker, when tripped, shall assume a distinct position between the ON and OFF positions to permit determination of the fact that it has been tripped.
All circuit breakers shall be sized by current rating and tripping time to protect both the associated equipment and the smallest wire size used in the circuit. All circuit breakers shall be sized to interrupt the maximum circuit fault current and shall be guaranteed by the manufacturer to successfully interrupt those, and all lower, currents.
Each circuit breaker pole shall be equipped with an arc chute and other devices for arc extinguishment.
The continuous current rating of thermal-magnetic trip circuit breakers shall be selected in accordance with ANSI C37.16 for the load and type of service specified. Circuit breaker current rating shall be clearly and permanently marked.
All thermal-magnetic trip circuit breakers shall conform to the requirements of ANSI C37.13 and ANSI C37.14.
Electrically operated circuit breakers shall be operated from the low voltage DC supply.
15.24.2 HIGH VOLTAGE CIRCUIT BREAKERS
High voltage circuit breaker poles may be connected in series to achieving the necessary voltage ratings. All such series connections shall be certified, in writing, by the manufacturer to be an acceptable application for the intended circuit voltage.
All distribution-type, high voltage circuit breakers shall be Heinemann type GH, or approved equal.
The trip elements shall be thermal-magnetic or magnetic, connected in series.
See Section 9 of these TECHNICAL SPECIFICATIONS for high speed circuit breaker requirements.
15.24.3 LOW VOLTAGE CIRCUIT BREAKERS
Low voltage circuit breakers shall be either one pole or two pole devices depending on the intended function. Trip elements shall be thermal-magnetic, or magnetic, as is appropriate for the application.
All low voltage circuit breakers shall be:
• General Use:
• Heinemann Series AM with center trip position, front connection or approved access arrangement, and approved labeling
• Fast Operation
Airpax type 205, dust sealed, magnetic breaker, or Airpax type UP, hermetically sealed, magnetic breaker, or an approved equal.
15.25 FUSES
Fuses are not permitted except where specified or approved.
Fuses shall be permanently identified adjacent to the fuse and the rating of each fuse shall be permanently and clearly marked on each fuse.
Fuses shall be readily accessible. All fuses mounted in equipment boxes outside of the car shall be accessible from the side of the vehicle.
Fuse holders shall contain fuse retention devices at both ends.
High voltage fuses shall be mounted in totally enclosed, dead front, fuseholders with no exposed high voltage connections. The fuse shall be extracted from the circuit when the fuse holder is opened and the exposed fuse shall be safely isolated from any circuit connection.
Air gap and creepage distances shall be as approved. Fuses and fuse holders used in nominal 750 V circuits shall be rated for no less than 1000 V.
15.26 BUS BARS
Bus bars are to be fabricated from OFE (Oxygen Free Electronic) or ETP (Electrolytic Tough Pitch) copper (CDA 101). The bus bar conductivity shall be 100 percent IACS. All bus bars shall be silver or tin plated.
15.27 CAPACITORS AND RESISTORS
Hermetically sealed, dry tantalum capacitors, in metal cases, shall be used in place of aluminum electrolytics, except for very high values which are not commercially practical or available, in which case long life grade aluminum electrolytics shall be used.
Capacitors shall be derated 20% for voltage based on the nominal supply voltage and maximum case temperature. If filter capacitors are exposed to low ripple voltages, lesser values of derating may be accepted if it can be shown that reduced operating temperatures can be achieved due to lower dissipation; however, the sum of the DC and AC ripple voltages shall always be less than the capacitor's voltage rating at a maximum case temperature of 85°C.
Except for braking and motoring resistors, all resistors shall be derated 50 percent for power dissipation.
15.28 TRANSFORMERS AND INDUCTORS
Transformers and inductors shall be derated 10% for current.
15.29 SWITCH, BREAKER, AND FUSE PANELS
All switch and breaker panels shall be dead front types mounted in the specified equipment enclosures.
Fuse panels shall incorporate fuse holders with additional devices, as approved, to minimize live exposed conductors. Fuse panels shall not share enclosures with other equipment, unless completely separated with separate covers.
All switches, breakers, fuses, and indicating lights shall be identified with a nameplate of raised or recessed letters.
Power distribution to circuit breakers and switches shall be from a bus bar or bus circuit. Distributing power by successive or daisy-chained connections between device terminals is not permitted.
END OF SECTION
SECTION 16 – SYSTEM SUPPORT
16.1 MANUALS AND CATALOGS
16.1.1 TYPES AND QUANTITIES
The Contractor shall furnish manuals for use by vehicle operators and maintenance personnel in accordance with the requirements of this Specification. Contractor shall supply the following manuals in electronic format acceptable to City and on a schedule acceptable to the City:
• Operator's Instruction and Troubleshooting Manual
• Maintenance, Servicing, and Heavy Repair Manuals
• Parts Catalogs
• Training Manuals
• Special Test Equipment Manuals
16.1.2 OPERATOR'S INSTRUCTIONAL AND TROUBLESHOOTING MANUAL
The Operator's Instructional and Troubleshooting Manual shall contain all information needed for the optimum operation of the vehicle. It shall include general vehicle familiarization material, such as:
(a) Location, function and operation of controls, gauges, indicators and switches;
(b) Discussion of the trucks, couplers, lights, environmental control, hydraulic brakes, and other features of the vehicle which the operator may not be in a position to control or adjust but of which the Operator should have some basic knowledge;
(c) Emergency procedures;
(d) Trouble symptoms and diagnosis methods; and
(e) Operator corrective action.
The manual shall be logically organized with systems and elements considered in descending order or importance. Care shall be taken that all statements are clear, positive, and accurate, with no possibility of incorrect implications or inferences.
16.1.3 MAINTENANCE AND SERVICING MANUAL
The Maintenance and Servicing Manual shall enable the maintenance staff to have all information needed for preventive maintenance inspections, on-vehicle running maintenance and adjustment, and on-line trouble diagnosis of each system including such data as troubleshooting guides, equipment specifications and schematics for the vehicle and each of its systems.
The Maintenance and Servicing Manual shall also contain a detailed analysis of each component of the vehicle so that the maintenance staff can effectively service, inspect, maintain, adjust, troubleshoot, repair, replace, and overhaul it.
An integrated set of schematics for all electrical and hydraulic systems and interfaces on the vehicle shall be supplied as a separate section. Schematics shall clearly show references to higher and lower levels of detail.
16.1.4 PARTS CATALOGS
The Parts Catalogs shall enumerate and describe every component with its related parts for the vehicles, including the supplier's number and the commercial equivalents.
Drawings showing subassemblies and components shall be used to permit identification of all parts down to the lowest level replaceable unit (LLRU). The LLRU is defined as the lowest level of component assembly which consists of a separate individually fabricated part. Parts common to different components - as, for example, bolts and nuts - shall bear the same Contractor's number in all components with a reference to the other components in which they are found. Commercially available items such as common fastenings, fuses, lamps, fittings, bearings, and relays shall be identified by standard hardware nomenclature adequate to order these items through commercial channels, besides the contractor's number.
16.1.5 TRAINING MANUALS
Training manuals shall contain sufficient material to aid the Contractor in performing the requirements of Section 16.4 below.
16.1.6 SPECIAL TOOLS AND TEST EQUIPMENT
Operations and Maintenance Manuals for each special device identified in Section 16.2 and Section 16.3 below shall include setup and testing procedures for each test device. It shall also include, in a separate section, all information needed for periodic inspection and servicing requirements, including lubrication, inspection and adjustment of all apparatus.
Only applicable for “NEW” or different equipment than what’s on the existing Portland Streetcars. Prototype only.
16.1.7 FORMAT AND CONTENT
The organization of the manuals shall treat the vehicle as an integrated system and not as a grouping of disassociated parts. The manuals shall highlight the precautions to be taken by operating and service personnel to assure their safety while operating vehicles and performing maintenance and servicing operations.
Following the issue of each publication, the Contractor shall provide revised pages covering any changes, whether required by change of design or procedures or due to error, and these revisions shall be kept current (revised every 6 months or less) during the warranty or maintenance period.
All publications shall be in loose-leaf form. They shall be in five general categories and sized as follow:
• Operator's Instruction and Troubleshooting Manual: Pocket Sized
• Maintenance Manual: Standard Sized
• Parts Catalog: Standard Sized
• Training Manuals: Standard Sized
The Contractor shall supply master reproducible copies of all documents. The quality of the master shall be such that duplicates may be made of the same quality as the original, approved submittals.
All documents or drawings which include information in a language other than English shall include an English translation adjacent to the non-English passage.
16.1.8 SOFTWARE
In addition to hardcopies, all manuals and the parts catalog, including drawings, shall be submitted in electronic media versions. The electronic media versions shall be revised in accordance with the hardcopy manual revisions. All drawings shall be done in dwg. or similar format with duplicate PDF files.
16.2 DIAGNOSTIC TEST EQUIPMENT
16.2.1 GENERAL
The Contractor shall provide all equipment specified in this Section for comprehensive in-service testing of vehicles. All of the test equipment shall be delivered at the same time as the final copies of manuals identified in Section 16.1 above.
Portable Test Units (PTUs) shall be supplied for all on-board systems to aid the maintenance staff in maintaining, troubleshooting, and calibration of the vehicle equipment.
If a system can be fully tested using a standard IBM PC compatible laptop, a PTU will not be required. All necessary diagnostic or operating system software for maintaining, troubleshooting, and calibration of the vehicle equipment shall be provided.
Each PTU shall be supplied with an instructional manual that describes how to use the tester along with expected results and how to troubleshoot and repair the tester. Complete parts lists and schematic diagrams of the PTU should be included.
The PTUs shall include all cables, connectors and associated equipment to interface with the test points.
The following is a minimum list of PTUs required for the vehicle:
(a) Propulsion system, including the Wheel slip system,
(b) Friction brake system,
(c) Auxiliary power supply (APS),
(d) Low voltage power supply (LVPS),
(e) Battery Charger,
(f) HVAC system
(g) Door control system.
(h) Communication system
(I) On board ticket vending machine – if applicable
(j) On board video equipment if applicable.
16.2.2 GAUGES AND SPECIAL TOOLS
Any special tools required shall be supplied by the Contractor. Special tools include but are not limited to any jigs, fixtures, equipment, hand tools, power tools, or other tools and equipment necessary to maintain, repair, overhaul, assemble, and disassemble the vehicle or sub-systems, that are not commonly available from commercial tool suppliers.
All gauges or special tools, other than the PTUs, that are required to maintain and overhaul the vehicle shall be supplied along with complete manuals explaining the use of the gauge or tool and its care and maintenance. Drawings showing all dimensions and materials and part lists must also be supplied.
All special tools and maintenance equipment shall be provided in quantities of two. The Contractor shall also provide manufacturer, part numbers and prices for all special tools and maintenance equipment to enable the City to purchase additional quantities.
Only applicable for “NEW” or different equipment than what’s on the existing Portland Streetcars subject to the City’s approval.
16.3 AVAILABILITY OF REPLACEMENT PARTS
The Contractor and its Subcontractors shall guarantee parts availability for the vehicle and all systems for a period of ten (10) years from Contract award. The Contractor shall provide the detail drawings to the City at the end of the 10-year period.
16.4 USER EDUCATION
16.4.1 GENERAL
The user education requirements for this section apply if the Contractor is not responsible for the maintenance or operation of the vehicles.
User education shall consist of the two (2) major categories listed below:
(a) Operator education (basic vehicle operation including how to detect and resolve in-service problems and emergencies); and
(b) Maintenance education (including preventive, corrective, and overhaul of components and/or assemblies).
The program shall be conducted at the Portland Streetcar facilities in Portland, Oregon, and include classroom and hands-on instruction for a selected group of Instructors, Supervisors, Mechanics, Technicians, and Train Operators. The Contractor shall provide an adequate supply of high quality, professionally prepared material on paper, and such other training aids to impart the essential knowledge to the people involved and leave them with authoritative and up-to-date reference material.
Manuals and other training materials to be used by the Contractor during training shall be delivered to the City sixty (60) days before training is conducted; the manuals shall be accurate, complete, and of professional quality.
All training materials, such as training aids and lesson plans, shall become the property of the City at the completion of the training program.
All maintenance and operations courses shall include a combination of classroom and hands-on instruction. Written and practical tests shall be designed and given at suitable points in each course to determine the extent to which students have learned and can apply the information.
The City reserves the right to video tape any or all training activities. The Contractor is welcome to copies of any such recordings.
As training materials are being developed, the Contractor shall work closely with the City's staff, to ensure City standards with respect to the course organization, content, and overall quality of all training materials are being met.
END OF SECTION
SECTION 17 – PROGRAM CONTROL AND QUALITY ASSURANCE
17.1 GENERAL
The design and production of the Prototype Streetcar shall be controlled by the Contractor to insure that a high-quality product suitable for long and trouble-free life is produced and that the requirements of this document are met.
The City may, at its option, monitor any or all Contractor activities and inspect or test any or all equipment. The Contractor shall not hinder or limit such activities.
17.2 MANAGEMENT PLAN AND PROGRESS SCHEDULE
The Contractor shall designate a project manager and submit a management plan within 30 days of NTP.
The plan shall include, but not be limited to:
(a) An organization chart for the Contractor's staff including primary personnel involved in this contract from senior executive positions to professional personnel such as, electrical engineers, mechanical engineers, material procurement and subcontractor administration, manufacturing, quality control and system assurance management personnel as a minimum.
The organization chart shall also indicate management personnel responsibilities in relation to engineering, manufacturing, quality control, material procurement and other supporting functions.
(b) A management chart which clearly depicts the design, manufacturing, and testing responsibilities of the Contractor and each subcontractor or supplier for all systems and major components described in this Specification. The company name, affiliation, principal contact and position, and the location at which the work will be performed shall be included. This information shall be consistent with, and expanded upon, the Contractor's approved Proposal and is considered a critical submittal in the initiation of the Contract. This management chart and any changes thereto, shall be as approved by the City during the course of the Contract.
(c) A progress schedule, with all critical paths indicated, showing all work tasks, including subcontractor contributions and all submittals, inspections, and tests as may be required by this document.
The progress schedule shall be updated at least every two (2) months and resubmitted to the City. All schedules shall be current within two (2) weeks of the time of receipt at the City.
(d) A description of the methods and communications to be employed to monitor, oversee, and control the progress schedule, technical performance, program changes, subcontracts, material procurement, in-service support, warranty, and tests.
(e) The Contractor shall submit for review and approval a Contract Data Requirements List (CDRL) within sixty (60) days after NTP. The CDRL shall contain a consolidated listing of all submittals required by this document such as data, test reports, material samples, and drawings.
17.3 MEETINGS
Meetings shall be held between the Contractor and the City on a regular basis for the purpose of reviewing program progress and other program activities that cannot be resolved by correspondence. The Contractor shall insure that persons knowledgeable in the topics to be discussed are present at all meetings. Meetings shall be held quarterly or as required by the City.
Meeting minutes shall be taken at all meetings by the Contractor. Minutes shall include a summary of all topics discussed and a listing of all understandings and agreements reached. Unless otherwise agreed, the Contractor shall be responsible for taking all meeting minutes.
The meeting minutes shall be distributed to all attendees for review within ten (10) calendar days from the end of the meeting.
Neither the meeting minutes nor their implications shall be considered valid until approved by the City. The City will respond in writing within ten calendar days from receipt of the minutes. Should the City fail to respond within ten (10) days, the minutes shall be considered approved as submitted.
17.4 DESIGN APPROVALS, CONTRACTORS DRAWINGS, DOCUMENTATION, AND DATA REQUIREMENTS
17.4.1 REVIEW PROCEDURES FOR DRAWINGS, DOCUMENTS AND DATA
The Contractor shall submit four copies of all documents, data, and assembly and installation drawings. Subassembly drawings shall also be submitted for information to facilitate the review of assembly and installation drawings. The City reserves the right to request additional drawings to support the review process of assembly and installation drawings.
When submitting drawings of structural parts or assemblies for the car body structure, equipment supports, and trucks, the Contractor shall also submit stress analyses for these parts or assemblies in summary form.
Review and approval of Contractor submittals shall be secured before manufacturing any parts.
All drawings, documents, and data submitted by the Contractor shall be accompanied by a letter of transmittal listing drawing and document titles, numbers, and revisions. If more than one drawing or document is submitted at a time, the drawings and documents shall be listed in the transmittal in numerical sequence.
Drawings shall be submitted in an orderly and logical sequence to enable the City to readily determine and review the interface relationships between all major structural elements and their subassemblies and also between the structural elements and the attached apparatus, equipment, wiring, piping and hardware.
Except as provided below, the City will return submittals approved, or with the required changes noted, within 30 calendar days after receipt by the City. The City will respond to the Contractor at an address designated by the Contractor. Due to the City's limited resources and to prevent grouping of drawings into one large package for transmittal, the City will not be obligated to review more than thirty (30) drawings, or other mutually agreeable number, in a 30-day period. In the event that more than thirty (30) drawings are submitted for review in a 30-day period, the City will make every effort to review them within the thirty (30) days. If this is not possible, the City will review them in accordance with priorities as mutually agreed to between the Contractor and the City.
No extension of Contract time will be allowed for revision of Contractor's drawings or documents which have been either "disapproved" or "conditionally approved". Such drawings and documents shall be resubmitted and will be reviewed and returned to the Contractor within the same time intervals as would be allotted to the drawings and documents when initially submitted. Resubmitted drawings shall count toward the thirty (30) drawings per month limit.
The Contractor shall maintain a record of Contractor and Subcontractor drawing and document status. This shall include drawing and document numbers, revision letter, drawing title, date submitted, transmittal document, disposition, and the document number identifying the disposition. This status shall be updated and submitted to the City not less than bi-monthly.
17.4.2 REQUIREMENTS FOR DRAWINGS, DOCUMENTS AND DATA
All dimensions shall be expressed in the SI system; all wording shall be in the English language.
All drawings submitted by the Contractor shall be in a format to be approved by the City and shall include a title block, drawing number, title, date, revision number, contract number, reference to next higher assembly, and signature of the Contractor's responsible engineer.
Contractor and Subcontractor drawings shall be of a scale to be of microfilm quality and to convey content. Drawing sizes shall conform to standards as follows:
• 841 x 1189 mm (DIN A0)
• 594 x 841 mm (DIN A1)
• 420 x 594 mm (DIN A2)
• 297 x 420 mm (DIN A3)
• 210 x 297 mm (DIN A4)
A revision block shall be provided for all documents, drawings, and data. The revision block shall identify the revision letter, date of revision, the initials of the Contractor's responsible engineer authorizing the revision, a description of the change, and the reason for making the change.
Schematic location (page number, for example) of the energization portion of each device (such as the coil in a relay) shall be noted adjacent to the operating portions (such as relay interlocks) of the device.
A set of device tables shall be located in a single section at the rear of the schematic book. This table shall be arranged in logical fashion by system device type. This table shall include data for all system and subsystem components including but not limited to:
• Electrical control and power components (groups, panels, PC cards, contactors, relays, circuit breakers, capacitors, inductors, resistors, specialized modules, rectifiers, thyristors, diodes, fuses, and other components, as appropriate)
• Electrical machinery (rotating equipment, reactors, transformers, pumps, fans, compressors, switchgear, and other machinery)
• Hydraulic control and power devices (valves, strainers, filters, and other components)
• As a minimum, device listings shall include the following:
• Location in schematic and schematic designation;
• Type, model, and part number;
• Locations on vehicle;
• Function;
• Schematic symbol;
• Appropriate ratings data; and
• Interface information, as appropriate.
Wiring diagrams shall be integrated connection diagrams and a wire list in book form based on the integrated schematic. The diagrams shall show all wiring, raceways, conduits, and connections.
As a minimum, the following information shall be provided for each wire segment:
• Wire code (schematic designation),
• Origin (FROM device and terminal),
• Destination (TO device and terminal),
• Wire size,
• Voltage rating,
• Length,
• Appropriate specifications,
• Jacket color, and
• Harness designation.
The following ANSI standard for the preparation of drawings shall apply: Y1.1, Abbreviations for Use on Drawings; V32.2, Graphics Symbols for Electrical and Electronic Diagrams; and V32.14, Graphic Symbols for Logic Diagrams. The requirements for ANSI standard graphic symbols and abbreviations may be waived by the City provided a system of standard abbreviations and symbols for all drawings submitted is used and the Contractor provides the City with five copies of a bound booklet showing all abbreviations and graphic symbols used on drawings.
17.4.3 DRAWINGS REQUIRING APPROVAL
Drawings to be furnished by the Contractor for approval by the City shall include but not be limited to those listed below. The City reserves the right to request additional drawings or documents as required to clarify and amplify the intent of drawings furnished.
(a) General:
Floor plan
Car body clearance drawings
(b) Framing and Miscellaneous Drawings:
Anticlimbers – plan, elevations, and sections
(c) HVAC:
Plan, elevations
Installation details
Electrical and piping schematics
Assembly details
Software design description
(d) Ducting (HVAC):
Plans, elevations, sections
Joining details
(e) Propulsion Equipment:
Software design description
(f) Seating:
Plan, elevations, sections
Wheelchair securement area plan, elevation, sections
(g) Auxiliary Electric Equipment:
Software design description
(h) Brake System:
Software design description
(i) Stanchions:
Plan, elevations, details
(j) Electrical Drawings:
Schematic wiring diagram – nominal 750 vdc equipment
Schematic wiring diagram – nominal 37.5 Vdc equipment
Schematic wiring diagrams – 120/208 vac equipment
17.4.4 DRAWINGS NOT REQUIRING APPROVAL
Drawings to be furnished by the Contractor for information and not requiring approval by the City shall include but not be limited to those listed below. The City reserves the right to request additional drawings or documents as required to clarify and amplify the intent of drawings furnished.
(a) General:
Exterior elevations of both sides of vehicle
Exterior elevations of both ends of vehicle
Reflected ceiling plan
Roof plan
Interior, longitudinal sections of both sides of vehicle
Interior elevations of both ends of vehicle
Plan layout, cab equipment
Layout of cab console
Interior elevations of cab layout
Reflected plan, under-car equipment layout
Reflected plan, conduit and cable layouts
Reflected plan, piping layout
Side elevation, undercar equipment layout
(b) Sections:
Transverse sections to show all variations in cross section such as through doors, windows, roof, etc.
Transverse section to show extreme movements of vehicle (including yaw) permitted by vehicle suspension and running gear
Transverse and longitudinal sections to show physical relationship of major undercar components
Transverse sections to show vertical and lateral undercar equipment clearances to rail and roadbed
(c) Framing and Miscellaneous Drawings:
Underframe and bolster - plan, elevations, and sections
Side frame(s) - plan, elevations, and sections
Roof frame - plan, elevations, and sections
End frame - plan, elevations, and sections
Towbar attachment to underframe - plan, elevations, and sections
(d) Trucks:
Truck assembly - plan and elevations and equipment application
Truck frame - details
Suspension - details
Wheels - details
Axle - details
Journal bearings - details
Gear units - assembly
Axle assembly - complete
Brake equipment - details
Traction motors - details
Speed sensors - details
Ground brushes - details
Track brakes – details
Axle load diagram
Axle stress analysis
(e) Car body Articulation Unit:
Plan, elevations, sections
Graphic depiction of movements and limits
(f) Current Collection Pantograph
Plan, elevations
Application details
(g) Doors, Windscreens;
Plan, elevations, sections
Hardware and attaching details
(h) Towbar:
Plan, elevations
Mechanical details
(i) Ducting (Traction, ECU):
Plans, elevations, sections
Joining details
(j) Propulsion Equipment:
Inverters - details.
Controls - details.
Tractive effort vs. speed curves
(k) Equipment Boxes, Compartments and Lockers:
Plan, elevation, sections
Hardware details
(l) Master Controller:
Plan, location
Details
(m) Lighting Fixtures:
Location
Details
(n) Seating:
Attaching details
Wheelchair Securement - details
(o) Auxiliary Electric Equipment:
Auxiliary power supply - details
Low voltage power supply - details
Battery charger - details
Battery - details
Circuit breaker panels - details
Knife switch - details
High speed circuit breaker - details
(p) Brake System:
Hydraulic pressure supply unit - details
Hydraulic control units - details
Electronic control units - details
Other brake hardware - details
Monitoring system - details
(q) Destination Signs:
Electronic control units - details
Software design description
Sign mechanism - details
(r) Interior Lining Panels and Bulkheads:
Plan, elevations, sections
Attaching details
(s) Sub-Floor and Finished Floor:
Plan, elevations, sections
Attaching details
(t) Hydraulic Diagram:
Schematic piping diagram - hydraulic brake equipment
(u) Diagnostic Test Equipment:
Design details on each unit
Software design description for each unit
Catalog data for standard instruments that are included in each unit
17.4.5 DOCUMENTS REQUIRING APPROVAL
Documents to be furnished by the Contractor for approval by the City shall include, but not be limited to, those listed below. The City reserves the right to request additional documents, as required, to clarify and amplify the intent of the vehicle design.
• Fault hazard analysis
• Equipment support stress analysis
• Software quality assurance plans for each system that uses a
• microprocessor or other computer
• All test procedures and reports
• Test and inspection plan
• Quality assurance plan
• Master test plan
• Maintenance, training and parts manuals
• Car history book
17.4.6 CONSTRUCTION PHOTOGRAPHS
Two (2) sets of color, unmounted progress and finished car photographs, approximately 8-in by 10-in size, with at least fifty (50) views of the Streetcar during stages representative of their complete construction, shall be furnished by the Contractor to the City before delivery of the last car. Each set of photographs shall be transmitted in a suitable album-type binder with transparent pockets. The album shall contain an index which identifies the photographs enclosed. Views shall include both sides and both ends of the car exterior, taken at right angles to the side or ends, as well as views of selected equipment. The date each picture was taken, the number of the car pictured, and the location on the car shall be recorded on the back of each print.
The City reserves the right to photograph, at its expense, any or all phases of car or equipment construction, including subcontractor work, without restriction.
17.4.7 APPROVAL OF CONTRACTOR DOCUMENTS, DRAWINGS AND DATA
The City's approval or disapproval will be provided in one of the four following categories:
(a) Approved as submitted
(b) Conditionally approved - the Contractor may proceed in accordance with changes indicated and shall revise and resubmit the document, drawing, and data for City approval
(c) Disapproved - the Contractor shall revise and resubmit the document, drawing, and data for City approval prior to commencing the affected portion of the work
(d) Accepted for Information Only - the submittal was provided as information to assist in review of a required submittal or to satisfy a request. Specific approval and comment not required.
All drawings, technical data, test procedures, test schedules, test results, test reports, progress schedules and reports, drawing lists, samples, and other data submitted by the Contractor and requiring review and approval by the City will be handled in accordance with the above provisions.
Approval does not relieve the Contractor of the obligation to meet all of the requirements of the Contract. Approval of a document, drawing, and data which contain deviations from, or violation of, the Specification does not constitute authority for that deviation or violation. Such deviations must be specifically requested and granted.
Approval is intended to mean that the City is aware of the Contractor's intent and there are no objections to the methods, procedures, designs, or calculations.
17.4.8 CORRESPONDENCE CONTROL
The Contractor shall identify all correspondence and submittals according to a coding scheme which will be provided by the City at NTP.
17.5 REPRODUCIBLE DRAWINGS TO BE FURNISHED BY CONTRACTOR
17.5.1 TIME AND SCOPE OF SUBMITTALS
Within ninety (90) days following the acceptance of the first Streetcar, the Contractor shall supply quality reproducibles for the following where such are "Streetcar specific" items:
• All Contractor's and suppliers' drawings, details, bills of material, and catalog cuts that are required by the City for future installation, maintenance, repair and overhaul purposes;
• All assemblies, subassemblies, and arrangements of the vehicle as finally furnished, modified and accepted;
• All items which are special purpose or fabricated by the Contractor; and
• All materials furnished by the Contractor and by its suppliers, down to and including the module and circuit board level. In every case, outline drawings shall not be considered acceptable.
Contractor drawings may be supplied in electronic media which are fully compatible with AutoCAD, latest version.
17.5.2 RESERVED
17.5.3 REVISION TO BE INCLUDED
Reproducibles shall include all revisions made during construction and be in as-built configuration.
17.5.4 LIST OF REPRODUCIBLES
The Contractor shall provide the City with a complete list of reproducibles to be supplied by the Contractor and each Subcontractor.
17.6 MODIFICATION AND CONFIGURATION CONTROL
Throughout the Contract, the Contractor shall implement and maintain a configuration control system. Changes to the documents, drawings, and data shall be controlled by the processing of engineering change requests (ECR's).
17.6.1 COMPONENT IDENTIFICATION AND SERIAL NUMBERS
All Streetcar equipment shall be permanently identified with a supplier's name, part number, and revision level.
In addition, the Contractor shall assign discrete serial numbers to certain equipment specified in this Section. Serial numbers shall be in sequential, numerical order for the total quantity of each component, including spares.
Serial numbers of all components shall be presented to the City as each vehicle arrives on the property or when spare components are received. The Contractor shall track all serial number transfers and prepare a list of all serial numbered apparatus installed on each vehicle for inclusion in the car history book.
At a minimum, the following equipment shall have serial numbers applied:
• HVAC apparatus
• Converters
• Inverters
• Pantographs
• Master Controller
• Door operators and controls
• Motors within equipment
• All electronic cards
• Principal communications equipment items (not speakers)
• Principal items of traction and braking equipment
• Truck castings or weldments
• Primary and Secondary Suspension
• Axles
• Truck gear units
• Journal bearings
• Truck wheels
• Brake Disks
17.6.2 CAR HISTORY BOOK
The prototype car shall have a "history book" that reflects the status of the car. The car history book shall accompany the car through the production line and be presented to the City when each car is accepted. The book shall contain the following minimum information:
• Description and completion dates of all car modifications, and list of modifications pending with expected completion dates;
• List of car defects that were identified by Contractor QA or City personnel during construction and the disposition of each as verified by inspection;
• List of serial-numbered apparatus;
• Shipping documents;
• Results of each functional test performed on the car or any part thereof;
• Wheels, journal bearings, and gear mounting records, including pressing charts;
• A record of any abnormalities that occur during the manufacture of the car or any of its subsystems, including their authorized, validated, repair procedures; and
• Open item status list.
17.7 QUALITY ASSURANCE
The Contractor shall plan, establish, and maintain a quality assurance program. The Contractor's QA program shall be imposed upon all entities within the Contractor's organization and on all subcontractors whenever Contract work is performed. The Contractor may accept established QA plans from its subcontractors and include these plans as part of its overall QA program.
17.7.1 QUALITY ASSURANCE PROGRAM PLAN
A QA program plan shall be submitted for review and approval prior to commencement of construction. The QA plan shall describe the methods for planning, implementing, and maintaining quality, schedules, and cost. The QA plan shall contain a company policy statement which clearly defines the authority and responsibilities of QA personnel. An organization chart shall be included to show the reporting relationships of all QA staff.
The QA plan shall also contain a collection of all forms to be used for the documentation of quality control activities which assure compliance of materials, processes, personnel, and products to the applicable specifications.
The QA plan shall incorporate and detail procedures for the following activities:
• Design control, including control of all technical documentation, including software;
• Transmission of all design, reliability, maintainability, system safety, and QA requirements to procurement sources;
• Surveillance over subcontractors for conformance with all specification requirements;
• Receiving inspection;
• Production and process control;
• Routine inspection during construction;
• Functional testing;
• Discrepancy control;
• Measuring and test equipment calibration and certification;
• Drawing control;
• QA records;
• Shipping inspection;
• Selection of qualified procurement sources;
• Evaluation and assessment of subcontractor's QA program.
• Monitoring of subcontractor's QA performance;
• Evaluation of procured articles against purchase order requirements;
• Feedback of problems and their resolutions to the Contractor's engineering and production departments; and
• Disposition of rejected material.
17.7.2 CITY OF PORTLAND QA ACTIVITIES
The City may, at its discretion, perform its own QA monitoring of work done under this Contract, including monitoring of the Contractor's or subcontractor's QA activities. Such activities shall not reduce or alter the Contractor's QA responsibilities, nor reduce or alter the Contractor's obligation to meet the requirements of this document.
After NTP, the City shall have the right of free access to facilities of the Contractor and subcontractors in accordance with the Uniform Commercial Code. This right shall permit the City to inspect, examine, and test items during manufacture and shipment, and within a reasonable time after shipment.
The Contractor shall provide to City personnel a heated, cooled and adequately lighted private office and shall have access to toilet facilities. A telephone shall be made available.
In addition, copies of all drawings, diagrams, schedules, changes, deviations, and QA records shall be made available promptly upon request.
17.7.3 INSPECTIONS AND TESTS
The QA plan shall provide for the inspection and testing of all equipment to determine conformance to this document, the Contractor's designs, and good workmanship.
The Contractor shall submit an inspection and test program that delineates all major inspection and test activities, including those below. Routine inspections and tests, such as production line functional tests, shall not be included.
The program shall include a schedule of all such activities. The schedule shall accommodate the fact that the City will witness all such activities and, as such, tests and inspections shall not be scheduled concurrently without approval.
17.7.4 CALIBRATION AND CERTIFICATION OF MEASURING EQUIPMENT AND TOOLS
The Contractor shall demonstrate an effective time-cycled or usage-cycled calibration and certification program. Validity of measurements and tests shall be ensured through the use of suitable inspection, measurement, and test equipment of the range and type necessary to determine conformance of items with Contract requirements. At intervals established to ensure continued validity, measuring devices shall be verified or calibrated against certified standards that have a known traceable relationship to the National Bureau of Standards, or approved equal. Tooling and fixtures used as media for inspection shall be included in this program.
Every device so verified shall bear an indication attesting to the current status and showing the date (or other basis) on which inspection or recalibration is next required. Devices suspected of being out of calibration before the stated recalibration date shall be promptly recalibrated. Items on which inspections have been performed with devices proven to be out of calibration shall be promptly reinspected. All calibration certifications shall be recorded and become part of the QA records.
17.7.5 FINAL INSPECTIONS
The progress schedule shall included at least one (1) day for final inspection by the City after it is fully completed, prepared for shipment, and free of all workers. All deficient items indicated in QA reports shall be corrected before final inspection takes place. The Contractor shall provide a qualified supervisor to accompany the City during the final inspection.
The Contractor shall provide the necessary labor to open enclosures, demonstrate functioning of equipment, and perform other similar activities.
All systems shall be proven to be operational and all necessary power sources shall be provided for that purpose.
The final inspection shall also included verification of completeness of the car history book.
17.8 TECHNICAL SUPPORT PERSONNEL
The Contractor shall furnish the services of at least one field service engineer at the Portland Streetcar facilities. The field service engineer shall be provided on a full time basis starting at least ten (10) days before arrival of the first car and shall remain until two (2) years after acceptance of the last car. The support personnel shall be fluent in English.
The support personnel shall provide assistance during inspection, operation, testing and adjustment of the Streetcar both before and after acceptance by the City.
The support personnel shall be available to work any of three, 8-hour shifts, as may be required by the City the working schedule.
The Contractor shall also insure that the expert services of equipment suppliers and designers are available, on short notice, during the same period to assist the on-site personnel in the investigation and resolution of car and equipment malfunctions.
If requested by the City, the Contractor shall provide on-site technical assistance within forty-eight (48) hours from receipt of request during the time period from delivery of the first car to final acceptance of the last car; and within 72 hours from receipt of a request for service during the warranty period.
END OF SECTION