Center City Connector Project Table of Contents Section 1 General Topics and Definitions Section 2 Design and Performance Criteria Section 3 Vehicle-Body Structure Section 4 Coupler Section 5 Operator’s Cab and Controls Section 6 Passenger Doors Section 7 Heating, Ventilating, and Air Conditioning Section 8 Lighting Section 9 Electrical Equipment Section 10 Propulsion System and Control Section 11 Truck Assemblies Section 12 Friction Brake System Section 13 Vehicle Communication Systems Section 14 Interior and Exterior Appointments Section 15 Testing Section 16 Materials and Workmanship Section 17 Electronic Controls, Software, and MDS Section 18 System Support Section 19 Program Control and Quality Assurance Section 20 Onboard Energy Storage System (OESS) LTK Standard Streetcar Specifications Volume 2 - Technical Specifications i June19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Revision History Date Section Name 6/7/2017 2.3.2.2 Seating 6/7/2017 2.4.2 Weights 6/7/2017 2.4.3 Weight Balance 6/7/2017 2.4.4 Vehicle Body Dimensions 67/2017 2.4.7.1 On the Project Alignment 6/7/2017 2.7.3 Speed Requirement 6/7/2017 2.7.6.3 Service Braking 6/7/2017 2.7.6.4 Maximum Brake 6/7/2017 2.13.2 Reliability Demonstration 6/7/2017 2.13.3 Mean Distance Between Failure (MDBF) 6/7/2017 3.4.14 Truck-to-Vehicle Body Attachment 6/7/2017 3.4.15.1 Equipment Loads 6/7/2017 4.3.3 Strength 6/7/2017 4.3.4 Draft Gear and Anchorage 6/7/2017 5.7.2 Interior View Display Screen 6/7/2017 5.9.5 Cab HVAC Unit Controls (Optional) 6/7/2017 6.11.5 Sensitivity Requirements 6/7/2017 6.17.1.2 ADA and Interface Requirements 6/7/2017 7.9.1 General 6/7/2017 7.9.3 Cab HVAC Units (Optional) 6/7/2017 7.9.4 Cab HVAC 6/7/2017 8.6.2.2 Main Linear Lighting 6/7/2017 8.7.2 Headlights 6/7/2017 11.12.2 Maximum Allowable Stresses 6/7/2017 11.12.4 Fatigue Allowable Stress levels 6/7/2017 12.5 Sanding System 6/7/2017 13.4.11.3 Destination Signs 6/7/2017 13.7.2 Cameras 6/7/2017 15.3.9 Traction Gear Unit Type Test 6/7/2017 20.1.1 OESS Description 6/7/2017 20.1.5 Service Life 6/7/2017 20.3.2 Acceleration LTK Standard Streetcar Specifications Volume 2 - Technical Specifications ii June19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Revision History Date Section Name 6/19/2017 2.8.2 Pure Tones 6/19/2017 5.7.2 Interior View Mirror 6/19/2017 13.7.2 Cameras 6/19/2017 13.7.8.6 Storage Capacity 6/19/2017 13.9.3 Vehicle Status and Health Data LTK Standard Streetcar Specifications Volume 2 - Technical Specifications iii June19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project THIS PAGE INTENTIONALLY LEFT BLANK LTK Standard Streetcar Specifications Volume 2 - Technical Specifications iv June19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions Table of Contents 1.1 Scope ...........................................................................................................................................1 1.2 General Requirements ..................................................................................................................1 1.3 Specifications ...............................................................................................................................1 1.3.1 Introduction ..................................................................................................................................... 1 1.3.2 Organization ..................................................................................................................................... 1 1.3.3 Language .......................................................................................................................................... 1 1.3.4 Contract Deliverables ....................................................................................................................... 2 1.4 Access to Contractor Facilities.......................................................................................................2 1.5 Materials and Equipment .............................................................................................................2 1.6 Industry Standards and Regulations ..............................................................................................2 1.7 Americans With Disabilities Act (ADA) ..........................................................................................3 1.8 System of Units ............................................................................................................................3 1.9 Definitions ...................................................................................................................................3 1.10 Acronyms and Abbreviations ......................................................................................................8 1.11 Units of Measure ...................................................................................................................... 12 1.12 Contract Data Requirements List (CDRL) .................................................................................... 14 LTK Standard Streetcar Specifications Section 1 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions 1.1 Scope This Section includes requirements that apply to every section included in the Specifications. 1.2 General Requirements The vehicles shall be modern articulated, low floor streetcars, designed to be safe, reliable, and maintainable. The Contractor shall have the following responsibilities: 1. Design, manufacture, test, and deliver the products as described by the Specifications. Deviations from these requirements are permitted only with specific approval of the Owner. 2. Design and integrate vehicle systems such that specified requirements are achieved without conflict or error within or between onboard systems and between vehicle systems and wayside systems. 3. Ensure that designers, suppliers, and subcontractors are informed of specified requirements and that appropriate engineering management tools are used to ensure that coordination and communication occurs between the designers of inter-related systems. 1.3 Specifications 1.3.1 Introduction The Technical Specifications (“the Specifications”) define the functional, performance, and interface design requirements for the vehicles and contract-required support systems. 1.3.2 Organization The Specifications are divided into sections according to technical discipline and traditional supplier arrangements. 1. The format is for convenience only and does not imply or suggest a preferred system integration approach. 2. Explicit references may appear within sections linking requirements appearing in other sections. Such references shall, in no way, be assumed to limit the range or applicability of the requirements in this document, whether referenced or not. 1.3.3 Language The Specifications are written in imperative mood and streamlined form: 1. Imperative language is directed to the Contractor, although work may be carried out by a subcontractor or supplier under the Contractor’s direction. 2. The words "shall be" are included by inference where a colon (:) is used within sentences or phrases. 3. Examples: a. "Prepare meeting minutes within three days following the meeting," means that the Contractor shall prepare the meeting minutes. b. "Stress Analysis Report: Submit minimum 60 days before starting manufacture of vehicle body structural parts” means that the Contractor shall submit the report within the time indicated. LTK Standard Streetcar Specifications Section 1 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions 1.3.4 Contract Deliverables The Specifications require the submittal of drawings, documents, analyses, technical data, test procedures and results, manuals, schedules, forms such as ECN, NCR, and waiver requests, samples, and similar information for review by the Owner to verify compliance with specified requirements, and for after-delivery support of the vehicles: 1. Unless otherwise noted, each specified submittal must be both reviewed and approved by the Owner, whether this is specifically stated or not. 2. Specific submittal requirements are listed at the conclusion of each section under the heading Contract Deliverables Requirements List or CDRL. 3. The Owner reserves the right to request additional drawings, documents, analyses, technical data, test procedures and results, or similar information, as required to clarify and amplify the intent of submittals furnished. 1.4 Access to Contractor Facilities The Owner shall have the right to visit facilities of the Contractor and its subcontractors: 1. Visits are to assess progress, monitor work being performed, conduct QA/QC audits, conduct quality inspections, and witness testing. 2. The Owner shall have the right to photograph, at its expense, any or all phases of vehicle or equipment construction, including subcontractor work. 1.5 Materials and Equipment Name brands, specific equipment, or specific materials may be referenced in the Specifications: 1. Such equipment has been shown to be successful in previous applications, where correctly applied and integrated with other equipment; however, such references shall not be interpreted as pre-approval of Contractor designs or applications. 2. The Contractor is responsible for the selection, application, and integration of equipment and materials as necessary to conform to the specified requirements. Equipment provided under this Contract shall be new: 1. Rebuilt or refurbished equipment is prohibited. 2. New equipment damaged during execution of this Contract may be restored to new condition only where approved in writing by the Owner on a case-by-case basis, and restorations shall be performed by the original equipment manufacturer. 1.6 Industry Standards and Regulations Comply with the following: 1. Where standards, codes, or reference books are referenced in the Specifications, use the most current version available at the time of bid, unless otherwise noted. 2. Where laws, statutes, or regulations are specified, such as the Code of Federal Regulations (CFR), use the version in force at the time of bid. 3. References to laws, statutes, or regulations are included in the Specifications to aid the Contractor. Whether referenced or not, applicable federal, state, and local laws, statutes, and regulations shall be included in this Contract. LTK Standard Streetcar Specifications Section 1 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions 1.7 Americans With Disabilities Act (ADA) The Americans with Disabilities Act (ADA) prohibits discrimination on the basis of disability in the provision of transportation services by public and private entities: 1. The Department of Transportation (DOT) issues legally enforceable regulations to implement the transportation provisions of the ADA, codified in 49 CFR Parts 37 and 38, and compliance with these regulations is mandatory whether referenced in the Specifications or not. 2. Compliance with interpretations by the Federal Transit Administration (FTA) in Administrators Policy Letters is also mandatory. References are provided to these parts in the Specifications: 1. 49 CFR 38, ADA Accessibility Specification for Transportation Vehicles: Technical requirements for vehicles are primarily found in this part. 2. 36 CFR 1191, ADA Accessibility Guidelines for Buildings and Facilities, Appendix D, Technical: Adopted by DOT in 49 CFR 37, Appendix A by reference with some modifications. In some cases, requirements from this part are applied to vehicles. 1.8 System of Units International System of Units (SI) units are shown with United States customary units following in parentheses: 1. Rounding: If a difference exists between SI and U.S. customary units due to rounding, SI units shall be primary. 2. Exception: Where laws, statutes, or regulations give dimensions only in U.S. customary units, the U.S. customary units shall be primary. 1.9 Definitions The following terms may appear in this document. They are defined as indicated: Acceleration, Average: The arithmetic difference between ending speed and initial speed, divided by the time elapsed between those speeds. See Section 15, Testing, for measurement method. Acceleration, Instantaneous: The value of acceleration at a specific instance of time, or speed. Adhesion, Coefficient of: During rolling contact, the ratio between the tangential force at the wheel-rail interface and the normal force. Approval: Acceptance in writing by the Owner or the Owner's Engineer. Approved or Approved Type: Design, type material, procedure, or method given approval by the Owner or the Owner's authorized representative. Auxiliary loads: Loads other than propulsion, such as lighting and HVAC. AW0: Weight of empty vehicle. AW1: Weight of vehicle with a full seated load, including one operator. AW2: Weight of vehicle with a full seated load, including one operator, plus standees at four passengers/m². AW3: Weight of vehicle with a full seated load, including one operator, plus standees at six passengers/m². LTK Standard Streetcar Specifications Section 1 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions AW4: Weight of vehicle with a full seated load, including one operator, plus standees at eight passengers/m². Blending: In braking, the simultaneous control of dynamic (rheostatic and regenerative) and friction braking, with the effort of each continuously proportioned to achieve the required total braking effort within the specified tolerances. Burn-In: Operating a component, system, or device in a test mode, often in an extreme or cycled temperature environment, for a specified period of time or distance, to confirm reliable operation. Coast: The mode of operation in which no propulsion or braking efforts are in effect, except for normal drivetrain losses. Component: Portions of equipment not typically repaired or disassembled, such as nuts, bolts, resistors, fittings, single-piece castings. Used interchangeably with "parts." Contract Deliverables Requirements List (CDRL): List of select documents and other deliverable items that the Contractor is required to deliver to the Owner. CDRL is also used to refer to a specific item on the list. Contract Drawings: Drawings and Specifications provided by the Owner as part of this procurement. Contractor: The person or persons, firm, partnership, corporation, or combination thereof that has entered into a procurement contract with the Owner to supply the vehicles. Contractor's Drawings: Items such as general drawings, detail drawings, graphs, diagrams, sketches, calculations, and catalog cuts prepared by the Contractor for use in its manufacturing facility, assembly facility, or shop, to fabricate, assemble, and install parts of the vehicle whether manufactured by it from raw materials or purchased from others in a ready-to-use condition. Data: Written presentations, plans, reports, schedules, forms, drawings, calculations, analyses, procedures, samples, photos and other items prepared by the Contractor, it subcontractors, or suppliers in response to requests from the Owner or its authorized representative or to otherwise meet the requirements of the contract documents. Days: Unless otherwise designated, days as used in the Contract Document will be understood to mean calendar days; that is, including weekends and holidays. Days, Working: Those calendar days during which regular business is conducted, excluding Saturdays, Sundays, and Federal, State, and municipal holidays that are observed in the Owner. Defect(s), Defective: A condition that does not meet the requirements of the Contract Documents; causes a vehicle or a portion of the work to cease operation or to operate in a degraded mode; or inflicts injury or damage to a vehicle, the work, other property, or persons. Drive: A system consisting of one or several motors or actuators, their direct power control equipment, and the associated mechanical devices required to produce a useful output. Dynamic Braking: Braking effort provided by using the traction motors as generators, dissipating vehicle energy by rheostatic braking, regenerative braking, or a combination of both. Equal: Providing the same function, performance, and reliability. Failsafe: A system is "failsafe" when it is designed such that a malfunction will not cause the system to achieve an unsafe state. LTK Standard Streetcar Specifications Section 1 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions Failure: A condition in which equipment does not function as specified, designed, or expected. Failure Rate: The frequency of failure, expressed as failures per hour or failures per mile. Failure rate is the mathematical reciprocal of Mean Time Between Failures (MTBF) or Mean Distance Between Failures (MDBF). First Article: The first item of production that fixes and defines each subsequent production item. First articles are production units intended for review by the Owner. Furnish: To supply and deliver to project site. Grab handle: A safety device mounted on the aisle-side corner of a seat and designed to be grasped by the hand to enable a person to maintain balance. Grab rail: A horizontal safety device mounted across the back of a seat and designed to be grasped by the hand to enable a person to maintain balance. Handhold: A vertical safety device mounted to a wall or other vertical surface and designed to be grasped by the hand to enable a person to maintain balance. Handrail: A horizontal safety device mounted to a wall or windscreen or hung from the ceiling and designed to be grasped by the hand to enable a person to maintain balance. Hotel loads: The same as auxiliary loads (see definition above). Inspector: The person(s) or firm designated by the Owner as its quality control representative. Install: To place in position for service or use. Interface: The points where two or more systems, subsystems, components, or structures meet, and transfer energy or information. Jerk: Time rate of change of acceleration and deceleration, equal to the second derivative of velocity. Light: The transparent portion of a window. Liner (as in interior liner): The visible covering material for the walls, ceiling, and other interior surfaces. Load Weighing: The measurement of passenger load for the purpose of adjusting tractive effort to produce a constant acceleration or braking rate regardless of load. Lowest Level Replaceable Unit (LLRU): The lowest unit (component) of a system or subsystem, which is removable and replaceable from an installed position by standard attachments (e.g., by bolts and nuts or quick-disconnects). Manufacturer: The builder or producer supplying materials, equipment, or apparatus for installation on the vehicle. Mask, Window: Interior liner that surrounds the windows, often molded to include the sill and other portions of the sash. Mean Distance Between Failures (MDBF): The mean operating mileage between independent failures. Mean Time Between Failures (MTBF): The mean operating time between independent failures. Mean-Time-To-Repair (MTTR): The average time required to repair a failed component or device. LTK Standard Streetcar Specifications Section 1 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions Mode Change Dead Time (MCDT): The time for a system to fully cease one state and initiate another state. Usually measured from the time of a command signal until the second state has achieved 10% of the full state change. Nominal, as in "nominal voltage": Exists in name only, not implying an actual operating value. No Motion Speed: The lowest speed detectable by the vehicle control systems. Normal, as in "normal operating conditions" or "operating normally": A condition in which relevant vehicle equipment is not in a failure mode and the environment is functioning as specified. Overspeed Protection: The process of vitally assuring that the vehicle speed does not exceed the speed limit. Part: See Component, above. Proof (used as a suffix), as in "splashproof" or "dustproof": The device and contents are impervious to, or unharmed by, application of the indicated action or material. Provide: To furnish and install, complete and ready for intended use. Regenerative Braking: Electrical energy produced by motors acting as generators, putting electrical power onto the distribution system for use by other equipment. Reliability: The probability of performing a specified function, without failure and within design parameters, for the period of time indicated. Rheostatic Braking: Electrical energy produced by motors dissipated as heat in resistors. Safe: Free from unreasonable risk of harm, injury, or danger. Safety: The condition in which persons are free from unreasonable risk of danger, harm, or loss arising from the design, manufacture, assembly, malfunction, or failure of the vehicle or any of its components or systems. Service, as in "service use" or "service braking": The operation of the vehicles under normal conditions. Service proven design: 1. Systems and subsystems: a. Used in revenue rail operation for at least three years; and b. Used in revenue rail operation for at least 1 million vehicle miles with at least 75 thousand miles per vehicle (i.e., 25 thousand miles per year per vehicle); and c. Has a minimum fleet size of 12 vehicles. 2. Complete vehicle: a. Used in revenue rail operation for at least two years; and b. Has a minimum operating fleet size of six vehicles. Shall: Denotes a mandatory specification or requirement. Shop: The Owner’s vehicle maintenance facility. Slide, Wheel: During braking, the condition existing when the rotational speed of the wheel is less than that for pure rolling contact between tread and rail. Speed: LTK Standard Streetcar Specifications Section 1 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions 1. Balancing Speed: The speed attained by the vehicle when resisting forces exactly equal the maximum available tractive forces. 2. Base Speed: The speed to which the maximum constant acceleration can be maintained at the nominal line voltage. 3. Civil Speed: The operating speed limit assigned to each track segment. 4. Maximum Operating Speed: The maximum speed at which the Owner presently intends the vehicle to operate in normal service. This speed may be as high as the vehicle design speed. The maximum operating speed may be automatically lowered by the vehicle under certain specified conditions. 5. Schedule Speed: The average speed of a vehicle, from terminal-to-terminal, obtained by dividing the distance between these points by the time taken to make the trip, including time for intermediate station stops. 6. Vehicle Design Speed: The speed at which the vehicle can operate continuously without damage to equipment, independent of any speed limits imposed by vehicle controls. Spin, Wheel: During acceleration, the condition existing when the rotational speed of the wheel is greater than that for pure rolling contact between tread and rail. Stanchion: A vertical safety device mounted to the floor and ceiling or from top of seat back or seat back grab rail to the ceiling and designed to be grasped by the hand to enable a person to maintain balance. Stop, Emergency: The stopping of a vehicle by an emergency brake application. Stop, Service: The stopping of a vehicle by application of service braking. Subassembly: A collection of components used to perform a distinct function, usually in conjunction with other subassemblies and components, as part of a larger system. Subassemblies are usually replaceable as units, such as circuit boards, bearings, and valves. Tight (used as a suffix), as in "watertight" or "airtight": Enclosed or protected so as to completely exclude the indicated material from passage. Time, Build-Up: In response to a step-forcing function (as in control signal), time interval from 10% of the total change in value to the attainment of 90% of the total change in value of the controlled variable. Build-up time is equal to response time minus dead time. Time Constant: Slope of controlled variable build-up curve in units of controlled variable per unit of time, measured during the build-up time interval. Time, Dead (also Time, Reaction): Time from the occurrence of a step change of the control signal to the attainment of 10% of the total change in value of the controlled variable. Time, Down: The time during which equipment is not capable of doing useful work because of maladjustment, malfunction, or maintenance in progress. Time, Response: Time from the occurrence of a step change of control signal to the attainment of 90% of the total change in value of the controlled variable. Time, Warm-up: The elapsed time from the application of power to an operable device until it is capable of performing its intended function. Tolerance: The total amount a specific dimension is permitted to vary, indicated either as plus or minus values or as a maximum value. LTK Standard Streetcar Specifications Section 1 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions Traction System: The system of wheels, motors, gears, brakes, axles, direct controls, and appurtenances that propels or retards a vehicle in response to control signals. Train: Any number of vehicles, from one to the maximum, coupled together and moving as one. Tram: "In tram" is the condition of ideal truck geometry in which the axles are perfectly parallel and the wheels are in perfect longitudinal alignment. The centers of the journal bearings represent the corners of a perfect rectangle. Verification that a truck is "in tram" is determined by measuring the diagonal and longitudinal distance between reference points on the axle bearing housings. Truck: An assembly of structural frame, with axles and four wheels, associated motors, gear units, friction brake components, magnetic track brakes, safety bars, and suspension elements that supports a portion of the vehicle weight. Also known as a Bogie. Vehicle: A complete assembly as described by the Specifications, ready to operate. Vital: A term applied to a device or circuit that has known failure modes, certain of which occur with extreme rarity. Wainscot: The lower portion of a wall, especially if finished differently from the upper portion. Warp, Track: The vertical distance between the plane of any three of four rail head contact points (two on each rail) forming a rectangle and the remaining point. Wheelset: An assembly that includes an axle and two wheels or, for stub-axle designs, two laterally opposed wheels and their associated stub axles. Yard: The Owner’s vehicle storage yard. 1.10 Acronyms and Abbreviations The following acronyms and abbreviations may appear in this document. They are defined as indicated: AAR Association of American Railroads ADA Americans with Disabilities Act AISC American Institute of Steel Construction AISI American Iron and Steel Institute ANSI American National Standards Institute APC Automatic Passenger Counter APIS Automatic Passenger Information System APS Auxiliary Power Supply APTA American Public Transportation Association AQL Acceptance Quality Limit ASHRAE American Society of Heating, Refrigeration and Air Conditioning Engineers ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials AVL Automatic Vehicle Locator LTK Standard Streetcar Specifications Section 1 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions AWG American Wire Gauge AWS American Welding Society CCN CANopen Consist Network CCT Correlated Color Temperature CDRL Contract Deliverables Requirements List CDS Central Diagnostic System CFR Code of Federal Regulations CGHAZ Coarse Grain Heat Affected Zone CMOS Complementary Metal Oxide Semiconductor COTS Commercial Off-The-Shelf DB Dry Bulb DBTT Ductile-to-Brittle Transition Temperature DIN Deutsche Industrie Norm (German Industrial Standard) DOI Distinctiveness of Image EB Emergency Brake ECN Ethernet Consist Network ECR Engineering Change Request ECU Electronic Control Unit EMC Electromagnetic Compatibility EMI Electromagnetic Interference EN European Norm (European Standards) FAA Federal Aviation Administration FAI First Article Inspection FCC Federal Communications Commission FEA Finite Element Analysis FRA Federal Railroad Administration FRP Fiber-Reinforced Plastic, or Polymer FSB Full Service Brake FTA Federal Transit Administration GPS Global Positioning System GUI Graphical User Interface HPCU Hydraulic Pressure Control Unit HSCB High Speed Circuit Breaker LTK Standard Streetcar Specifications Section 1 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions HSLA High-Strength Low-Alloy (Steel) HVAC Heating, Ventilating, and Air Conditioning ICEA Insulated Cable Engineers Association IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IGBT Insulated-gate, bipolar transistor ISO International Organization for Standardization JIC Joint Industrial Council LDTS Local Diagnostic and Test System LED Light Emitting Diode Li-Ion Lithium-Ion LLRU Lowest Level Replaceable Unit LRU Line Replaceable Unit LRV Light Rail Vehicle LVPS Low-Voltage Power Supply max maximum MB Maximum Brake MC Master Controller MCDT Mode Change Dead Time MDS Monitoring and Diagnostic System MIL U.S. Military Specification min minimum MOV Metal Oxide Varistor MS Margin of Safety MDBF Mean Distance Between Failures MTBF Mean Time Between Failure MTP Master Test Plan MTTR Mean Time to Repair MVB Multifunction Vehicle Bus NBS National Bureau of Standards NDT Nil-Ductility Temperature NEC National Electrical Code NEMA National Electrical Manufacturer's Association LTK Standard Streetcar Specifications Section 1 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions NFL No Field Lubrication NFPA National Fire Protection Association NiCd Nickel Cadmium NiMH Nickel Metal Hydride NIST National Institute of Standards and Technology NTP Notice to Proceed OCS Overhead Contact System OESS Onboard Energy Storage System OIL Open Items List OSI Open Systems Interconnection PA Public Address PI Passenger Intercom PIV Peak Inverse Voltage PMTTR Predicted Mean Time to Repair ppm parts per million PTU Portable Test Unit PWM Pulse Width Modulation QA Quality Assurance QAP Quality Assurance Plan QC Quality Control QCIP Quality Control and Inspection Plan RFI Radio frequency interference RFP Request for Proposal rms root mean square ROW Right of Way RSTP Rapid Spanning Tree Protocol SAE Society of Automotive Engineers SCM Specification Compliance Matrix SDS Safety Data Sheet SFD System Functional Description SHA Safety Hazards Analysis SHGC Solar Heat Gain Coefficient SI International System of Measurement LTK Standard Streetcar Specifications Section 1 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions SIC Standard Industrial Code, U.S. Department of Labor SoC State of Charge SPB Shortest Path Bridging SSP System Safety Program SVPU Shop Vehicle Power Unit TCP/IP Transmission Control Protocol/Internet Protocol TCN Train Communication Network TIG Tungsten Inert Gas TIR Total Indicated Runout TOD Train Operator Display TOR Top of Rail TVM Ticket Vending Machine TWC Train to Wayside Communication UL Underwriters Laboratories, Inc. USASI United States of America Standards Institute USDOT United States Department of Transportation UV Ultraviolet (light) VCU Vehicle Control Unit VNC Vehicle Network Controller VPI Vacuum Pressure Impregnation VSWR Voltage Standing Wave Ratio WB Wet Bulb 1.11 Units of Measure A ampere A/V ampere per volt Btu/h British thermal units per hour C Celsius cd candela cm centimeter dB decibel dBA decibel on the 'A' weighted scale F Fahrenheit LTK Standard Streetcar Specifications Section 1 12 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions fc footcandle fps frames per second ft foot ft³ cubic foot ft-lbf foot pounds force ft³/min cubic feet per minute g acceleration due to gravity (9.81 m/s²) g gram gpm gallons per minute h hour in inch in/s inch per second Hz hertz J joule K kelvin kg kilogram kgf kilogram force kg/mm kilogram per millimeter kHz kilohertz km kilometer km/h kilometers per hour kN kilonewton kWh kilowatt-hour l liter lb pound lbf pound force lb/in pound per inch l/s liter per second m meter m³ cubic meter mg milligram MHz megahertz mi mile LTK Standard Streetcar Specifications Section 1 13 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project General Topics and Definitions min minute mm millimeter mm/s millimeters per second MPa megapascal mph miles per hour mph/s miles per hour per second ms millisecond m/s meters per second m/s² meter per second squared µsec microsecond mV millivolt µV microvolt N newton N-m newton-meter Pa pascal ppm parts per million psi pounds force per square inch s second V volt Vac volt alternating current Vdc volt direct current Wh watt hour Wh/m² watt hour per square meter 1.12 Contract Data Requirements List (CDRL) No submittals are required for this Section. END OF SECTION LTK Standard Streetcar Specifications Section 1 14 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria Table of Contents 2.1 General ........................................................................................................................................1 2.1.1 Scope ................................................................................................................................................ 1 2.1.2 Service Proven Design ...................................................................................................................... 1 2.1.3 Service Life ....................................................................................................................................... 1 2.2 Operating Environment ................................................................................................................1 2.2.1 General ............................................................................................................................................. 1 2.2.2 Climatic Conditions .......................................................................................................................... 1 2.2.2.1 General...................................................................................................................................... 1 2.2.2.2 Historical Climate Data ............................................................................................................. 1 2.2.3 Fordability ........................................................................................................................................ 2 2.2.4 Alignment ......................................................................................................................................... 2 2.2.4.1 Description ................................................................................................................................ 2 2.2.4.2 Wireless Segments .................................................................................................................... 2 2.2.4.3 Track Geometry ........................................................................................................................ 3 2.2.5 Station Platform Interface................................................................................................................ 3 2.3 Vehicle Description.......................................................................................................................3 2.3.1 Vehicle Type and Characteristics ..................................................................................................... 3 2.3.2 Vehicle Configuration Requirements ............................................................................................... 4 2.3.2.1 Doorways .................................................................................................................................. 4 2.3.2.2 Seating ...................................................................................................................................... 4 2.3.2.3 Bicycle Racks ............................................................................................................................. 4 2.3.3 Mobility Impaired Accommodations ............................................................................................... 5 2.3.3.1 General...................................................................................................................................... 5 2.3.3.2 Accessible On-Board Circulation Path (AOCP) .......................................................................... 5 2.3.3.3 Vehicle Entryway Width............................................................................................................ 5 2.3.3.4 Mobility Aid Parking Areas........................................................................................................ 5 2.4 Vehicle Weights and Dimensions ..................................................................................................6 2.4.1 General ............................................................................................................................................. 6 2.4.2 Weights ............................................................................................................................................ 6 2.4.3 Weight Balance ................................................................................................................................ 6 2.4.4 Vehicle Body Dimensions ................................................................................................................. 7 2.4.5 Doorway and Door Dimensions ....................................................................................................... 7 2.4.6 Pantograph Dimensions ................................................................................................................... 7 LTK Standard Streetcar Specifications Section 2 i January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.4.7 Vehicle Clearance ............................................................................................................................. 8 2.4.7.1 On the Project Alignment ......................................................................................................... 8 2.4.7.2 In Owner’s Shop ........................................................................................................................ 8 2.4.7.3 Under-Vehicle ........................................................................................................................... 8 2.4.8 Wheel Dimensions ........................................................................................................................... 9 2.5 Wheel-to-Rail Interface ................................................................................................................9 2.5.1 General ............................................................................................................................................. 9 2.6 Supply Voltages ............................................................................................................................9 2.6.1 Primary Line Voltage ........................................................................................................................ 9 2.6.1.1 General...................................................................................................................................... 9 2.6.1.2 Traction Power Substation Supply ............................................................................................ 9 2.6.1.3 Line-Voltage Range ................................................................................................................... 9 2.6.1.4 Performance Upon Loss of Primary Power ............................................................................. 10 2.6.2 Auxiliary and Low-Voltage Systems ............................................................................................... 10 2.6.3 Regenerative Braking Voltage ........................................................................................................ 10 2.6.4 Line Current Limit........................................................................................................................... 10 2.6.5 Transients and Abnormal Electrical Conditions ............................................................................. 10 2.7 Performance Requirements ........................................................................................................ 10 2.7.1 General ........................................................................................................................................... 10 2.7.2 Load Compensation ....................................................................................................................... 10 2.7.3 Speed Requirements ...................................................................................................................... 11 2.7.4 Propulsion and Braking Design Criteria.......................................................................................... 11 2.7.5 Acceleration Requirements............................................................................................................ 11 2.7.6 Braking Requirements .................................................................................................................... 12 2.7.6.1 General.................................................................................................................................... 12 2.7.6.2 Non-Powered Truck Braking ................................................................................................... 12 2.7.6.3 Service Brake........................................................................................................................... 13 2.7.6.4 Maximum Brake ...................................................................................................................... 13 2.7.6.5 Emergency Brake .................................................................................................................... 13 2.7.6.6 Dynamic Brake Failure ............................................................................................................ 14 2.7.6.7 Parking Brake .......................................................................................................................... 14 2.7.7 Wheel Spin/Slide Detection and Correction .................................................................................. 15 2.7.8 Jerk Limits....................................................................................................................................... 15 2.7.9 Mode Change Dead Times (MCDT) ................................................................................................ 16 LTK Standard Streetcar Specifications Section 2 ii January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.7.10 No-Motion Detection System ...................................................................................................... 16 2.7.11 Speed Sensing .............................................................................................................................. 16 2.7.12 Rollback Prevention ..................................................................................................................... 17 2.7.13 Duty Cycle .................................................................................................................................... 17 2.7.13.1 Normal Duty.......................................................................................................................... 17 2.7.13.2 Abnormal Duty ...................................................................................................................... 17 2.7.14 System Redundancy and Recovery .............................................................................................. 18 2.8 Noise and Vibration Limits .......................................................................................................... 18 2.8.1 General ........................................................................................................................................... 18 2.8.2 Pure Tones ..................................................................................................................................... 18 2.8.3 Interior Noise Limits ....................................................................................................................... 19 2.8.4 Wayside Noise Limits ..................................................................................................................... 19 2.8.5 Vibration Limits .............................................................................................................................. 19 2.8.6 Effects of Vibration on Vehicle Equipment .................................................................................... 20 2.9 Ride Quality ............................................................................................................................... 20 2.10 Electromagnetic Interference (EMI) and Compatibility (EMC) ..................................................... 20 2.10.1 General ......................................................................................................................................... 20 2.10.2 Design and Implementation......................................................................................................... 20 2.10.3 Individual Subsystems .................................................................................................................. 21 2.10.3.1 General EMC Compliance ..................................................................................................... 21 2.10.3.2 Conductive and Inductive Emissions .................................................................................... 21 2.10.4 Vehicle-Level ................................................................................................................................ 21 2.10.4.1 Radiated Emission Limits ...................................................................................................... 21 2.10.4.2 Conductive Emission Limits .................................................................................................. 22 2.10.4.3 Inductive Emission Limits...................................................................................................... 22 2.11 Vehicle Safety........................................................................................................................... 22 2.11.1 General ......................................................................................................................................... 22 2.11.2 Vehicle Safety Analyses ................................................................................................................ 23 2.11.2.1 Hazard Listing........................................................................................................................ 23 2.11.2.2 Hazard Analyses .................................................................................................................... 23 2.11.2.3 Mitigation of Hazards ........................................................................................................... 23 2.11.3 Vehicle Safety Design ................................................................................................................... 24 2.11.3.1 Safety Under Normal Operating and Maintenance Conditions............................................ 24 2.11.3.2 Safety Design Principles ........................................................................................................ 24 LTK Standard Streetcar Specifications Section 2 iii January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.11.3.3 Fire and Life Safety Design .................................................................................................... 26 2.11.4 Safety Certification Support ......................................................................................................... 26 2.12 Testability and Accessibility ...................................................................................................... 26 2.13 Reliability ................................................................................................................................. 27 2.13.1 General ......................................................................................................................................... 27 2.13.2 Reliability Demonstration ............................................................................................................ 27 2.13.3 Mean Distance Between Failures (MDBF) ................................................................................... 27 2.14 Maintainability ......................................................................................................................... 28 2.14.1 General ......................................................................................................................................... 28 2.14.2 MTTR Requirements .................................................................................................................... 28 2.14.3 Scheduled and Preventive Maintenance ..................................................................................... 29 2.14.4 Maintainability Demonstration .................................................................................................... 29 2.15 Contract Data Requirements List (CDRL) .................................................................................... 30 LTK Standard Streetcar Specifications Section 2 iv January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.1 General 2.1.1 Scope This Section describes the operating environment in which the vehicle must perform, and establishes general design criteria and system performance. Related and other requirements may appear in other sections of the Specifications. 2.1.2 Service Proven Design Base the vehicle and its systems on “service proven designs,” as defined in Section 1, General Topics and Definitions. 1. Derivations from, or extensions of proven designs will be permitted solely at the discretion of the Owner. 2. The Owner will assess changes to service proven designs according to, among other factors, the risks to the success of the Project. 2.1.3 Service Life Base service life on the Project environment, subject to the maintenance intervals specified in this Section and the Contractor's recommended maintenance practices and normal industry accepted operating procedures. Comply with the following service life requirements: 1. Vehicles: Minimum 30 years. Annual average mileage is estimated to be 40,000 km (25,000 mi) per vehicle. 2. Vehicle body, truck, and drive train structures: Minimum 30 years without the need for structural repairs. 2.2 Operating Environment 2.2.1 General The vehicle shall perform as specified in the Project operating environment, as described in this Section. 1. The vehicle shall be functionally compatible with the existing signal systems, and structurally compatible with the existing streetcars. 2.2.2 Climatic Conditions 2.2.2.1 General 1. Actual temperatures and conditions local to the vehicle along the alignment, including those within, underneath, and above the vehicle, may be much more severe than the historical climatic conditions below. 2. The vehicle shall accommodate the environmental extremes on the alignment. 2.2.2.2 Historical Climate Data 1. Ambient air temperature extremes, external to the vehicle: a. Low: -20 degrees C (-4 degrees F) b. High: 38 degrees C (100 degrees F) LTK Standard Streetcar Specifications Section 2 1 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2. Precipitation: a. Maximum rainfall rate in 24 hours: 66 mm (2.6 in) b. Maximum snowfall in 24 hours: 150 mm (5.9 in) c. Icing conditions: Vehicles must be capable of operating under freezing rain and ice conditions without damage to equipment or reduction of useful service life 3. Relative Humidity: a. Minimum: 50% b. Maximum: 100% 4. Wind Speed: a. Maximum sustained: 56 km/h (35 mph) b. Maximum gusting: 96 km/h (60 mph) 2.2.3 Fordability The vehicle shall operate without impairment or damage in standing water of depths up to 75 mm (3 in). 2.2.4 Alignment 2.2.4.1 Description The vehicles will operate on the Project streets in mixed traffic with traffic congestion, traffic lights, bicycles, and pedestrians. 1. Vehicle speeds: See the Speed Requirements section, below. 2. Track bed cross section: Primarily level, with cross slopes of 2% between rails for drainage toward the center of the track. 3. Alignment plan and profile: See Appendix C, Alignment. 2.2.4.2 Wireless Segments The following segments of the alignment will be wireless. Wireless Segments Broadway and Denny to South Jackson and Occidental Stations Jackson and Occidental to First and Cherry Stations Stewart and 2nd to Westlake and 6th Stations Stewart and 2nd to Jackson and Occidental Stations Right of Way Mixed Traffic Exclusive Exclusive Exclusive Notes to Table: 1. Operation on wireless segments will be in mixed auto traffic, subject to random and significant delays due to intersection conflicts, pedestrians in the streets, entertainment or sports events, police and emergency responder activities, and similar. 2. Refer to Section 20, Onboard Energy Storage System (OESS), for operating conditions on these segments and OESS requirements. LTK Standard Streetcar Specifications Section 2 2 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.2.4.3 Track Geometry Track Geometry Rail Types: Minimum horizontal curve radius: Minimum vertical curve radius, crest: Minimum vertical curve radius, sag: Minimum frog number: Nominal track gauge and tolerance, new: Nominal track gauge and tolerance, maintenance: Maximum track superelevation: Maximum sustained gradient: Reverse vertical curves: Compound curves: 112 Tram, 115 RE, Ri 52N/Ri 59N 18 m (60 ft) 250 m (1150 ft) 250 m (1150 ft) 4 1435 mm (4 ft 8.5 in) 1435 mm (4 ft 8.5 in) +/- 6mm (0.25 in) 75 mm (3 in) 9.02% for 1000 ft, or the worst case on alignment drawings, whichever is greater Either a crest and a sag of 250 m (820 ft) separated by a tangent section of 7.5 m (25 ft) or a crest and sag of 350 m (1148 ft) separated by no tangent track An 18 m (59 ft) horizontal curve superimposed on a 450 m (1476 ft) vertical crest or sag. 2.2.5 Station Platform Interface Comply with the following requirements for interface with station platforms: 1. Platform Loading Zone Length: Approximately 15.24 m (50 ft). The vehicle doorway location and arrangement shall allow for loading and unloading of passengers on the platform within the platform loading zone. 2. Platform Edges: At a horizontal distance of 1280 +/- 6 mm (50.4 +/- 0.25 in) from track centerline. 3. Platform Interface: Vehicle dimensions and tolerances shall provide the dimensions below: a. Lateral Motion of Vehicle from Track Centerline: +/- 19 mm (0.75 in) at the low floor section, on tangent track with normal wheel/rail wear allowances and normal lateral truck suspension deflections. b. Vehicle Width at Door Threshold: No less than vehicle-body width at floor level. Coordinate threshold extensions, if used, with platform dimensions. c. Vertical Motion Range: Floor height in the low floor section shall be nominal 356mm, (14 in) at AW0, with maximum deflection of 76 mm (3 in) under maximum passenger load, AW3. d. Station Platform Height: 250 mm + 0/- 6 mm (10 in +0/- 0.25 in) above top of rail. 2.3 Vehicle Description 2.3.1 Vehicle Type and Characteristics The vehicle shall be an articulated, modern urban streetcar with contemporary styling. The vehicle shall have the following characteristics: 1. Body sections: Minimum three, each separated by an articulated joint. LTK Standard Streetcar Specifications Section 2 3 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2. Low floor: a. Low floor shall span the distance between high floor sections over the two end trucks and be continuous longitudinally without change in floor level. b. Partial low floor vehicles: Provide at least 42% low floor, measured by the longitudinal length of the low floor section divided by the distance between cab walls. c. 100% low floor vehicles: Low floor section shall extend from cab wall to cab wall. 3. Transition from low floor to high floor: Via steps, or via ramps with ramp angle 6 degrees or less. 4. Bi-directional: Provide a fully functional cab at each end with operating control and performance equal from both cabs. 5. Single-unit operation: Include provisions for towing a non-operable vehicle. 6. Heated and air conditioned: Consistent with the Project environment and the Specifications. 7. Powered trucks: At least two-thirds of the trucks shall be powered. Provide motoring, dynamic braking, and spin protection for all wheels of powered trucks. See Section 10, Propulsion System and Control, for related requirements. 8. All trucks: Provide friction disc braking and slide protection for all wheels of all trucks. Provide track braking on all trucks. See Section 12, Friction Brake System, for related requirements. 2.3.2 Vehicle Configuration Requirements 2.3.2.1 Doorways Comply with the following: 1. Total doorway span: Shall not exceed the length of the shortest platform loading zone, as specified above, to preclude doors from opening off-platform. 2. Quantity of doors per side: a. Vehicles less than 22 m (72 ft): Minimum two double-wide doors per vehicle side in the low floor section b. Vehicles 22 m (72 ft) or greater: • • Minimum two double-wide doors per vehicle side in the low floor section, and One single door at each end of the vehicle 2.3.2.2 Seating Arrange seating laterally as follows, except as may be defined elsewhere: 1. Vehicle width less than 2460 mm: Seats 2 x 1 abreast preferred alternative arrangements maybe proposed for review and approval by the Owner. 1.2. 100% low floor vehicles: Seats 1 x 1 abreast, over the trucks. See Section 14, Interior and Exterior Appointments, for seat requirements, including dimensions. 2.3.2.3 Bicycle Racks Provide bicycle stowing racks: 1. Location: Center section of the vehicle. 2. Capacity: 2 bicycles. 3. Rack requirements: See Section 14, Interior and Exterior Appointments. LTK Standard Streetcar Specifications Section 2 4 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.3.3 Mobility Impaired Accommodations 2.3.3.1 General Mobility impaired accommodations shall comply with 49 CFR 38, Subpart D. 2.3.3.2 Accessible On-Board Circulation Path (AOCP) The AOCP connects accessible features on the vehicle, including accessible doorways and mobility aid parking areas: 1. AOCP Clear Width: Minimum 32 inches. 2. Bridge Plates Provide two, one on each side of the vehicle, at double-leaf doorways in the low floor section. 3. AOCP Route: Between each bridge plate doorway and the specified mobility aid parking areas. 4. Signage: Provide the international symbol of accessibility on vehicle interior and exterior at each bridge plate door. See Section 14, interior and Exterior Appointments, for additional signage requirements. 2.3.3.3 Vehicle Entryway Width Comply with the following requirements for vehicle entryway width: 1. Vestibule: Vehicles where wind screens, modesty panels, or other partitions establish an entrance or “vestibule” area separate from the occupied passenger space: a. Vestibule width: Minimum 44 inches over the most restrictive protrusion, where 90 degree or similar turns are required immediately upon entering the vehicle b. Exception: If the vestibule is arranged to allow a free-flowing path into the passenger area or aisle leading to that area, then the most restrictive width of the vestibule near the door may be less than 44 inches, but in no case can the accessible on-board circulation path be less than 32 inches 2. No Vestibule: Vehicles that do not have physically defined separation between entrance areas and passenger occupied areas but require 90 degree or similar turn on to the Accessible Onboard Circulation Path: a. Clear path dimension: Minimum 44 inch wide across the vehicle free from panels or stanchions b. Path configuration: Should be a straight line across the doorways on opposite sides of the vehicle c. Exception: Entrances that are not on the Accessible On-Board Circulation Path or do not lead to a mobility aid parking area are not bound by this requirement 2.3.3.4 Mobility Aid Parking Areas Provide mobility aid parking areas in each vehicle according to door configuration: 1. Two double-wide doors on each side: Minimum two mobility aid parking areas, adjacent to the doorways with bridge plates. 2. Three double-wide doors on each side: Minimum two mobility aid parking areas and one area with flip-up seats to allow space for mobility aid parking, each adjacent to a doorway with bridge plate. LTK Standard Streetcar Specifications Section 2 5 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 3. Four double-wide doors on each side: Minimum two mobility aid parking areas and two areas with flip-up seats to allow space for mobility aid parking, each adjacent to a doorway with bridge plate. See Section 14, Interior and Exterior Appointments, for mobility aid parking area requirements. 2.4 Vehicle Weights and Dimensions 2.4.1 General Weights and dimensions shall be as indicated below. Construction tolerances of dimensions shall be as stated on the Contractor's drawings unless specifically stated in the Specifications. 2.4.2 Weights Vehicle weight is based on a ready-to-run vehicle, complete in all respects with all equipment, materials and fluids. The weight of each vehicle, including passengers at 70 kg (154 lbs) each, shall be defined as follows: AW1 Empty vehicle operating weight, maximum 1710 1875 kg/m (1150 1260 lbs/ft) of total vehicle length Full seated load (passengers plus operator), plus AW0 AW2 Standees at four persons per m² of suitable standing space per passenger, plus AW1 AW3 Standees at six persons per m² of suitable standing space per passenger, plus AW1 AW4 Standees at eight persons per m² of suitable standing space per passenger, plus AW1 AW0 Notes to Table: 1. Suitable standing space shall include areas of the aisles where it is possible for passengers to stand. 2. The ratings of vehicle equipment and systems shall be based on the actual weight and passenger capacity of the vehicle. 2.4.3 Weight Balance Arrange equipment so that its weight is distributed to maximize adhesion and minimize the tendency to derail. Each vehicle shall meet the following balancing requirements when complete with all necessary apparatus and for all specified passenger loading conditions: 1. A-end and B-end trucks: The difference in vehicle weight supported by each truck at the rail shall not exceed 900 1500 kg (1984 3307 lb) for all loading conditions from AW0 to AW3. 2. Center truck (if provided): The vehicle weight supported at the rail shall be within the range of 25% to 40% of the total vehicle weight for all loading conditions from AW0 to AW3. 3. Lateral imbalance: Maximum 290 kg-m (2098 lb ft) for all loading conditions, AW0 to AW3. LTK Standard Streetcar Specifications Section 2 6 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.4.4 Vehicle Body Dimensions Vehicle length: Allowed range, measured over anticlimbers Nominal vehicle width: Allowed range Vehicle width at low-floor doorway thresholds: Height of roof equipment: Maximum (excluding pantograph) above TOR with new wheels at AW0, including roof shrouds Coupler height: Nominal, vertical centerline above TOR with new wheels at AW0 Anticlimber height: Above TOR with new wheels at AW0 Nominal low floor height above TOR: Interior ceiling height: Minimum, including anything mounted on the ceiling in normal walking and standing areas Cab Interior ceiling height: Minimum 19.8 m to 2223 m (65 ft to 72 75.5 ft) 2450 mm (96 in) Same as approved nominal vehicle width +/- 3 mm (+/- 0.125) 3790 mm (149 in) 525 mm (20.7 in) 701.5 mm (27.6 in) 356 mm (14 in) 2030 1980 mm (80 78 in) 1980 mm (78 in) 2.4.5 Doorway and Door Dimensions Minimum side doorway clear opening width: Single-leaf door: Double-leaf door: Minimum side doorway clear opening height: 813 mm (32 in) 1220 mm (48 in) 1955 mm (77 in) 2.4.6 Pantograph Dimensions The pantograph location on the vehicle body, combined with pantograph head and carbon dimensions, shall provide for optimum operation and current collection under all conditions on the Project alignment. LTK Standard Streetcar Specifications Section 2 7 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria Pantograph Dimensions Maximum height above TOR in the lockdown position, new wheels, vehicle at AW0 passenger weight: Pantograph to operate on contact wire within this height range, vehicle weight from AW0 to AW3, and with new to fully worn wheels Maximum collector width over horns: Minimum carbon shoe length: Carbon spacing: Maximum lateral displacement from centerline of pantograph shoe at any operating height: Two-Truck Design - Maximum longitudinal distance from truck centerline to center of pantograph shoe, locked down: Three-Truck Design - Maximum longitudinal distance from centertruck centerline to center of pantograph shoe, locked down: 3800 mm (150 in) 3950 to 6250 mm (13 to 20.5 ft) 1700 mm (67 in) 1050 mm (41 in) 300 mm ([12] in) +/- 50 mm (2 in) 1275 mm (50 in) 2.4.7 Vehicle Clearance 2.4.7.1 On the Project Alignment Operate in the Project environment without physical interference with equipment and structures along the wayside. Do not exceed the dimensions shown for Dynamic Envelope and Curve Offsets in Appendix A, under the worst case combinations of the following: 1. 2. 3. 4. 5. Construction tolerances. Wheel and rail wear. Maximum possible body roll. Suspension motions. All other variables within the Contractor’s control. After contract award, the Owner and the contractor shall meet to discuss, clarify and finalize the vehicle dynamic envelope. 2.4.7.2 In Owner’s Shop Verify clearance dimensions between existing overhead shop walkways at the level of vehicle roof. 2.4.7.3 Under-Vehicle Vertical under-vehicle clearance is defined from top-of-rail with the maximum suspension deflection and vehicle body roll, minimum vertical curve radius, maximum track super-elevation, and fully worn wheels. 1. Vertical clearance: Minimum 50 mm (2 in), excluding track brakes, safety bars, and sanding nozzles. 2. Clearances between truck components and vehicle body: As specified in Section 11, Truck Assemblies. LTK Standard Streetcar Specifications Section 2 8 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.4.8 Wheel Dimensions Nominal Diameter, new: 510 mm to 660 mm (20 in to 26 in) Wear on diameter, at condemning limit: No less than 50 mm (2 in) Wheel Profile: Appendix B Back-to-Back Dimension: 1367 mm 2.5 Wheel-to-Rail Interface 2.5.1 General The vehicle truck design and wheels shall be compatible with the chosen rail sections and track design. The combined design of the truck, wheels, and rail shall optimize the wheel-to-rail interface for the following: 1. 2. 3. 4. Minimum wheel and rail wear. Minimum propensity to derail. Wheel/rail noise reduction. Ride quality enhancement. 2.6 Supply Voltages 2.6.1 Primary Line Voltage 2.6.1.1 General Vehicle equipment operated directly from the primary input source shall not suffer damage or reduction of required service life under any continuous primary input voltage from zero up to, and including, the maximum values defined below. 2.6.1.2 Traction Power Substation Supply The vehicle primary input power will be provided by an OCS supplied by dc substations: 1. Substation voltage: 750 Vdc at 100% rated load. 2. Substation regulation: 6%. 3. Rectification: a. Mainline: 6-pulse and 12-pulse b. Yard: 12-pulse c. Shop: 6-pulse 2.6.1.3 Line-Voltage Range Comply with the following: 1. Equipment operating directly from OCS line voltage: a. Shall not suffer damage or reduction of required service life under any continuous line voltage from zero up to, and including, the highest non-permanent voltage value as defined in IEC 60850 under 750 V nominal category. b. Equipment shall shut down or disconnect from the source if necessary to protect against damage for line voltages outside the range between 525 V and 925 V. LTK Standard Streetcar Specifications Section 2 9 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria Existing alignment: 1. Adjust control parameters via software to not exceed the voltage or current limitations of the existing infrastructure and vehicles. See Section 10, Propulsion System and Control, for maximum braking voltage limitation. 2. These parameters shall be resettable to IEC 60850 compliant values at any time by the Owner. 2.6.1.4 Performance Upon Loss of Primary Power Loss of primary power shall not cause an abrupt change in vehicle performance: 1. In power mode: Change to coast or a minimum brake. 2. In brake mode: Remain in same brake mode at same brake rate. 3. Other systems: Shut down in a controlled manner, without spurious behavior or damage. 2.6.2 Auxiliary and Low-Voltage Systems See Section 9, Electrical Equipment, for ac auxiliary power supply and low-voltage dc power system voltages. 2.6.3 Regenerative Braking Voltage See Section 10, Propulsion System and Control, for maximum permissible regenerative braking OCS voltage. 2.6.4 Line Current Limit Limit maximum line current, including all OCS-connected vehicle loads, to 1200 A. 2.6.5 Transients and Abnormal Electrical Conditions Protect equipment on the vehicle from the following: 1. Damage or continued shutdown caused by random interruptions of the OCS power due to isolation gaps, pantograph bounce, or other conditions. 2. Transients and voltage surges typical of rail transit, and as specified in IEC 60850 for line voltageconnected equipment, and IEC 61287 for all other equipment. 2.7 Performance Requirements 2.7.1 General Specified performance shall be independent of wheel wear, climatic conditions, and vehicle weights, unless otherwise indicated. 2.7.2 Load Compensation Provide an independent passenger load measuring system for each truck: 1. Propulsion and braking efforts shall compensate for variations in the total vehicle passenger load, apportioned among the trucks according to passenger load distribution, to meet specified performance requirements. 2. Provide appropriately conditioned signals to the propulsion and braking systems for load compensation to meet the specified performance requirements. 3. This system shall be active at stand still and with open doors only. Load values shall be memorized once the doors are closed and the vehicle starts moving. LTK Standard Streetcar Specifications Section 2 10 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 4. Sensors and associated circuits shall be continuously or periodically checked to verify that they are functioning properly. 5. If independent control logic units are provided as part of load compensation, they shall comply with Section 17, Electronic Controls, Software, and MDS. See also Section 10, Propulsion System and Control, Section 11, Truck Assemblies, and Section 12, Friction Brake System. 2.7.3 Speed Requirements When operating from the OCS, vehicle speeds, as defined in Section 1, shall be as follows: 1. Vehicle design speed: Minimum 80 70 km/h (50 43.5 mph). 2. Maximum operating speed: 48 km/h (30 mph), or the maximum speed limit on the operating alignment, whichever is greater. 3. Overspeed set point: Initially set at 48 km/h (30 mph) in the forward direction, 10 km/h (6 mph) in the reverse direction. 3.4. Minimum safe operating speed for all equipment with fully worn wheels: 80 Km/h (50 mph) See Section 10, Propulsion System and Control, for overspeed protection. 2.7.4 Propulsion and Braking Design Criteria Propulsion and braking equipment shall interface to produce the required performance values. The basis for performance calculations, designs and evaluation shall be as follows: 1. Acceleration, braking and jerk rates shall be based on level tangent dry track in still air except when otherwise noted. 2. Propulsion equipment shall provide required performance as specified above in the Performance Over Line-Voltage Range section, and as described below. 3. For voltages between 525 Vdc and 925 Vdc initial acceleration rates shall be as required per Section 2.7.5. 4. Braking rates shall be independent of the OCS voltage: a. Performance in dynamic braking shall be available at all line voltages down to, and including, 0 V, assuming line voltage is present at initiation of braking. b. Performance in friction braking modes shall be available at all line voltages down to, and including, 0 V. c. Friction braking shall automatically supplement dynamic braking, on a per-truck basis, whenever dynamic braking is not providing the requested braking effort. 5. Provide specified performance capabilities over the specified full range of the following: a. Wheel wear b. Ambient temperatures c. Low voltage power supply voltage 2.7.5 Acceleration Requirements When operating from the OCS, the instantaneous acceleration rate with the master controller (MC) at maximum power position shall be as shown below at all vehicle weights from AW0 to AW2 at the nominal line voltage and higher. LTK Standard Streetcar Specifications Section 2 11 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria Acceleration requirements: 1. Acceleration rate at MC Max Power: 1.34 m/s2, +/- 5%, from 0 to 32 km/h (20 mph). 2. Time to reach 40 km/h (25 mph) from 0 km/h: Less than 10 seconds. 3. Time to reach 70 km/h (43 mph) from 0 km/h: Less than 25 seconds. Reduced acceleration requirements: 1. Weights greater than AW2: Acceleration may be reduced in direct proportion to the ratio of AW2 weight/actual vehicle weight. 2. Line voltages less than nominal: Provide the specified acceleration, except that the speed to which the acceleration is maintained may be reduced in direct proportion to line voltage/nominal voltage. a. Line voltages between 525 and 650 Vdc: The propulsion system shall include an automatic current limiting scheme: • • • Current limiting parameters Adjustable Initial setting: 5 A/V Final setting: Optimize this value during commissioning 2.7.6 Braking Requirements 2.7.6.1 General Vehicle braking shall be provided by dynamic braking, friction disk braking, and track brakes. Adhesion may be augmented by the application of sand, as specified. Provide the instantaneous and average brake rates indicated below for vehicle weights from AW0 to AW3. Above AW3, brake efforts may be fixed at no less than the AW3 levels. 2.7.6.2 Non-Powered Truck Braking Comply with the following if a non-powered truck is provided: 1. Normal braking conditions: Minimize friction braking effort for the non-powered truck to maximize use of dynamic brake. 2. Slide controlled or emergency braking: Each wheel/axle shall be braked to ensure an equal distribution of adhesion levels for each wheel/axle, subject to review and approval of the Owner. 3. Dynamic brake failure conditions: Friction braking effort among the wheels/axles may be redistributed, subject to review and approval of the Owner. LTK Standard Streetcar Specifications Section 2 12 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.7.6.3 Service Brake Comply with the following: 1. Composition: Provide service braking (SB) using dynamic and friction disk braking. At all vehicle weights, SB shall be 100% dynamic braking down to the dynamic brake fade point. For speeds greater the 50 km/h and vehicle weights above AW2 dynamic braking maybe supplemented using the friction brakes. (see Section 10, Propulsion System and Control). 2. Braking rate: At FSB position on the MC, provide the following braking rates from any entry speed to zero: a. Instantaneous braking rate: • • • • All dynamic brakes functional: 1.34 m/s², +/- 5% (above low-speed fade point) One dynamic brake unit inoperative: 1.34 m/s², +/- 10% Transition between dynamic and friction brakes (fade point): 1.34 m/s² +/- 20% 100% friction braking: 1.34 m/s², +/- 20% b. Average braking rate: • 100% friction braking: 1.34 m/s², +/- 20% 2.7.6.4 Maximum Brake Comply with the following: 1. Composition: Provide maximum brake (MB) using dynamic, track brake, and friction braking as necessary to achieve specified performance. Maximize the use of dynamic braking, filling in with friction braking only as necessary. Slide protection shall be active. 2. Braking rate: At MB position on the MC, provide the following braking rates from any entry speed to zero: a. Instantaneous braking rate: Less than 3.5 m/s² b. Average braking rate: • • All dynamic brakes functional: 2.25 m/s² +10%, -0% One dynamic brake unit inoperative: 2.25 m/s², +15%, -05% ○ • 1 stop, then speed restriction maybe implemented With 100% friction braking: 2.25 m/s², +20%, -010% ○ 1 stop, then speed restriction maybe implemented 2.7.6.5 Emergency Brake Comply with the following: 1. Operator control: Provide an Emergency Brake Switch as specified in Section 5, Operator’s Cab and Controls. 2. Composition: Provide emergency braking (EB) using a combination of friction disc brakes, track brakes, dynamic brakes, and the application of sand. Friction brake effort shall be independent of dynamic brake effort: a. AW1 and below: Provide minimum EB rate using only friction disc brakes, track brakes, and application of sand. LTK Standard Streetcar Specifications Section 2 13 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria b. Above AW1: Dynamic brakes may supplement friction disc brakes, track brakes, and application of sand to achieve minimum EB rate. 3. Braking rate: When EB is commanded, provide the following braking rate from any entry speed to zero: a. Instantaneous braking rate: Shall not exceed 3.5 m/s² b. Average braking rate: 2.25 m/s², +20%, -0% 4. Function of systems during EB: a. b. c. d. Spin-slide system: Cut out during EB Jerk limiting: Shall not be applied to EB Other vehicle systems: Shall not inhibit EB Interlock with vehicle speed: • • • EB command: Irretrievable to the no-motion detection speed Track brake release: At approximately 5 km/h, to be fine-tuned during commissioning Sanding termination: At no-motion detection speed 5. EB is a safety system: a. Control line: Double-wire double-break as follows: • • Separate positive and negative control wires with duplicate switching contacts for each control function in the positive and negative control lines. Both positive and negative supply leads to the EB relay shall be switched by the cab console emergency brake switch, and interlock relays. b. Vital circuits: Treat EB control circuits, including wiring, as vital, with maximum isolation maintained from possible sources of false energization. c. Failsafe: Arrange EB circuits in a failsafe manner, such that control lines must be energized to sustain a permissive condition. 2.7.6.6 Dynamic Brake Failure In the event of dynamic brake failure, comply with the following: 1. Friction disk brakes shall automatically provide the necessary braking efforts to achieve the requested braking rate. 2. After the initial stop with a dynamic brake failure, the system shall automatically reduce vehicle maximum operating speed as a function of vehicle weight, as approved by the Owner, as necessary to conform to friction brake thermal limitations. 2.7.6.7 Parking Brake Provide parking brakes capable of stopping and holding a vehicle as follows: 1. Weight: Up to AW4. 2. Grade: Maximum 9.02%. 3. Duration: Indefinitely. See Section 12, Friction Brake System, for parking brake requirements. LTK Standard Streetcar Specifications Section 2 14 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.7.7 Wheel Spin/Slide Detection and Correction Provide a wheel spin/slide system complying with the following: 1. Performance: a. Detect and correct wheel spin and slide on all wheels of the vehicle, both in acceleration and braking. b. Spin/slide protection shall be active in all motoring and braking modes except for emergency braking. 2. Safety: a. Design the system for safe operation such that a spin/slide system failure shall not prevent the application of braking at any level less than desired, in any braking mode. b. Include a safety supervision algorithm to override the brake release on a per truck basis if a slide condition is determined to be excessive, subject to the Owner’s approval. 3. Detection: a. The system shall detect both individual and synchronous slides or spins by evaluation of axle or wheel speed differences and axle/wheel acceleration/decelerations. b. The system shall use the speed information from all axles (including stub axles) of the vehicle. c. The system shall detect a locked axle or loss of speed sensor. d. The system shall modify the deceleration detection level during track brake applications. 4. Correction: a. Spin/slide correction shall use modern methods of tractive effort modulation that are in proportion to the magnitude of the detected spin or slide. b. Sanding shall be applied automatically during correction of major spins and slides. Sanding shall be cancelled at no-motion or if the spin/slide condition is corrected. c. Removal of effort shall not be jerk limited during spin/slide corrections. d. The correction system shall function as specified independent of wheel diameter differences. 5. Efficiency: a. Minimum 90% at all adhesion levels down to and including 5%, as measured by an inertial accelerometer on rails with artificially reduced adhesion. b. Calculate efficiency as the ratio of actual acceleration to achievable acceleration, using an approved calculation method. c. Take measurements only during periods of actual spin/slide activity when wheels are spinning or sliding. 2.7.8 Jerk Limits Comply with the following: 1. Rate of change in acceleration (jerk): Actively limit to 2.0 m/s³, or other agreed value. 2. Jerk limiting applies: a. During all requested changes in power and brake efforts b. To all normal power and service braking applications LTK Standard Streetcar Specifications Section 2 15 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 3. Jerk limiting does not apply: a. During emergency brake applications b. To friction brake release at less than 5 km/h (3 mph) c. Where rate of change request is less than the jerk limit: The system shall follow the command signal rate of change within specified accuracy limits 4. Jerk limiting cancellation: a. For direct mode change between Power and Brake via master controller, cancel jerk limiting of power removal when the master controller reaches any brake position. b. For direct mode change between Brake and Power via master controller, cancel jerk limiting out of brake when the master controller reaches any power position. 2.7.9 Mode Change Dead Times (MCDT) Comply with the following: 1. MCDT: Less than 400 ms for the following direct mode changes: a. b. c. d. e. Power to Coast Power to Brake Coast to Brake Coast to Power Brake to Coast 2. MCDT for Brake to Power: a. Braking fully dynamic: 400 ms b. Friction brakes involved: 800 ms c. If traction motors must be magnetized: Less than 1 second, as approved by the Owner 3. MCDT for EB: 400 ms or less, regardless of original mode. 4. Measurement of MCDT: From the time that the control line(s) change(s) state, until the vehicle has achieved 10% of the requested acceleration or deceleration. 2.7.10 No-Motion Detection System Provide a no-motion detection system complying with the following: 1. Range: Detect vehicle motion down to, and including, 1 km/h (0.6 mph). 2. Safe signal: Provide a signal to indicate no-motion state, for other vehicle systems that require such information. 3. Redundancy: System shall monitor all axles and include at least two independent circuits to generate the no-motion state. 2.7.11 Speed Sensing Provide and integrate speed sensing devices for all systems that require speed information, and as specified: 1. Systems may share speed information if buffering and isolation between signals is provided, and only as approved. 2. Integrate systems’ requirements to minimize the types of sensors. 3. Select sensor types and installation methods such that mechanical adjustments are not required for installation or replacement. LTK Standard Streetcar Specifications Section 2 16 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 4. Incorporate speed sensors into truck or gearbox designs, as appropriate: a. Speed sensors shall not be shared among systems, except as approved. b. Provide at least one spare sensor port on each truck for each sensor type. 5. Speed sensing devices shall meet the requirements of Section 10, Propulsion System and Control. 2.7.12 Rollback Prevention Configure the propulsion and braking systems and provide sufficiently precise controls to prevent the vehicle from rolling in a direction opposite to that selected by the reverser on any specified grade: 1. Accelerating from a stop: a. Limit vehicle rollback until motor torque is sufficient to hold or move the vehicle. b. Maximum rollback distance (AW3 vehicle): 400 mm (16 in). 2. Moving MC from motoring to coast: a. Detect and prevent rollback either by maintaining motor torque to hold the vehicle at zero speed, or by applying friction brakes upon detection of reverse motion. b. Maximum rollback distance (AW3 vehicle): 400 mm (16 in). c. Maximum speed during rollback (AW3 vehicle): 1.6 km/h (1 mph). 2.7.13 Duty Cycle The vehicle shall operate on the intended alignment, under worst case ambient conditions, without exceeding the thermal ratings of equipment. 2.7.13.1 Normal Duty The vehicle shall be capable of operating continuously over the specified alignment, in all directions, at AW3 passenger loading, on the following duty cycle: 1. 2. 3. 4. 5. 6. Full power acceleration to the civil speed for each track segment (except as noted below). Maintaining that speed until brake. Full service deceleration to a stop. Eight-second dwell time at each station. Two-minute layover at each end of the line. For traffic stops, see Appendix C. 2.7.13.2 Abnormal Duty Comply with the following: 1. An operating vehicle shall have the capacity to tow or push an inoperative vehicle as follows: a. Operating vehicle: • • Full acceleration and braking tractive effort AW0 weight b. Inoperative vehicle: • • Brakes released (not functional) AW3 weight LTK Standard Streetcar Specifications Section 2 17 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria c. Operating vehicle performs the following: • • Tows or pushes inoperative vehicle to the next available unloading location Moves empty vehicle to Shop via worst case (most severe duty cycle) routing 2. Dynamic braking on a vehicle or truck inoperative: a. A maximum operating speed restriction may be imposed, as specified in the Dynamic Brake Failure section, above. b. Vehicle shall have the capacity to perform the following: • • Travel to the next station at the restricted speed with AW2 load weight Travel from that station to the Shop at the restricted speed with AW0 load weight 2.7.14 System Redundancy and Recovery Comply with the following: 1. Configure the vehicle such that it can continue to operate under failure conditions: a. Provide devices and procedures to disable the failed system and allow the remaining systems to continue operation. b. Performance may be limited, except where specifically indicated otherwise. 2. The following systems shall be physically and functionally redundant and share no components except where specifically permitted: a. b. c. d. Propulsion Friction braking HVAC AC and dc power sources (see Section 9, Electrical Equipment, for allowed alternative arrangements) Specific requirements for each system are provided elsewhere in the Specifications. 2.8 Noise and Vibration Limits 2.8.1 General Unless otherwise noted, specified noise limits apply to equipment that operates on a regular basis and do not apply to equipment that operates infrequently, such as a circuit breaker or pneumatic pressure relief device. Perform sound measurements as specified in Section 15, Testing. 2.8.2 Pure Tones The maximum allowable noise levels specified below shall be reduced by at least 3 5 dB under the following circumstances: 1. Significant pure tones in the range from 250 500 Hz to 8,000 Hz are present in the noise. 2. Pure tone noise shall be considered significant in this context if any one-third octave band sound pressure level is 3 dB, or more, higher than the arithmetic average of the two adjacent bands containing no pure tones. LTK Standard Streetcar Specifications Section 2 18 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.8.3 Interior Noise Limits Interior Noise Limits Limit 68 dBA Location Interior Conditions Vehicle stationary, windows and doors closed, air conditioning equipment operating in full cool, and all auxiliary equipment operating simultaneously under normal operating conditions. 65 dBA Cab, at seated operator’s ear height Vehicle stationary, windows and doors closed, and air conditioning equipment operating in cooling mode. 75 dBA Interior Vehicle operating on the Project alignment, on smooth rail, at any speed up to 56 km/h (35 mph), and under any acceleration or deceleration condition. 48 dBA 300 mm (12 in) from any lighting fixture Fixtures installed and energized at rated voltage and frequency. 2.8.4 Wayside Noise Limits Wayside Noise Limits Limit Conditions 70 dBA Vehicle stationary and empty, air conditioning equipment operating in full cool, and all auxiliary equipment operating simultaneously under normal conditions. 75 dBA Vehicle operating on the Project alignment, on smooth rail, at any speed up to 56 km/h (35 mph), under any acceleration or deceleration condition. See Section 15, Testing, for detailed noise testing parameters. 2.8.5 Vibration Limits Comply with the following interior vibration limits: Frequency Below 1.4 Hz 1.4 Hz to 20 Hz Above 20 Hz Interior Vibration Limits Vibration Limit Maximum deflection (peak-to-peak): 2.5 mm (3/32 in) Peak acceleration: 0.1 m/s² Peak velocity: 0.75 mm/s Vehicle equipment operation shall not cause visible or audible vibrations: 1. Anywhere on the vehicle floor, walls, ceiling panels, or seat frames 2. At any specified operating speed 3. Under any acceleration or braking condition except emergency braking LTK Standard Streetcar Specifications Section 2 19 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.8.6 Effects of Vibration on Vehicle Equipment Comply with the following: 1. Equipment shall operate without damage or degradation of performance when subjected to vibration and impacts encountered during normal service. 2. Equipment shall comply with IEC 61373, including functional and durability requirements. 2.9 Ride Quality Provide ride quality according to ISO 2631 as applicable to the rail vehicle design: 1. Root mean square (rms) acceleration values: Maximum 0.32 m/s² for each measurement point for operators and passengers, seated or standing. 2. Vibration total value (root sum of squares summation): Maximum 0.5 m/s² for each when calculated for each measurement point. 3. Evaluate acceleration data over the range of 0.5 Hz to 80 Hz. Where appropriate, use frequency weighting Wb instead of Wk. 2.10 Electromagnetic Interference (EMI) and Compatibility (EMC) 2.10.1 General The vehicle, its systems, and its components shall not cause electromagnetic interference that results in malfunctions of the following: 1. Onboard equipment and systems. 2. Existing vehicles on the Project alignment. 3. Existing and new wayside equipment, including the following: a. b. c. d. Signaling system Train to wayside communications GPS/automatic vehicle location system Traffic signal controllers Limit vehicle emissions as defined below, and verify by test as specified in Section 15, Testing. 2.10.2 Design and Implementation Comply with the following requirements: 1. Limit and apportion individual equipment emissions as necessary to limit point-source emissions and to achieve defined vehicle limits. 2. To contain EMI emissions, wherever possible, suppress transients at their source. 3. Employ design techniques, construction methods, and whatever equipment is required to prevent interference caused by internal sources from affecting the proper operation of vehicle and external systems: a. Coordinate frequencies, EMI levels, and susceptibility levels. b. Provide necessary on-board grounding, balancing, filtering, shielding, modulating techniques, and isolation to meet the requirements of this Section. c. Employ electrostatic and magnetic shielding methods to minimize the effect of stray signals and transient voltages on interconnecting cables. d. Physically separate power and signal cables. LTK Standard Streetcar Specifications Section 2 20 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.10.3 Individual Subsystems 2.10.3.1 General EMC Compliance Each individual subsystem containing electronics shall comply with all applicable requirements of EN 50121-3-2 and shall be tested for compliance in an EMC testing laboratory, in accordance with Section 15, Testing. Electronic components and assemblies classified as intentional radiators in accordance with 47 CFR 15.3, Definitions, shall comply with provisions of 47 CFR 15 or 47 CFR 90, as applicable for specific devices and their operating frequencies. Irrespective of qualification test results, Contractor shall be responsible to resolve EMC issues arising from operation of equipment in service as provided in 47 CFR 15.5, General conditions of operation. 2.10.3.2 Conductive and Inductive Emissions Each OCS-powered subsystem shall comply with conductive emissions limits into high-voltage supply, as apportioned by the Contractor, in order to meet vehicle-level allocations per the Conductive Emission Limits section, below. Each individual unit of power equipment shall meet the limits indicated below for vehicle-level inductive emission limits into the loop formed by the vehicle and running rails. 2.10.4 Vehicle-Level 2.10.4.1 Radiated Emission Limits Vehicle radiated emissions shall not exceed the limits defined by the standards and regulations indicated in the table below, when measured in accordance with Section 15, Testing. If a conflict exists at a given frequency, the more stringent limit shall apply. Frequency 9 kHz to 150 kHz 150 kHz to 1 GHz: 1 GHz to 6 GHz Radiated Emission Limits Limit EN 50121-3-1, Annex C, Emission values for lower frequency range EN 50121-3-1 EN 50121-3-2, Table 3, Emission - Enclosure port Notes to Table: 1. See Section 15, Testing, for measurement methods. LTK Standard Streetcar Specifications Section 2 21 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.10.4.2 Conductive Emission Limits Conductive emissions shall have a current limit (amperes rms) defined as follows, when measured in accordance with Section 15: Frequency 30 Hz to 40 Hz: 40 Hz to 120 Hz: 120 Hz to 320 Hz: 320 Hz to 600 Hz: 600 Hz to 7 kHz: 7 kHz to 31 kHz: 31 kHz to 120 kHz: Conductive Emission Limits Limit 10 A maximum 2 A maximum 10 A maximum 2 A maximum Limit follows a smooth curve through 2 A at 600 Hz, 0.08 A at 2 kHz, 0.016 A at 4 kHz and 0.0046 A at 7 kHz 4.6 mA 0.5 mA 2.10.4.3 Inductive Emission Limits The inductive emissions shall be limited as follows, when tested in accordance with Section 15: Frequency 20 Hz to 20 kHz: 20 kHz to 31 kHz: 31 kHz to 120 kHz: Inductive Emission Limits Limit 20 mV rms, rail-to-rail maximum Linear decrease from 20 mV rms to 1 mV rms 1 mV rms maximum 2.11 Vehicle Safety 2.11.1 General Design and construct the vehicle to be safe to passengers, persons nearby, and the Owner’s employees, both under normal operating conditions, and in the event of equipment failure: 1. Perform the required safety analyses and apply safety design requirements. 2. Ensure that all systems' safety aspects have been considered for each individual system, and for systems integrated to complete the vehicle design. 3. Ensure that the vehicle meets the requirements of NFPA 130. 4. Terms used have the following meanings: a. Device: Includes any component, subsystem, or system, whether electrical, mechanical, pneumatic, or hydraulic. b. Failure: Includes both the initial device failure and consequential device failures caused by the initial failure. c. Hazard: A real or potential condition that can cause injury, death, or damage to or loss of equipment or property. d. Permissive: Potential system response that results in a less safe condition such as proceed versus stop, a higher speed versus a lower speed, acceleration versus deceleration, brakes released versus brakes applied, or no actuation of alarm versus actuation of alarm. e. Restrictive: Potential system response that results in a more safe condition such as stop versus proceed, a lower speed versus a higher speed, deceleration versus acceleration, brakes applied versus brakes released, or actuation of alarm versus no actuation of alarm. LTK Standard Streetcar Specifications Section 2 22 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.11.2 Vehicle Safety Analyses 2.11.2.1 Hazard Listing Identify all failure-induced and normal operating (non-failure condition) hazards. In addition to those hazards identified by the Contractor, the following hazards shall be included in the hazard listing and shall be considered hazards: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Emergency brake fails to apply when requested Service brakes fail to apply when requested Propulsion fails to cease when requested No-motion detection system indicates no-motion when vehicle is moving Door opens spontaneously when not commanded Door opens on the wrong side of the vehicle Door closes on an obstacle and indicates door closed and locked to control system Door interlocks erroneously indicate door is closed and locked Excessive currents or overheated equipment cause fire Vehicle moves in wrong direction 2.11.2.2 Hazard Analyses Perform hazard analyses on each hazard in the hazard listing: 1. Analyses shall demonstrate that the vehicle conforms to the requirements of the Specifications and that all identified hazards are either eliminated or reduced to levels of risk in accordance with Federal Transit Administration document DOT-FTA-MA-26-5005-00-01. 2. Adjust or amend hazard analyses as the vehicle design and construction progresses. 3. Select the analysis methods as appropriate for the system under evaluation and the hazard severity, subject to approval by the Owner. Demonstrate, by test, the validity of any portion of analyses if requested by the Owner. 4. Use standard failure and safety analysis methods and published failure rates for components wherever possible. 5. For each hazard in the hazard listing, submit design documentation. If the design is modified to mitigate a hazard, submit construction documentation. 6. Existing hazard analyses of like equipment operating under like conditions may be offered in lieu of performing a complete analysis of proposed equipment, subject to the Owner's approval. 2.11.2.3 Mitigation of Hazards Resolve failure-induced and normal operating (non-failure condition) hazards such that the likelihood of injury or damage is remote or improbable: 1. Employ high quality components, proven systems, redundancy, checking devices, and other techniques to resolve hazards. 2. Design and construct vehicle equipment and systems to revert to safe modes under failure conditions. 3. Apply design principles in the Safety Design Principles section, below, to vehicle systems, the failure of which could result in injury to a person or damage to equipment. 4. Prevent unsafe conditions resulting from human error: a. No sequence of operations, or the simultaneous activation of any controls, shall result in unsafe conditions. LTK Standard Streetcar Specifications Section 2 23 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria b. Where conflicting commands, such as simultaneous power and brake, are requested, the more restrictive shall result. c. Arrange maintenance of safety-related equipment such that the effects of errors are minimized. Employ methods such as limitation of adjustment ranges, unalterable software, non-interchangeable parts, and visible wear indicators. 2.11.3 Vehicle Safety Design 2.11.3.1 Safety Under Normal Operating and Maintenance Conditions Comply with the following: 1. Protect passengers and operators from hazards: a. Eliminate tripping hazards, pinching hazards, sharp points and edges, lethal or injurious voltages, toxic materials, abrupt or unexpected accelerations, or similar hazards. b. Enhance visibility of step edges, windscreens, controls, and other objects with which the passengers and operators must interface via appropriate selections of location, illumination levels, colors, graphics, and surface finishes. c. Clearly identify normal and emergency equipment and controls that the passengers or operators may operate, and where required, provide operating procedures in both printed and graphic formats. 2. Protect maintenance and operating staff from hazards: a. Manuals and training materials: Clearly identify hazardous materials and equipment and indicate their proper handling, storage, and disposal. b. Maintenance procedures: Clearly identify hazards and provide instructions to reduce or eliminate hazards during the procedure. c. High voltage: Reduce exposure of maintenance personnel to lethal or injurious voltages through compartmentalization, interlocks, and similar measures. d. Cutting hazards: Equipment shall be free from sharp points and edges. e. Signage: Clearly label equipment containing hazardous materials, lethal or injurious voltages, or other risks on both the outside and inside of the equipment. 2.11.3.2 Safety Design Principles Incorporate the following design principles into vehicle systems affecting safety: 1. Service proven: Use only components with high reliability and predictable failure modes that have been proven in conditions similar to the projected service. 2. Vehicle environment: Systems shall function safely under all combinations of supply voltages, fluid pressures, shock, vibration, dirt accumulation, and the Project environment. 3. Devices: a. Use vital devices, that is, devices with known, guaranteed-by-the-manufacturer failure modes, such as signal grade relays, combined in circuits in such a way that the requirements of this Section are met. b. The failure of a single device shall not result in a permissive condition. c. An undetected failure of any device shall not permit a subsequent device failure to result in a permissive condition. LTK Standard Streetcar Specifications Section 2 24 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 4. Circuits: a. Assume electronic circuits are capable of failing in permissive modes. b. Base systems on closed circuit principles in which energized circuits result in permissive conditions, while interrupted or de-energized circuits result in restrictive conditions. c. Vital circuits not wholly within the system apparatus enclosure shall be double-wire, doublebreak, with the exception of connections to non-vital circuits, which may be single-wire, single-break. d. A component or wire becoming grounded shall not cause a permissive condition. Keep safety circuits free of any combination of grounds that could permit a flow of current equal to, or in excess of, 75% of the release value of any safety device in the circuit. e. Select circuit impedances, signal encoding, shielding, layout, and isolation to reduce the effects of interference to the extent that safety is maintained under all conditions. 5. Channels: a. Provide independent channels with independent checking of each. b. All channels shall indicate a permissive state in order for the controlled system to achieve a permissive state. c. Failure in any channel shall not affect any other channel, or force the system into a permissive state, unless other actions are required by other parts of the Specifications. d. Differences in state between channels shall be alarmed and shall force a restrictive state on the system. 6. Signals: a. Commands that result in permissive conditions shall be propagated by minimum two independent signals. b. For a controlled system to achieve a permissive state, all signals shall indicate a permissive state. The lack of one or more output signal(s) shall be interpreted as a restrictive command. c. Variable-level signals: • • Arrange systems such that zero signal level results in the most restrictive condition. Minimum one enabling signal, independent from the variable-control signal, shall be present before the control signal can modulate the system to a more permissive level. 7. Overcurrent protection: a. Circuit breakers and fuses shall be guaranteed by the manufacturer to successfully interrupt rated currents. b. Apply circuit breakers and fuses such that the maximum circuit fault currents cannot exceed the manufacturer's guaranteed operating ranges. 8. Software: Considered unsafe unless verified as safe by an approved method. Approved methods shall comply with the requirements of IEEE 1483 or EN 50128. 9. Structural: Systems that rely on structural integrity for safety shall have sufficient safety factors such that failures are not possible within the life of the vehicle under all possible normal conditions. LTK Standard Streetcar Specifications Section 2 25 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 10. Mechanical: a. Systems that apply force to achieve safe states shall not depend upon the application of fluid pressure or electrical energy, unless specifically approved. b. Locks, catches, and similar devices affecting safety shall be either self-engaging without application of power or, if engaged by application of power, shall remain fully and safely engaged in the absence of power. 11. Wear: a. Systems and devices subject to wear shall not wear to permissive states within a time period equal to minimum three times the recommended and approved overhaul period under the worst-case combination of duty cycle, environment, and all other influences. b. Clearly indicate such systems and devices as SAFETY CRITICAL in the maintenance manuals. 12. Identification: Clearly identify safety related systems, and devices within those systems, as SAFETY CRITICAL in operation and maintenance manuals, procedures, and training materials. 13. False indications: a. Failures in equipment that result in an indication of danger, whether or not actual danger exists, shall be considered to have occurred in a safe manner. b. A failure that results in an indication of safety when, in fact, a dangerous condition may exist, shall not be considered safe. 2.11.3.3 Fire and Life Safety Design Comply with the following: 1. Design vehicle components, subsystems, and systems per NFPA 130 for the following: a. Prevention of fire and protection of the public, employees, and emergency response personnel from injury due to fire, smoke, explosion, or panic due to these occurrences b. Protection of system elements from damage by fire or explosion 2. Whenever practical, locate equipment outside the passenger compartment, unless specified otherwise, to isolate potential ignition sources from combustible materials. 3. Design the articulation, floor, sides, and roof to retard propagation of an underfloor or roof fire to the vehicle interior. Provide fire-stops at floor and roof penetrations. 2.11.4 Safety Certification Support The Federal Transit Administration (FTA) requires a certification program to address safety and security. A Safety Certification process will be implemented by the Owner to certify the delivered vehicles: 1. Comply with and support the requirements of the Safety Certification process. 2. Participate in the Safety Certification process and furnish supporting documentation to facilitate required audits of the Safety Certification documentation, as required, by the Department of Transportation and the FTA. 3. The Conditional Acceptance and final determination of readiness of delivered vehicles for revenue service is contingent upon completion of Safety Certification. 2.12 Testability and Accessibility Comply with the following: 1. Provide serial connectors on each individual system to facilitate testing. LTK Standard Streetcar Specifications Section 2 26 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2. See instrumentation requirements in Section 15, Testing, and ensure coordination between equipment design and testing requirements. 3. Test and data ports shall be directly accessible without removal of equipment. No special tools or adapters shall be required for access. 2.13 Reliability 2.13.1 General This section includes the reliability demonstration and MDBF requirements. Additional reliability requirements for specific equipment may appear elsewhere in the Specifications. 2.13.2 Reliability Demonstration Demonstrate vehicle reliability during the Demonstration Period, using the approved Reliability Demonstration Plan (see CDRL section, below): 1. Demonstration Period: An agreed initial time period. Demonstrate reliability in actual revenue service during the warranty period. 2. MDBF: During the reliability demonstration, record all vehicle failures and establish the numerical reliability values (MDBF) for each system. 3. Redesign: Systems that fail to meet reliability goals during the demonstration period shall be redesigned and retrofitted by the Contractor, at the Contractor's expense, before the end of the warranty period. 2.13.3 Mean Distance Between Failures (MDBF) Vehicle systems shall meet the Mean Distance Between Failures (MDBF) requirements listed below: 1. Assumption: Maintenance, preventive and corrective, is performed as recommended by the Contractor. 2. Mean distance: MDBF is based on actual vehicle mileage, which is approximately 3525,000 miles per year, 20 hours per day. 3. Failures: Unscheduled maintenance activities resulting from equipment failures, whether occurring in revenue service or not. LTK Standard Streetcar Specifications Section 2 27 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 4. Equipment furnished by the Contractor shall be considered as belonging to one of the systems listed below: MDBF Requirements System Vehicle Body & Appointments, including seating, windows, cab equipment Propulsion, Dynamic Brake & Controls including gear case Friction Braking, including track brake and sanders Communications and passenger information Passenger Doors, Bridgeplates & Controls Lighting Fixtures and Power Supplies / Ballasts Electrical, including the vehicle network and cab controls, and apparatus not included in other systems. Excludes equipment internal to other systems. HVAC Trucks & Suspension OESS MDBF (miles per vehicle) 40,000100,000 40,00020,000 35,00017,000 75,00040,000 25,00020,000 200,000100,000 50,00030,000 60,00030,000 100,00050,000 25,000 2.14 Maintainability 2.14.1 General The vehicle shall incorporate design standards that minimize Mean Time To Repair (MTTR) and costs throughout its intended useful life. 2.14.2 MTTR Requirements The quantitative MTTR requirements for the vehicle shall consist of the following subsystem requirements: System Element Vehicle Body & Appointments Propulsion, Dynamic Brake & Controls Friction Braking Electrical HVAC Communications (except communications front end) Passenger Doors & Controls Lighting Couplers & Draft Gear Trucks & Suspension Total MTTR (hours) 2.13 1.77 1.94 1.50 2.12 0.82 0.84 0.50 1.50 1.57 14.7 Notes to Table: 1. The MTTR for each element shall be derived from Predicted Mean Time To Repair (PMTTR) analyses as required. LTK Standard Streetcar Specifications Section 2 28 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2. The Owner may approve subsystem MTTRs that take more time than specified, provided the average for any system element is not changed significantly and total MTTR hours for the vehicle are not exceeded. 2.14.3 Scheduled and Preventive Maintenance Maintenance includes the tasks necessary to service the vehicle, to defer or prevent failures, and to maximize equipment life: 1. Scheduled maintenance tasks shall be defined in the Maintenance and Servicing Manual (see Section 18, System Support), and shall be no more frequent or take more time than specified in the Service Levels Schedule, below. 2. The Contractor's Reliability Demonstration and Maintainability Demonstration shall assume the service levels specified in the Service Levels Schedule, below, with no augmentation. Service Levels Schedule Cycle (Operating Miles) 1,000 10,000 20,000 30,000 150,000 300,000 Scheduled Maintenance Person (in Hours) 6 8 24 36 50 1200 (First Major Overhaul) Notes to Table: 1. An exception is made for HVAC filter maintenance, which may occur at 5,000 mile intervals, or greater. 2. Scheduled activities during the 10,000 mile cycle shall be limited to inspection, filter cleaning or replacement, and replacement of consumables. 3. Ensure that maintenance requirements for vehicle equipment have been established through the operating and maintenance training and manual publication. The Owner will verify that this schedule can be achieved three months after Final Acceptance of the first vehicle. 2.14.4 Maintainability Demonstration As part of the training program for maintenance personnel, verify that durations of maintenance tasks fall within the times established by the Scheduled Maintenance Plan (see CDRLs, below): 1. Demonstrate the following and record the duration of each task: a. Selected servicing, scheduled and preventive maintenance, troubleshooting, change-out of components, corrective maintenance, and use of special tools, where special emphasis, instruction, or proficiency is needed. b. Vehicle movement under disabling conditions. LTK Standard Streetcar Specifications Section 2 29 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2.15 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. Detail drawings: Top level assemblies, and other drawings if requested 2. Functional description 3. Component ratings: Top level components, and ratings of other components if requested 2-1 General Arrangement Drawings: 1. Plan, profile, and front elevation drawings of the vehicle exterior, showing visible features, with dimensions. 2. Plan view of seating arrangement, including seat dimensions and spacing, aisle widths, accessible on-board circulation path, mobility aid parking areas, bicycle areas, and doorway dimensions. 3. Longitudinal section drawings of the vehicle, showing seating arrangements, stanchions, interior steps, cab, and similar features. 4. Plan view drawing of roof equipment, with dimensions. 5. Plan view drawing of under-floor equipment, including trucks, with dimensions. 2-2 Vehicle Detail Dimensions: 1. Detail drawings of vehicle and systems: a. Show compliance with specified Vehicle Weights and Dimensions. b. Include the location of center of gravity, with vertical, lateral, and longitudinal coordinates. 2-3 Weight Plan and Calculations: 1. Plan view of the vehicle showing standing space. 2. Calculations for each of the weights AW0 through AW4. 2-4 Vehicle Excursions: 1. Drawings showing dynamic vertical and horizontal excursions of the vehicle under normal and worst case conditions of truck and suspension motions and vehicle body roll on tangent track: a. Show vehicle clearance dimensions with maximum suspension deflection and maximum body roll. b. Identify the location of the roll center(s). 2-5 Vehicle Curve Capabilities: 1. Evidence that the vehicle can operate within specified limits on the specified horizontal and vertical curve radii. 2-6 No-Motion Detection Design Package 2-7 EMI/EMC Design Package: 1. Description of the design approach used to ensure that specified EMC and EMI requirements are met and that proper emphasis is placed on the control of interference, interface design, and FCC requirements. LTK Standard Streetcar Specifications Section 2 30 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 2. List of vehicle-borne EMI sources. 3. List of vehicle-borne equipment potentially susceptible to this interference. 4. Failure conditions, proposed techniques and methods for resolution of potential EMC problems. 2-8 Vehicle Safety Design Package: 1. Plans, documents, and analyses demonstrating that the vehicle is safe, and complies with this Section, and other safety requirements in the Specifications. 2. At a minimum, include the following: a. A system safety plan, delineating the steps and processes that will be used by the Contractor to ensure vehicle safety. b. A hazard listing, as described in this Section. c. Failure analyses, both top-down and bottom-up, as appropriate and as approved, demonstrating that the hazards identified will not occur. d. Other analyses, drawings, material property data sheets, or other information appropriate for demonstrating safety. 2-9 Mitigation of Hazards Design Documentation: 1. Changes that were made to the design to mitigate hazards identified during the Vehicle Safety Analysis. 2-10 Mitigation of Hazards Construction Documentation: 1. Evidence that design changes made to mitigate hazards were implemented during construction, as applicable. 2-11 Predicted Reliability Design Package: 1. Predicted reliability of each system, with supporting data. 2-12 Reliability Demonstration Plan: 1. Submit before the start of revenue service. 2. Methods of collecting failure data, analysis of failures, and assignment of failures to the appropriate system, corrective action processes, and similar processes. 3. Processes by which corrective actions are applied to systems that fail to meet reliability goals. 2-13 Predicted MTTR: 1. Predicted MTTR of indicated systems, with supporting data 2-14 Scheduled Maintenance Plan: 1. Schedules and activities for the vehicle's corrective and preventive maintenance recommended by the Contractor and its equipment suppliers. 2. Include the following: a. b. c. d. Outline of each maintenance task Time schedules Recommended tools Personnel and skill levels required 3. Periodic updates as required. LTK Standard Streetcar Specifications Section 2 31 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Design and Performance Criteria 4. Verification that actual durations of specified maintenance tasks demonstrated during training fell within the times established. END OF SECTION LTK Standard Streetcar Specifications Section 2 32 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure Table of Contents 3.1 General ........................................................................................................................................1 3.1.1 Scope ................................................................................................................................................ 1 3.1.2 Configuration ................................................................................................................................... 1 3.1.3 Materials .......................................................................................................................................... 1 3.1.4 Venting and Drainage....................................................................................................................... 1 3.1.5 Definitions ........................................................................................................................................ 1 3.1.6 Verification of Design ....................................................................................................................... 2 3.2 Structure Arrangements ...............................................................................................................2 3.2.1 General ............................................................................................................................................. 2 3.2.2 Front End .......................................................................................................................................... 2 3.2.2.1 Front End Frame Structure ....................................................................................................... 2 3.2.2.2 Anticlimber................................................................................................................................ 3 3.2.2.3 Front End Enclosure .................................................................................................................. 3 3.2.3 Floor ................................................................................................................................................. 4 3.2.3.1 General...................................................................................................................................... 4 3.2.3.2 Floor Structure .......................................................................................................................... 4 3.2.3.3 Floor Profile............................................................................................................................... 4 3.2.3.4 Floor Fire Requirements ........................................................................................................... 4 3.2.3.5 Sub-Floor ................................................................................................................................... 4 3.2.3.6 Floor Insulation ......................................................................................................................... 5 3.2.4 Roof .................................................................................................................................................. 5 3.2.4.1 General...................................................................................................................................... 5 3.2.4.2 Roof Fire Requirements ............................................................................................................ 5 3.2.4.3 Roof Equipment ........................................................................................................................ 5 3.2.5 Articulation....................................................................................................................................... 5 3.2.6 Jacking Pads and Hoists.................................................................................................................... 6 3.3 Shrouds and Skirts ........................................................................................................................6 3.3.1 Roof Shroud ..................................................................................................................................... 6 3.3.2 Skirts ................................................................................................................................................. 6 3.4 Structural Design Requirements....................................................................................................7 3.4.1 General ............................................................................................................................................. 7 3.4.2 Interoperability ................................................................................................................................ 8 3.4.2.1 General...................................................................................................................................... 8 LTK Standard Streetcar Specifications Section 3 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.4.2.2 Energy Absorbing Bumper, OPTIONAL ..................................................................................... 8 3.4.2.3 Project-Specific Requirements.................................................................................................. 8 3.4.3 CEM Option ...................................................................................................................................... 8 3.4.3.1 Design ....................................................................................................................................... 8 3.4.3.2 Crashworthiness Analysis ......................................................................................................... 9 3.4.3.3 Crashworthiness Analysis Interactive Review .......................................................................... 9 3.4.4 Vertical Design Load Strength Requirements .................................................................................. 9 3.4.4.1 Static Load................................................................................................................................. 9 3.4.4.2 Fatigue Load .............................................................................................................................. 9 3.4.5 End Sill Compression Loads ............................................................................................................ 10 3.4.6 Coupler Anchorage......................................................................................................................... 10 3.4.6.1 Coupler Anchor Compression Load ........................................................................................ 10 3.4.6.2 Coupler Anchor Tensile Load .................................................................................................. 10 3.4.7 Collision Posts ................................................................................................................................ 10 3.4.7.1 Design ..................................................................................................................................... 10 3.4.7.2 Collision Post Shear Load ........................................................................................................ 11 3.4.7.3 Collision Post Load .................................................................................................................. 11 3.4.8 Corner Posts ................................................................................................................................... 11 3.4.8.1 Design ..................................................................................................................................... 11 3.4.8.2 Corner Post Shear Load........................................................................................................... 11 3.4.8.3 Corner Post Load..................................................................................................................... 12 3.4.9 Structural Shelf............................................................................................................................... 12 3.4.10 Side Wall....................................................................................................................................... 12 3.4.10.1 Side Wall Load at Side Sill ..................................................................................................... 12 3.4.10.2 Side Wall Load at Belt Rail .................................................................................................... 12 3.4.11 Articulation Joint Anticlimber Loads ............................................................................................ 12 3.4.12 Floor Load..................................................................................................................................... 13 3.4.13 Roof Load ..................................................................................................................................... 13 3.4.14 Truck-to-Vehicle-Body Attachment ............................................................................................. 13 3.4.15 Equipment .................................................................................................................................... 13 3.4.15.1 Equipment Loads .................................................................................................................. 13 3.4.15.2 Equipment Fasteners and Supports...................................................................................... 14 3.4.16 Jacking and Hoisting Loads........................................................................................................... 14 3.4.17 Steps ............................................................................................................................................. 14 LTK Standard Streetcar Specifications Section 3 ii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.4.18 Natural Frequency........................................................................................................................ 15 3.5 Stress Analysis............................................................................................................................ 15 3.5.1 Purpose .......................................................................................................................................... 15 3.5.2 General ........................................................................................................................................... 15 3.5.3 Stress Analysis Content .................................................................................................................. 15 3.5.4 Initial Stress Analysis ...................................................................................................................... 15 3.5.5 Buckling Analysis ............................................................................................................................ 15 3.5.6 Finite Element Analysis (FEA) ......................................................................................................... 16 3.5.7 Validation of Linear Elastic Analysis ............................................................................................... 16 3.6 Contract Data Requirements List (CDRL)...................................................................................... 16 LTK Standard Streetcar Specifications Section 3 iii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.1 General 3.1.1 Scope These requirements apply to all vehicle structural elements above the trucks, including articulation joints and related structures, and any equipment mounting point but exclusive of any composite body cladding panels, if used, except as noted. 3.1.2 Configuration Configure vehicle as specified in Section 2, Design and Performance Criteria. 1. Body sections: Articulated and semi-permanently coupled together with articulating joints to form a single operating vehicle. 2. Vehicle structures: Construct according to the methods and requirements below. 3. Clearance: Design vehicle and attached equipment to provide specified wayside clearances for the specified track profiles, and specified vehicle/truck clearances, except for stops attached to the vehicle body for limiting truck movement. 4. Weight: Optimize the vehicle-body structure for minimum weight. 3.1.3 Materials Comply with the following requirements: 1. Vehicle structures: Aluminum, high-strength low-alloy (HSLA) steel, stainless steel, or a combination of these materials. 2. Vehicle non-structural exterior elements: May be glass-fiber reinforced plastic (FRP) or similar service-proven materials. 3. For specific material and painting requirements, see Section 16, Materials and Workmanship. 3.1.4 Venting and Drainage Provide venting and drainage throughout the vehicle body to prevent build-up of condensation: 1. Vent enclosed structural cavities. 2. If subject to rusting or oxidation, treat in accordance with the paint and coating requirements of Section 16, Materials and Workmanship. 3.1.5 Definitions The following definitions apply to terms used in this section: Failure The complete separation of a member such that it can no longer perform its intended function–the rupture point on the stress-strain curve. Load Factor A number by which the actual or specified load is multiplied in computing the calculated stress. The load factor shall include all applicable safety factors. Margin of Safety (MS) MS = Allowable Stress Calculated Stress LTK Standard Streetcar Specifications Section 3 -1 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure The calculated stress shall include the applicable load factors. MS shall be a minimum value, but a positive number. Permanent Deformation A member shall be considered as having developed permanent deformation if one of the following conditions is met: 1. The minimum yield strength as published by ASTM for the specified material and grade is exceeded. 2. For materials or grades not covered by an ASTM specification, the minimum yield strength as guaranteed by the manufacturer is exceeded. 3. The material has buckled or deformed and will not return to its original shape or position after the load is released. For materials without a specific yield point, the 0.2% offset method shall be used to determine yield strength. Ultimate Load Carrying Capacity The maximum load that a member can support, or before it completely fails as a column. 3.1.6 Verification of Design Verify the design as follows: 1. Perform any required analyses; 2. Perform tests on the finished vehicle in accordance with Section 15, Testing, to verify conformance of vehicle structures with Specification requirements and requirements of the Contractor's design, and validate the design analysis. 3.2 Structure Arrangements 3.2.1 General Comply with the following general requirements: 1. Design portions of the roof, side frame, and underframe to form a girder to carry the specified static and dynamic loads. 2. Select type and thickness of material to be used to maximize strength and reliability, minimize weight, and produce the desired appearance. 3. Incorporate tie down points into the vehicle in order to secure the vehicle for shipment and for body straightening after an accident. 3.2.2 Front End 3.2.2.1 Front End Frame Structure Comply with the following requirements: 1. Provide a front end frame structure consisting of the following: a. Partial height collision posts at the approximate one-third points (horizontal plane) of the end frame (but in any case maximum 915 mm (36 in) apart) welded to the top and bottom of the end sill; b. Structural corner posts at each extreme vehicle body corner welded to the top and bottom of the end sill; LTK Standard Streetcar Specifications Section 3 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure c. A horizontal beam ("structural shelf") at the bottom of the windshield tying the tops of the collision posts to each other and to the corner posts. 2. The design shall accommodate a wide, single-piece windshield that maximizes operator field of view and compliments the approved appearance. 3. Crashworthiness: a. Securely weld the above elements to the end frame sheathing to resist telescoping in collisions such that the connection can support the ultimate strength of the members supporting structure. b. Provide equivalent anti-telescoping and crashworthy elements at the articulation joint and support structure. Alternative structural arrangements with equal or better performance may be proposed, with appropriate supporting technical justification, for the Owner's approval. 3.2.2.2 Anticlimber Provide anticlimbers at each end of the vehicle that comply with the following requirements: 1. Location: Extended laterally over the full width of the vehicle front end frame. 2. Connection: Welded or bolted to the end sill. 3. Width: Sufficient to engage the anticlimber of an opposing vehicle under the worst horizontal track curves. 4. Height and Configuration: a. Such that opposing anticlimbers of like vehicles or other rail vehicles sharing the route engage over the full range of vertical vehicle-body motions. b. Where necessary to accommodate interoperability with multiple types of rail vehicles, provide additional anticlimber engaging adapters that meet the same requirements as those specified for the anticlimber. 5. Jacking pad: Provide under the center of each anticlimber. 6. Cover: Frangible plastic to cover the anticlimber ribs and provide a visual impression similar to an automotive bumper. It shall not deter engagement of anticlimbers in a collision. 3.2.2.3 Front End Enclosure Design the front end to divert, to the extent possible, pedestrians, cyclists, and road vehicles that may be struck by a rail vehicle: 1. Enclose the front end with a full-width, smooth enclosure, designed for optimized crash compatibility. 2. Continue front end enclosure to meet the side body and skirts such that there is no gap except a flexible element, if required, to accommodate the energy-absorbing bumper. 3. Design with ground clearance as low as feasible; maximum 203 mm (8 in). 4. Coordinate the front end enclosure with the anticlimber cover and bumper to comply with design requirements and provide an overall aesthetically pleasing appearance. LTK Standard Streetcar Specifications Section 3 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.2.3 Floor 3.2.3.1 General Design and construct the floor to meet applicable noise, vibration, and strength requirements in these Specifications. 3.2.3.2 Floor Structure Comply with the following requirements for floor structure: 1. Transverse beams: Provide to transmit vertical floor loads to side sills and for support of floor panels. 2. Longitudinal beams: Provide a continuous side sill and support members. 3. Floor panels: a. Material: Phenolic composite floor panels, as specified in Section 16, Materials and Workmanship, or approved equal. b. Support: Attach to the floor beams, end sills, side sills, body sills (if used), and body bolsters, depending upon location. c. Transverse joints: Locate over structural members. d. Insulation: Provide elastomeric tape between panel and metal structure. 3.2.3.3 Floor Profile Design floor to be slightly higher at the center than the specified height at doorways to allow water to drain to the outside. See Section 2, Design and Performance Criteria, for floor height at the doorways. 3.2.3.4 Floor Fire Requirements Design floor to withstand specified fire requirements and fire performance tests specified in Section 15, Testing. If an alternate floor design is proposed, submit the following: 1. 2. 3. 4. Detailed design of the proposed floor Detailed description of the proposed standard Evidence of compliance to the standard Evidence that the proposed floor design provides safety to passengers and the operator equal to a floor compliant with the standards specified in Section 15 in the event of a vehicle fire 3.2.3.5 Sub-Floor Provide a sub-floor (floor pans) below the floor beams throughout the length of the vehicle: 1. 2. 3. 4. Design: Shall not permit the entrance of water into the vehicle body. Material: Stainless steel. Thickness: Minimum 0.5 mm (0.02 in). Assembly: Weld to bottom flanges of floor beams and to draft sills, end sills, side sills, and body bolsters. Riveting of floor pans will be allowed only if sealing of the pan can be guaranteed for the life of the vehicle. 5. Seams and edges: Permanently watertight and fireproof. If clearances prohibit the application of the subfloor pan at particular locations, alternative designs may be proposed that provide the specified fire barrier properties. LTK Standard Streetcar Specifications Section 3 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.2.3.6 Floor Insulation Comply with the following requirements: 1. Fill the space between the floor and subfloor with insulation in accordance with Section 14, Interior and Exterior Appointments. 2. If clearances provide less than normal separation between the subfloor and floor panels, alternative designs may be proposed that provide the specified thermal and acoustic insulation requirements. 3.2.4 Roof 3.2.4.1 General Construct the roof of carlines, purlines, and roof sheathing covering the entire roof area. 3.2.4.2 Roof Fire Requirements Design roof to withstand the fire performance tests specified in Section 15. If an alternate roof design for fire safety is proposed, submit the following: 1. 2. 3. 4. Detailed design of the proposed roof Detailed description of the proposed standard Evidence of compliance to the standard Evidence that the proposed roof design provides safety to passengers and the operator equal to a roof compliant with the standards specified in Section 15 in the event of a vehicle fire 3.2.4.3 Roof Equipment Comply with the following to accommodate roof-mounted equipment: 1. Provide framing members and structural wells for support of roof-mounted equipment. 2. Provide equipment wells with adequate drainage for the worst case environmental conditions described in Section 2, Design and Performance Criteria. 3. Design and install roof equipment, including wiring and pipe work, so as to present a clean and simple appearance when viewed from above. 3.2.5 Articulation Comply with the following requirements: 1. Articulation: a. Considered an integral part of the vehicle body, including during testing required by these Specifications. b. Shall provide stable connection between vehicle-body sections and maintain each body section upright on level tangent track. 2. Articulation Bellows: Cover on the inside as an integral part of the interior finish. See Section 14 for additional articulation requirements. 3. Maintenance Access: Articulation components that require periodic service, inspection, and maintenance shall be easily accessible either from the passenger compartment, side of the vehicle, or bottom of the vehicle at inspection pit. LTK Standard Streetcar Specifications Section 3 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 4. Friction Material: a. If the articulation uses friction material for rotation, it shall have adequate life over a scheduled heavy maintenance interval but not shorter than 12 months. b. Material shall provide a coefficient of friction as constant as possible so that turning at curves is smooth and consistent over time without excessive flanging of the adjacent truck. 3.2.6 Jacking Pads and Hoists Provide each vehicle-body section with jacking pads at structural points to sustain jacking loads: 1. Features: Non-slip, easy to reach. 2. Location: Consider jack placement, derailment clearances, and similar factors arising when jacking the vehicles in the shop and in the field with modern portable rerailing equipment. 3. Asymmetrical jacking: Clearly indicate limitations of any body-section in maintenance and rerailing instructions, such that cosmetic damage, deformation, or dislocation does not occur. 3.3 Shrouds and Skirts 3.3.1 Roof Shroud Roof shroud (if provided): 1. Aesthetics: Consistent with vehicle body styling. 2. Strength: Sufficient for worst case combination of specified wind and vehicle design speed. 3. Design: Shroud roof-mounted equipment so that, when viewed from the side, the vehicle will have unbroken lines at top and bottom. 4. Material: HSLA steel, aluminum, or FRP complying with Section 16, Materials and Workmanship. 5. Attachment: Secure to roof structure using mechanical fasteners removable using ordinary tools. 3.3.2 Skirts Comply with the following requirements: 1. Skirt Locations: a. Sides of the vehicle to enclose trucks, tow bar, open spaces that may be accessible by pedestrians along the right of way b. On the sides between trucks if the vehicle structure does not cover these areas 2. Specific Location Requirements: a. Skirts of high-floor areas below end sill: Carry around corners and down sides of vehicle to blend with line of bottom of vehicle in low floor area. b. Skirts of low floor areas: Form a uniform lower edge with bottom of vehicle body. c. Skirts in vicinity of trucks: May be modified to accommodate turning. d. Coordination with Front End Enclosure: Design skirts to comply with the Front End Enclosure section, above. 3. Design: Removable, not load bearing members. 4. Material: HSLA steel, aluminum, or FRP complying with Section 16. 5. Appearance: a. Skirts: Integral part of vehicle body. LTK Standard Streetcar Specifications Section 3 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure b. Ventilation openings: If required, in harmony with overall vehicle aesthetic design. 6. Repair: Skirts at ends and corners shall be readily repairable following minor collisions. 7. Attachment where access is not required: a. Provide standard threaded fasteners, removable with common hand tools; or b. Provide a key (see Section 14, Interior and Exterior Appointments, for the Key Assignment Table). 8. Attachment where access is required: a. Design such that removal is not necessary for equipment access or maintenance. b. For easy access to trucks, skirts over trucks shall be hinged, lift-assisted, and removable by sliding the moveable portion off of hinge pins. c. Provide quick-release closures of truck-access panels. 3.4 Structural Design Requirements 3.4.1 General Base the structural design on the following: 1. 2. 3. 4. Proven rail vehicle techniques and elements. Structural static, dynamic, and fatigue loads encountered in revenue service. Specified loads, load factors, deflections., and crashworthiness requirements CEM Option: a. Passive safety design concepts (Crash Energy Management) per ASME RT-1. b. If the CEM Option is selected, apply all sections of the Specifications noted with "CEM Option." If CEM Option is not selected none of the CEM Options shall be applied. 5. Structural and geometric compatibility with the existing vehicles for either the Strength-Based or CEM design approach. 6. Design primary structural connections, including equipment brackets per the Equipment Loads section, below, so that the ultimate strength of the connection exceeds the ultimate strength of the weakest member in the connection. 7. The vehicle body shall be designed to maximize energy-absorbing capability within the specified static strength parameters. 8. In the event of a collision occurring on level, tangent track between two vehicles with mating anticlimbers locked together, deformation of the structure shall commence at the extreme ends and progress toward the coupler anchor, with all of the end structural members retaining their attachments to one another and to the roof and floor structures. 9. The design shall also: a. Minimize the possibility of injury during a collision due to detached equipment mounted anywhere on the vehicle; b. Minimize loss of occupied volume from penetration. LTK Standard Streetcar Specifications Section 3 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.4.2 Interoperability 3.4.2.1 General As a minimum, comply with interoperability requirements of ASME RT-1. These include 1. Requirements for anticlimber and coupler interface (where applicable), and leading end structure, intended to mitigate damage in case of engagement between rail vehicles of the same or different types operating on the same routes. 2. Requirements for rail vehicles operating in urban environments, intended to cause the vehicle to deflect struck objects from its path; and minimize entrapment, override, and penetration of automobiles and light trucks. 3.4.2.2 Energy Absorbing Bumper, OPTIONAL Provide a bumper designed to minimize damage, to the extent possible, to struck pedestrians, cyclists, road vehicles, and other rail vehicles: 1. Bumper style: Wraparound, continuous or segmented with separate front and corner/side segments, with corner/side segment designed to reduce damage in corner collisions with automobiles or other struck vehicles. 2. Minimum bumper coverage: Full width of the vehicle and wrapped around sides minimum 450 mm (18 in) 3. Minimum bumper width (in vertical direction): 457 mm (17 in) 4. Mounting height: Maximum 203 mm (8 in) from TOR to bottom of bumper 5. Energy absorbing mechanism: Self-restoring and capable of absorbing collision energies between two streetcars at speeds of minimum 8 km/h (5 mph) with no structural damage 6. Stroke before anticlimber contacts struck vehicle or object: 100 mm to 150 mm (4 in to 6 in) 7. Cladding: Cushioning and aesthetically pleasing 8. Maintainability: Attached with quick release pins or other similar mechanism to allow easy and quick replacement following a collision 9. Vertical Stability: Withstand the anticlimbing load requirement. 3.4.2.3 Project-Specific Requirements The Owner’s new streetcars will share the alignment with existing streetcars and will operate in an urban environment with road vehicles. 3.4.3 CEM Option 3.4.3.1 Design A CEM design is to comply with the following: 1. Design the vehicle-body structure in accordance with ASME RT-1 crashworthiness requirements and crash energy management (CEM) principles per Table 2, Structural Load Requirements for Streetcars: a. Design the structure with minimum two sequential energy absorption zones, Zone 1 and Zone 2, as defined in ASME RT-1. b. Collapse shall not commence until the end sill compression load has been exceeded, with the exception of the energy absorption in Zone 1. LTK Standard Streetcar Specifications Section 3 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure c. The Optional requirements of the Energy Absorbing Bumper section, above, are considered to satisfy ASME RT-1, Table 4, Crashworthiness for Streetcars, Item 1, Collision Scenario 1 – low-severity impact scenario, for the CEM Option. 2. Demonstrate compatibility with the existing vehicles under the scenarios noted in this Section. 3. Subject to approval by the Owner, European standards such as EN 15227 may be proposed, provided that it can be shown that results are essentially equivalent to ASME RT-1 and achieve structural compatibility with the existing vehicles. 4. Quasi-Static or Dynamic tests on the various structural elements may be required to validate the analysis and show the actual energy absorbed by the elements during crushing, in accordance with Section 15, Testing, or ASME RT-1 Section 10.4, Crash Energy Management Tests, depending on the availability of validated models matching the specified design. 3.4.3.2 Crashworthiness Analysis Demonstrate performance of the energy absorption zones in accordance with ASME RT-1 Crashworthiness Analysis: 1. Collision between two like streetcars: a. Simulation conditions: ASME RT-1 Section 9.3, Crashworthiness Analysis. b. Vehicle closing speed: ASME RT-1 Table 4, Crashworthiness for Streetcars, Collision Scenarios 1 and 2. c. Acceptance criteria: ASME RT-1 Section 9.3 and Table 4. 3.4.3.3 Crashworthiness Analysis Interactive Review At the discretion of the Owner, models and results shall be reviewed during live interactive sessions with the engineers who performed the crashworthiness analysis, three weeks after each submittal. 1. At these sessions, provide the Owner with full access to the model input and output, and use of the software on a computer. 2. Provide access to view the crushing simulation on the computer. 3.4.4 Vertical Design Load Strength Requirements 3.4.4.1 Static Load Design the completely equipped vehicle body to carry the maximum vehicle loading of weight AW4 distributed uniformly along the vehicle, less truck weight or running gear weight. Stresses shall not exceed the following: 1. 65% of the guaranteed minimum material yield strength; and 2. 65% of the buckling strength, and no loss of local stability; and 3. The allowable fatigue stress for joints and structural details that are fatigue critical. 3.4.4.2 Fatigue Load For fatigue-critical joints, structural details, and connections including bolted joints, determine allowable fatigue stress according to the requirements of the following standards and handbook: 1. 2. 3. 4. AWS D1.1/D1.1M AWS D1.2/D1.2M AWS D1.3/D1.3M AWS D1.6/D1.6M LTK Standard Streetcar Specifications Section 3 9 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 5. AWS Welding Handbook requirements for dynamically loaded structures 6. Other recognized standards, as approved, for connections not covered by Items 1 to 5 above. For each joint design, the static stress at the AW2 load shall be less than the mean stress that determines the allowable fatigue limit. The fatigue stress range shall be calculated at AW2 loading times a dynamic factor. The dynamic factor shall be as determined by the Contractor, but shall be minimum plus or minus 20% under constant amplitude loading. The fatigue limit shall be established for 10 million cycles. The fatigue stress range shall not exceed the allowable range(s) in Items 1 to 6 above for a given joint detail. 3.4.5 End Sill Compression Loads Under an end sill compression load of 400 kN (90,000 lbs.) applied on the anticlimbers at the longitudinal centerline of the vehicle, comply with the following: 1. There shall be no permanent deformation in any structural member, including sheathing. 2. At no point inboard of the coupler anchors on a complete ready to run vehicle, shall the margin of safety be less than the lowest margin of safety outboard of the coupler anchor. 3. That structural element with the lowest margin of safety inboard of the coupler anchor shall not be located in any part of the articulation or the yoke arms that attach the vehicle-body sections to the articulation. CEM Option: Comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 2, End sill compression. For all designs, the end sills shall be capable of transmitting the loads from the collision posts into the draft sill and side sills, without failure, when the posts are loaded to their ultimate strength. 3.4.6 Coupler Anchorage 3.4.6.1 Coupler Anchor Compression Load Comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 3, Coupler anchorage compression load, as applicable to the specified coupler. 3.4.6.2 Coupler Anchor Tensile Load Comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 5, Coupler anchorage operational tensile load and towing loads, as applicable to the specified coupler. 3.4.7 Collision Posts 3.4.7.1 Design Comply with the following requirements: 1. Collision posts shall be continuous through the end sill, extending from the bottom of the end sill to the structural shelf. 2. Design the posts and/or supporting structures in the end frame such that when the post is overloaded, the initial failure shall begin as bending or buckling in the structure. a. Primary connections between the collision post and other structure shall not fail before the ultimate strength of the post itself is reached; failure shall occur in the post. b. Ultimate failure shall not be in any connections, the underframe, or roof structure, and shall not occur by shearing or fracturing of any member. LTK Standard Streetcar Specifications Section 3 10 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3. If the post is designed to support more than the specified load, then the supporting structure must be strong enough to support the increased bending capacity of the posts. The posts shall fail before the supporting structure. 3.4.7.2 Collision Post Shear Load The minimum ultimate shear strength of each collision post shall be 250 kN (56,200 lbf) applied inward even with the top of the underframe centered on the post. The loading direction shall be +/- 15 degrees from the longitudinal centerline. The ultimate shear strength of the post shall be calculated from the area of the webs of the post. CEM Option: Comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 6, Collision post shear load. 3.4.7.3 Collision Post Load The minimum load for each collision post shall be 80 kN (17,985 lbf), loaded in a horizontal plane 1000 mm (39.37 in) above top of rail and within +/- 15 degrees from the longitudinal direction applied independently. There shall be no permanent deformation in the vehicle structures. CEM Option: The capacity of each collision post shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 7, Collision post load. 3.4.8 Corner Posts 3.4.8.1 Design Comply with the following requirements: 1. Corner posts shall extend full height from the underside of the end underframe to the roof rail. 2. The connections of the posts to the supporting structure, and the supporting structure itself, shall be strong enough to develop the bending capacity of the posts. a. Primary connections between the corner post and other structure shall not fail before the ultimate strength of the post itself is reached; failure shall occur in the post. b. Ultimate failure shall not be in any connections, the underframe, or the roof, and shall not be by shearing or fracturing of any member. 3. If the posts are designed to support more than the specified loads, then the supporting structure must be strong enough to support the increased bending capacity of the posts. The posts shall fail before the supporting structure. 3.4.8.2 Corner Post Shear Load The minimum ultimate shear strength of each corner post shall be 78 kN (17,540 lbf) applied inward even with the top of the underframe centered on the post in any inward direction from longitudinal to transverse. The ultimate shear strength of the post shall be calculated from the area of the webs of the post. CEM Option: The ultimate shear strength of each corner post shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 8, Corner post shear loads. LTK Standard Streetcar Specifications Section 3 11 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.4.8.3 Corner Post Load The minimum load for each corner post shall be 40 kN (9,000 lbf), loaded in a horizontal plane 1000 mm (39.37 in) above top of rail in any inward direction from longitudinal to transverse applied independently. There shall be no permanent deformation in the vehicle structures. CEM Option: The capacity of each corner post shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 9, Corner post loads (elastic design loads). 3.4.9 Structural Shelf Comply with the following requirements: 1. Design: a. Provide a horizontal structural shelf below the windshield connecting the tops of the collision posts to each other and to the corner posts. b. The outer ends of the structural shelf shall be supported by the corner posts, which shall be attached to both the underframe and roof structures. 2. Capacity: a. A longitudinal load of 80 kN (17,985 lbf) applied at any location on the span without permanent deformation at any location on the vehicle. b. Sufficient to support the upper reactions of the collision posts. c. CEM Option: Comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 10, Structural shelf. 3.4.10 Side Wall 3.4.10.1 Side Wall Load at Side Sill Side sill and supporting structures shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 11, Side wall load, at side sill. 3.4.10.2 Side Wall Load at Belt Rail Belt rail (at the lower side window edge) and supporting structures shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 12, Side wall load, at belt rail. 3.4.11 Articulation Joint Anticlimber Loads The articulation joint shall withstand the resulting forces from the following combined loads with no permanent deformation or failures that may result in telescoping of the vehicle sections: 1. Vertical load of 1.1 times the static load required to raise the end of the vehicle with truck or running gear attached 2. Longitudinal compressive load applied at the vehicle-body centerline of 60 % of the end strength. 3. CEM Option: Resist vertical and longitudinal loads developed over the collision scenarios in the Crashworthiness Analysis section, above, per the requirements above. LTK Standard Streetcar Specifications Section 3 12 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.4.12 Floor Load Meet the following conditions for a fully equipped vehicle with a vehicle weight of AW4 evenly distributed: 1. Floor panels shall deflect maximum 1/250 of the shortest span between supports, up to a maximum of 4.3 mm (0.17 in). 2. Floor beams shall deflect maximum 1/250 of the span between supports. 3.4.13 Roof Load All parts of the roof structure and walkways shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 13, Roof, concentrated load, as might be applied by maintenance personnel walking on the roof carrying tools and equipment. 3.4.14 Truck-to-Vehicle-Body Attachment Comply with the following requirements: 1. Trucks (or running gear): Shall be raised with the vehicle unless intentionally detached. 2. Attachment structure: Stresses shall not exceed 50% of yield with the truck or running gear hanging from the body. 3. Attachment Strength: Minimum load equivalent to 5 times the weight of the truck applied in any horizontal direction through the actual or virtual pivot. a. The ultimate strength of the truck connection, supporting vehicle body, and truck or running gear shall not be exceeded. b. This requirement shall apply with or without the weight of the truck being applied, i.e. the truck hanging from the vehicle body with the horizontal load applied. 4. CEM Option, Attachment Strength: The structural connection of the truck (or running gear) to the vehicle body shall comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 14, Truck-to-carbody attachment, or approved alternative standard. 3.4.15 Equipment 3.4.15.1 Equipment Loads Comply with the following requirements for design of equipment attachments: 1. Scope: Underfloor, roof, and interior equipment, any portion of the equipment, equipment boxes, equipment hangers, standby supports, safety hangers, and the vehicle body supporting structure. 2. Design load: At a minimum, comply with ASME RT-1, Table 2, Structural Load Requirements for Streetcars, Item 15, Equipment attachments, or approved alternative standard. Equipment within an equipment box: 1. Not required to meet the above criteria provided it can be shown that the equipment will not penetrate the walls of the equipment box when exposed to these load levels. 2. The equipment box shall conform to these load criteria with the rearranged equipment (i.e., equipment that is presumed to have broken loose) in addition to its normal arrangement. LTK Standard Streetcar Specifications Section 3 13 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.4.15.2 Equipment Fasteners and Supports Comply with the following requirements for the support of equipment enclosures: 1. Fastenings shall be designed so that in no case will the limit of the carrying capacity of a member be the strength of one fastener or the shearing of fasteners through the base material. 2. Equipment weighing more than 12 kg (26 lb) shall not be supported by threaded fasteners in tension or shear, unless they are provided with an unstressed secondary support. 3. No equipment shall be supported by bolts in holes tapped in the structural elements of the vehicle. However, it is permissible to use tapping plates in accordance with Section 16, Materials and Workmanship. 4. For bolts used to support equipment, the minimum diameter shall be 10 mm (3/8 in). 5. Underfloor equipment shall be mounted on rails, hangers, brackets, or support structure such that the equipment rests on the top side of the support member and thus does not rely solely on bolted connections for mechanical integrity. 6. Waivers of these requirements may be requested for enclosures that weigh maximum 12 kg (26 lb) or are agreed to be crushable, such as terminal boxes, or where the arrangement is service proven, as defined in Section 1, General Topics and Definitions. 3.4.16 Jacking and Hoisting Loads For design purposes, the vehicle shall comply with the following: 1. Symmetrical Jacking: a. Loading condition on each jack point: • • Vertical load: Static, AW0, with a load factor of 2; combined with Horizontal load: 10% of the vertical load applied in any horizontal direction. b. Result: No permanent deformation of any vehicle-body structure. 2. Diagonal Jacking: a. Scope: Vehicle-body jacking pads, jacking sockets, and supporting structure; b. Loading condition: Empty vehicle with trucks (AW0 condition), under the load imposed by diagonal jacking. c. Diagonal jacking is defined as when the entire vehicle, including trucks, is support first symmetrically, then one jack is lowered until the load on that jack is 10 % of its original value. ; d. Diagonal jacking must be considered for each jack pad and socket adapter. e. Result: No permanent deformation. The stress analysis shall include an analysis of the jack pads, jack sockets, their connections to the vehicle body, and the immediate supporting vehicle structure under symmetric jacking and the worst case of diagonal jacking The same load factors as above shall apply for hoisting. 3.4.17 Steps If provided, steps shall be designed to support one person as follows: 1. Load: 135 kg (298 lb) per 305 mm (12 in) of tread 2. Load factor: 2 LTK Standard Streetcar Specifications Section 3 14 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure The resulting stresses in any part of the steps assembly, and its supporting structures, shall not exceed the yield strength of the material. 3.4.18 Natural Frequency The natural frequency of each vehicle section under a vehicle weight of AW4 and supported at the articulation yokes and at the bolsters shall be minimum 2.5 times the natural frequency of the secondary suspension. 3.5 Stress Analysis 3.5.1 Purpose Stress analyses shall be used to design the vehicle structures in compliance with the requirements of the Specifications and to obtain the lightest-weight vehicle consistent with those requirements. 3.5.2 General Comply with the following general requirements: 1. The approved stress analysis shall be a prerequisite for approval of the structural test procedures and structural drawings required by the Specifications, and shall be used as an aid in determining strain gauge locations for use during testing. 2. During the design and manufacture of the vehicles, update the input to the stress analysis to reflect the as-built configuration of the structure. 3. For any portion of the proposed design that is based on a service-proven vehicle, data may be furnished from previous tests, historical data from operations, or stress analyses as required to satisfy the corresponding portion of these requirements. 3.5.3 Stress Analysis Content Include the following as a minimum: 1. Show the calculated stresses, allowable stresses, and margins of safety for all elements for all specified loading conditions. 2. Include calculations of stresses in joints, joint elements, and other important elements. 3. Calculate the elastic stability of plates, webs, and flanges for members subject to compression and shear. 4. Prototype and test critical connections that cannot be adequately analyzed to demonstrate compliance with the requirements of the design and the Specifications. 5. If stainless steel is used, consider the variation in the stainless steel compression modulus with stress in calculating compressive stability of stainless steel members. 6. See the Contract Data Requirements List (CDRL) section, below, for detailed requirements. 3.5.4 Initial Stress Analysis The initial stress analysis will require temporary assumptions as to configuration and weights. If the initial design changes due to manufacturing considerations or other factors, revise and resubmit the stress analysis. 3.5.5 Buckling Analysis Calculate the buckling strength of structural framing members. Include each member that was found to have a calculated compressive stress greater than or equal to 35% of material yield strength in any of the analyses. LTK Standard Streetcar Specifications Section 3 15 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3.5.6 Finite Element Analysis (FEA) As part of the stress analysis, perform a linear-static finite element analysis (FEA) of the complete vehicle body. 1. Purpose: To show that the vehicle body design meets the requirements of this Section. 2. FEA software: Perform analysis using a recognized computer program such as NASTRAN, ANSYS, ABAQUS, or approved equal. 3. Non-linear static analysis: a. Perform if FRP skin is used and the material and/or the connection between the material and the supporting structure exhibit non-linear properties. b. This may be instead of the linear static FEA, or a local analysis in addition to a global static analysis. 4. Interactive Owner Review: a. At the discretion of the Owner, review finite element models and results during live interactive sessions with the engineers who performed the FEA, three weeks after each submittal. b. At these sessions, provide the Owner with full access to the finite element model input and output, and use of the software on the computer used for the analysis. c. Provide access to view the simulation on the computer. 3.5.7 Validation of Linear Elastic Analysis Perform Vehicle-Shell Structural Type Tests in accordance with Section 15, Testing, to confirm the accuracy of the analysis: 1. For each test required for Vehicle-Shell Structural Type Tests in Section 15, compare the vehiclebody structural test measured results with the corresponding stress analysis analytical results. 2. Tabulate and submit this information with the vehicle-body structural test reports for each test, as required in Section 15. 3. The test and analysis results shall correlate within the following ranges: a. Longitudinal deflections: Within +/- 10% b. Vertical deflections: Within +/- 10% c. Stresses: Within +/- 20% 3.6 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. Detail drawings: Top level assemblies, and other drawings if requested 2. Functional description 3. Component ratings: Top level components, and ratings of other components if requested 3-1 Jacking Pad Design Package: 1. Drawing showing locations of jacking pads for both maintenance and re-railing equipment. 2. Details of vehicle-body inserts, if provided, sufficient to enable the Owner to procure adapters for portable jacks. LTK Standard Streetcar Specifications Section 3 16 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3-2 Roof Shroud Design Package: 1. Drawing showing side and end views as mounted on vehicle. 2. Drawing showing details of roof shroud construction, materials, and attachment methods. 3-3 Skirt Design Package: 1. Drawings showing side and end views as mounted on vehicle, with ventilation openings, if used. 2. Drawing showing details of skirt construction, materials, and attachment methods. 3. Drawing showing details of skirts over trucks, including hinges, lift-assist mechanism, and removal method. 3-4 CEM Option, CEM and Collision Survivability Plan: 1. Submit maximum 30 calendar days after NTP. 2. The report shall include the requirement of ASME RT-1, in Sections 8 and 4, to present the design strategy that defines the specific features to meet the required zones of energy absorption. 3. Include the CEM testing plan, or waiver justifications, as specified in Section 15, Testing. 3-5 CEM Option, Crashworthiness Analysis Report: 1. 2. 3. 4. Submit minimum 60 calendar days before starting manufacture of structural parts. The report shall demonstrate that the crushing of the vehicle body is stable. Include sufficient analysis to demonstrate compliance with the specified requirements. Organize the report and furnish sufficient detail so that the Owner’s representative can readily follow the theory and its application to this vehicle. 5. Include the same reference information, such as drawing numbers, material properties, references for formulas, and buckling coefficients, as required in the Stress Analysis Report CDRL. 6. Include the following: a. Animations of the time-dependent, large-deflection analysis: • • Format: Compatible with one of the current commonly available video formats, such as DVD or Quicktime®. Content: Sufficient detail, view directions, and magnifications to review the behavior and stability of the following: ○ ○ ○ ○ Energy absorption elements Frangible elements Non-crushable structure inboard of the crush zones The vehicle body as a whole b. Description of the model in sufficient detail to show that the model is appropriate for this application, including as a minimum the following: • • • Descriptions of the elements and restraints The conditions of the simulation The output of the simulation to show that relevant Specification requirements have been met, including force-displacement plots c. Table for non-crushable structure inboard the crush zones: LTK Standard Streetcar Specifications Section 3 17 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure • • Show locations where the MS is less than 0.20, with a discussion of the results. There shall be no permanent deformation in this area of the structure. d. References for formulas, calculation procedures, buckling coefficients, material strengths, and other physical and mechanical properties that appear in the report. • If a cited reference is not readily available to the Owner, furnish the following: ○ ○ • Reference; or Copies of the pages that show the cited formula or data, and the pages that show the development and interpretation of the formula or data References shall be in the English (USA) language: ○ ○ If an English (USA) reference cannot be found, furnish an English (USA) translation Include both the original and the translation in the report e. Test reports required to verify the results of the analysis: • • f. 3-6 Include the entire test report, which shall include the test procedure, raw data, reduced data, and a summary The Owner will determine the adequacy of the submitted test reports Electronic input and output files. Vehicle-Body Stress Analysis and Tests Plan: 1. 2. 3. 4. Submit within 30 days after NTP. Follow the general requirements of the Stress Analysis Report. This Plan must be submitted and approved before approval of the Stress Analysis Report. Update and resubmit whenever the Plan for the analysis and testing of the vehicle body is revised, but not more often than monthly. 5. With each revision submit detailed revision notes that explain each change and indicate where changes were made in the report as a result of the change. 6. Include the following: a. Table including the Specification subsection or standard met, load case number, load, and criteria. b. Outline of the procedure the Contractor will use to analyze and test the design of the vehicle body. c. Listing of load conditions to be used during analysis and test, with load magnitudes, supports, and points of application. d. Description of the analysis to be used for each load condition. e. Structural sketch of the vehicle body, showing sheathing thickness, framing member locations and shapes, and the materials and thicknesses of each. Define methods of joining. f. Diagrams of load applications and supports g. Procedure for analyzing the static and fatigue capability of FRP side skin and its connections, if used. h. Table of material properties. i. Description of major assumptions. j. Description of how analysis results will be correlated with test results, as required in Section 15, Testing. LTK Standard Streetcar Specifications Section 3 18 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3-7 Stress Analysis Report: 1. Submit as follows: a. Initial stress analysis report: Within 90 days after NTP. b. Complete stress analysis report: Minimum 60 days before starting manufacture of any vehicle body structural parts. c. Revisions: Any time the design, and/or the stress analysis plan is updated but not more than monthly. 2. With each revision include detailed revision notes that explain each change and indicate where changes were made in the report as a result of the change. 3. General Requirements: a. Final submitted and approved stress analysis report shall be for vehicle in as-built configuration. b. Certify that analysis and calculations have been reviewed and checked before submitting report. c. Follow procedure outlined in Vehicle-Body Stress Analysis and Tests Plan. d. Report shall demonstrate that structure satisfies requirements of Contractor's design and the Specifications. e. Report shall be sufficiently complete and analysis sufficiently accurate for the Owner to use report to design repairs during life of vehicles. f. Organize report in a logical way such that content can be easily found by the Owner’s reviewer. Furnish sufficient detail so the Owner’s reviewer can readily follow the theory and its application to this vehicle. 4. Include the following: a. b. c. d. Sections that organize the material into logical units. Consecutive page numbering. Table of Contents Listing each section with page number on which it starts. Manual analysis: Each page shall be initialed by analyst and checker, and include the following: • • • Date Revision level For revisions, include revision letter with revision date and initials of analyst and checker e. Computer-generated analysis: Each page shall be initialed by checker and include the following as a minimum: • • • Page number Date Revision level 5. Include the following drawings: a. Approved structural sketch of the vehicle body showing structural elements and their connections (submitted with the Vehicle Body Stress Analysis and Tests Plan, above). LTK Standard Streetcar Specifications Section 3 19 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure b. Framing and miscellaneous drawings: • • • • • • Underframe and bolster - plan, elevations, and sections Anticlimbers - plan, elevations, and sections Side frame(s) - plan, elevations, and sections Roof frame - plan, elevations, and sections End frame - plan, elevations, and sections Drawbar attachment to underframe - plan, elevations, and sections 6. In drawings, or body of the analysis, indicate materials and weights of all components. 7. In body of analysis, include the following: a. References for formulas, calculation procedures, buckling coefficients, material strengths, fatigue strengths, and other physical and mechanical properties where these items appear in the stress analysis: • • If a cited reference is not readily available to the Owner, furnish the reference or copies of the pertinent pages. In addition to the pages that show the cited formula or data, include the pages that show the development and interpretation of the formula or data. References shall be in English (USA). If an English reference cannot be found, furnish an English translation. Include both original and translation in report. b. Algebraic statement of formulas and equations before related calculations are performed. Define terms, and state values and units to be applied to these terms. c. Units for each quantity. d. Diagrams displaying, for each load case, loads applied externally to the vehicle body and points of support. e. Analysis showing compliance with each design load and condition, as required by Section 3.4, Structural Design Requirements. f. Detailed calculations of stresses with Margins of Safety (MS) in all structural framing members and sheathing, with a summary of the results. g. Table showing locations where MS is less than 0.20, along with design or operating conditions (loads) that cause the stresses. h. Reference to particular elements including, but not limited to the following: • • • • • • • • • • • • • Side sill Body sills (if used) End sill Anticlimber Draft sills Tow bar supports Side frame rails Side frame posts Transverse and longitudinal sections at doorways Body bolster Floor and floor beams Collision posts Corner posts LTK Standard Streetcar Specifications Section 3 20 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure • • • • • • i. Structural shelf Articulation end frame Roof structure Equipment supports Connections between structural elements Any FRP skin and bonded connections used Tabulation or diagram of calculated deflections of vehicle body under full vertical loading and under combined vertical and compression loads specified in: • • • Section 3.4.4, Vertical Design Load Strength Requirements; Section 3.4.5, End Sill Compression Load; and Section 3.4.7, Collision Posts. j. Analysis of critical and highly loaded connections, as required in Section 3.4.4, Vertical Design Load Strength Requirements, showing joint is stronger than weakest member being joined. k. Analysis of the strength of connection of trucks to vehicle body, including calculated vertical and horizontal connection capacities. l. Analyses of the vehicle-body structure under: • • Torsional loading resulting from diagonal jacking described in Section 3.4.16, Jacking and Hoisting Loads; and Torsional loadings resulting from anticipated normal operations. m. Tabulation of Contractor's selection of: • • Allowable fatigue stresses, with sources; and Assumed applied fatigue stress ranges for structural members and connections that are critical in fatigue, and for FRP skin and its connections if used. n. Table showing engineering properties of each grade and temper of each material used in vehicle structure: • • • Include material designation, yield strength, ultimate strength, elongation, Young's modulus for tension, and compression and shear elastic moduli. For each, use minimum-guaranteed values for grade and heat treatment of material used, from the specifications. Do not include in the table materials, grades, or tempers not used in vehicle body construction. o. Table showing geometric properties, such as area and section moduli. p. Table(s) showing minimum static and fatigue strengths of single and multiple spot welds: • • Give values for each material, temper, weld size, and thickness combination used in vehicle body. Include source of data. q. Test reports, if tests are conducted to furnish necessary data. Submit entire test report, which shall include test procedure, raw data, reduced data, and summary. LTK Standard Streetcar Specifications Section 3 21 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure 3-8 Equipment Support Stress Analysis Report: 1. Submit minimum 60 calendar days before starting manufacture of any vehicle body structural parts. 2. Include a stress analysis of equipment supports for equipment weighing over 91 kg. Stress analyses for supports for items weighing less than 91 kg may be requested for review at the discretion of the Owner. 3. In addition to stress analysis, include the following: a. Detailed drawings of equipment supports. b. Outline drawings and weights of equipment. c. Material lists for all components and fasteners. 3-9 Finite Element Analysis Model: 1. Submit within 90 days after NTP. 2. Submit and receive approval of finite element model before performing FEA analysis. 3. Include the following: a. Element mesh b. Assumptions c. Plots with legends showing input data such as loads, boundary conditions, area properties, and material properties d. Key to symbols and colors e. Boundary reaction forces of the shell at AW0 f. Input file on electronic media 4. With each revision include detailed revision notes that explain each change and indicate where changes were made in the report as a result of the change. 5. Upon completion of final design, update Finite Element Analysis Model to represent final configuration of structure. 3-10 Finite Element Analysis Report: 1. Submit minimum 60 days before starting manufacture of any vehicle body structural parts. 2. Submit Finite Element Analysis Report after receiving approval for Finite Element Analysis Model and performing complete analysis. 3. In addition to the items required for this submittal, include those items required for the FEA Model submittal. 4. Upon completion of final design, update Finite Element Analysis Report to represent final configuration of structure. 5. Each load condition submittal shall include diagrams of areas of mesh refinement, assumptions, input data, reaction forces, and a table to show static equilibrium. 6. For input and output files, number each page and clearly label columns of data on each page using terms, symbols, abbreviations, and units defined in the analysis report. 7. Prepare color plots showing the following: a. b. c. d. e. Deflections in all three axes separately plotted and imposed over the deflected shape Von Mises, or other approved failure criteria, depending on the material Maximum and minimum principal stresses Direction of maximum and minimum principal stresses Meshing accuracy index LTK Standard Streetcar Specifications Section 3 22 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle-Body Structure f. Maximum and minimum values and values that are greater than 80% of specified maximum value. g. Triad showing direction of global axes. h. For plots at high magnification, key to a plot showing structure to an extent sufficient to orient high-magnification plots. 8. Furnish a sufficient number of plots for each load case to see the stresses in all areas of the vehicle body, with special attention given to the following components: a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. Side sill Body sills (if used) End sill Anticlimber Draft sills Tow bar supports Side frame rails Side frame posts Transverse and longitudinal sections at doorway Body bolster Floor and floor beams Collision posts Corner posts Structural shelf Articulation end frame Roof structure Equipment supports Connections between structural elements 9. Show in detail areas with an MS less than 2.0. 3-11 FEA Input and Output Data on Electronic Media: 1. Submit FEA input and output data on electronic media, and if requested by the Owner, hard copy. 2. Obtain approval from the Owner for proposed media type before submitting. 3. Resubmit each time file is changed, but not more often than monthly. 4. Fully configured input data files must be submitted before final approval of the stress analysis required by this Section. END OF SECTION LTK Standard Streetcar Specifications Section 3 23 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 4, Coupler Table of Contents 4.1 General ........................................................................................................................................1 4.1.1 Purpose ............................................................................................................................................ 1 4.1.2 Description ....................................................................................................................................... 1 4.1.3 Compatibility with Existing Vehicles ................................................................................................ 1 4.2 Geometry .....................................................................................................................................1 4.3 Mechanical Coupler ......................................................................................................................1 4.3.1 Coupler Head ................................................................................................................................... 1 4.3.2 Lateral Stops..................................................................................................................................... 2 4.3.3 Strength............................................................................................................................................ 2 4.3.4 Draft Gear and Anchorage ............................................................................................................... 2 4.3.5 Coupler Storage................................................................................................................................ 2 4.4 Electrical Connections...................................................................................................................3 4.5 Contract Data Requirements List (CDRL)........................................................................................3 LTK Standard Streetcar Specifications Section 4 i January 30, 2016June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 4, Coupler 4.1 General 4.1.1 Purpose Provide coupling devices to allow one vehicle to tow or push another vehicle under emergency conditions. See Section 2, Design and Performance Criteria, for specific towing or pushing conditions. 4.1.2 Description The coupler system shall be an automatically- or manually-operated, storable unit with resilient draft gear, presently in use on similar vehicles for the same purpose. 4.1.3 Compatibility with Existing Vehicles The coupler must be mechanically compatible with the Owner's existing vehicle fleet for towing or pushing: 1. Type: Drawbar. 2. Height: Approximately 525 mm (20.7 in). 4.2 Geometry The coupler system shall permit vehicles to operate over track profiles specified in Section 2, Design and Performance Criteria, including the following conditions, without damage or stress outside the system design limits: 1. Worst-case combination of horizontal and vertical curves, superelevation, track wear, and track misalignment. 2. Variations between adjacent vehicles resulting from uneven loading, wheel wear, maximum suspension travel, and suspension failure. 4.3 Mechanical Coupler 4.3.1 Coupler Head Comply with the following: 1. Purpose: a. Provides the connecting mechanism between two couplers b. Provides devices necessary to safely lock coupler heads together when coupled 2. Shape: a. Allows for vertical and lateral misalignment between coupler heads b. Provides self-alignment with the mating coupler when the couplers are brought together during a coupling operation 3. Coupling: a. Manual coupling: Mechanism shall be engaged by inserting a pin, throwing a latch, or similar manual process; or b. Automatic coupling: Coupler heads may latch automatically. LTK Standard Streetcar Specifications Section 4 1 January 30, 2016 June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 4, Coupler 4.3.2 Lateral Stops Provide lateral stops as follows: 1. Purpose: To positively limit lateral coupler swing and prevent damage to the vehicle-body structure and other equipment in the event that the vehicle is operated with the coupler unstowed. 2. Strength: Sufficient to withstand the impact loading of the coupler, without damage, when it is accelerated from one stop to the other, at the maximum lateral acceleration possible on the specified right of way. 3. Failure: Design the stop to fail before the structure to which it is attached. 4. Maintainability: Bolted to the vehicle structure to facilitate replacement after accident damage. 4.3.3 Strength Comply with the following: 1. The coupler, coupling mechanisms, and draft gear shall be capable of withstanding buff or draft loads of not less than 133% (or tested to 110%) of the maximum forces experienced during coupling, towing, or pushing, with no permanent deformation. 2. The coupler assembly strength shall be sufficient to meet the towing requirements and operational requirements specified in Section 2. 3. Coupling at speeds up to 1 km/h (0.6 mph) shall be possible without damage to coupler assembly components. 4. See Section 3, Vehicle-Body Structure, for coupler anchor requirements. 4.3.4 Draft Gear and Anchorage Comply with the following: 1. Draft gear: a. Rubber cushioning: Provide in both buff and draft b. Resilient mounting: Provide in the vertical direction to maintain nominal coupler height above top of rail. 2. Supporting device at coupler anchor point: a. Shall maintain coupler and draft gear assembly at the specified coupler height above top of rail. b. Shall provide a means of vertical height adjustment of the coupler head to compensate for vehicle and coupler variations and wear. 3. Coupler assembly mounting: Bolt to the vehicle structure under the cab floor. See also Section 3. 4.3.5 Coupler Storage When not in use, the coupler shall fold or retract under the vehicle behind a removable or hinged cover: 1. Operation: The storage mechanism shall permit a maintainer to manually deploy and stow the coupler with minimal physical effort. 2. Operating position lock: a. Provide a device to lock the coupler into its operating position, and to release the coupler for storage. LTK Standard Streetcar Specifications Section 4 2 January 30, 2016 June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 4, Coupler b. The device may be integral to the coupler mechanism, or a separate device. If separate, it shall be stowed on the coupler. 3. Stowed position lock: Retain the coupler assembly rigidly in its stowed position to prevent movement due to vehicle motion. 4.4 Electrical Connections Provide a connector, wiring, and related hardware for a temporary electrical connection for communication between vehicle cabs, as described in Section 13, Vehicle Communication Systems: 1. The connection may be made manually or automatically. 2. The arrangement shall provide for all coupler motions without damage to connectors or wiring. 3. The connectors and wiring system shall be watertight, and meet the multi-pin connector requirements of Section 16, Materials and Workmanship. 4. Provide a watertight cap to protect the connector when not in use. The cap shall be retained by chain, lanyard, or similar device when not applied. 4.5 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. Detail drawings: Top level assemblies, and other drawings if requested 2. Functional description 3. Component ratings: Top level components, and ratings of other components if requested 4-1 Coupler Design Package: 1. Operating Description: Narrative describing how to deploy, couple, uncouple, and store coupler assembly. 2. General Arrangement Drawings: Show coupler components with dimensions 3. Detail Drawings: Include details of the draft gear, folding or storing mechanism, coupler head, and latching mechanism. 4. Material Properties: a. Indicate the material used for each component, unless indicated on Detail Drawings. b. Furnish data on properties of each material used. c. Include coatings, lubrication requirements, and similar 5. Strength Analysis: a. Furnish sufficient information to demonstrate that the specified strength requirements have been met. b. If available, manufacturer’s test data may be used for this purpose. 6. Electrical Connections: a. Detail drawings with manufacturer’s part numbers for standard parts. b. Include connector material details. END OF SECTION LTK Standard Streetcar Specifications Section 4 3 January 30, 2016 June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls Table of Contents 5.1 General ........................................................................................................................................1 5.1.1 Scope ................................................................................................................................................ 1 5.1.2 Controls and Indicators .................................................................................................................... 1 5.2 Cab Console .................................................................................................................................1 5.2.1 Cab Console Design .......................................................................................................................... 1 5.2.2 Cab Console Layout .......................................................................................................................... 1 5.3 Master Controller Group...............................................................................................................1 5.3.1 General ............................................................................................................................................. 1 5.3.2 Master Controller Key Switch .......................................................................................................... 1 5.3.3 Reverser Switch ................................................................................................................................ 2 5.3.4 Master Controller ............................................................................................................................. 2 5.3.4.1 General...................................................................................................................................... 2 5.3.4.2 Ergonomics ............................................................................................................................... 3 5.3.4.3 Handle Positions ....................................................................................................................... 3 5.3.4.4 Deadman ................................................................................................................................... 3 5.4 Cab Console Switches ...................................................................................................................3 5.4.1 General ............................................................................................................................................. 3 5.4.2 Summary of Control Functions with Basic Switch Types ................................................................. 3 5.4.3 Emergency Brake Switch .................................................................................................................. 5 5.4.4 Special Switch-Layout Requirements ............................................................................................... 5 5.5 Foot Switches ...............................................................................................................................5 5.6 Cab Console Indication and Annunciation .....................................................................................6 5.6.1 General ............................................................................................................................................. 6 5.6.2 Cab Console Indication and Annunciation ....................................................................................... 6 5.7 Other Displays and Control Groups on the Cab Console ................................................................. 6 5.7.1 Train Operator Display (TOD)........................................................................................................... 6 5.7.2 Interior View Mirror ......................................................................................................................... 7 5.7.3 Exterior Side-View Display Screens .................................................................................................. 7 5.7.4 Speedometer.................................................................................................................................... 7 5.7.5 Discrete Indicator Group .................................................................................................................. 7 5.7.6 Radio and Communications Group .................................................................................................. 8 5.7.7 TWC Group ....................................................................................................................................... 8 LTK Standard Streetcar Specifications Section 5 i January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 5.8 Cab Console Functional Descriptions .............................................................................................8 5.8.1 Scope ................................................................................................................................................ 8 5.8.2 Door Controls ................................................................................................................................... 8 5.8.3 Bridge Plate Controls ....................................................................................................................... 9 5.8.4 Public Address (PA) System............................................................................................................ 10 5.8.5 Initiation of APIS Announcements ................................................................................................. 10 5.9 Other Cab Controls ..................................................................................................................... 10 5.9.1 General ........................................................................................................................................... 10 5.9.2 Bypass/Aux Switch Control Panel .................................................................................................. 11 5.9.3 Hotel Load Timer ............................................................................................................................ 11 5.9.4 Auxiliary On/Off Switch .................................................................................................................. 12 5.9.5 Cab HVAC Unit Controls (Optional) ................................................................................................ 12 5.9.6 Sander Control ............................................................................................................................... 12 5.9.7 Incident Alarm Switch .................................................................................................................... 13 5.10 Automatic Controls................................................................................................................... 13 5.10.1 Interior Lighting Control............................................................................................................... 13 5.10.2 Exterior Lighting Control .............................................................................................................. 13 5.10.3 HVAC Control ............................................................................................................................... 13 5.10.4 Parking Brake Control .................................................................................................................. 14 5.11 Control Configurations and Interlocks ....................................................................................... 14 5.11.1 General ......................................................................................................................................... 14 5.11.2 Cab Interlock ................................................................................................................................ 14 5.11.3 Direction Control .......................................................................................................................... 14 5.11.4 Track Brake Control...................................................................................................................... 14 5.11.5 Hazard Lights ................................................................................................................................ 15 5.12 Contract Data Requirements List (CDRL) .................................................................................... 15 LTK Standard Streetcar Specifications Section 5 ii January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 5.1 General 5.1.1 Scope This Section includes controls located in or originating from the operator's cab at each end of the vehicle. The cab area shall contain all controls, displays, and appurtenances necessary for normal and abnormal vehicle operation. Design and furnish the cab as specified in Section 14, Interior and Exterior Appointments. 5.1.2 Controls and Indicators Comply with the following: 1. Locate all controls and indicators necessary for vehicle operation in the cab. 2. Provide status and fault indicators for major systems. 3. Provide specified controls and indicators in both cabs; cabs shall be identical. 5.2 Cab Console 5.2.1 Cab Console Design Provide good visibility of controls and labels to the operator. For Cab Console design and materials, see Section 14, Interior and Exterior Appointments. 5.2.2 Cab Console Layout Comply with the following: 1. Unless otherwise specified or permitted, locate controls and indicators on the Cab Console directly in front of the operator's seat. 2. Arrange controls in an ergonomic manner based on the relative frequency and criticality of each task, the size range of operators as specified in Section 14, and the design principles of The Measure of Man and Woman: Human Factors in Design (“Measure of Man and Woman”). 3. Arrange controls according to frequency of use, design to avoid unintentional activation, and locate to minimize reach and to reduce operator strain and fatigue. 5.3 Master Controller Group 5.3.1 General The Master Controller (MC) group consists of a MC key switch, Reverser switch, and MC. Alternative arrangements with functionality similar to that described below may be considered by the Owner. 5.3.2 Master Controller Key Switch Provide a two-position MC key switch to select cab status. Mechanically interlock the MC key switch with the MC and Reverser switch, as described in the Reverser Switch and Master Controller sections, below. Provide the following functionality: 1. MC key switch keyed to On position: a. The Cab Console, other cab controls and displays, hotel load systems, and all other vehicle systems activate and function in their normal operating modes. b. Systems already energized remain energized without interruption. LTK Standard Streetcar Specifications Section 5 1 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls c. Doors remain in last commanded state (OPEN, CLOSED, or ENABLED) d. Cab Console controls and indicators in the other end of the vehicle are disabled, except as specified otherwise. e. The MC key shall not be removable in this position. f. Keying more than one MC key switch On in a vehicle shall be detected by software and considered an invalid command, and the additional cab shall not be activated. Annunciate the attempt to activate an additional cab on the TOD in the active cab. 2. MC key switch keyed to Off position (both cabs OFF): a. Hotel Load timer activates (see description of operation below). b. The Cab Console and other cab controls de-activate and are non-functional, except the following remain active: • • • • Emergency Brake pushbutton Battery charging Other systems specified to be active at all times Systems maintained by the Hotel Load timer c. Doors remain in the last commanded state (OPEN, CLOSED, or ENABLED) d. The MC key shall be removable in this switch position. Additional MC key switch and cab interlock controls are detailed within this Section. 5.3.3 Reverser Switch Provide a three-position Reverser switch with these positions: Forward, Neutral, Reverse. 1. Mechanically interlock MC key switch and Reverser switch as follows: a. Reverser switch cannot be moved from Neutral position unless associated MC key switch is in On position; and b. MC key switch cannot be moved from On position unless Reverser switch is in Neutral position. 2. Electrical Interlocking: a. Vehicle operation shall not be possible unless Reverser switch in controlling cab is in either Forward or Reverse position; b. Reverser switch and MC: MC handle must be in FSB position in order to move Reverser switch out of either Forward or Reverse position; c. Initiate FSB if forward and reverse commands are given simultaneously, record error state by MDS, and indicate error on TOD. 5.3.4 Master Controller 5.3.4.1 General Provide a Master Controller (MC) to allow manual selection of braking and motoring efforts. The MC shall be arranged to move linearly fore and aft, with motoring in the forward direction and braking towards the rear (that is, towards the operator). LTK Standard Streetcar Specifications Section 5 2 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 5.3.4.2 Ergonomics The handle shall be shaped, located, and oriented to minimize strain and fatigue on the operator. Locate the MC for left hand operation. 5.3.4.3 Handle Positions There shall be distinct tactile positions in the handle travel, indicated by stops or detents, as indicated below: Function Maximum Brake (MB): Full Service Brake (FSB): Minimum Brake: Coast: Minimum Power: Maximum Power: Position/Tactile Indication Stop (rearmost position) Detent Slight Stop Detent Slight Stop Stop (forward-most position) Rate See Section 2 See Section 2 Approximately 10% of FSB Approximately 10% of Max Power See Section 2 Notes to Table: 1. Between Maximum Power and Full Service Brake, braking and power efforts shall be linearly proportional to handle position. 2. The MC shall stow in the FSB position when the cab is inactive. 5.3.4.4 Deadman The MC handle shall incorporate a deadman feature with associated circuitry, to perform as follows: 1. Release of MC handle: a. Initiate an audible alarm. b. After a two-second time delay apply FSB. 2. If deadman is picked up during the alarm and before FSB is initiated, the dead man timer shall be reset and the alarm cancelled. 3. Cycling the MC to FSB after alarm initiation: Brake application shall be retrievable. 4. MC handle in FSB or MB position: Deadman function shall be disabled. The circuit and timing function shall be a safe function as defined in Section 2. 5.4 Cab Console Switches 5.4.1 General Comply with the following requirements for switches: 1. Type: Heavy-duty industrial grade, IP65 rated in conformance with IEC 60529. 2. Illuminated Type: Backlighted by LEDs. 3. Identification: Provide a durable and permanent label for each control switch. 5.4.2 Summary of Control Functions with Basic Switch Types Provide control functions on the Cab Console as shown in the table on the following page. Typical switch and control types are presented, although the Contractor may propose alternative designs, including via TOD touch screen, if similar functionality is provided. LTK Standard Streetcar Specifications Section 5 3 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls Additional control functions with special requirements are described separately. Summary of Control Functions with Basic Switch Types Control Function Type Code (see key below) Master Controller Group See Master Controller Group Section, above Left Door Close MPB (illuminates green) Left Door Open MPB (illuminates red) Left Door Enable MPB (illuminates yellow) Right Door Close MPB (illuminates green) Right Door Open MPB (illuminates red) Right Door Enable MPB (illuminates yellow) Wiper, Off/Intermittent/Low/High 4R Wiper Delay Adjust Rotary Potentiometer Windshield Washer, On/Off MPB Headlight, High/Low LPB (illuminates for high beams) Turn Signal, Left/Off/Right 3MTRC Hazard Lights, On/Off LPB (illuminates yellow) Cab Ceiling Light (general Illumination) On/Off LPB Cab-Console-Mounted Light, dimmer Rotary Potentiometer Cab Console lights and indicators dimmer Rotary Potentiometer Indicator Lamp Test MPB Horn, On/Off (automobile warning) MPB Bell, High/Low Volume (pedestrian warning) 2R PA MPB Cab-to-Cab Intercom MPB Passenger Emergency Intercom acknowledge/pick MPB up call on hold Windshield Heating (embedded heater) LPB Cab Heater Off/Fan/Low Heat/High Heat 4R Track Brake, On/Off MPB Emergency Brake See switch description below HSCB (Propulsion) Reset 3MTRC Pantograph Up/Down 3MTRC Auxiliaries On/Off See switch description below TWC Control Module See Section 13 Left Bridge Plate Retract/Extend MPB (illuminates) Right Bridge Plate Retract/Extend MPB (illuminates) LPB MPB 3MTRC 2R 3R 4R Rotary Potentiometer Type Code Key Pushbutton with latching circuitry (push on, push off) Momentary pushbutton Three-position momentary toggle switch, spring return to center Two-position rotary Three-position rotary Four-position rotary Continuously adjustable control LTK Standard Streetcar Specifications Section 5 4 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls Notes to Tables Above: 1. See Section 8, Lighting, for LED dimming requirements. If the Cab Console and other cab lights do not have integrated dimming functionality, dedicated LED PWM supplies shall be provided and controlled by the dimmer potentiometers. 2. Provide the indicated latching functions using electrical circuitry or software. Mechanically latching switches are prohibited, with the exception of the emergency brake switch described below. 3. Pushbutton switches shall be flush or recessed to prevent inadvertent operation. 4. Illuminated switches shall show the state of the controlled circuit, not the state of the switch. 5. The Indicator Lamp Test will illuminate all discrete indicators on the console. 5.4.3 Emergency Brake Switch Comply with the following: 1. Type: Heavy duty, industrial grade self-latching pushbutton gang switch with a large, red mushroom-shaped twist-to-unlatch actuating head. 2. Location: Cab Console in each cab. 3. Configuration: The switch mechanism shall be arranged with two switches for the main emergency brake circuits, with a switch contact in each of the positive and negative portions of the circuits. 4. Strength: The actuation mechanism shall be sufficiently robust such that striking the mushroom head will ensure breaking the circuit even with welded contacts. 5. Function: Shall be functional in all cabs, regardless of cab active status. See additional control requirements below. 6. Release: Twist to unlatch an activated (latched) EB pushbutton. 7. Circuits: The active cab shall provide the only power and return circuits for control of all emergency brake equipment in the vehicle. 8. See Section 2, Design and Performance Criteria, for additional emergency brake requirements. 5.4.4 Special Switch-Layout Requirements Comply with the following layout requirements for specific switches: 1. Passenger Doors: Position controls for safe actuation, with the right-side door controls on the right side of the Cab Console, and the left-side door controls on the left side of the Cab Console. 2. Pantograph Up/Down: Locate near HSCB reset and away from commonly used controls. 3. Pedestrian bell: Provide a momentary switch on the operator’s hand hold and a sound level selector switch on the Cab Console. 5.5 Foot Switches Provide a footswitch for manual operation of the sander system. The switch shall be of the momentary, spring-loaded type. LTK Standard Streetcar Specifications Section 5 5 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 5.6 Cab Console Indication and Annunciation 5.6.1 General Comply with the following requirements for indicators: 1. Type: LED, heavy-duty industrial grade devices, IP65 rated in conformance with IEC 60529. 2. Activation: Indicators shall illuminate only in the active cab. 3. Identification: Provide a durable and permanent label for each indicator, on the indicator itself, wherever possible. 5.6.2 Cab Console Indication and Annunciation Provide indications in the cab as shown in the table below. Indicating switches (illuminate to show state of circuit) are shown above in the Cab Console Switches section: Indication/Annunciation Left turn signal Right turn signal Odometer Passenger Stop Request Interior Manual Door Release (Passenger Emergency Switch) Door Open or Unlocked Door Cutout Overhead Heat high-limit temperature indication Tripped or Open HSCB Passenger Bridge Plate Request Bridge Plate Extended Bridge Plate Cutout Symbol/ Action Left-facing arrow/ flashing Right facing arrow/ flashing Visual and audible Activation Description Flashes when corresponding turn signal is active Flashes when corresponding turn signal is active See below See Sect 6 See Sect 6 See Sect 6 See Sect 6 See Sect 7 Visual and audible Visual Visual See Sect 9 See Sect 6 See Sect 6 See Sect 6 Notes to Table: 1. Some of these annunciations may be part of the TOD, if approved by the Owner. 5.7 Other Displays and Control Groups on the Cab Console 5.7.1 Train Operator Display (TOD) The TOD shall be part of the Monitoring and Diagnostic System (MDS) specified in Section 17, Electronic Controls, Software, and MDS. See Section 17 for TOD display and control requirements. Provide a TOD in the cab complying with the following requirements: 1. Location: Near the center of the Cab Console, in a location free of glare and reflections under all natural and artificial lighting conditions. 2. Purpose: Display information useful to the operator when the vehicle is in motion or during a normal station stop, including all status indications. Provide vehicle control functions, as approved, via the touch screen interface. LTK Standard Streetcar Specifications Section 5 6 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 3. Odometer: The propulsion system shall provide distance information to the MDS that will display the odometer mileage for the vehicle on the TOD, or on a dedicated display. An alternative source for the distance information to the odometer may be presented during design review. 5.7.2 Interior View Display ScreenMirror Display a view of the passenger compartment on a dedicated LCD screen to replace the view from a cab interior mirror: 1. Camera: a. Type: Comply with requirements for CCTV cameras. See Section 13, Vehicle Communication Systems. b. Location: Outside the cab, aimed to view down the center of the vehicle. 2. Display: a. Type: Comply with requirements for the exterior side-view display screens. See Section 13. b. Location: On upper cab console, where a mirror would typically sit. c. Activation: When cab is active. One or more interior mirrors shall be provided in the cab. The mirrors shall be located and adjustable to provide the operator with a view of the passenger compartment. The mirror shall be of distortion free glass installed in an edge covering frame. The mirror reflecting area shall be at least 360 cm2 5.7.3 Exterior Side-View Display Screens Provide two LCD display screens in each cab for viewing the exterior sides of the vehicle, as specified in Section 13: 1. Mount displays on the right and left sides of the Cab Console or on the corner posts. 2. Arrange displays to be viewed easily by seated and standing operators. 5.7.4 Speedometer Provide a round speedometer display: 1. Size: Minimum diameter 125 mm (5 in). 2. Range: 0 to 50 mph, spanning approximately 270 degrees of the face, with speed indicated in miles per hour. 3. Illumination: Evenly illuminated over the entire display, with a dimmer control. 4. Color of indicator and face: Select for maximum visibility, as approved by the Owner. 5. Accuracy: +/- 2.5% of actual vehicle speed or better. Provide a dedicated speed sensor, or a speed processed by one of the vehicle systems, and automatically compensate speed signal for actual wheel diameter. 5.7.5 Discrete Indicator Group Provide minimum 12 LED indicators that duplicate selected status indications shown on the TOD. Indicators shall provide sufficient information to operator to allow safe operation of vehicle in service with a non-functioning TOD. At a minimum, continuously display the following indications: 1. Door Closed indication LTK Standard Streetcar Specifications Section 5 7 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 2. Brake Released indication 3. Bypass Active indication 5.7.6 Radio and Communications Group Install radio equipment furnished by the Owner in accordance with Section 13, Vehicle Communications. 1. Locate audio and radio system control heads on right side of Cab Console, close enough to allow the operator easy access. Arrangement shall permit safe operation of the vehicle with the operator's left hand on the Master Controller. 2. Automatic Passenger Information System (APIS) Control Panel: a. Provide a separate APIS Control Panel to the right of audio and radio system control heads to control automatic destination signs and announcements. b. APIS control may be incorporated into TOD with the Owner's approval. See Section 13, Vehicle Communication Systems, for details of the APIS. 5.7.7 TWC Group Provide a TWC Cab Control Panel in each cab, as specified in Section 13, Vehicle Communication Systems. TWC status information shall also be shown on the Operating Status Screen of the TOD. 5.8 Cab Console Functional Descriptions 5.8.1 Scope This section includes specific functionality that originates in the cab. Other cab functionality, and functional descriptions for systems that require a response from the operator, such as passenger emergency intercom and passenger stop request, are described in other sections. 5.8.2 Door Controls Comply with the following: 1. Door Open: a. Pressing the Door Open pushbutton shall open all doors on the selected vehicle side; b. Doors shall remain open until the Door Close pushbutton is pressed. 2. Door Enable: a. Pressing the Door Enable pushbutton for the doors on a given side of the vehicle shall enable the local door pushbuttons on the inside and outside of the vehicle on the selected side; 3. Door Close: a. Pressing the Door Close pushbutton shall close all doors on the selected vehicle side, including doors opened by a Crew switch and doors fixed open by the obstruction detection counter; b. The Close command shall cancel door Enable and Open commands; c. The Close command shall cancel passenger stop request. LTK Standard Streetcar Specifications Section 5 8 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 4. Optional Control: The door system shall have the option to have the Bridge Plate Extend command open all doors on the selected side of the vehicle. The option shall be user selectable using a PTU connected to each associated door control unit. 5.8.3 Bridge Plate Controls Comply with the following: 1. Door Open: a. Pressing the Door Open pushbutton shall enable the local bridge plate pushbuttons on the inside and outside of the vehicle on the selected side. b. If a passenger bridge plate request has been stored within the system, pressing the Door Open pushbutton shall cause the actions described in 4 b, below. 2. Door Enable: a. Pressing the Door Enable pushbutton for the doors on a given side of the vehicle shall enable the local bridge plate pushbuttons on the inside and outside of the vehicle, on the selected side. b. If a passenger bridge plate request has been stored within the system, pressing the Door Enable pushbutton shall cause the actions described in 4 b, below. 3. Door Close: a. Pressing the Door Close pushbutton shall close the door and retract the bridge plate on selected side of vehicle. b. The Close command shall cancel passenger bridge plate request. c. Upon successful closing, the bridge plate obstruction detection shall be disabled. 4. Bridge Plate Retract/Extend: Pressing a Bridge Plate Retract/Extend pushbutton will have different consequences depending upon positions of the doors and bridge plate. The following actions will occur in the sequence listed with the positions stated: a. Door open and bridge plate retracted: • • • • • • Door closing warning Close door Start interior and exterior bridge plate movement audible warning Extend bridge plate Stop interior and exterior bridge plate movement audible warning Open door b. Door closed and bridge plate retracted: • • • • • Keep door with bridge plate request closed Start interior and exterior bridge plate movement audible warning Extend bridge plate Stop interior and exterior bridge plate movement audible warning Open door c. Door open and bridge plate extended: • • Close door Start interior and exterior bridge plate movement audible warning LTK Standard Streetcar Specifications Section 5 9 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls • • • Retract bridge plate Stop interior and exterior bridge plate movement audible warning Cancel passenger bridge plate request d. All other system combinations shall alert the operator of a system fault 5.8.4 Public Address (PA) System Comply with the following: 1. The operator shall be able to select where operator PA announcements are broadcast: a. Interior of the vehicle only b. Exterior of the vehicle only c. Both interior and exterior 2. Operator initiated PA messages shall override passenger information system and door system messages. 5.8.5 Initiation of APIS Announcements Comply with the following: 1. APIS announcements shall be initiated by the operator entering a route ID number, which shall determine which message sequence and special features are to be used by the system. 2. The present location of the vehicle in the route's station sequence may also be entered if vehicle location is not known at initiation. 3. Once initiated, the system shall be automatic, as specified in Section 13, Vehicle Communication Systems. 4. System initiation shall also establish the settings for the end destination signs in each cab and side destination signs in the vehicle. 5. The system shall give a positive indication to the operator when all signs in the vehicle have the proper display. 5.9 Other Cab Controls 5.9.1 General For devices located off the Cab Console, comply with requirements for Cab Console switches and indicators in the sections above. LTK Standard Streetcar Specifications Section 5 10 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 5.9.2 Bypass/Aux Switch Control Panel Provide a Bypass Control Panel mounted under Cab Console on right side of operator. At a minimum, include the following switches, bypass controls, and switch types in the Bypass/Aux Switch Control Panel: Control Auxiliaries Switch, Off/On Audible Alert Bypass No Motion Bypass Door Interlock Bypass Speed Restriction Bypass Pantograph-Down Bypass Friction Brake Applied Bypass MPB 3MRC Type 3MRC MPB, sealed MPB, sealed MPB, sealed MPB, sealed MPB, sealed MPB, sealed Type code key Momentary pushbutton Three-position momentary rotary, return to center The sealed bypass switches listed above shall function as described below: 1. Seal: Breakable by the operator without the need for tools. 2. Bypass Active indication: Shall illuminate if any bypass switch is activated, and shall flash if more than one bypass is active. 3. Availability: Bypass switches shall be enabled only if the MC key switch is ON in the same cab as the bypass switches. 4. Automatic Reset: When MC key switch is switched Off, all bypassed systems shall return to normal function and remain so when that cab's MC key switch is returned to On position. 5. Audible Alert Bypass: Acknowledges and cancels the following audible alarms: a. Emergency door operating device activated b. Friction brake or dynamic brake fault 6. No-Motion Bypass: This switch shall bypass the local no-motion detection circuits, which prevent door operation. 7. Door Interlock Bypass: This switch shall bypass the summary door interlock circuit, which prevents propulsion in the event of an open door (see also Section 6, Passenger Doors). 8. Speed Restriction Bypass: Deactivates the circuit that limits or restricts vehicle speed due to dynamic brake failure. 9. Friction brake applied bypass: Allows propulsion to move the vehicle when there is a brake applied indication. 5.9.3 Hotel Load Timer Provide a user-programmable timer that controls hotel load systems and functions in conjunction with the Auxiliary On/Off switch, below: 1. Enabled: Only when no cab is active. 2. Activated: Whenever MC key switch is switched Off, or if Auxiliary On/Off switch is switched to On. 3. Hotel load systems: HVAC, cab heat, interior lights, exterior lights, passenger door controls. LTK Standard Streetcar Specifications Section 5 11 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 4. Timer setting: Adjustable from 1 to 30 minutes in 1-minute increments, initially set to 20 minutes. 5. Function: a. Upon activation: • • Resets timer to full value, and turns On all hotel load systems, into their normal operating states. If hotel load systems are already ON when the timer is activated, maintains those systems in their ON state without interruption. b. End of the timer setting: Shuts down hotel load systems and activates HVAC layover mode, as specified in Section 7, Heating, Ventilating, and Air Conditioning. c. Delayed Off: When Auxiliary On/Off switch is placed in Off position, and the Hotel Load timer has not expired, set the timer for 1 minute. The Delayed Off time setting shall be user settable to any value less than the timer setting, including zero. 5.9.4 Auxiliary On/Off Switch Provide an Auxiliary On/Off switch in each cab that functions in conjunction with the Hotel Load timer, above: 1. Switch type: Momentary, three-position, return to neutral center. 2. Enabled: Only when no cab is active. 3. Function: a. On position: Activates the Hotel Load timer. b. Off position: • • Sets the Hotel Load timer to the Delayed Off setting. Coordinate between Auxiliary Off command and other vehicle systems as necessary for HVAC shut down procedures. c. Activating a cab shall return auxiliaries control to the active cab. 4. Exterior Auxiliary On function: See Crew Door-Switch section in Section 6, Passenger Doors. 5.9.5 Cab HVAC Unit Controls (Optional) Provide a temperature controller: 1. Type: Digital, as provided by the HVAC supplier 2. Location: In the cab in one of the following locations, as approved by the Owner: a. Cab wall next to side window b. Overhead console 5.9.6 Sander Control Comply with the following: 1. Automatic: Apply sand in response to emergency brake applications and spin/slide activities, in accordance with the Emergency Brake section in Section 2, Design and Performance Criteria, and Section 12, Friction Brake System. 2. Manual: a. Apply sand in response to operation of the Manual Sander switch by the operator. LTK Standard Streetcar Specifications Section 5 12 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls b. Manual operation of the sanders via the switch shall not be canceled below the no-motion detection point. 5.9.7 Incident Alarm Switch Provide a hidden switch in the cab to initiate broadcast of an emergency radio transmission and initiate the high frame rate DVR function. See Section 13, Vehicle Communications, for the DVR. 5.10 Automatic Controls 5.10.1 Interior Lighting Control Lighting in the passenger compartment shall be on whenever either cab is ON. It shall remain active with both cabs OFF when controlled by the Hotel Load timer or the Auxiliary On/Off switch as described above. 5.10.2 Exterior Lighting Control With a cab active and Reverser Switch in Neutral: 1. Red marker lights at both ends of vehicle are illuminated 2. Amber marker lights on sides of vehicle are illuminated 3. Taillights on front and rear ends of vehicle are illuminated With a cab active, Reverser Switch in Forward or Reverse, as determined by the forward and reverse directional control lines: 1. 2. 3. 4. 5. 6. Amber marker lights on the front end of vehicle only are illuminated Red marker lights on the rear end of vehicle only are illuminated Amber marker lights on front sides and midpoint of vehicle only are illuminated Red marker lights on rear sides of vehicle only are illuminated Headlights only at the front of vehicle are illuminated Taillights only at rear of vehicle are illuminated Stop lights shall be illuminated at the rear of the vehicle whenever a direction has been selected and any brake mode has been selected, including manual track brake application. 5.10.3 HVAC Control Provide HVAC control as follows: 1. Passenger compartment: a. HVAC system shall activate automatically whenever the MC key switch in either cab is placed in On position b. HVAC system shall activate automatically when the Auxiliary Switch has been activated, and shall remain active until the Hotel Load timer expires. c. HVAC system shall remain active when both cabs are OFF until the Hotel Load timer expires or when activated by the HVAC Layover mode circuitry (see Section 7, Heating, Ventilating, and Air Conditioning). 2. Operator’s cab: a. Cab air comfort controls shall activate automatically when a Cab Console is activated and deactivate after a time delay when the Cab Console is deactivated. See Hotel Load timer section, above. LTK Standard Streetcar Specifications Section 5 13 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls b. Cab HVAC shall maintain temperature automatically when in HVAC Layover mode or in an inactive cab as described in Section 7. 5.10.4 Parking Brake Control Parking brake shall be applied automatically when reversers in each cab are both in the Neutral position. For additional control requirements, refer to Section 12, Friction Brake System. 5.11 Control Configurations and Interlocks 5.11.1 General Control of the vehicle shall be via control signals, as specified in Section 17, Electronic Controls, Software, and MDS. 1. Implement vehicle control schemes as described below. 2. Control of cab systems not described below or in other sections shall be determined by the Contractor. 3. Unless otherwise indicated or approved, all control signals, interlocks, and other vehicle controls shall operate from the low-voltage power supply. 5.11.2 Cab Interlock Interlock cab controls using control lines and associated circuitry such that no more than one cab can take control of a vehicle at the same time. 1. Interlocking shall be provided by relay logic. 2. Interlocking that depends on mechanical locking of transfer switches with electrical solenoids is prohibited. 5.11.3 Direction Control Direction signals shall be given by a pair of control lines, designated Forward and Reverse: 1. Direction signals shall originate at the controlling cab's Reverser Switch. 2. Arrange associated circuitry such that one control line must be energized while the other must be de-energized for correct operation. 3. Energization or de-energization of both control lines at the same time shall inhibit propulsion and display a fault on the TOD. 5.11.4 Track Brake Control Provide a track brake switch for operator control of track braking: 1. 2. 3. 4. Location: Cab Console in each cab. Switch type: See switch requirements above. Control configuration: See Section 12, Friction Brake System. Switch function: a. Shall activate all track brakes on the vehicle. b. Shall not be canceled below the minimum track brake speed as specified in Emergency Brake section of Section 2, Design and Performance Criteria. c. Shall not inhibit propulsion. LTK Standard Streetcar Specifications Section 5 14 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Operator’s Cab and Controls 5.11.5 Hazard Lights Provide a hazard light switch to cause turn signals to function as hazard lights: 1. 2. 3. 4. Location: Cab Console in each cab. Switch type: See switch requirements above. Activation: Switch shall be enabled at all times in all cabs. Function: a. Switch activated: All turn signals in the vehicle flash. b. Deactivation: Lights shall remain flashing until switch is turned Off, regardless of cab activation. Hazard light indicator: Illuminates and flashes only in the cab with the activated switch. 5.12 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. Detail drawings: Top level assemblies, and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values 5-1 Master Controller Group Design Package 5-2 Cab Controls Design Package: 1. Manufacturer’s literature and detail drawings for each type of switch and indicator, and for displays and devices not submitted under other sections. 2. List names of switches and indicators for which each submitted type will be used. 3. Drawings of all controls, indicators, and labels with components identified. END OF SECTION LTK Standard Streetcar Specifications Section 5 15 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors Table of Contents 6.1 Scope ...........................................................................................................................................1 6.2 General Description ......................................................................................................................1 6.3 Door Design Requirements ...........................................................................................................1 6.3.1 Accessibility ...................................................................................................................................... 1 6.3.2 Door ADA and Interface Requirements ........................................................................................... 1 6.3.3 Safety ............................................................................................................................................... 1 6.3.4 Dynamic Performance...................................................................................................................... 1 6.3.5 Adjustability ..................................................................................................................................... 2 6.4 Door Panels ..................................................................................................................................2 6.4.1 Material and Construction ............................................................................................................... 2 6.4.2 Windows .......................................................................................................................................... 2 6.4.3 Strength Requirements .................................................................................................................... 2 6.4.4 Sealing Requirements ...................................................................................................................... 2 6.5 Manufacturing and Installation Requirements...............................................................................3 6.6 Performance Requirements ..........................................................................................................3 6.7 Door Operator..............................................................................................................................4 6.7.1 General ............................................................................................................................................. 4 6.7.2 Operator Mechanical Requirements................................................................................................ 4 6.7.3 Operator Electrical Requirements ................................................................................................... 4 6.8 Door Control System ....................................................................................................................4 6.8.1 General ............................................................................................................................................. 4 6.8.2 Control and Monitoring ................................................................................................................... 5 6.8.3 Diagnostics, Data Network, and Adjustments ................................................................................. 5 6.8.3.1 Diagnostics ................................................................................................................................ 5 6.8.3.2 Data Network ............................................................................................................................ 5 6.8.3.3 Adjustments .............................................................................................................................. 6 6.9 Door Operation ............................................................................................................................6 6.9.1 General ............................................................................................................................................. 6 6.9.2 Door Operation Restrictions ............................................................................................................ 6 6.9.3 Cab Console Controls ....................................................................................................................... 6 6.9.4 Passenger Controls........................................................................................................................... 7 6.9.4.1 Pushbuttons and Tape Switch .................................................................................................. 7 6.9.4.2 Door Open Function.................................................................................................................. 7 LTK Standard Streetcar Specifications Section 6 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.9.4.3 Passenger Stop Request Function ............................................................................................ 7 6.9.5 Crew Door-Switch ............................................................................................................................ 8 6.9.6 Loss of Control Power ...................................................................................................................... 8 6.10 Door Locks .................................................................................................................................8 6.11 Door Obstruction Detection ........................................................................................................9 6.11.1 General ........................................................................................................................................... 9 6.11.2 Detection Methods ........................................................................................................................ 9 6.11.3 Operation Requirements ............................................................................................................... 9 6.11.4 Maximum Force ............................................................................................................................. 9 6.11.5 Sensitivity Requirements ............................................................................................................... 9 6.11.6 Obstructions Not Detected .......................................................................................................... 10 6.12 Manual Door Release Mechanism ............................................................................................. 10 6.12.1 Functional Description ................................................................................................................. 10 6.12.2 Interior Manual (Emergency) Door Release ................................................................................ 10 6.12.3 Exterior Manual Door Release ..................................................................................................... 10 6.12.4 Reset Device ................................................................................................................................. 10 6.13 Door Interlock Requirements .................................................................................................... 11 6.13.1 No Motion Interlock ..................................................................................................................... 11 6.13.2 Door Status (Open) Interlock ....................................................................................................... 11 6.14 Door Bypass Devices ................................................................................................................. 12 6.14.1 General ......................................................................................................................................... 12 6.14.2 Door Interlock Bypass .................................................................................................................. 12 6.14.3 Door Cutout ................................................................................................................................. 12 6.15 Indicators and Annunciators ..................................................................................................... 12 6.15.1 Door Open Indications ................................................................................................................. 12 6.15.2 Manual (Emergency) Door Release.............................................................................................. 12 6.15.3 Door Closing Warning Announcements ....................................................................................... 13 6.16 Door Control Signals ................................................................................................................. 13 6.17 Bridge Plates ............................................................................................................................ 13 6.17.1 Design........................................................................................................................................... 13 6.17.1.1 Integration ............................................................................................................................ 13 6.17.1.2 ADA and Interface Requirements ......................................................................................... 13 6.17.1.3 Safety .................................................................................................................................... 13 6.17.1.4 Dynamic Performance .......................................................................................................... 14 LTK Standard Streetcar Specifications Section 6 ii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.17.1.5 Adjustability .......................................................................................................................... 14 6.17.2 Manufacturing and Installation.................................................................................................... 14 6.17.3 Location, Size, and Strength ......................................................................................................... 14 6.17.4 Ramp Configuration ..................................................................................................................... 14 6.17.5 Material and Components ........................................................................................................... 15 6.17.6 Operator ....................................................................................................................................... 15 6.17.7 Control System ............................................................................................................................. 15 6.17.7.1 General.................................................................................................................................. 15 6.17.7.2 Control and Adjustment ....................................................................................................... 16 6.17.7.3 Monitoring and Position Sensing .......................................................................................... 16 6.17.8 Operation ..................................................................................................................................... 16 6.17.8.1 General.................................................................................................................................. 16 6.17.8.2 Operation Restrictions .......................................................................................................... 16 6.17.9 Passenger Controls....................................................................................................................... 16 6.17.9.1 Control Switches ................................................................................................................... 16 6.17.9.2 Passenger Control Functional Description............................................................................ 17 6.17.10 Loss of Control Power ................................................................................................................ 17 6.17.11 Locks........................................................................................................................................... 17 6.17.12 Performance............................................................................................................................... 18 6.17.13 Obstruction Detection ............................................................................................................... 18 6.17.13.1 General................................................................................................................................ 18 6.17.13.2 Detection Methods ............................................................................................................. 18 6.17.13.3 Operation Requirements .................................................................................................... 18 6.17.13.4 Sensitivity Requirements .................................................................................................... 18 6.17.14 Indicators and Annunciators ...................................................................................................... 19 6.17.14.1 Bridge Plate Extended Indicators........................................................................................ 19 6.17.14.2 Bridge Plate Warning Announcement ................................................................................ 19 6.17.14.3 Status Indicators ................................................................................................................. 19 6.17.15 Bridge Plate Interlock Requirements ......................................................................................... 19 6.17.16 Bridge Plate Bypass Devices ....................................................................................................... 20 6.17.16.1 General................................................................................................................................ 20 6.17.16.2 Door Interlock Bypass Applied to Bridge Plate ................................................................... 20 6.17.16.3 Bridge Plate Cutout ............................................................................................................. 20 6.18 Contract Data Requirements List (CDRL) .................................................................................... 20 LTK Standard Streetcar Specifications Section 6 iii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.1 Scope This Section includes: 1. Passenger doors and related equipment and controls 2. Bridge plates 6.2 General Description Comply with the following: 1. Door type: Sliding-plug, flush with the vehicle body exterior skin when closed. 2. Protrusion from vehicle: Maximum 75 mm (3 in) during any portion of the open or close cycle. 3. Door size and configuration: As specified in Section 2, Design and Performance Criteria. 6.3 Door Design Requirements 6.3.1 Accessibility Comply with the following for door controls, cutouts, access covers, and other specified functions: 1. Location: Accessible by the fifth-percentile female, as defined in The Measure of Man and Woman: Human Factors in Design. 2. Operating forces: Suitable for the same fifth-percentile female group. 6.3.2 Door ADA and Interface Requirements The doors and doorways shall meet ADA requirements, 49 CFR 38 Subpart D, and the station platform interface requirements of Section 2. 6.3.3 Safety Design the door system in accordance with the safety requirements of Section 2. No single point failure in the door system or the vehicle controls shall cause: 1. A door to unlock or open when an Open request has not been commanded 2. A Door Open or Enable command to be transmitted or responded to when the vehicle is in motion 3. A Door Closed indication to be transmitted when any door is unlocked or open 4. A traction interlock OK status when any door is unlocked or opened 5. A Door Closed indication to be transmitted when an Enable or Open command is stored anywhere in the system 6.3.4 Dynamic Performance Comply with the following: 1. Doors shall be vibration and rattle free while the vehicle is underway, and while doors are operating when the vehicle is stationary. 2. The door system, in conjunction with the vehicle's aerodynamics, shall prevent whistling and other objectionable noises at all vehicle speeds. LTK Standard Streetcar Specifications Section 6 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.3.5 Adjustability Comply with the following: 1. Door system: Include provisions for independent adjustments to location and alignment of the door operator, door panels, and other components to accommodate equipment installation, replacement, and system wear. 2. Mounting of sensors and switches: No readjustment shall be possible when a device is replaced. 6.4 Door Panels 6.4.1 Material and Construction Comply with the following: 1. Material: HSLA steel, aluminum honeycomb, or similar. 2. Construction: a. Join into an integral unit by adhesive bonding or resistance welding. b. Completely seal edges and joints to prevent the entrance of moisture. c. Provide interior cavities with drain holes at the bottom if it is possible for condensation to form. 6.4.2 Windows Each door panel shall contain a window: 1. Type: Laminated safety glass of the same materials and color as the side windows. 2. Size: a. As high and wide as possible to allow passengers maximum view of station platforms and to make door positions more clearly identifiable to waiting passengers. b. Height shall be sufficient to permit a passenger on the platform to see the door closing warning signal when the doors are closed. 3. Mounting: Windows shall be retained in the door panel by the same method used for passenger windows. The arrangement shall be watertight. 6.4.3 Strength Requirements The door panel skin, structure, and mounting hardware shall sustain the following load with the door supported at the top and bottom in an agreed fixture: 1. 2. 3. 4. Concentrated load: 890 N (200 lbf). Load application: Perpendicular to the plane of the door at any location on the panel. Load-bearing surface: 100 mm by 100 mm (4 in by 4 in). Deflection under these conditions: Maximum 10 mm (0.4 in), with no permanent deformation after the force is removed. 6.4.4 Sealing Requirements Seal door panels and doorways: 1. Weather seal: Watertight under these conditions: a. When the vehicle is being washed LTK Standard Streetcar Specifications Section 6 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors b. For all service speeds with the worst case combination of climatic conditions described in Section 2, Design and Performance Criteria 2. Air seal: Sufficient to maintain required HVAC pressurization 3. Seal locations: a. b. c. d. Vehicle body edges Forward edge of the door where the panels meet in the closed position Top edge of the door Bottom edge of the door 4. Maintainability: Apply seals in a manner that enables them to be easily replaced with the door panels in place. 6.5 Manufacturing and Installation Requirements Comply with the following requirements for doors and door equipment: 1. Manufacturing: a. Use jigs and fixtures for doorways, mounting points, hardware, and other door-related features of the vehicle, with dimensions and tolerances as defined by the door manufacturer, and in accordance with the standards of workmanship specified in Section 16, Materials and Workmanship. b. Doors and door equipment shall be interchangeable from one location to any other location and from vehicle to vehicle without modification. 2. Installation: a. Install according to the door manufacturer's requirements and tolerances. Modifications to door equipment is prohibited. b. Make permanent to each doorway shimming or other adjustments made to achieve proper door fit. 6.6 Performance Requirements Comply with the following: 1. Door motion: Smooth and free of shock and impact. At the end of travel, provide smooth deceleration in both the opening and closing directions. 2. Control delay-time: Maximum 0.15 second from receipt of a door command signal from the Cab Console or local door pushbutton to the first motion of a door panel. 3. Door panel operating speed: a. Initial setting: 200 mm/s (8 in/s) in opening and 200 mm/s in closing, plus or minus 30 mm/s (1.2 in/s), from time of first motion to the point of completion, including cushioning. b. Maximum door closing speed: 300 mm/s (12 in/s). c. Operating speeds shall be adjustable by the Owner via PTU (see Section 17, Electronic Controls, Software, and MDS). LTK Standard Streetcar Specifications Section 6 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.7 Door Operator 6.7.1 General Provide door movement via one electrical operator per doorway: 1. Power: Sufficient to open and close doors at specified performance levels with the most unfavorable ambient wind, vehicle pressurization conditions, and grade. 2. Operation: Left and right door panels shall move simultaneously. 6.7.2 Operator Mechanical Requirements Comply with the following: 1. Connection between door operator and door panels: a. Mechanical via screw shaft, linkages, or toothed belts. b. Fluid or pneumatic devices are not permitted. 2. Location of operator equipment: a. In the transom area above the doorway. b. Concealed, except as necessary for the sliding mechanism, such that it is not directly visible when the door is opening and closing, or when door is in fully closed position. 3. Access to operator: a. By opening a cover or removing an access panel, without the need to move or disconnect other equipment. b. Provide sufficient clearance and access space to maintain components on the operator assemblies, and to remove the assemblies as complete units. 4. Door tracks: Locate within the vehicle body or within the door panel. 5. Separate sliding door lock assemblies: Locate within the vehicle body, if required by the door design. 6.7.3 Operator Electrical Requirements Comply with the following: 1. Power source: Low-voltage dc power system. 2. Voltage range: Capable of operating over the entire voltage range of the low-voltage dc power system without affecting the reliability, specified performance, or service life of the operator. 3. Stall current: a. The operator shall be capable of withstanding stall current indefinitely. b. Alternately, it shall be capable of detecting stall current and removing power if it persists for a preset time, and shall reset automatically when the door controls are cycled. c. Stall current shall have no adverse effect on the reliability and service life of the equipment. 6.8 Door Control System 6.8.1 General Comply with the following: 1. Door operator control type: Microprocessor-based control logic unit. 2. Location: Either immediately adjacent to, or within the door operator compartment. LTK Standard Streetcar Specifications Section 6 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 3. Design requirements: Comply with Section 2, Design and Performance Criteria, and Section 17, Electronic Controls, Software, and MDS. 6.8.2 Control and Monitoring The door control system shall control and monitor the door system, including the following: 1. Door motion control: a. b. c. d. e. f. Opening speed Closing speed Closing forces Detection of stalls Acceleration and deceleration Door-close time delays 2. Command and status monitoring: a. Commands from the Cab Console and local passenger switches b. No-motion status c. Door obstructions 3. Door Position Monitoring: a. Monitor continuously from fully opened to fully closed. b. Provide position sensing via non-contact proximity-type sensors not requiring adjustment. c. This position sensing is in addition to the position sensing requirements in the Interlock Requirements section, below. 6.8.3 Diagnostics, Data Network, and Adjustments 6.8.3.1 Diagnostics Comply with the following: 1. Status of door system: Available via a diagnostic system integral to the door control system software. 2. Monitored items: a. b. c. d. Critical internal functions External inputs Mechanical door system, including door open, closed, and lock status Actual door performance, such as door speeds on opening and closing 3. Access to diagnostics: Available from each door control logic unit either via separate connector at the control logic unit, or via the network connector itself. 6.8.3.2 Data Network Each door control logic unit shall be linked to the vehicle's data network: 1. Status and diagnostic information: Shall be available at a single common location, and on the TOD, from each door. See Section 17, Electronic Controls, Software, and MDS. 2. Inter-communication: Door control logic units in the vehicle may communicate with each other, but interfaces with the vehicle door and commands and no-motion interlocks shall be on a perdoorway basis. LTK Standard Streetcar Specifications Section 6 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 3. Failure of network links: a. Shall have no effect on door operation. b. Shall be announced at the diagnostics port and TOD. 6.8.3.3 Adjustments Comply with the following for adjustments of the door control system: 1. Permissible adjustments: All operating variables, including but not limited to the following: a. Door opening and closing speeds b. Door closing forces c. Door timing 2. Adjustment access: Locally and via the vehicle’s network, using a laptop computer and software provided by the door supplier. 6.9 Door Operation 6.9.1 General Doors may be opened using switches on the Cab Console, passenger switches, or the crew door-switch. 6.9.2 Door Operation Restrictions Door operation shall be possible only under the following conditions: 1. The vehicle has achieved no-motion; and 2. The Master Controller is in the FSB position; and 3. If the MC key switch is in the Off position, the Hotel Load timer has not yet expired. 6.9.3 Cab Console Controls Provide pushbutton door controls on the Cab Console as described in Section 5, Operator’s Cab and Controls. In addition, comply with the following: 1. Door Open: a. The Open command shall be interlocked with the no-motion circuitry both in the cab, and at each doorway, independently of the Enable command; b. An Open command shall override any ongoing obstruction detection activities, and reset the obstruction detection counter to zero. 2. Door Enable: a. The Enable command shall be interlocked with the no-motion circuitry both in the cab and at each doorway. b. The door enable function shall not be affected by vehicle or local network failures. 3. Door Close: Upon successful closing, the door obstruction counter shall be reset to zero. LTK Standard Streetcar Specifications Section 6 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.9.4 Passenger Controls 6.9.4.1 Pushbuttons and Tape Switch At each doorway: 1. Provide illuminated pushbuttons, one inside the vehicle and one outside the vehicle, to control doors: a. Type: Momentary contact, heavy-duty, recessed to prevent inadvertent operation, suitable for frequent use in the Project rail transit environment, rated IP65. b. Illumination: Red and green LED, to indicate active and non-active status. c. Color: Pushbutton and surrounding bezel color-coded with an approved color. d. Identification: Switch nomenclature or symbol molded into the switch in raised lettering, dimensioned to permit sensing by a visually impaired person. At each mobility aid parking area: 1. Provide a means for passengers in mobility aids to activate the passenger stop request, such as with a linear or tape switch, mounted horizontally: a. Type: Momentary contact, heavy-duty, impact resistant, easy to operate, suitable for frequent use, rated IP65. b. Color: Provide colored switch, or mount over a colored band at least 25 mm (1 in) wide to improve visibility, using an approved color. c. Identification: Nomenclature or symbols indicating function of switch and how to operate, as suitable for the type of switch, dimensioned to permit sensing by a visually impaired person, on or adjacent to switch. 6.9.4.2 Door Open Function Door Enable command activated by the operator: 1. Inside and outside passenger door pushbuttons shall illuminate green. 2. Pressing a passenger door pushbutton shall cause the respective door to open. 3. Door shall stay open for a preset time, then automatically close: a. Initial preset time: 10 seconds. b. Adjustability: May be set by the Owner to any value between 0 and 60 seconds, and to infinite time such that the doors remain open until commanded closed. Door open: The associated passenger pushbuttons shall be disabled and go dark. 6.9.4.3 Passenger Stop Request Function Door Enable command not activated by the operator: 1. Interior passenger pushbuttons shall provide passenger stop request function. 2. Activation of the passenger stop request anywhere in the vehicle: a. Passenger area: Sound the local stop request chime only. b. Operator's cab: • • Sound an audible alert for 0.5 seconds, then latch Off. Illuminate a light on the Cab Console. LTK Standard Streetcar Specifications Section 6 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors • Reset audible alert and light after the doors have been closed by the operator via the Door Close cab control. 6.9.5 Crew Door-Switch Provide crew door-switches on each vehicle: 1. Location: a. At each doorway closest to the cab, on each side of the vehicle. b. Inside and outside the vehicle, a total of two per each doorway. c. Locate outside switches beyond the open position of the door panel. 2. Switch Description: a. Weatherproof, momentary electrical rotary switch. b. Three positions: Open, Neutral, and Close with spring return to center (Neutral). c. Operated by a key (see Section 14, Interior and Exterior Appointments, for the Key Assignment Table). 3. Switch Operation: a. Turning the switch momentarily to the Open position, without holding it in that position, shall cause the adjacent door to open fully. If both cabs are keyed Off it shall turn On the Auxiliary On/Off switch and start the Hotel Load timer (See Section 5, Operator’s Cab and Controls). b. Turning the switch momentarily to the Closed position, without holding it in that position, shall cause the door to completely close and lock. 4. Comply with the following: a. Crew door-switch and related circuits shall have applied power only when both cabs in the vehicle are keyed Off, or when the vehicle has reached no motion and the Master Controller is in a brake position. b. Arrange crew door-switch and adjacent door operator such that they can function independently of the Cab Console controls. c. Crew door-switches and associated circuits shall be considered a safety circuit, and shall meet the safety requirements of Section 2, Design and Performance Criteria. 6.9.6 Loss of Control Power In the event of loss of local control power, doors shall remain in the last commanded position during absence of control power and when power is restored. 6.10 Door Locks Door panels shall be positively retained in the closed position via mechanical means: 1. Lock function: Separate mechanical lock, or an over-center function of the operating linkage, if the linkage is directly connected to the door panels. 2. Drive belt (if used): Lock mechanism shall not rely on the belt. 3. Lock engagement: Automatic when both door panels reach the closed position; electrical power shall not be required to maintain locked status. LTK Standard Streetcar Specifications Section 6 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.11 Door Obstruction Detection 6.11.1 General The door system shall automatically detect obstructions, prevent a person from becoming entrapped, and limit the forces imparted to a person standing anywhere in the doorway. 6.11.2 Detection Methods Provide two means of detection: 1. Electrical sensitive edge: Incorporate within the leading edge of each door panel. The design, sensitivity, and response of each panel to obstructions shall be the same. 2. Restrictions in door motion: Detect via current sensing, speed vs. time tracking, or other approved method. 6.11.3 Operation Requirements Upon detection of an obstruction, the door panels in the affected doorway shall perform as follows: 1. Immediately decelerate. 2. Open and remain open for a preset period controlled by an adjustable time delay circuit, adjustable in software from 0 to 10 seconds. 3. Attempt to close. 4. If the obstruction is no longer detected, close and lock. 5. If the obstruction is still detected, continue to recycle for a preset number of times. 6. If the recycle count is exceeded, remain in the open position until reset by the vehicle operator via cab controls (see Section 5, Operator’s Cab and Controls, for a functional description of door controls). The recycle count shall be software settable by the user, initially set to 5. 6.11.4 Maximum Force The kinetic energy contained within the door system during door closing shall be maximum 10 J (7.4 ft-lbf). 6.11.5 Sensitivity Requirements Comply with the following: 1. Each door panel's obstruction detection system shall detect any force opposing door motion (stall force), at any position in the door travel from fully open to fully closed, as follows: a. Single panel doors: Greater than 130 N (29 lbf). b. Dual panel doors: Greater than 200 N (45 lbf). 2. The obstruction detection system shall detect the following for each panel separately: a. Flat bar: • • • Size: 10 mm (0.4 in) wide and 75 mm (3 in) high; Position: Held rigidly between and perpendicular to the door panel, as a hand might be held to stop the doors; Sensitive Area: Everywhere along the length of the panel except the uppermost 75 mm (3 in) of the nosing seal. b. Cylindrical object: LTK Standard Streetcar Specifications Section 6 9 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors • • • Size: 20 mm (0.8 in) in diameter; Position: Held rigidly between and perpendicular to the door panels; Sensitive Area: All locations along the length of the door nosing seal, except the uppermost 75 mm (3 in) and lowermost 25 50 mm (1 2 in) of the seal. 6.11.6 Obstructions Not Detected The door edge shall allow a thin flexible object not detected by the obstruction detection system, such as an article of clothing, to be pulled free from the leading edge of a door that is fully closed and locked. 6.12 Manual Door Release Mechanism 6.12.1 Functional Description Provide interior and exterior manually-operated door release mechanisms to permit doors to be opened locally regardless of the availability of electrical power or door status, including a previously cut out door: 1. Activation of the release device shall unlock the door and open the door approximately 25 mm (1 in) to permit the door to be manually pushed open. 2. Power shall be removed from the door motor, but the door controller shall remain active if power is available. 3. The door controller shall monitor and annunciate activation of the manual release to the vehicle network. 4. The release device shall not electrically bypass the local no-motion interlock. 5. Activation of the release device shall interrupt the door status interlock, causing propulsion power to be removed and a FSB brake application to be applied. 6.12.2 Interior Manual (Emergency) Door Release Provide a lever or pull knob device at each doorway in a location accessible to all passengers: 1. Design and location: Select to prevent inadvertent operation and discourage everyday use. 2. Signage: Explain operation in an emergency, warn against unlawful use, and advise that emergency door opening device is also an emergency stop device. 3. Annunciation when activated: As specified in the Indicators and Annunciators section, below. 6.12.3 Exterior Manual Door Release Provide two manual door release devices meeting the following requirements: 1. Location: Diagonally opposite each other on each side of the vehicle, above platform level. 2. Mechanism: Waterproof; operable without a key. 3. Functionality: Same as the interior device, except Passenger Emergency message shall not be sent when activated. 4. Cover: Flush with the side of the vehicle when closed, locking (see Section 14, Interior and Exterior Appointments, for the Key Assignment Table) 5. Graphics: Provide adjacent to each cover, suitable for emergency responders or other users. 6.12.4 Reset Device Comply with the following: 1. Function: Restores doors to normal operating condition after use of the manual release mechanism. LTK Standard Streetcar Specifications Section 6 10 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 2. Operation: Via key (see Section 14, Interior and Exterior Appointments, for the Key Assignment Table). 3. Location: Within the door control panel or transom area above the doors. 6.13 Door Interlock Requirements 6.13.1 No Motion Interlock Electrically interlock door operators and controls in a failsafe manner with the vehicle's no-motion circuits, such that doors can be powered, opened, or released only when the vehicle has reached nomotion: 1. No-motion lost: Door motor Open wiring shall be switched Open with critical circuit relays. Door motor's Close circuits shall remain connected. 2. Motion detected: Close command shall be issued to all doors in the vehicle. 3. Vehicle in motion: Diagnostic and fault monitoring and logging shall remain active. 4. Controllers: a. Shall monitor no-motion circuits independent of the motor interlocks. b. Shall ignore Open or Enable commands without a no-motion signal present and if this condition occurs, issue a fault indication. 6.13.2 Door Status (Open) Interlock Provide circuitry to monitor door panel position and door lock status for each side of the vehicle: 1. Components: High reliability position-sensing switches for each panel, and separate switches for detection of lock status. a. Switches shall positively and directly detect actual panel and lock positions. These switches are in addition to those specified above for the Door Control System. b. Switch mounting shall be such that no readjustment is necessary when a switch is replaced. c. Tolerances for switch, switch mounting device, and door component shall not permit a newly installed switch to indicate a false close or locked status. 2. Circuitry: Wire switches on each side of the vehicle in series. 3. Function: a. Door panels properly closed and locked: Activate a Summary Door Status non-welding critical circuit relay. b. One or more closed or locked switches not made up: • • • • De-energize the Summary Door Status relay; Illuminate the Cab Console Door-Open light for that side of the vehicle; Remove propulsion power; and Apply Full Service Brake (FSB). c. Operating sequence if the vehicle operator attempts to apply power with a door panel not closed and locked: • • • Summary Door Status relays must be energized Master Controller must be moved to the FSB position Brakes can be released and power applied LTK Standard Streetcar Specifications Section 6 11 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 4. No false signals: a. No single point failure in the loop circuit shall cause a false door closed and locked signal. b. Where failures in the loop circuit are not self-annunciating, they shall not lead to a false doors closed and locked signal, from the door interlock circuit, or in association with other single point failures. 6.14 Door Bypass Devices 6.14.1 General Provide bypass devices to circumvent specific door system faults so that the vehicle can continue in revenue service, or be removed from revenue service and returned to the maintenance facility, or moved to clear the line. 6.14.2 Door Interlock Bypass Provide a door interlock bypass feature in each cab (see Section 5, Operator’s Cab and Controls): 1. It shall permit movement of the vehicle under emergency conditions in the event that not all doors are sensed as being closed and locked, and the source of the fault cannot be readily determined. 2. It shall bypass the door status interlock so that the brakes can be released and power applied. 3. It shall not provide a false Doors Closed indication. 6.14.3 Door Cutout Provide a door cutout device in an approved location adjacent to each door, behind a locked cover, that performs the following functions: 1. Disconnects door motor from any source of electrical power; 2. Bypasses door-closed and door-locked interlocks for that door. 3. Ensures that the door remains closed by mechanical restraint, but allows override by the manual door release devices, which allow the door to be opened in case of emergency. 4. Illuminates the local passenger pushbutton light Red. The door controller shall remain active when the door is cut out. 6.15 Indicators and Annunciators 6.15.1 Door Open Indications Provide two Door Open indicator status lights on the TOD, one for each side of the vehicle. The indicators shall be illuminated when any door on the associated side of the vehicle is sensed as being unlocked, open, or both. 6.15.2 Manual (Emergency) Door Release Activation of an interior manual door release (Passenger Emergency) shall cause the following: 1. At the doorway: Audible and visual warning. 2. In each cab (door controller active): a. Audible alert b. On TOD: Annunciation of "PASSENGER EMERGENCY" LTK Standard Streetcar Specifications Section 6 12 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.15.3 Door Closing Warning Announcements Provide audible and visual door closing warnings independently for each doorway: 3. Audible door closing warning: a. Duration: For 2 seconds prior to doors closing (adjustable 0 - 2 seconds) b. Sound: Pleasant two-tone alarm, audible inside and outside the vehicle c. Source: The warning may be generated by any of the systems, with the Owner’s approval, such as the following: • • • The local door control system The PA system The automatic passenger information system 4. Visual door closing warning: a. b. c. d. Timing: Provide at the same time as audible warning Appearance: Flashing amber Location: Both sides of each doorway on the side of the door frame Visibility: Inside and outside the vehicle with doors in the open position 6.16 Door Control Signals See Section 17, Electronic Controls, Software, and MDS, for door system control signal requirements. 6.17 Bridge Plates 6.17.1 Design 6.17.1.1 Integration Integrate the bridge plate system with the door system. 6.17.1.2 ADA and Interface Requirements Comply with the following: 1. Bridge plates shall meet ADA requirements, 49 CFR 38 Subpart D, and the station platform interface requirements of Section 2. 2. The bridge plate ramp design shall comply with 49 CFR Part 38.83 (c), Vehicle ramp or bridge plate, except that the bridge plate width shall be no less than the width of the fully open doorway: a. The referenced bridge plate side barriers are not required. b. The referenced 50% load requirement shall be interpreted as AW2 loading. 6.17.1.3 Safety Design bridge plates in accordance with the safety requirements of Section 2. No single point failure of the bridge plate system shall cause: 1. A bridge plate to unlock or deploy when a deploy request has not been commanded. 2. A bridge plate deploy command to be transmitted or responded to when the train is in motion. 3. A bridge plate retracted and locked indication to be transmitted when any bridge plate is unlocked or deployed. 4. A traction interlock okay status when a bridge plate is unlocked or deployed. LTK Standard Streetcar Specifications Section 6 13 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 5. A bridge plate retracted indication to be transmitted when an unlock or opening command is stored anywhere in the system. 6.17.1.4 Dynamic Performance Comply with the following: 1. Bridge plates shall be vibration and rattle free while the vehicle is underway and when the vehicle is stationary and bridge plates are deployed. 2. The bridge plate system, in conjunction with the vehicle's aerodynamics, shall prevent whistling and other objectionable noises at all vehicle speeds. 6.17.1.5 Adjustability Include provisions in the bridge plates for independent adjustments to location and alignment of the operator and other components to accommodate equipment installation, replacement, and system wear. 6.17.2 Manufacturing and Installation Comply with the following: 1. Manufacturing: a. Bridge plates and related equipment shall be interchangeable from one location to any other location and from vehicle to vehicle. b. Use jigs and fixtures for bridge plate, components, and mounting holes for hardware to ensure interchangeability, in accordance with the standards of workmanship specified in Section 16, Materials and Workmanship. 2. Installation: According to the manufacturer's requirements and tolerances. 6.17.3 Location, Size, and Strength Comply with the following: 1. Location: The bridge plate and its mechanisms shall be beneath the door threshold at locations specified in Section 2, Design and Performance Criteria. 2. Size: The bridge plate shall span the full useable width of the door opening, and be capable of filling the vertical and horizontal gaps encountered at station platforms. 3. Strength: The ramp shall support a load per 49 CFR 38.83 (c) (1), Design load. 6.17.4 Ramp Configuration Comply with the following: 1. Doorway threshold: a. Include an interior hinged portion that extends with the bridge plate, such that the bridge plate and doorway threshold form a continuous ramped surface. b. The threshold specified in Section 14, Interior and Exterior Appointments, may be integral to the bridge plate assembly at bridge plate doors. 2. Ramp slope: Shall not exceed ADA requirements, referenced above, under the following conditions: a. Minimum platform height LTK Standard Streetcar Specifications Section 6 14 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors b. New wheels c. Maximum floor height of vehicle loaded to 50% of AW2 passenger load 3. Ramp and threshold edges: a. Thickness: Minimum 3 mm (1/8 in) and maximum 13 mm (1/2 in) b. Treatment: Beveled, and rounded to eliminate sharp edges 4. Wear strip: a. Type: Replaceable b. Material: Same as ramp c. Location: At or beneath the outboard edge of the ramp where it contacts the wayside platform 5. Platform interface: The bridge plate shall function correctly, and without interference, at the maximum platform height with all vehicle weights of AW0 to AW3, wheel wear of up to 10 mm (0.4 in) radius unless compensated. 6.17.5 Material and Components Comply with the following: 1. 2. 3. 4. 5. Structural components: Aluminum or stainless steel. Guide rollers (if used): Stainless steel with permanently lubricated bearings. Other rolling and sliding surfaces: Designed not to require periodic lubrication. Ramp and threshold: Cast aluminum or stainless steel. Ramp surface: Slip resistant, with static coefficient of friction 0.8. Adhesive backed, non-skid "tape" or sheets are not permitted. 6.17.6 Operator Comply with the following: 1. Type: Electrically operated. 2. Operation: a. Deploy bridge plate horizontally outward and then allow it to tilt downward to meet and rest on platform surface. b. The bridge plate shall be able to extend and then retract without landing on a platform. 3. Vertical range of motion: Sufficient to allow ramp to rest on the platform surface by gravity alone under all specified conditions. 4. Manual operation: Provide a manual operator that allows bridge plate to be manually deployed or retracted in the event of power failure: a. The mechanism shall not be readily accessible to passengers, or require removal of any floor paneling. b. Bridge plate interlocks shall not be defeated by manual operation. 6.17.7 Control System 6.17.7.1 General The bridge plate controller may be integrated with the door controller. LTK Standard Streetcar Specifications Section 6 15 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.17.7.2 Control and Adjustment The bridge plate control system shall control and allow adjustment of the following, and similar features via laptop computer and software provided by the bridge plate supplier: 1. 2. 3. 4. Extend speeds, forces and timing Extend obstruction detection threshold force Retract speeds, forces and timing Retract obstruction detection threshold force 6.17.7.3 Monitoring and Position Sensing The bridge plate controller shall monitor the performance and position of the bridge plate to accomplish the following: 1. Detect stalls or obstructions over the full travel length 2. Detect positioning on extension and retraction 3. Detect lock status Position and lock status shall be via non-contact proximity-type sensors not requiring adjustment. 6.17.8 Operation 6.17.8.1 General Bridge plates may be extended by the vehicle operator, or by passengers on the inside or outside of the vehicle. See Section 5, Operator’s Cab and Controls, for operator control. 6.17.8.2 Operation Restrictions Bridge plate operation shall be possible only under the following conditions: 1. 2. 3. 4. The vehicle has achieved no-motion, and The Master Controller is in the FSB position, and The associated door is in the closed position, and The MC Key Switch is in one of the following positions: a. On position. b. The operator has Enabled the doors, then moved the MC key switch to the Off position. This shall enable the local bridge plate request pushbuttons until the Hotel Load timer has expired. 6.17.9 Passenger Controls 6.17.9.1 Control Switches At each bridge plate doorway: 1. Provide illuminated bridge plate request pushbuttons, one inside the vehicle and one outside the vehicle: a. Type and illumination: Comply with the Pushbuttons and Tape Switch section, above. b. Color: Comply with the Pushbuttons and Tape Switch section, above, except color shall be different from door control switches. c. Identification: Comply with the Pushbuttons and Tape Switch section, above, except also provide the International Symbol of Accessibility (wheelchair) on or adjacent to the switch. LTK Standard Streetcar Specifications Section 6 16 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors At each mobility aid parking area: 1. Provide a means for passengers in mobility aids to activate the passenger bridge plate request, such as with a linear or tape switch, mounted horizontally: a. Combined switch: The passenger bridge plate request switch may replace the passenger stop switch specified in the Pushbuttons and Tape Switch section, above. b. Identification: Comply with the Pushbuttons and Tape Switch section, above, except also provide the International Symbol of Accessibility (wheelchair) on or adjacent to the switch. 6.17.9.2 Passenger Control Functional Description The local passenger bridge plate request pushbuttons shall operate as follows: 1. When not enabled by the Door Enable or Door Open command, the inside passenger bridge plate pushbuttons shall function as a passenger bridge plate request. When a pushbutton is depressed: a. In the passenger area, sound the local passenger stop request chime. b. In the operator’s cab, sound an audible alert for 0.5 seconds and illuminate Bridge Plate Request indicator. Once activated, the audible alert shall be latched off and indicator shall stay illuminated until the doors have been closed or the bridge plate retracted by the operator. c. Send a bridge plate request to all bridge plate controllers on the vehicle. The operator door and bridge plate commands shall control which bridge plate is extended. 2. When enabled by Door Enable command: a. The inside and outside passenger bridge plate pushbuttons shall illuminate. b. Pressing a pushbutton with the bridge plate door open shall: • • • • • Close associated door Start interior and exterior bridge plate movement audible warning Extend bridge plate Stop interior and exterior bridge plate movement audible warning Open associated door c. Pressing a pushbutton with the bridge plate door closed shall: • • • • Start interior and exterior bridge plate movement audible warning Extend bridge plate Stop interior and exterior bridge plate movement audible warning Open associated door 6.17.10 Loss of Control Power In the event of a loss of local control power, the bridge plate shall remain in the last commanded position during absence of control power and when power is restored. 6.17.11 Locks The bridge plate shall be positively retained in the retracted position via mechanical means: 1. Type: May be a separate mechanical lock or an over-center function of the operating linkage, if the linkage is directly connected to the bridge plate. LTK Standard Streetcar Specifications Section 6 17 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 2. Drive belt (if used): Lock mechanism shall not rely on the belt. 3. Operation: Lock shall automatically engage when bridge plate reaches retracted position, and shall not require electrical power to remain locked. 6.17.12 Performance Comply with the following: 1. Bridge plate motion: Smooth and free of shock and impact. 2. Control delay-time: Maximum 0.15 seconds from receipt of a bridge plate command signal by the operator or local bridge plate pushbutton to the first motion of the bridge plate. 3. Bridge plate operating speed: a. Initial setting: 200 mm/s (8 in/s) in extending and 200 mm/s (8 in/s) in retraction plus or minus 30 mm/s (1.2 in/s), from time of first motion to the point of completion, including cushioning. b. Maximum speed: 300 mm/s (12 in/s). c. Operating speeds shall be adjustable by the Owner via PTU (see Section 17, Electronic Controls, Software, and MDS). 6.17.13 Obstruction Detection 6.17.13.1 General The bridge plate system shall automatically detect obstructions, prevent a person from becoming entrapped, and limit the forces imparted to a person when the bridge plate is extending or retracting. 6.17.13.2 Detection Methods The bridge plate control equipment shall detect restrictions in bridge plate motion via current sensing, speed vs. time tracking, or other approved method. If the bridge plate is equipped with movable side barriers, the detection shall detect an obstruction within the movement of the side barriers. 6.17.13.3 Operation Requirements Comply with the following: 1. Upon reaching the detection threshold, the bridge plate shall perform as follows: a. Immediately decelerate and stop. b. Send a fault message to the operator. 2. Fault reset: After activation of operator bridge plate Retract/Extend command the bridge plate shall continue with the last commanded movement, extend or retract. 6.17.13.4 Sensitivity Requirements Comply with the following: 1. Detection threshold: Force opposing bridge plate motion exceeding 130 N (29 lbf). 2. Threshold adjustment: User adjustable from 130 N (29 lbf) to 400 N (90 lbf). LTK Standard Streetcar Specifications Section 6 18 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.17.14 Indicators and Annunciators 6.17.14.1 Bridge Plate Extended Indicators Provide bridge-plate-extended indicator status lights: 1. Quantity: Two, one for each side of the vehicle. 2. Location: On the TOD 3. Activation: When any bridge plate on the associated side of the vehicle is sensed as being unlocked, extended, or both. 6.17.14.2 Bridge Plate Warning Announcement Provide audible and visual door closing warnings independently for each bridge plate indicating that bridge plate is moving, extending, or retracting: 1. Audible bridge plate warning: a. Activation: 2 seconds prior to the bridge plate moving (adjustable 0 - 2 seconds) b. Termination: When extension or retraction is complete c. Sound: Different from the audible door warning, generated electronically by the local bridge plate control system, audible inside and outside the vehicle d. Location: Vehicle exterior, adjacent to the bridge plate e. The warning shall function only at bridge plates where motion is commanded 2. Visual bridge plate warning: a. b. c. d. Timing: Provide at the same time as audible warning Appearance: Flashing amber Location: Both sides of each doorway on the side of the door frame Visibility: If the visual door warning cannot be seen from outside the vehicle with the doors closed, provide a duplicate weatherproof device on the outside of each doorway e. The door closing visual warning can be used for the bridge plate movement visual warning 6.17.14.3 Status Indicators Show the following bridge plate status indications on the TOD: 1. 2. 3. 4. 5. Extended Enabled Retracted and Locked Cutout Failure and/or fault 6.17.15 Bridge Plate Interlock Requirements The following door interlocks shall also apply to bridge plates: 1. No Motion Interlock: Requirements for door operators and controls shall apply to bridge plate operators and controls, such that the bridge plates can be powered and released only when the vehicle has reached no motion. 2. Door Status (Open) Interlock: Requirements for components and circuitry to monitor door panel position and lock status shall apply to bridge plates, and shall indicate whether door panels are properly closed and locked and bridge plates are retracted and locked. LTK Standard Streetcar Specifications Section 6 19 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors 6.17.16 Bridge Plate Bypass Devices 6.17.16.1 General Refer to the Door Bypass Devices section, above, for details related to these devices. Requirements for doors apply also to bridge plates. 6.17.16.2 Door Interlock Bypass Applied to Bridge Plate This door interlock bypass switch shall bypass the interlock which prevents propulsion in case of a deployed bridge plate, in addition to its function related to the door interlock circuit, as specified in Section 5 and this Section. 6.17.16.3 Bridge Plate Cutout Provide a bridge plate cutout device in an approved location adjacent to each bridge plate door, behind a locked panel, that performs the following functions: 1. Disconnects bridge plate motor from any source of electrical power. 2. Ensures that the bridge plate remains retracted by mechanical restraint. 3. Indicates bridge plate cutout on TOD. 6.18 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. 6-1 Detail drawings: Top level assemblies, and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values Door and Bridgeplate Platform Interface Design Report: 1. Vehicle dynamic envelope drawing. 2. Detail drawings: Show platform interface dimensions, including platform and vehicle tolerances. 6-2 Door System Design Package: 1. Door Design Report a. b. c. d. e. Door drawing with general description and materials Door operator details and drawings Door lock and details Interior and exterior manual (emergency) release details and drawings Door Diagnostics and Adjustments 2. Obstruction Detection Design Report: a. Design and methods for door obstruction detection b. Door closing kinetic energy calculation and results. 3. Door Indication and Warning Design Report: LTK Standard Streetcar Specifications Section 6 20 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors a. Functional description b. Location drawing c. Part specification and drawing d. Audible warning tone and intensity 4. Vehicle door integration Design report a. Dimensioned vehicle door equipment location drawing, plan and elevation views b. Door Control Switches: • • • 6-3 Data sheets for crew door-switches and passenger control-switches, including sizes, bezels, colors, graphics, and other features Sample of each switch, pushbutton, and tape switch. Switches will be returned to the Contractor. Submit door control switches located in cab under Section 5, Operator’s Cab and Controls, not as part of this package Door Control System Design Package: 1. 2. 3. 4. 5. Door controller System circuit diagrams Sneak circuit and single point failure analysis Interlocks and safety critical functions Door Interlock Design Report: a. No motion interlock: • • System circuit diagrams Critical circuit relays b. Door Status (Open) Interlock: • • • 6-4 System circuit diagrams Position sensing switches Non-welding critical circuit relay Bridgeplate System Design Package: 1. Bridgeplate Design Report a. b. c. d. Bridgeplate details and drawings Bridgeplate lock and details Interior and exterior manual (emergency) release details and drawings Bridgeplate Diagnostics and Adjustments 2. Obstruction Detection Design Report: a. Design and methods for Bridgeplate obstruction detection b. Bridgeplate opening kinetic energy calculation and results. 3. Bridgeplate Indication and Warning Design Report: a. Functional description b. Location drawing c. Part specification and drawing LTK Standard Streetcar Specifications Section 6 21 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Passenger Doors d. Audible warning tone and intensity 4. Vehicle Bridgeplate integration Design report a. Dimensioned vehicle door equipment location drawing, plan and elevation views b. Bridgeplate Control Switches: • • • 6-5 Data sheets for crew door-switches and passenger control-switches, including sizes, bezels, colors, graphics, and other features Sample of each switch, pushbutton, and tape switch. Switches will be returned to the Contractor. Submit Bridgeplate control switches located in cab under Section 5, Operator’s Cab and Controls, not as part of this package Bridgeplate Control System Design Package: 1. 2. 3. 4. 5. Bridgeplate controller System circuit diagrams Sneak circuit and single point failure analysis Interlocks and safety critical functions Bridgeplate Interlock Design Report END OF SECTION LTK Standard Streetcar Specifications Section 6 22 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning Table of Contents 7.1 General ........................................................................................................................................1 7.1.1 Scope ................................................................................................................................................ 1 7.1.2 Power Source ................................................................................................................................... 1 7.1.3 Quality Requirements ...................................................................................................................... 1 7.2 System Design ..............................................................................................................................1 7.3 Unitized Package ..........................................................................................................................1 7.3.1 HVAC Units ....................................................................................................................................... 1 7.3.2 HVAC Enclosure ................................................................................................................................ 2 7.4 Air Distribution.............................................................................................................................2 7.4.1 General ............................................................................................................................................. 2 7.4.2 Ducts and Diffusers .......................................................................................................................... 2 7.4.3 Air Filters .......................................................................................................................................... 3 7.5 Controls .......................................................................................................................................3 7.5.1 General ............................................................................................................................................. 3 7.5.2 Pump Down ...................................................................................................................................... 3 7.5.3 Controllers........................................................................................................................................ 3 7.5.4 Temperature Variation..................................................................................................................... 3 7.5.5 Overhead Heat Control .................................................................................................................... 3 7.5.6 Floor Heat Control............................................................................................................................ 4 7.5.7 HVAC Layover Mode ........................................................................................................................ 4 7.6 Heating ........................................................................................................................................4 7.6.1 General ............................................................................................................................................. 4 7.6.2 Heating Design Criteria .................................................................................................................... 5 7.6.3 Heating Temperatures ..................................................................................................................... 5 7.6.4 Overhead Heat ................................................................................................................................. 5 7.6.5 Floor Heat......................................................................................................................................... 5 7.7 Ventilation ...................................................................................................................................5 7.8 Air Conditioning ...........................................................................................................................6 7.8.1 General ............................................................................................................................................. 6 7.8.2 Cooling Design Criteria ..................................................................................................................... 6 7.8.3 Cooling Temperatures and Humidity ............................................................................................... 6 7.8.4 Refrigerant ....................................................................................................................................... 6 7.8.5 Compressors..................................................................................................................................... 7 LTK Standard Streetcar Specifications Section 7 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.8.6 Evaporators and Condensers ........................................................................................................... 7 7.8.7 HVAC System Devices ...................................................................................................................... 7 7.8.8 Air Conditioning System Piping and Fittings .................................................................................... 7 7.8.8.1 Layout and Design..................................................................................................................... 7 7.8.8.2 Type........................................................................................................................................... 8 7.8.8.3 Fabrication ................................................................................................................................ 8 7.8.8.4 Refrigerant Line Soldering ........................................................................................................ 8 7.8.8.5 Insulation .................................................................................................................................. 8 7.8.9 Air Conditioning System Charging and Testing ................................................................................ 8 7.9 Operator’s Cab Air Comfort System...............................................................................................9 7.9.1 General ............................................................................................................................................. 9 7.9.2 Cab Heaters ...................................................................................................................................... 9 7.9.2.1 General...................................................................................................................................... 9 7.9.2.2 Cab Heater Housing, Ducting, and Vents .................................................................................. 9 7.9.2.3 Cab Heater Capacity................................................................................................................ 10 7.9.2.4 Cab Heater Controls ................................................................................................................ 10 7.9.3 Cab HVAC Unit (Optional) .............................................................................................................. 10 7.9.3.1 General.................................................................................................................................... 10 7.9.3.2 Overhead Heat ........................................................................................................................ 10 7.9.3.3 Ventilation .............................................................................................................................. 11 7.9.3.4 Air Conditioning ...................................................................................................................... 11 7.9.3.5 Cab HVAC Unit Controls .......................................................................................................... 11 7.9.4 Cab HVAC ....................................................................................................................................... 11 7.9.4.1 Diffusers .................................................................................................................................. 11 7.9.5 Windshield Defrosting and Defogging ........................................................................................... 11 7.10 Contract Data Requirements List (CDRL) .................................................................................... 11 LTK Standard Streetcar Specifications Section 7 ii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.1 General 7.1.1 Scope This section includes air comfort systems for the passenger areas and for the operator's cab. 7.1.2 Power Source Provide power to the systems in this Section as follows (see Section 9, Electrical Equipment): 1. Air comfort systems: Three-phase ac from the auxiliary power supply. 2. Control systems: Low-voltage dc system. 7.1.3 Quality Requirements Comply with the following: 1. Quality Control: The equipment manufacturer shall have an ISO 9001 certified factory quality control program, as a minimum. 2. Manufacturer’s Instructions: Comply with manufacturer’s instructions for receiving, storing, lifting, installing, and commissioning equipment. 3. Service-Proven: Provide a system and components that meet the requirements for serviceproven design, as defined in Section 1, General Topics and Definitions. 7.2 System Design Provide required capacity in both heating and cooling/dehumidification to bring outside ventilation air and recirculated air to the specified interior temperature. Comply with the following design requirements: 1. 2. 3. 4. 5. Perform heat loss/heat gain calculations for each interior space. Base calculations upon recognized heating, ventilating, and air conditioning industry criteria. Use actual thermal transmission characteristics of the materials used in vehicle construction. Outdoor ambient temperatures: See the Design Criteria sections for heating and cooling, below. Heating Calculations: a. Do not include on-board electrical loads, such as lights. b. Assume no passengers. 6. Air Conditioning Calculations: a. Include all on-board electrical devices adding heat to the compartment. b. Assume AW2 passenger load. 7. Assume the adverse effects of exterior solar and wind conditions in all calculations, but assume no beneficial effects due to these outside influences. 7.3 Unitized Package 7.3.1 HVAC Units Provide HVAC in independent unitized packages (“HVAC units”) containing heating, ventilating, and air cooling components, and related controls, with the exception of floor heaters: 1. Location: Roof of the vehicle. LTK Standard Streetcar Specifications Section 7 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 2. Rapid removal: Attached using bolted fasteners and multi-pin electrical connectors only; no refrigerant circuit connections shall be required. 3. Quantity: Minimum one HVAC unit for each vehicle body section, with independent temperature regulation for each body section. 4. Independence: Failures in one HVAC unit shall not affect operation of the other units. 5. Communication link: Provide between all HVAC units. Alternative HVAC arrangements may be proposed for review and approval by the Owner. 7.3.2 HVAC Enclosure Provide HVAC enclosure including the following elements and meeting the specified requirements: 1. Frame: Stainless steel or corrosion-resistant aluminum. 2. Cover: a. Material: Same as frame, or composite material. Composite materials, where used in weather-exposed conditions, shall have appropriate UV inhibitors against break down in ambient sunlight sufficient for a 30-year life. b. Strength: Horizontal covers shall be capable of withstanding, without damage or permanent deformation, the loads from a 95th percentile male walking on the cover with a 12 kg (25 lb) toolbox. c. Design: Hinged-type that allows open access to all serviceable parts. 3. Drain pans: Stainless steel. 4. Gaskets: Units shall be fully gasketed to prevent ingress of rain and snow. 7.4 Air Distribution 7.4.1 General Provide an air distribution system throughout the vehicle: 1. Design: Based upon temperature uniformity requirements in the Temperature Variation section, below. 2. Air quantities: Sufficient to provide heating and cooling capacities calculated for vehicle interior spaces. 7.4.2 Ducts and Diffusers Convey supply air and return air through dedicated and sealed duct work: 1. Main air distribution ducts: a. Location: In vehicle ceiling. b. Insulation: Suitable to minimize noise, heat transfer through ducts and roof by direct conduction, and formation of condensation. c. Material: Non-flammable. 2. Air leakage: Maximum 5%, by volume, when measured at 20 degrees C (68 degrees F). 3. Supply air: Deliver to both sides of vehicle at ceiling level through continuous slot diffusers. 4. Diffusers: Adjustable by the vehicle manufacturer only, to permit adjustment of the airflow balance to maintain temperature differences within specified limits throughout vehicle interior. 5. Return air: Convey from the passenger area through ceiling return air grilles and dedicated ducts of the shortest possible length to HVAC unit. LTK Standard Streetcar Specifications Section 7 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.4.3 Air Filters Provide air filters for fresh and return air to remove airborne dirt, lint, and other fibrous material: 1. Access and replacement: Via a single cover opening/removal using common hand tools. 2. Size: Readily available commercial size. 3. Frames: Designed to accommodate both disposable cardboard-frame filters and metal-frame washable filters. 4. Filter type: Cardboard frame and Metal-frame, washable, reusable 5. Face velocity: Not to exceed filter manufacturer’s recommendation. 7.5 Controls 7.5.1 General Provide air comfort controls to accomplish the following: 1. Automatically activate appropriate operating modes. 2. Achieve specified temperature and humidity inside the vehicle depending on ambient and vehicle interior conditions and variable passenger and solar loads. 7.5.2 Pump Down Provide an automatic pump down circuit to reduce the possibility of refrigerant migration during off cycles. 7.5.3 Controllers Control HVAC functions using microprocessor-based control logic units: 1. Control logic units: Comply with Section 17, Electronic Controls, Software, and MDS. 2. Design requirements: Comply with Section 2, Design and Performance Criteria, and with Section 17. 3. Temperature sensors: Locate as necessary in the vehicle to achieve specified temperature regulation and other performance requirements. 4. Network: Link controllers to the vehicle’s data network, and provide warnings, status, and diagnostics information to the network and TOD (see Section 17). 5. Controls: Provide with status and fault indication displays, and locate for convenient observation by maintenance personnel. 7.5.4 Temperature Variation Vehicle interior temperatures shall not vary by more than 3 K (5.4 degrees F) per the following: 1. At any given time, except during pull-down and warm-up, among all points in the same horizontal plane from one end of the vehicle to the other, except for the articulation section. 2. At any given time, except during pull-down and warm-up, in the plane 1200 mm (47 in) above the floor and any point directly underneath, 150 mm (6 in) above the floor. 3. At any given point within the vehicle after stabilization, with the doors closed, due to cycling of HVAC equipment. 7.5.5 Overhead Heat Control Provide control circuitry to accomplish the following: 1. Regulate the required heat to the interior space. LTK Standard Streetcar Specifications Section 7 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 2. Prevent damage from excessive heat buildup in the heating element plenum, such as may occur with loss of air flow. As a minimum, provide the following sensors and controller functions: 1. Heater duty cycle: Regulate to meet control parameters corresponding to interior temperature requirements stated below in the Heating Temperatures section. 2. Air flow: Switch off overhead heat without sufficient air flow acknowledged by the controller. 3. High-limit temperature sensors: Provide adjacent to each overhead heater unit to detect excessive temperature: a. Upon detection of excessive temperature by either sensor, heater shall switch off and provide an indication to controller and TOD. b. If temperature cools below lower limit at both sensors, heater may switch on automatically. 4. Back-up protection device: Provide in addition to the heater circuit breaker, to remove power in the event of excessive current draw or excessive heat: a. The device shall be a fusible link, or approved equal, in the power line to the overhead heating elements. b. Provide a means to suppress the arc at rupture, if fusible links are used. 5. In the event of a controller failure, the heating elements shall fail in the power-off condition. 7.5.6 Floor Heat Control Provide controls to modulate floor heat and avoid temperature fluctuations in the passenger area. 7.5.7 HVAC Layover Mode Provide an HVAC layover mode: 1. Temperature settings: User-adjustable. 2. Initial settings: a. Layover heat: Maintain average vehicle temperature at 7 degrees C +/- 3 K (45 degrees F +/- 5 degrees F). b. Layover air conditioning: Maintain average temperature at 26 degrees C +/- 3 K (79 degrees F +/- 5 degrees F). 3. Activation: Automatic when the Hotel Load timer expires, as specified in Section 5, Operator’s Cab and Controls. 4. Cab dedicated HVAC: Apply HVAC Layover mode to cab HVAC units, also. 7.6 Heating 7.6.1 General Provide thermostatically controlled electrical heating using overhead heat and floor heaters. LTK Standard Streetcar Specifications Section 7 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.6.2 Heating Design Criteria Design the system based on the following winter conditions: Heating Design Ambient Temperature Passenger Load: Solar Load: Heating Load: -4 degrees C DB (25 degrees F DB) None None None 7.6.3 Heating Temperatures Comply with the following: 1. Heating capacity: a. Sufficient to maintain heating interior temperature within the range specified below. b. Sufficient without reliance on passenger heat contribution or solar loading as heat sources. 2. Heating interior temperature range: 18 to 22 degrees C (64 to 72 degrees F) with an ambient exterior temperature equal to the Heating Design Ambient Temperature. 3. Heating equipment surface temperature: Maximum 52 degrees C (125 degrees F) where exposed to passengers or operator. 7.6.4 Overhead Heat Incorporate heating elements into HVAC units: 1. Capacity: Sufficient to temper outside fresh air to required vehicle interior temperature for all heating conditions, as a minimum, and to compensate for the deficiency of floor-heater capacity (if used) if floor heaters cannot fully compensate for the vehicle-body heat loss due to lack of space. 2. Reheat function: Use overhead heating elements to provide reheat for dehumidification and cooling offset at conditions lower than design cooling conditions. 7.6.5 Floor Heat Provide floor heat using baseboard convection units: 1. Capacity: a. Sufficient to compensate for vehicle-body heat loss through conduction and radiation without consideration of any internal vehicle heat sources or heat from passengers. b. If every wall space suitable for floor heat has been used and floor heat capacity is still insufficient to compensate for vehicle-body losses, use overhead heat to supplement floor heat. 2. Surface temperature of heater guards: Maximum 52 degrees C (125 degrees F) in their installed configuration. 7.7 Ventilation Provide ventilation of each vehicle-body section of the vehicle, as part of the HVAC unit, using the air conditioning system evaporator unit blower fans: 1. Full ventilation: Continuously available in the event of cooling or heating apparatus failure. 2. Air distribution: By ducts and diffusers. LTK Standard Streetcar Specifications Section 7 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 3. Fresh air: a. Deliver minimum 3.5 l/s (7.5 ft³/min) per passenger at AW2 load. b. Fresh air intakes shall be on HVAC units. 4. Static pressure: Positive, minimum 25 Pa (0.1 inches of water) within a closed or stopped vehicle. 7.8 Air Conditioning 7.8.1 General Provide cooling and dehumidification as part of each HVAC unit: 1. Type: Vapor-compression direct-expansion refrigeration cycle. 2. Capacity: Adequate to provide the required interior temperatures and humidity throughout the entire range of operating conditions. 7.8.2 Cooling Design Criteria Design the system based on the following summer conditions: Cooling Design Ambient Temperatures: 29.5 degrees C DB (85 degrees F DB) 18.5 degrees C WB (65) degrees F WB) Maximum Operating Conditions 34 degrees C DB (93 degrees F DB) 28.5 degrees C WB (83 degrees F WB) Passenger Load: 450 Btu/h per passenger at 55% Sensible Heat Ratio Solar Load: Follow ASHRAE recommendations Heating Load: Total wattage of interior lights and vehicle equipment 7.8.3 Cooling Temperatures and Humidity Comply with the following: 1. Cooling capacity: a. Sufficient to maintain cooling interior temperature range specified below. b. Conditions: • • AW2 passenger load Maximum solar load based on worst case sun position and vehicle orientation 2. Cooling interior temperature range: a. Ambient Temperature Within Design Ambient Temperature Range: • • Interior temperature: Within the range of 22 to 26 degrees C (72 to 79 degrees F). Relative humidity: Below 60% with the design and less than design load conditions. b. Ambient Temperature Above Design Ambient Temperature (by maximum 5 K): Maintain interior temperature below the ambient temperature by at least 3.5 K. 7.8.4 Refrigerant HVAC units shall use Owner-approved refrigerant meeting the following requirements: 1. Listed in U.S. EPA SNAP list for Motor Vehicle Air Conditioners for Passenger Train end-use. LTK Standard Streetcar Specifications Section 7 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 2. ASHRAE Safety Rating of not less than A1. Comply with current environmental regulations governing refrigerant use, handling, and recovery. 7.8.5 Compressors Refrigerant compressors shall comply with specified requirements and include each listed item: 1. Type: Hermetically sealed, scroll type design. 2. Power: Three-phase ac. 3. Capacity control: Include a thermo-expansion valve (for each evaporator circuit), and compressor capacity control, whether single-circuit or multi-circuit units are provided. 7.8.6 Evaporators and Condensers Comply with the following requirements for heat exchanger coils: 1. Material: Copper tubing, copper or corrosion resistant aluminum fins. 2. Fin spacing: Adequate to facilitate cleaning in transit vehicle service conditions. Demonstrate cleanability and procedure. 3. Fin strength: Capable of withstanding 175 kPa (25 psi) water or air pressure from a cleaning wand. 4. Fin thickness: Minimum 0.2 mm (0.008 in). If less than the minimum thickness is proposed, demonstrate fin/coating strength and longevity by a salt spray test according to ASTM B117 or ISO 9227 and by similar rail transit reliability data. 5. Coil tube sheets: Die-formed support collars for each tube. 7.8.7 HVAC System Devices Provide the following: 1. Filter-drier: Replaceable; provide in refrigerant liquid lines. 2. Sight glass with moisture indicator: Provide in refrigerant liquid lines. 3. Pressure relief device: To protect the refrigeration system against explosion. Comply with ASHRAE 15, and applicable requirements of UL 1995 and UL 207. 4. Schrader valves: a. Location: External, to connect pressure gauges while unit is running. b. Type: Self-sealing, with chain-retained, metal-to-metal seal caps. 7.8.8 Air Conditioning System Piping and Fittings 7.8.8.1 Layout and Design Comply with the following requirements: 1. Design tubing installations such that a single length of tubing may be replaced without dismantling or removing surrounding equipment, piping, wiring or other appurtenances. 2. Keep joints to a minimum with no inaccessible joints or fittings; inaccessible runs of tubing shall be without joints. 3. Provide suction lines without traps. Size the liquid line adequately to prevent flashing due to pressure drop. 4. Mount and support copper piping such that shock and vibration do not cause failure of solder joints. Provide vibration eliminators in piping connections to the compressor. Equipment and piping shall meet the criteria of IEC 61373. LTK Standard Streetcar Specifications Section 7 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.8.8.2 Type Comply with the following standards: 1. Air conditioning refrigerant lines: Per ASTM B280 or ASTM B88 type L, seamless copper tubing. Fittings shall be wrought copper sweat type. 2. Condensate drain lines: ASTM B88 type K. 7.8.8.3 Fabrication Comply with the following fabrication requirements: 1. Tubing may be bent only with an appropriate tube bending tool. 2. Deburr piping after cutting and thoroughly clean after installation. 3. After pre-fabrication, clean piping and pipe subassemblies, dry (if required), and cap all openings. 4. Caps shall remain in place until immediately prior to incorporation into the final assembly. 7.8.8.4 Refrigerant Line Soldering Comply with the following soldering requirements: 1. Soldering of copper piping and fittings: a. Perform to AWS A5.8M/A5.8; or b. Equivalent standard used in the country of equipment origin (i.e.: AWS A5.8M/A5.8, welding procedure BAg-5 is commonly used on refrigerant pressure lines in the U.S.). 2. Refrigerant pressure piping filler metal: a. Silver content: Minimum 15% for copper-to-copper joints; between 35% and 45% for dissimilar metal joints. b. Cadmium free. 3. Non-pressure copper lines silver content: Minimum 15%. 7.8.8.5 Insulation Insulate lines subject to condensation forming: 1. Insulate condensate drain lines and suction line piping with insulation that meets the flammability, smoke emission, and toxicity requirements of Section 16, Materials and Workmanship. 2. Insulate the liquid line in all areas where required to provide additional mechanical or thermal protection. 3. Apply the insulating material to the piping with suitable contact cement. 4. Miter and seal joints and directional changes in the insulation. 7.8.9 Air Conditioning System Charging and Testing Charge and test each self-contained air conditioning unit at the factory before shipping: 1. Perform system charging to the manufacturer’s own procedure, but as a minimum incorporate the following steps: a. Leak test per procedure approved by the Owner. LTK Standard Streetcar Specifications Section 7 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning b. Evacuate and dehydrate the entire refrigeration system to a pressure of 100 microns of mercury, or less. c. Maintain this vacuum level for minimum two hours with the vacuum pump running. d. After two hours, isolate the vacuum pump from the system. • • • The system pressure should not rise above 300 microns of Mercury in a two-hour period after vacuum pump isolation Decay in the vacuum indicates that moisture remains in the system, or a leak Measure vacuum levels at the system, not at the entrance to the vacuum pump e. Charge with the predetermined amount of refrigerant by weight. 2. Factory testing shall include air conditioning unit routine tests specified in Section 15, Testing. 7.9 Operator’s Cab Air Comfort System 7.9.1 General Provide heating, cooling, and defrosting in each cab as specified below. Provide conditioned air into the cab from a dedicated HVAC unit, or from the adjacent passenger HVAC unit as described below. In the event of cab unit failure, provide conditioned air from the passenger area to the cab. 7.9.2 Cab Heaters 7.9.2.1 General Provide each operator's cab with one or two forced-air cab heaters for defrosting and heat. 7.9.2.2 Cab Heater Housing, Ducting, and Vents Provide listed components and comply with the following requirements: 1. Heater housing: a. Material: Heat-resistant, nonflammable b. Configuration: Fully enclose the heater elements. c. Surface temperature: Maximum 52 degrees C (125 degrees F) where exposed to operating personnel. 2. High limit thermostat: Provide in the heater housing to remove power in the event of excessive temperature. 3. Grounding: Permanently ground heater assembly and enclosure to vehicle structure, as specified in Section 9, Electrical Equipment. 4. Ducting and vents: a. Direct heater output onto side windows and windshield. b. Direct heater output onto the operator’s feet and provide manually adjustable damper. c. Ducting and damper arrangements shall not permit airflow to be blocked to the extent that the heater overheats or trips the over-temperature sensor. LTK Standard Streetcar Specifications Section 7 9 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.9.2.3 Cab Heater Capacity Comply with the following: 1. Cab heaters shall have capacity adequate to maintain a temperature of minimum 21 degrees C (70 degrees F) in the full-width cab compartment under the following conditions: a. Exterior ambient temperature equal to the Heating Design Ambient Temperature in the Heating Design Criteria section, above. b. Overhead air diffuser shut-off. c. Side windows closed. 2. Provide sufficient capacity to defrost the cab side windows and windshield, without aid of the windshield’s electrical defrosting heater circuits, as follows: a. Time period: Maximum 20 minutes b. Exterior Ambient Temperature: Equal to the Heating Design Ambient Temperature in the Heating Design Criteria section, above. c. Condition: Vehicle is activated after being de-energized for a period of 8 hours and exposed to specified ambient temperature during that time period. 7.9.2.4 Cab Heater Controls Heater functions must include Off, Fan (no heat), and at least two stages of heat with appropriate fan speeds for each. 1. Active Cab: Provide control of heaters from the Cab Console, described in Section 5. 2. Inactive cab: a. Provide low-temperature control independent of the state of the heater control switches on the Cab Console. b. Maintain temperatures in inactive cab at 16 degrees C (60 degrees F) via modulation of cab heater controls using temperature sensors in each cab, under the following conditions. • • Cab inactive (but other cab active) Ambient temperatures below 10 degrees C (50 degrees F) 7.9.3 Cab HVAC Unit (Optional) 7.9.3.1 General Provide an independent HVAC unit installed on the roof of each cab. Comply with the requirements above for vehicle HVAC units, but provide temperature regulation in each operator’s cab for the dedicated cab HVAC unit, independent from the adjacent passenger section. 7.9.3.2 Diffusers Provide adjustable diffusers for the operator to set air flow and direction: 1. Air flow adjustment range: Include full off. 2.1. Direction adjustment range: Include the ability to direct air flow away from operator. 7.9.3.37.9.3.2 Overhead Heat Incorporate heating elements into the cab HVAC unit. Heating capacity, as a minimum, shall be as required to temper the outside air from the design ambient to design interior condition. LTK Standard Streetcar Specifications Section 7 10 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7.9.3.47.9.3.3 Ventilation Provide ventilation of each cab using the cab air conditioning system evaporator unit blower fans. 1. Full ventilation shall be continuously available in the event of refrigeration failure. 2. The air comfort system shall deliver fresh air to the cab in the amount of minimum 10 l/s (21 ft³/min). 7.9.3.57.9.3.4 Air Conditioning Comply with the following: 1. All requirements above for air conditioning for the vehicle passenger sections, including maximum solar load into the cab based on worst case sun position and vehicle orientation. 2. Use same refrigerant as for passenger HVAC units. 7.9.3.67.9.3.5 Cab HVAC Unit Controls Provide controls in each operator’s cab for the cab HVAC as specified in Section 5, Operator’s Cab and Controls. 7.9.4 Cab HVAC 7.9.4.1 Diffusers Provide adjustable diffusers for the operator to set air flow and direction: 1. Air flow adjustment range: Include full off. 2. Direction adjustment range: Include the ability to direct air flow away from operator. 7.9.47.9.5 Windshield Defrosting and Defogging Provide electrical defrosting heater circuits embedded in the cab windshield controlled via the Cab Console (see Section 5, Operator’s Cab and Controls). See related windshield requirements in Section 14, Interior and Exterior Appointments. The windshield heater system shall have sufficient capacity to defrost the windshield, without aid of the cab heater defroster, as follows: 1. Time period: Maximum 20 minutes. 2. Exterior Ambient Temperature: Equal to the Heating Design Ambient Temperature in the Heating Design Criteria section, above. 3. Interior Dew Point: 20 degrees C (68 degrees F). 4. Condition: Sufficient moisture has condensed to just begin to run down the glass. The windshield heater system shall have controls to detect and limit over temperatures, so the heating elements, windshield, and windshield wiper blades will not be damaged due to an over temperature. 7.10 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. Detail drawings: Top level assemblies, and other drawings if requested 2. Functional description 3. Control schematics LTK Standard Streetcar Specifications Section 7 11 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 4. Component ratings: Top level components, and ratings of other components if requested 5. Software functional descriptions: Include top level control parameters and values 7-1 HVAC System Design Calculations: 1. 2. 3. 4. 7-2 Include assumptions Heat Loss/Heat Gain Heating and cooling capacity Include both the operator and passenger cabins and show separately HVAC Unit Design Package: 1. HVAC unit arrangement drawing showing the quantity, location, heating/cooling capacity of each unit on the vehicle. 2. Certifying letter of manufacturer’s ISO 9001 certified factory quality control program. 3. Manufacturer’s dimensioned layout drawings for all types of HVAC units. 4. Electrical data for all types of HVAC units. 5. Electrical load (or coefficient of performance) for heating and cooling at maximum capacity for each unit on the vehicle. 6. Details of overhead heating. 7. Details of ventilation. 8. Air Conditioning: a. b. c. d. e. f. Component identification Materials identification General layout drawings Electrical and controls schematic Piping schematic Make and model number for compressor, purchased controls, sensors, and instrumentation. g. Acceptable charging procedure for the system charged with blended refrigerant. 9. Air Conditioning Piping: a. Description of all fastening and joining methods for refrigerant piping, including silver solder procedures. b. Manufacturer’s data for air conditioning system piping insulation and insulation jointsealing material. 10. HVAC Control Design Report: a. Include the following: • • Brand(s), type, and model of microprocessor-based control units or PLC and control devices Manufacturer’s data on overhead heat back-up protection device used to remove power in the event of excessive current draw. Include the means used to suppress the arc at rupture. b. Layover Climatic Control: • • Manufacturer’s data on components. Location of the layover thermostat, if a separate thermostat is used. LTK Standard Streetcar Specifications Section 7 12 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services City Center Connector Project Heating, Ventilating, and Air Conditioning 7-3 In-Factory Charging and Testing Booklet: 1. Include one booklet for each self-contained air conditioning unit. 2. Booklet must contain charging certification and results of air conditioning unit routine tests, as specified in Section 15, Testing. 7-4 Air Distribution Design Package: 1. 2. 3. 4. Airflow velocity calculations for both the operator and passenger cabins, shown separately Pressure drop calculations. Overhead ductwork and diffuser drawings. Air Filters: a. Manufacturer’s data on air filter including brand, type, and size. b. Include quantity. 7-5 Floor Heat Design Package: 1. Design drawings, including details of heating units and layout. 2. Manufacturer’s data on heating elements. 7-6 Operator’s Cab Air Comfort System Design Package: 1. Description and details of controls 2. Cab HVAC Unit: a. Details of overhead heat b. Details of ventilation c. Air conditioning: Submit all items required for passenger section air conditioning. 3. Details of how passenger compartment conditioned air will be supplied to the cab, including the following: a. Ducting size and locations b. Airflow c. Heat gain/loss and verification that airflow is sufficient to maintain specified temperatures 4. Cab Heaters: a. Manufacturer’s heater details, including the following: • • • Electrical requirements Housing material Automatic high-limit thermostat in the heater housing to remove power in the event of excessive temperature b. Layout drawing indicating ducting and vents and showing how heat will be directed for both heat and defrosting c. Details of windshield embedded defroster, including controls, temperature limits, and over-temperature protection END OF SECTION LTK Standard Streetcar Specifications Section 7 13 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting Table of Contents 8.1 General ........................................................................................................................................1 8.2 Lighting System Design .................................................................................................................1 8.3 Lighting Levels ..............................................................................................................................1 8.4 Power Source and Control ............................................................................................................1 8.5 General Fixture and Lamp Requirements.......................................................................................2 8.6 Interior Lighting............................................................................................................................2 8.6.1 General ............................................................................................................................................. 2 8.6.2 Passenger Area Lighting ................................................................................................................... 3 8.6.2.1 General...................................................................................................................................... 3 8.6.2.2 Main Linear Lighting ................................................................................................................. 3 8.6.2.3 Doorway Floor Lights ................................................................................................................ 3 8.6.2.4 Stairway Floor Lights ................................................................................................................. 3 8.6.3 Cab Lighting ...................................................................................................................................... 3 8.6.3.1 Operator's Cab Ceiling Light...................................................................................................... 3 8.6.3.2 Cab-Console-Mounted Light ..................................................................................................... 4 8.7 Exterior Lighting ...........................................................................................................................4 8.7.1 General ............................................................................................................................................. 4 8.7.2 Headlights ........................................................................................................................................ 4 8.7.3 Tail Lights and Stop Lights ................................................................................................................ 5 8.7.4 Marker Lights ................................................................................................................................... 5 8.7.5 Turn Signals ...................................................................................................................................... 5 8.8 Emergency Lighting ......................................................................................................................6 8.9 Wiring Requirements....................................................................................................................6 8.10 Contract Data Requirements List (CDRL) ......................................................................................6 LTK Standard Streetcar Specifications Section 8 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting 8.1 General All lighting shall be via LEDs. Except for console and similar small low-intensity indicator lamps, all lamps shall be LED clusters. Provide lamps with standard dimensions and electrical connections. Lamps, sockets, and connectors are considered consumable items, and shall be commonly stocked and available from US suppliers. 8.2 Lighting System Design The lighting system design and illumination requirements shall meet the following federal regulations, APTA standards, and other applicable standards for vehicle lighting: 1. 49 CFR 38 subpart D, ADA Accessibility Specifications for Transportation Vehicles, Light Rail Vehicles and Systems 2. APTA SS-E-013-99, Standard for Emergency Lighting System Design for Passenger Cars 3. APTA PR-E-RP-012-99, Recommended Practice for Normal Lighting System Design for Passenger Cars 4. For exterior lighting, 49 CFR 571.108, Lamps, Reflective Devices, and Associated Equipment. Apply requirements for buses of 2032 mm (80 inches) or more in overall width. 5. ANSI and SAE standards, as specified in sections below. Where a conflict exists, the most restrictive requirement shall apply. 8.3 Lighting Levels Lighting levels specified below shall be achieved at the nominal rated voltage: Area Within the vehicle Passenger aisles and articulation section Vehicle entrances and exits Door thresholds and platform Stairways Cab (from ceiling light) Within passenger area of vehicle with emergency lighting only Measurement Type and Location Average, at elevation of 840 to 1675 mm (33 to 66 in) above the floor Average, at the floor Average, within 500 mm (20 in) of the doors at the floor On platform surface 915 mm (36 in) from vehicle side Surface of the steps Average, at 840 mm (33 in) above the floor Average, 640 mm (25 in) above the floor Minimum Lighting Level 215 lux (20 fc) 110 lux (10 fc) 110 lux (10 fc) 55 lux (5 fc) 55 lux (5 fc) 215 lux (20 fc) 22 lux (2 fc) 8.4 Power Source and Control Lighting power source: Low-voltage dc power system, without intermediate power supplies or dropping resistors. See Section 9, Electrical Equipment, for requirements of the low-voltage dc power system. LTK Standard Streetcar Specifications Section 8 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting Lighting Control: 1. Dimming (where specified): PWM circuitry appropriate for the LED design, such that dimming levels may be set by voltage level. LEDs used as indicators, such as on the cab console, may be powered from a separate PWM supply. 2. Electronic controllers: Comply with the design requirements specified in Section 17, Electronic Controls, Software, and MDS. 3. See Section 5, Operator’s Cab and Controls, for additional control requirements. 8.5 General Fixture and Lamp Requirements Comply with the following general requirements: 1. Maintainability: All lighting fixtures shall provide ease of lamp replacement, cleaning, and maintenance: a. Except for permanently sealed light fixtures, lamp access shall be by gasketed enclosure covers secured by captive, stainless steel fasteners. b. Where possible, covers shall be retained by hinges. Hinges located on the vehicle exterior shall be stainless steel. 2. Lighting fixtures: Integral frosted diffuser/lens. Clear lenses are not permitted except for indirect lighting applications. 3. Lamps: a. For illumination purposes: • • • • Type: White LED assemblies Voltage range: Provide full illumination within the range specified in Section 9, Electrical Equipment Passenger area: Energy Star Qualified, or equivalent documented performance, when installed in the proposed fixtures Life expectancy: Minimum 50,000 hours, in the proposed fixtures b. For indicators: • Life expectancy: Minimum 100,000 hours 8.6 Interior Lighting 8.6.1 General Comply with the following general requirements for interior lighting: 1. 2. 3. 4. Performance: Provide lighting free from glare. Diffusers: Frosted-type, such that individual LEDs are not discernible. Lighting levels: Provide as specified in the Lighting Levels table, above. Environmental: a. All fixtures shall be dustproof. b. Fixtures within 610 mm (2 ft) of a doorway shall be watertight except for interior ceiling lights. c. All floor level fixtures shall be watertight LTK Standard Streetcar Specifications Section 8 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting 5. Flammability, Smoke Emission, and Toxicity: Light fixture, lamp, and associated parts or equipment shall meet the guidelines specified in Section 16, Materials and Workmanship. 8.6.2 Passenger Area Lighting 8.6.2.1 General Comply with the following requirements for all passenger area lighting: 1. Correlated Color Temperature (CCT): Mimic the color of warm white (3000K) or cool white (4100K) fluorescent tubes in accordance with ANSI C78.377, Table 1, Nominal CCT Categories. 2. Color Rendition: Adjust CCT as necessary to complement the Owner’s choice of interior colors. 8.6.2.2 Main Linear Lighting Provide linear lighting fixtures in the main passenger areas: 1. Type: Ceiling mounted, recessed, and integrated into the interior finish. 2. Layout: Two parallel rows. 3. Continuous Illumination: When viewed from the end of the vehicle, there shall be no visible dark spots, such as where electronic controllers might be located. 4. Circuits: Power each row of light fixtures from a separate circuit. Fixtures across the aisle shall be connected to different circuits. 5. Door area: Provide a minimum of one overhead standard length light fixture at each door area. See Emergency Lighting, below, for requirements in case of power failure. 8.6.2.3 Doorway Floor Lights Provide light fixtures at each doorway for threshold and platform illumination: 1. Location: Mount near floor on doorposts, windscreen, or other location that will provide the required minimum illumination (see Lighting Levels table, above). 2. Operation: The light shall be illuminated when the passenger door starts to open and extinguished when the door is closed and locked. 3. Alternate: If emergency passenger area lights furnish the required lighting level for door threshold and platform illumination, dedicated doorway floor lights may be omitted. 4. Fixtures shall be watertight 8.6.2.4 Stairway Floor Lights Provide light fixtures at each stairway: 1. Step illumination: Provide the required minimum (see Lighting Levels table, above). 2. Control: The lights shall be illuminated when the interior lights are illuminated. 3. Fixtures shall be watertight 8.6.3 Cab Lighting 8.6.3.1 Operator's Cab Ceiling Light Provide each cab with a light fixture located in the ceiling to illuminate the Cab Console: 1. Location: The light beam shall be placed to avoid glare on the windshield. 2. Control: By the Cab Console, as specified in Section 5, Operator’s Cab and Controls. LTK Standard Streetcar Specifications Section 8 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting 8.6.3.2 Cab-Console-Mounted Light Each Cab Console shall be illuminated to enable the operator to see the console labels, pushbuttons, and switches under varying lighting conditions: 1. Light Location: Mount at the top edge of Cab Console, shielded from operator's eyes. 2. Glare: When illuminated, light shall not cause glare on the windshield or the Cab Console. 3. Control: a. The console light shall be energized automatically when the Cab Console is powered. b. Provide a dimmer control as specified in Section 5, Operator’s Cab and Controls. 8.7 Exterior Lighting 8.7.1 General Comply with the following general requirements for exterior lighting: 1. Fixture assemblies shall be dustproof and inherently waterproof. 2. Mount fixtures to vehicle with gaskets to prevent water ingress into the vehicle. Caulks, sealers, and similar materials are prohibited. 3. Bezels and trim: a. Stainless steel: If light fixtures are specified to have bezels and trim, or if proposed fixtures have bezels and trim. b. Fasteners: Captive stainless steel, and consistent with good mechanical mounting principles. 4. Tail lights, stop lights, marker lights, and turn signals: Permanently sealed plastic LED assemblies, colored as indicated. 5. Headlights, taillights, stoplights, marker and clearance lights, and turn signals: Conform to 49 CFR 571.108 for buses of 2032 mm (80 inches) or more in overall width. 8.7.2 Headlights Comply with the following requirements for headlights: 1. Type: LED or Halogen with high beam and low beam; adjustable to permit proper aiming of beams. 2. Location: Provide on each side of each end of the vehicle. 3. Life: Minimum 50,000 hours. 4. Heat management: a. Comply with headlight manufacturer’s clearance and airflow recommendations to maintain temperatures within LED manufacturer’s recommended limit. b. Ensure that adjacent components have sufficient clearance and protection from hightemperature areas of the headlights to prevent heat damage. 5. Visibility: Capable of revealing a person or motor vehicle in clear weather at a distance of 107 m (350 ft). 6. Adjustment: Set so as not to interfere with the vision of drivers of motor vehicles. 7. Control: As defined in Section 5, including appropriate circuitry for low/high beam cycling function. LTK Standard Streetcar Specifications Section 8 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting 8.7.3 Tail Lights and Stop Lights Comply with the following requirements for tail lights and stop lights: 1. Tail lights: a. b. c. d. Quantity: Two at each end of each vehicle Color: Red Standard: Comply with requirements of SAE J2040 Visibility: Plainly visible from a distance of minimum 150 m (500 ft), when illuminated 2. Stop lights: a. b. c. d. Quantity: Two at each end of each vehicle Color: Red Intensity: Approximately 150% of the intensity of the tail lights Standard: Comply with requirements of SAE J2261 3. Combination: Alternatively, the tail lights and stop lights may be combined. 4. Control: Automatic; see Section 5. 8.7.4 Marker Lights Comply with the following requirements for marker lights: 1. Standard: Comply with the requirements of SAE J2042. 2. Visibility: Plainly visible from a distance of minimum 150 m (492 ft), when illuminated. 3. Quantity and Location: a. On each side of the vehicle: • • • One amber light located as close to each end as possible for a total of two (front side marker lights) One amber light located at or near the midpoint (intermediate side marker light) One red light located as close to each end as possible for a total of two (rear side marker lights) b. On each end of the vehicle: • • Two amber marker lights located symmetrically about the vertical centerline to indicate the overall width, located as near the top as practicable (front clearance lamps) Two red marker lights located symmetrically about the vertical centerline to indicate the overall width, located as near the top as practicable (rear clearance lamps) 4. Control: Automatic; see Section 5. 8.7.5 Turn Signals Comply with the following requirements for turn signals: 1. Type: Flashing 2. Location: Front, sides, and rear of vehicle. On vehicle ends, turn signals may be integrated with headlights or other lights in accordance with 49 CFR 571.108 and as approved by the Owner. 3. Standards: a. Front and rear turn signals: Comply with the requirements of SAE J2261. b. Side turn signals: Comply with the requirements of SAE J2039. LTK Standard Streetcar Specifications Section 8 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting 4. Visibility: Plainly visible from a distance of minimum 150 m (492 ft), when illuminated. 5. Control: See Section 5, Operator’s Cab and Controls, for normal control and use of turn signals as hazard lights. 8.8 Emergency Lighting Comply with the following requirements for emergency lighting: 1. Standard: Comply with the minimum performance requirements of APTA-SS-E-013-99. 2. Power Source: Low-voltage dc power system, and in the event of loss of normal power, from emergency power. See Section 9, Electrical Equipment, for additional information on the lowvoltage dc power system and emergency power. 3. The following are considered emergency lighting: a. b. c. d. e. f. g. Doorway overhead lights Doorway floor lights Stairway lights Sufficient number of overhead lights to illuminate aisles in accordance with NFPA 130. Active cab, overhead lights Active cab, Cab Console lights Exterior lights 8.9 Wiring Requirements Comply with the following requirements for wiring of lighting: 1. Lamp circuits shall be electrically isolated from the fixture and the vehicle structure. 2. Metallic fixtures and exposed metallic surfaces shall be grounded to the vehicle structure as specified in Section 9. 8.10 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. 8-1 Detail drawings: Top level assemblies, fixture, part and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values Lighting System Design Package: 1. The design package may be submitted as two packages, interior and exterior lights. 2. Include the following: a. b. c. d. e. f. Verification of lighting performance by computer analysis, including emergency lighting. Drawing of the vehicle showing light fixture locations and identities. Listing of lamps by function, type, part numbers, and source of U.S. supply. Energy Star Certification for passenger area lighting, or comparable documentation. Warranty information for all equipment, including LED lamps. Nominal electrical load of the lighting system, measured in kW. LTK Standard Streetcar Specifications Section 8 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Lighting 8-2 Emergency Lighting System Design Package: 1. Emergency lighting load calculations. END OF SECTION LTK Standard Streetcar Specifications Section 8 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment Table of Contents 9.1 General ........................................................................................................................................1 9.1.1 Scope ................................................................................................................................................ 1 9.1.2 Definitions ........................................................................................................................................ 1 9.2 General Electrical Requirements ...................................................................................................1 9.2.1 Equipment Enclosures...................................................................................................................... 1 9.2.2 Electrical/Electronic Design Standards ............................................................................................ 1 9.2.3 Equipment Voltage Range................................................................................................................ 1 9.2.4 Circuit Protection ............................................................................................................................. 1 9.2.5 Grounding and Return Circuits......................................................................................................... 2 9.2.5.1 Shunting Resistance .................................................................................................................. 2 9.2.5.2 Safety Grounding ...................................................................................................................... 2 9.2.5.3 High-Voltage Return Circuits..................................................................................................... 2 9.2.5.4 Low-Voltage Return Circuits ..................................................................................................... 3 9.2.5.5 Ground Brushes ........................................................................................................................ 3 9.2.5.6 Grounding Conductors .............................................................................................................. 3 9.2.5.7 Grounding Connections ............................................................................................................ 3 9.2.6 Ground Fault Detection and Protection........................................................................................... 4 9.3 Equipment Temperature Management .........................................................................................4 9.4 Primary Power System (OCS) ........................................................................................................4 9.4.1 General ............................................................................................................................................. 4 9.4.2 Pantograph....................................................................................................................................... 5 9.4.2.1 General...................................................................................................................................... 5 9.4.2.2 Contact Assembly ..................................................................................................................... 5 9.4.2.3 Contact Force ............................................................................................................................ 5 9.4.2.4 Dynamic Stability ...................................................................................................................... 5 9.4.2.5 Pantograph Raising and Lowering ............................................................................................ 5 9.4.3 High Speed Circuit Breaker .............................................................................................................. 6 9.4.4 Battery Charging .............................................................................................................................. 6 9.4.5 Dead Battery Operation ................................................................................................................... 7 9.4.6 Surge Arrester .................................................................................................................................. 7 9.5 Maintenance Shop Power .............................................................................................................7 9.5.1 General ............................................................................................................................................. 7 9.5.2 Coordination .................................................................................................................................... 7 LTK Standard Streetcar Specifications Section 9 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.5.3 Shop Switch ...................................................................................................................................... 7 9.5.4 Receptacle and Plug ......................................................................................................................... 8 9.5.5 Auxiliary Loads Under Shop Power .................................................................................................. 8 9.6 AC Auxiliary Power Supply (APS) ...................................................................................................9 9.6.1 General ............................................................................................................................................. 9 9.6.2 Voltage and Frequency .................................................................................................................... 9 9.6.3 Auxiliary Inverters ............................................................................................................................ 9 9.6.4 Inverter Controls .............................................................................................................................. 9 9.6.5 Auxiliary Inverter Fault Monitoring................................................................................................ 10 9.6.6 Failure Management ...................................................................................................................... 10 9.7 Low-Voltage DC Power System ................................................................................................... 10 9.7.1 General ........................................................................................................................................... 10 9.7.2 Voltage ........................................................................................................................................... 10 9.7.3 Low-Voltage Power Supply ............................................................................................................ 10 9.7.4 Battery Charger .............................................................................................................................. 11 9.7.5 Vehicle Battery ............................................................................................................................... 12 9.7.5.1 Battery .................................................................................................................................... 12 9.7.5.2 Battery Enclosure .................................................................................................................... 12 9.7.5.3 Battery Circuit Breaker............................................................................................................ 12 9.7.5.4 Battery Heat Detection and Emergency Cutoff ...................................................................... 12 9.7.6 Battery Load Control ...................................................................................................................... 13 9.7.7 Emergency Power .......................................................................................................................... 13 9.7.8 Failures and Fault Indications ........................................................................................................ 13 9.8 Vehicle-to-Truck Wiring .............................................................................................................. 14 9.9 Line Filters.................................................................................................................................. 14 9.9.1 General ........................................................................................................................................... 14 9.9.2 Performance................................................................................................................................... 14 9.9.3 Self-Test.......................................................................................................................................... 14 9.9.4 Configuration ................................................................................................................................. 15 9.9.5 Components ................................................................................................................................... 15 9.9.5.1 Line Inductors ......................................................................................................................... 15 9.9.5.2 Filter Capacitors ...................................................................................................................... 15 9.10 Panelboards and Control Panels ................................................................................................ 16 9.11 Fuses and Circuit Breakers ........................................................................................................ 16 LTK Standard Streetcar Specifications Section 9 ii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.11.1 General ......................................................................................................................................... 16 9.11.2 Fuses and Fuse Holders ................................................................................................................ 16 9.11.3 AC and Low-Voltage DC Circuit Breakers ..................................................................................... 17 9.11.4 Circuit Breaker Prohibited Locations ........................................................................................... 17 9.12 Contactors and Relays .............................................................................................................. 17 9.12.1 General ......................................................................................................................................... 17 9.12.1.1 Contactors ............................................................................................................................. 18 9.12.1.2 Relays .................................................................................................................................... 18 9.13 Switches ................................................................................................................................... 18 9.13.1 High-Voltage DC Switches ............................................................................................................ 18 9.13.2 Low-Voltage Switches .................................................................................................................. 18 9.14 Low-Voltage DC-DC Power Supplies .......................................................................................... 19 9.15 Contract Data Requirements List (CDRL) .................................................................................... 19 LTK Standard Streetcar Specifications Section 9 iii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.1 General 9.1.1 Scope This Section specifies general electrical requirements; electrical systems not addressed in their own sections; and electrical components used throughout the vehicle. Electrical materials, including but not limited to conduit, wireway, junction boxes, wire, and cable are specified in Section 16, Materials and Workmanship. 9.1.2 Definitions High-Voltage DC: DC power as provided by the OCS or regenerative braking. Low-Voltage DC: DC power as provided by the low-voltage dc power system or vehicle battery. Auxiliary: Circuits and systems for loads other than propulsion. 9.2 General Electrical Requirements 9.2.1 Equipment Enclosures Electric or electronic equipment shall be enclosed in equipment enclosures, unless specified otherwise. Equipment enclosures are specified in Section 14, Interior and Exterior Appointments. 9.2.2 Electrical/Electronic Design Standards Electrical and electronic equipment shall comply with the requirements of IEC 60571 or IEEE Std 16. 9.2.3 Equipment Voltage Range Comply with the following: 1. Electrical equipment shall operate as specified and without damage over the full operating range of its source voltage, and the worst-case voltage drop in the distribution system. 2. All equipment shall be protected against damage from voltages outside the specified range, or their design range, whichever is greater. 3. Equipment operating from the ac system shall operate as specified and without damage at any voltage within the limits specified in the Auxiliary Power Supply (APS) section, below. 4. Equipment operating from the low-voltage dc power system shall be rated for continuous operation at the actual LVPS terminal voltage, in compliance with the Low-Voltage DC Power System section, below. 5. Equipment operating from the battery without the battery charger shall operate as specified and without damage at the battery voltage resulting from discharge down to 1 V per battery cell. 9.2.4 Circuit Protection Comply with the following: 1. Arrange circuit protection in a logical branching organization to facilitate fault isolation and minimize operational impacts on other systems: a. Coordinate local circuit protection with main source protection such that faults or overloads downstream of the local protection shall trip the local protection only, and not trip the main source protection. LTK Standard Streetcar Specifications Section 9 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment b. Local protection trip settings shall be lower than the main source power or current limit settings. 2. Size circuit breakers and fuses, where approved, to protect both the equipment and the minimum wire size used for power distribution within the protected circuit. 3. Individually protect each circuit as follows: a. b. c. d. Propulsion high-voltage dc circuits: HSCB Auxiliary high-voltage dc circuits: High speed fuses AC circuits: Circuit breakers Low-voltage dc circuits: Circuit breakers 4. Location of circuit protection devices: a. Mount ac and low-voltage dc circuit breakers in panelboards located in electrical lockers in each operator's cab (see Section 14, Interior and Exterior Appointments, for electrical locker and key requirements). Group low-voltage dc control breakers logically. b. AC loads that are in the cab shall have their respective breakers in the cab. c. Locate other ac distribution breakers within the vehicle such that they may be readily inspected by the operator, but are not accessible to passengers. d. AC and low-voltage dc circuit breakers may be located elsewhere only as approved, or as specified. 5. Display the OFF state of all circuit breakers for those systems that do not report failure status to the TOD upon loss of power, such as track brakes. 9.2.5 Grounding and Return Circuits Size all grounding and high voltage return conductors, ground brushes, and related components to limit voltage rise to less than 50 V under worst case fault currents. 9.2.5.1 Shunting Resistance See Section 11, Truck Assemblies, for wheel shunting resistance requirements. See Section 15, Testing, for required resistance tests. 9.2.5.2 Safety Grounding Comply with the following: 1. Safety ground all conductive equipment on the vehicle to the vehicle structure, including metallic raceways, resiliently mounted equipment, enclosures, the truck frame, and truck mounted equipment. 2. Safety ground the vehicle structure to the axles using dedicated safety ground brushes. 3. Safety ground axles to wheel tread with shunts as specified in Section 11. 9.2.5.3 High-Voltage Return Circuits Comply with the following: 1. Connect all high-voltage return circuits to an isolated return current terminal for each propulsion and APS unit per vehicle section. 2. Interconnect these isolated return current terminals throughout the vehicle. LTK Standard Streetcar Specifications Section 9 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 3. Connect these isolated terminals to all brushes on the corresponding truck by ground wires of identical impedance. 4. Install an isolated ground plate within the truck if needed to facilitate impedance balance for each ground brush. 5. Provide high-voltage dc current return to the running rails as follows: a. Connect the high-voltage dc return circuits to the axle using ground brushes and to the rail using the wheels with appropriate visible shunts around the wheel resilient elements. See Section 11, Truck Assemblies, for additional requirements related to wheel assembly conductive paths. b. Prevent any current return through the journal bearings, gear units, or motor bearings. 9.2.5.4 Low-Voltage Return Circuits Provide return wiring for each system or circuit fed from a circuit breaker or fuse. 1. Each circuit return wire shall be connected, via its own separate terminal, to a return bus located in the same electrical locker that contains the circuit breaker that supplies the circuit. 2. Ground the return circuits as follows: a. Connect the low-voltage dc return circuits to the vehicle structure through an RC filter at a single point only. b. Ground the ac neutral at a single-point. 3. The vehicle structure shall not be used as a normal circuit-return path for any electrical equipment. 9.2.5.5 Ground Brushes Provide ground brushes for each wheel or for each through-axle in a conventional (non-stub axle) truck: 1. Rating: 2.0 times the circuit rms current, and 1.5 times the circuit peak current. 2. Life: Minimum 500,000 km (310,686 mi). 9.2.5.6 Grounding Conductors Grounding wires to fixed equipment may be standard vehicle wiring (see Section 16, Materials and Workmanship). Provide tinned, braided copper ground cables fitted with flared terminal barrels designed for strain relief for the following applications: 1. Grounding connections to resiliently mounted equipment. 2. Grounding connections between the vehicle body and truck frame. 3. Grounding connections in other locations with relative movement. 9.2.5.7 Grounding Connections Grounding connections to vehicle body, truck frame, and other vehicle structures: 1. Ground pads: Provide welded stainless steel pads, or tinned or silver electro-plated copper pads silver soldered or brazed to both the vehicle body and the grounded item, through-drilled. 2. Connection: Fasten the ground wire to the ground pad using a bolt, flat washer, and locknut. The flat washer shall bear on the ground wire terminal. LTK Standard Streetcar Specifications Section 9 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 3. Aluminum structures: a. Weld an aluminum ground pad onto the structure. Thick aluminum structures may not require a separate ground pad, if approved. b. Through-bolt the ground cable to the structure with zinc-plated steel fasteners and washers. c. Treat the connection with an anti-corrosion paste. 4. DC resistance: Maximum 0.0025 ohms. 5. AC impedance: Maximum 0.025 ohms at 150 kHz for an applied ac voltage. 9.2.6 Ground Fault Detection and Protection The vehicle shall provide ground-fault protection at the inputs of high-voltage dc equipment, and generic ground-fault protection for ac circuits, low-voltage circuits, and ac convenience outlets. 9.3 Equipment Temperature Management Comply with the following: 1. Cooling systems may be water- or air-cooled, except for traction motors, which shall be aircooled. 2. Forced-air cooled systems: Use ambient air only where exposed voltage is 50 V or less. 3. Water-cooled systems: a. b. c. d. e. f. Use tap or distilled water treated with anti-corrosives and antifreeze. Use of chlorofluorocarbons (CFCs) is prohibited. Provide fluid pH as appropriate to minimize corrosion on all components. Permanently sealed, with no preventive maintenance required for life of equipment. If cooling system must be opened for other maintenance purposes, this shall not be required more often than yearly. Provide no-leak quick-disconnect fittings. 4. Motors for cooling pumps or fans: Three-phase ac or dc brushless, except as specified in the Failure Management section, below. 5. Equipment temperatures: a. Continuously monitor via sensors or, where appropriate, by calculation. b. Manage system power levels as necessary to protect equipment from over-temperature damage. c. Record abnormal temperatures, temperature trends, and resulting equipment power limitations and present to the MDS and TOD. 9.4 Primary Power System (OCS) 9.4.1 General Equipment operated from the OCS shall comply with the Primary Line Voltage requirements specified in Section 2, Design and Performance Criteria. LTK Standard Streetcar Specifications Section 9 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.4.2 Pantograph 9.4.2.1 General Vehicle power shall be collected from the OCS by a roof-mounted pantograph: 1. Type: Service-proven, single-arm design, with a spring-suspended contact assembly capable of stable bi-directional operation at all specified vehicle speeds and external system characteristics. 2. Dimensions and operating height range: Comply with Section 2. 3. Bearing Shunts: Provide tinned, braided copper conductors around all pantograph moveable joints. 9.4.2.2 Contact Assembly Comply with the following: 1. Type: Double carbon with replaceable curved carbon inserts of one-piece design. 2. Carbon lateral radius: 6 m to 10 m (20 ft to 33 ft), or other approved value. 3. Maintainability: Contact assembly and carbon inserts shall be individually replaceable with common hand tools. 9.4.2.3 Contact Force Contact force on the contact wire shall be adjustable and shall be selected for optimum tracking and minimum wear: 1. Range: 80 N to 110 N (18 lbf to 25 lbf). 2. Linearity: Contact force shall vary by maximum 25 N (6 lbf) over the combined full ranges of operating height, vehicle speed, and direction. 9.4.2.4 Dynamic Stability Pantograph dynamic stability shall be sufficient to maintain contact and stable wire tracking at the specified speeds on all tracks at all contact wire heights and transition grades. 9.4.2.5 Pantograph Raising and Lowering Comply with the following: 1. Manual raising and lowering: a. Make provision for manually lowering and raising the pantograph in the event of a loss of power or control. b. The manual mechanism shall be operated from within the vehicle, using a hand crank or similar tool. c. Provide a switch in the manual operator socket that disconnects motor power while the manual operator is inserted. d. Provide one tool for each vehicle, plus five spares. e. Provide tool storage in the cab. See Section 5, Operator’s Cab and Controls. 2. Pantograph raising: a. The pantograph shall be spring raised when the restraining mechanisms are released. b. The raising speed shall be damped or otherwise controlled to prevent carbon strip damage upon striking the OCS. This speed control and damping shall be active only during the raising process, and shall be inactive during normal wire tracking. LTK Standard Streetcar Specifications Section 9 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 3. Raising and lowering circuit: a. Shall be operable from either cab, by a Pantograph Up/Down Switch on the Cab Console, but only while the vehicle is at rest or moving in a coast or brake mode. b. Lowering of the pantograph by any means shall not affect any requested brake rate and shall result in a coast mode if the vehicle is in a coast or power mode. c. Lowering command of the pantograph shall open the HSCB and turn off the APS. d. Electric raising and lowering mechanisms shall operate throughout the voltage range specified for low-voltage equipment. 4. Pantograph restraining mechanism: a. Provide a mechanism to automatically restrain the pantograph in the fully lowered position. b. The mechanism shall function at all times regardless of failures in power, control, or other system elements. c. The mechanism shall be released automatically when the pantograph is commanded to be raised. 9.4.3 High Speed Circuit Breaker Provide a roof-mounted, high speed circuit breaker (HSCB) to protect the propulsion high-voltage dc power circuits: 1. Standards: Comply with IEC 60077-1, IEC 60077-3, and IEC 61373. 2. Power supply: Low-voltage dc power system. 3. Performance: a. Tip opening in maximum 10 ms b. Complete arc extinguishment and fault interruption in less than 50 ms 4. Trip values and ratings: Coordinate with the traction electrification system supplier such that the HSCB will clear all vehicle system fault currents without nuisance trips of the wayside breakers. 5. Trip and reset capability: a. Remote trip by the propulsion logic, as specified in Section 10, Propulsion System and Control, and reset from the cab, as part of the HSCB (Propulsion) Reset switch specified in Section 5, Operator’s Cab and Controls. b. Limit the number of electrical resets to three within any 15-minute period, after which resetting must be done via the portable test unit (PTU) or MDS maintenance screen. c. If locked after too many trips, reset via a PTU or MDS maintenance screen. 6. Provide annunciation of a tripped or open HSCB to the operator. 9.4.4 Battery Charging The LVPS shall provide battery charging whenever the pantograph is raised and OCS power is available: 1. Battery charging shall not depend on the state of the HSCB. 2. See Low-Voltage DC Power System section, below, and Section 5, Operator’s Cab and Controls, for additional requirements. LTK Standard Streetcar Specifications Section 9 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.4.5 Dead Battery Operation All vehicle systems shall start automatically, and function as specified, whenever there is high-voltage dc available at the pantograph, regardless of the charge state of the vehicle battery. 9.4.6 Surge Arrester Provide an MOV-type surge arrester suited for rail application, on or adjacent to the pantograph base: 1. Type: Rated by the manufacturer for outdoor dc operation. 2. Standards: Designed, constructed, and tested in accordance with the general requirements of IEEE C62.11. 3. Rating: Selected to prevent voltage transients and surges from damaging or degrading vehicleborne equipment, including the arrester itself. 9.5 Maintenance Shop Power 9.5.1 General Power to the vehicle while in the Shop will be 750 Vdc, supplied by a plug-in cable from the Shop Vehicle Power Unit (SVPU), provided by others. 9.5.2 Coordination Coordinate with the Owner to ensure compatibility of the vehicle with the existing Shop and any ongoing Shop expansion: 1. Furnish a summary of vehicle auxiliary loads that will be powered from the Shop to ensure compatibility of Shop circuit sizes with vehicle loads. Reduce loads if necessary for compatibility with the Shop. 2. Ensure that Owner-furnished SVPUs are compatible with vehicle plugs and interlocking. 3. Furnish a dimensioned sketch showing the location of the receptacle on the vehicle to allow designers to locate SVPUs correctly in the Shop. 9.5.3 Shop Switch Provide a dedicated transfer switch on the vehicle as follows: 1. Type: Fully enclosed, three-position rotary-type. 2. Positions: a. Off, Normal mode, and Shop mode. b. Clearly marked on the outside. 3. Operating handle: a. Easily operable with one hand. b. Grounded to the enclosure. 4. The switch shall operate as follows: a. Off mode: • • Disconnect pantograph from all vehicle circuits Disconnect shop voltage from all vehicle circuits LTK Standard Streetcar Specifications Section 9 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment b. Normal mode: • • Disconnect shop voltage from all vehicle circuits Connect pantograph to APS, traction inverters, and other line-voltage-operated equipment c. Shop mode: • • • Disconnect pantograph from all vehicle circuits Connect shop voltage only to APS, and LVPS if powered directly from line voltage Provide an interlock in the shop switch to prevent the pantograph from moving in this mode d. Under no circumstances shall the propulsion system, pantograph, or pantograph frame be energized by shop power. 5. Shop Switch Enclosure: a. Box: Painted steel, stainless steel, or aluminum; grounded to the vehicle structure. b. Cover: Latching hinged type or threaded, watertight when subjected to a water test equal in severity to that for the vehicle body; grounded to the enclosure with ground strap. c. Interior: Fully insulated with no grounded components inside. 6. Location: Roof or an alternate location if approved by the Owner. 9.5.4 Receptacle and Plug Provide receptacle, mating plug, and associated equipment rated for the maximum continuous and peak auxiliary currents to allow connection to the SVPU: 1. Receptacle: a. Location: On the shop switch enclosure, or in an alternate location if approved by the Owner. b. Grounding: If the receptacle body is metallic, it shall be grounded to the vehicle structure. c. Model: ITT Cannon CB2-32-1PS-LMFB-A-C-D. Verify that this receptacle is acceptable for the proposed load. 2. Plug: For each vehicle furnished under this Contract, furnish one mating plug to the Owner for installation on the shop cable by others. 3. Interlocking: The receptacle and plug shall include interlock contacts to ensure that the SVPU is energized only when the SVPU cable is plugged into the receptacle. Arrange interlock contacts on the receptacle/plug to break before the main receptacle/plug power contacts separate when removing the plug. 9.5.5 Auxiliary Loads Under Shop Power Under Shop power, the following loads shall be powered, unless otherwise agreed by the Owner: 1. All ac loads, including maximum HVAC loads. 2. All low-voltage dc loads and battery charging. Verify that vehicle circuits and loads stay within the limits furnished to and approved by the Owner, as specified in the Coordination section, above. LTK Standard Streetcar Specifications Section 9 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.6 AC Auxiliary Power Supply (APS) 9.6.1 General Provide a source of three-phase ac and single-phase ac power for ac auxiliary loads identified in the Specifications. 1. Provide one or two independent auxiliary inverters, powered from the high-voltage dc power system and supplying power to the ac auxiliary loads. 2. Each inverter shall supply the loads for either the complete vehicle or in its respective vehicle half (see Failure Management section, below). 9.6.2 Voltage and Frequency The three-phase ac source voltage may be 208 or 480 Vac, 60 Hz. The single-phase ac source voltage shall be 120 Vac, 60 Hz. 9.6.3 Auxiliary Inverters Comply with the following: 1. The auxiliary inverters shall start automatically and provide full performance when the steadystate input voltage is within the supply normal voltage range specified in Section 2, Design and Performance Criteria. 2. The inverters may shut down when the steady-state input voltage is less than or greater than the range specified in Section 2. 3. The output of the inverters shall be galvanically isolated from the high-voltage dc power system. 4. The inverters shall be sized for the worst case continuous operation of all loads, and the maximum peak individual load with all other steady-state loads applied, plus 10% additional capacity. If forced ventilation is provided, it shall be maintenance free. 5. The inverters shall provide the output voltages specified above, with the three-phase output in compliance with the following requirements: Output frequency tolerance: Distortion under nominal load: Maximum dv/dt of the output voltage: Maximum allowable phase current imbalance: plus or minus 2% less than 10% less than 10 V/μsec less than 10% 9.6.4 Inverter Controls The controls for the auxiliary inverters shall prevent damage to connected equipment and the inverter itself, resulting from the following: 1. 2. 3. 4. 5. 6. 7. 8. High and low frequency Over- and under-voltage Out-of-tolerance voltage-to-frequency ratio Frequent repetitive starts (manufacturer defined limits) Rapid variations and transients in line voltage or loads High-voltage dc power interruptions Excessive harmonic distortion Phase loss LTK Standard Streetcar Specifications Section 9 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment The control logic shall permit the equipment to automatically restart after shutdowns caused by selfcorrecting failure conditions. Major faults shall latch the equipment off until reset by maintenance personnel. 9.6.5 Auxiliary Inverter Fault Monitoring Provide a fault monitoring system to automatically detect auxiliary inverter status and transmit the information to the Train Operator’s Display (TOD) in the operator's cab via the vehicle network (see Section 17, Electronic Controls, Software, and MDS). 9.6.6 Failure Management Loss of a single auxiliary inverter shall not result in loss of propulsion, brakes, or other functions critical for vehicle operation: 1. Vehicle equipped with two auxiliary inverters: a. Include provisions to transfer ac power for essential loads to the second or a back-up inverter in the event of an inoperable inverter. b. As a minimum, a vehicle with a failed inverter must be able to operate over the whole alignment without speed restriction on its own power from the remaining inverter with all safety and vehicle operation related functions operational, including maintaining power to the following: • • Circuits for propulsion cooling, and other ac loads required by the propulsion system Critical friction brake loads, where permitted to be powered by ac c. The ratings of each inverter shall include these redundancy transfer loads in addition to its normal loads. d. The transfer mechanism may be via three-phase transfer breakers, or other approved methods. 2. Vehicle equipped with one auxiliary inverter: a. The critical loads, including propulsion cooling, shall be operated from the vehicle’s lowvoltage dc power system. b. A vehicle with a failed inverter must be able to operate over the whole alignment without performance restriction. c. Motors used in critical components shall be brushless dc motors. 9.7 Low-Voltage DC Power System 9.7.1 General Provide a nominal 24 Vdc low-voltage dc power system including low-voltage power supplies, battery charger, and vehicle battery for specified vehicle loads. 9.7.2 Voltage Comply with IEC 60571, except as may be specified elsewhere. 9.7.3 Low-Voltage Power Supply Comply with the following: 1. IEC 60571 for a nominal 24 Vdc system, except as may be specified elsewhere. LTK Standard Streetcar Specifications Section 9 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 2. Provide one or two independent regulated low-voltage dc power supplies (LVPS) for each vehicle. Each LVPS shall have a separate, independently controlled output for battery charging. 3. Battery charging shall be controlled independently of the other dc load outputs. The LVPS and battery charging shall be activated automatically when OCS voltage is present and when connected to shop power. See Section 5, Operator’s Cab and Controls, for additional battery charging requirements. 4. Designs that include the LVPS as part of the auxiliary inverter will be acceptable. If combined, operation or failure of the LVPS shall not affect operation of the auxiliary inverter. 5. The LVPS shall provide complete galvanic isolation of the output from the high-voltage dc power system. 6. The LVPS shall have the following capabilities: a. Each LVPS or LVPS output channel shall have sufficient capacity to maintain terminal voltage at the regulated value while simultaneously charging a dead battery and providing adequate power to all vehicle low-voltage dc loads, for all body sections, with the assumption that the other LVPS or output channel is not functioning. b. If necessary, the LVPS may limit its peak current during track brake applications, allowing the battery to supplement the loads. c. Transfer of loads to one LVPS with the loss of the other LVPS shall be automatic, and not require any action by the Owner’s personnel. The transfer of loads shall include battery charging. When the failed LVPS resumes operation the load transfer control shall detect this and automatically restore operation and load distribution between the two LVPS units. d. The LVPS shall automatically start when high-voltage dc power is applied. Battery power shall not be required as a prerequisite to starting, or for closing circuit breakers or contactors needed to permit LVPS operation. e. If forced ventilation is provided, it shall be maintenance free. 9.7.4 Battery Charger Float-charge the battery via the dedicated battery charging circuit that is part of the LVPS: 1. Charging algorithm to be optimized for battery type. 2. The charger shall include a current-limiting feature that ensures the battery manufacturer's recommended charging current level is not exceeded. 3. The battery charging voltage shall be optimized for the battery selected by the Contractor, per the battery manufacturer's recommendations. The charging voltage shall be adjustable by the user via software to allow alternative battery vendors. The adjustment may be restricted such that only authorized personnel can make adjustments. 4. Adjust charging voltages and currents automatically for battery temperature via a temperature sensor in the battery compartment. 5. Battery charging shall be provided and managed by one LVPS. If more than one LVPS is provided, include provisions to transfer battery charging between LVPSs in the event of LVPS/battery charging failure. The transfer circuit shall be automatic, or via a dedicated manual circuit. LTK Standard Streetcar Specifications Section 9 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.7.5 Vehicle Battery 9.7.5.1 Battery Provide a vehicle battery to power emergency loads in the event of failure of the low-voltage power supplies: 1. 2. 3. 4. 5. 6. Type: Low-maintenance 19 or 20 cell NiCd, or Li-ion. Quality: Service-proven railway or transit quality. Capacity: Sufficient to power emergency loads for the durations specified below. Charging: From the LVPS battery charging output. Charging voltage: Set as recommend by the battery manufacturer. Installation: Battery and associated circuitry shall comply with NFPA 130. 9.7.5.2 Battery Enclosure Provide a ventilated battery enclosure on the roof or under the vehicle and outside the passenger compartment: 1. General: a. Size: Large enough to accommodate batteries from at least two independent suppliers. b. Integral Tray: Provide for capture of spilled electrolyte. c. Paint: If battery enclosure components are painted, they shall be impervious to electrolyte. 2. Roof: a. Enclosure Covers: • • Hinged, large enough to permit battery removal and inspection. With features that prevent cover or hinge damage from over-rotation. b. Enclosure Structural Strength: Sufficient to withstand a 275 lb man walking on the covers without permanent deformation or contact with underlying circuits. 3. Under Vehicle: Provide roll-out tray to hold the batteries: a. Material: Stainless steel. b. Support: Ball-bearings. c. Extension Depth: Sufficient to permit battery to be fully extended such that all cells may be inspected and filled. 9.7.5.3 Battery Circuit Breaker Provide a circuit breaker for battery and battery-circuit protection: 1. 2. 3. 4. Type: Two-pole dc breaker. Parallel circuit breakers are not permitted. Rating: Sufficient to withstand the short circuit capacity of the battery. Connection: To the B+ and B- leads from the battery terminals. Vehicle battery disconnect: Include provision to trip the breaker from the side of the vehicle, by persons standing on the ground. 9.7.5.4 Battery Heat Detection and Emergency Cutoff Provide a heat detection system: 1. It shall trip the battery circuit breaker upon detection of excessive heat. LTK Standard Streetcar Specifications Section 9 12 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 2. The temperature setting shall be as recommended by the battery manufacturer. Provide an accessible emergency battery-cutoff switch if the battery circuit breaker is not accessible from the side of the vehicle or at a convenient interior location. 9.7.6 Battery Load Control Provide automatic controls to prevent discharge of the vehicle battery by parasitic loads when the MC key is switched to Off and the battery is not being charged. Allow operation of passenger area lights until the Delayed Off timer expires, if the vehicle loses battery charging after the Hotel Load timer is triggered (see Section 5, Operator’s Cab and Controls). 9.7.7 Emergency Power The vehicle battery shall provide emergency power upon the loss of LVPS units or outputs: 1. Capacity: Sufficient to supply all the loads at the duty cycles shown in the table below as follows: a. First 45 minutes: All loads. b. Next 45 minutes: Only emergency lighting and communications, without discharge to below 1.0 V per cell. 2. Voltage: All indicated loads and systems shall have sufficient input voltage to operate for the specified duration. Emergency Load Emergency Lighting Communications Door Control Propulsion Control Braking power and control, including pumps if dc operated Operator's console indicators and interlocks Horn and bell Track brakes Pantograph Control Headlights, tail and stop lights Windshield wiper Passenger Information System Operation Continuous Continuous Cycle doors open for 20 seconds every 5 minutes Continuous Continuous Duration (minutes) 90 90 45 45 45 Continuous 45 On for 10 seconds every 2 minutes On for 10 seconds at end of each 20 minute period Raise and lower twice Continuous Continuous Normal station announcements 45 45 45 45 45 45 9.7.8 Failures and Fault Indications Include circuitry in the low-voltage dc power system to detect LVPS and battery charging failures: 1. The circuit shall provide fault indications to the Train Operator’s Display (TOD) in the operator's cab via the vehicle's network. LTK Standard Streetcar Specifications Section 9 13 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 2. See Section 17, Electronic Controls, Software, and MDS, for design and submittal requirements. 9.8 Vehicle-to-Truck Wiring For each wiring system on a truck, provide flexible cable connecting the vehicle and truck, with waterproof quick disconnect cable connectors as specified in Section 16, Materials and Workmanship, to facilitate removal of trucks: 1. Route cable to accommodate all truck motions without interference or excess strain. 2. Provide cable with strain relief on both the vehicle end and the truck end. 3. Flexible cable construction shall be selected for 30-year life under repeated flexing caused by truck motions. 4. Waterproof quick disconnect connectors shall be selected for the shock and vibration environment. 5. Cabling to connectors on the truck side shall be restrained to prevent fatigue and chafing to the wiring or connectors. 6. Wire lengths, supports, and dress shall minimize strain at termination and support points under worst-case truck motions. 7. See Section 10, Propulsion System and Control, for additional requirements related to connection to traction motors. 9.9 Line Filters 9.9.1 General Provide devices to perform the following filtering functions: 1. Protect vehicle equipment from line transients. 2. Filter ac voltage and currents impressed on the line by the propulsion system and all other systems fed by dc line voltage. 3. Suppress high-frequency voltage transients caused by converter or inverter switching operations. 9.9.2 Performance Comply with the following: 1. Filters shall suppress all frequencies to the levels specified in Section 2, Design and Performance Criteria, under normal and abnormal equipment operation, at any location along the Project tracks: a. Prove through reliable simulations that the vehicle complies with these requirements for any allowable line voltage and any combination of active and inactive substations. b. If the simulations are inconclusive, or cannot be performed to the full extent, include an EMI frequency monitor for all critical frequencies used by the Owner. 2. The resonant frequency of each filter shall be less than 40 Hz, and shall be inductive above 50 Hz. 9.9.3 Self-Test Provide a line-filter self-test feature that operates during the power-up or power-down sequence: 1. If the tested capacitance value is outside of the allowed tolerance band, a failure message shall be sent to the MDS. LTK Standard Streetcar Specifications Section 9 14 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 2. The detection of a failure shall not immobilize the vehicle, but upon detection of a failure, the power draw of the inverter with the defective filter shall be reduced by 50% until the defective condition is corrected. 9.9.4 Configuration Line filters may be configured as follows: 1. As individual elements of various systems that are fed by high-voltage dc power; or 2. Combined, with the following limitations: a. If APS/LVPS is integral to propulsion inverter, they can share the input filters. b. Line inductors only may be shared; capacitor banks shall not be shared. c. If line inductors are shared, system isolation switches or contactors shall be supplied to permit independent operation of each supplied system. 9.9.5 Components 9.9.5.1 Line Inductors Comply with the following: 1. Thermal rating: Sufficient for maximum power dissipation under worst case conditions defined in Section 2. 2. Forced ventilation cooling: Allowed only if part of the inverter cooling. Standalone inductors shall be convection cooled. 3. Insulation and construction: Provide the indicated service life in the specified environment. 4. Physical protection: a. Full enclosure; or b. Protected from physical damage by screens 5. Electrical connections: Environmentally sealed. 6. Standards: a. Construction and testing: Comply with IEC 60310 b. Shock and vibration: Comply with IEC 61373, or other approved standard 7. Service life: 30 years. 9.9.5.2 Filter Capacitors Comply with the following: 1. 2. 3. 4. Capacitor life: Minimum 20 years, as used in this application. Prohibited types: Electrolytic capacitors. Location: Install in the same enclosure as the system’s power components. Bleeder resistor: Permanently connect across the terminals of each capacitor in the capacitor bank: a. Resistance: Select value to reduce voltage at the terminals of the capacitor bank to maximum 50 V within 3 minutes after high-voltage dc is removed from the bank. b. Traction inverter: Use the brake resistor to discharge the input filter capacitors when inverter is shut down. LTK Standard Streetcar Specifications Section 9 15 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 5. Signage: Provide a permanent sign to warn maintenance personnel: a. Warning language: Lower the pantograph, wait 5 minutes, manually bleed, then short circuit the capacitor before commencing work. b. Sign location: Adjacent to the capacitors, visible when the door to the enclosure that houses the capacitor bank assembly is open. 9.10 Panelboards and Control Panels Comply with the following: 1. Panelboards, control panels, circuit breakers, and related devices shall be rail industry proven. 2. Panelboards: Conform to NFPA 70 Article 408, Switchboards, Switchgear, and Panelboards, except as specifically specified otherwise or as approved by the Owner. 3. Control panels: Conform to NFPA 70 Article 409, Industrial Control Panels, except as specifically specified otherwise or as approved by the Owner. 4. Dead fronts: Moisture-proof, electrically insulating, laminated phenolic; or grounded metal. 5. 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. 6. Provide minimum 10% spare capacity in distribution panels but not less than one space for future circuit breakers for each voltage class, except provide minimum four spaces for low voltage. Provide covers for unused spaces. 7. Provide a nameplate for each breaker, switch, and indicating light: a. Lettering: Raised or recessed b. Required information: • • • Circuit designation Operating voltage Instructions such as “Do Not Operate Under Load” as appropriate c. Location: On the dead front 9.11 Fuses and Circuit Breakers 9.11.1 General Fuses may be used only where specifically required or allowed in the Specifications, and where applicable circuit breakers are not commercially available. Fuse assemblies are subject to Owner approval. Each circuit breaker and fuse shall have a permanent label installed adjacent to the device. 9.11.2 Fuses and Fuse Holders High-voltage dc fuses: High speed, with minimum rating of 2000 Vdc: 1. Provide totally enclosed fuse holders with no exposed high-voltage connections. When the fuse holder is opened the fuse shall be extracted from the circuit and the exposed fuse safely isolated from any circuit connection. 2. Mount on the vehicle roof. LTK Standard Streetcar Specifications Section 9 16 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.11.3 AC and Low-Voltage DC Circuit Breakers Circuit breakers shall be rugged, fully suitable for the service intended, and of the highest quality procurable. Comply with the following: 1. Circuit breakers of the same rating shall be of the same manufacture and model throughout the vehicle. 2. A circuit breaker operated continuously at its full rating must be listed for operation at 100% of its rating by a nationally recognized testing laboratory, such as UL, and the breaker must be housed in the same enclosure used to establish the listing. A continuous load is a load where the maximum current is expected to continue for three hours or more. 3. Type: Molded case, DIN-rail mounted whenever possible. 4. Standards: Conform to UL 489; IEC 60947-2 may be proposed for approval by the Owner. 5. Circuit breaker terminals shall not be used as junction points. 9.11.4 Circuit Breaker Prohibited Locations Circuit breakers shall not be installed in the following locations, regardless of ventilation methods: 1. Within any location or arrangement that would permit accumulation of explosive gases near the breaker. 2. Within the vehicle battery enclosures. 3. Within assemblies that may enclose the vehicle battery enclosures. 9.12 Contactors and Relays 9.12.1 General Comply with the following general requirements for both contactors and relays: 1. Document successful history of operation in rail transit control applications. 2. Mount and orient as recommended by the supplier. 3. Identify 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. 4. Terminate maximum two wires on a terminal. 5. Contacts: a. Current rating: • • Based on continuous, inrush, or interrupting requirements, whichever is worse, and then derated by at least a factor of four. Based on the worst condition of reduced surface contact which may result from tip misalignment during normal operation of the device. b. Material: • • Selected for the actual loads, and not solely on the device rating. Provide silver bifurcated contacts for low-level circuits and gold-alloy bifurcatedcrossbar contacts for dry circuits. c. Series connected: Shall not be operated in circuits where the voltages and currents exceed the single derated contact ratings. d. Parallel connected: Not permitted. LTK Standard Streetcar Specifications Section 9 17 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 6. Coils: a. Shall operate within the voltage range specified in IEC 60571. b. Shall have MOV suppression except where performance may be affected. c. Unsuppressed coils are permitted only with the explicit approval of the Owner. 9.12.1.1 Contactors Comply with the following additional requirements for contactors: 1. Provide with series fed arc-blowout coils. 2. Guaranteed mechanical service life: Minimum 5 million switching operations, except as approved where infrequent operation is expected. 9.12.1.2 Relays Comply with the following additional requirements for relays: 1. Guaranteed mechanical service life: Minimum 10 million switching operations. 2. Contact rated electrical life: Minimum 500,000 operations, or 10 years, whichever is greater. 3. Time delay relays: R-C or solid state type. Mechanical or pneumatic time delay devices are not permitted. 4. Plug-in relays: Provide 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. Shall be keyed to prevent incorrect installation of relays with the wrong contact configuration. 9.13 Switches 9.13.1 High-Voltage DC Switches There shall be no high-voltage dc switches capable of manual operation. High-voltage dc circuits shall be manually interrupted only as follows: 1. By activating the respective circuit breaker; or 2. By activating a low-voltage switch that subsequently controls a high-voltage contactor. 9.13.2 Low-Voltage Switches Comply with the following: 1. Type: Industrial grade, rated at least IP65 in conformance with IEC 60529. 2. Use prohibited: Switches shall not directly control highly inductive or high inrush loads. 3. Contacts: a. b. c. d. e. f. Operate only at voltages or currents within manufacturer's recommendations. Type: Silver, double break. Mechanism: Provide a wiping motion when contacts make or break. Current ratings: Derated by at least a factor of four. Series connected: Shall not be operated in circuits where the voltages and currents exceed the single derated contact ratings. Parallel connected: Not permitted. 4. Switch bodies: Keyed to prevent rotation. 5. Mounting hardware: Metal, including the body portion extending through the panel. 6. Connections: Maximum two wires to each switch terminal. LTK Standard Streetcar Specifications Section 9 18 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9.14 Low-Voltage DC-DC Power Supplies Comply with the following: 1. DC power supplies shall be high efficiency, industrial grade, switching supplies providing rated voltage and power over the full range of LVPS and battery voltage specified elsewhere. 2. Transient and short term overload ratings shall be as appropriate for the application. 3. Power supplies shall be commercially available units from established power supply manufactures, except where designed and integrated into specific systems. 4. Each power supply shall have the following protective features: a. Input voltage transient and surge protection in accordance with IEC 61000-4-4 and IEC 61000-4-5 respectively b. Galvanic Input-to-output isolation of 1500 Vdc c. Short-circuit-proof output d. Automatic output current limiting e. Output overvoltage protection 5. Power supplies shall be powered from the vehicle's LVPS, with a dedicated circuit breaker for each in accordance with the requirements in this section. See Section 13, Vehicle Communication Systems, for requirements for the dedicated dc-dc power supply to power radio equipment. 9.15 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. 9-1 Detail drawings: Top level assemblies, and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values One-Line Power Distribution Diagrams: 1. Include diagrams for each voltage level 2. The diagrams shall show loads, return current paths, protection, and grounds. 9-2 AC and DC Load Calculations: 1. 2. 3. 4. Submit CDRL 9-1 before or at the same time as CDRL 9-2. Include ac and dc load calculations in both normal and emergency (battery) modes. Emergency loads shall include the emergency loads specified in this Section. List the power for each load, assumptions used, and derating of loads, if any. Include wire sizes and breaker ratings. 5. Include calculations showing loads that must be supplied during loss of a single auxiliary inverter. Furnish a narrative and schematics, as necessary, to demonstrate the ability of the system to power necessary loads. LTK Standard Streetcar Specifications Section 9 19 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 9-3 Safety Grounding Design Package: 1. 2. 3. 4. 5. 9-4 Furnish sufficient information to show the complete grounding scheme. Data sheets for ground conductors and ground connections. Ground path impedance for all ground paths. Shop drawings showing routing of ground conductors. Assembly drawings. Ground Brush Design Package: 1. 2. 3. 4. 5. 6. Description of the ground brushes Calculations showing rms and peak current Data sheets showing ratings of hardware Hardware drawings Assembly drawings showing ground brush arrangements and ground connections Circuit diagram for both high-voltage dc current return and safety grounding showing physical current path 7. Impedance calculation for high-voltage ground wires between ground brushes and corresponding insulated ground pad 9-5 Ground Fault Detection and Protection Design Package: 1. 2. 3. 4. 9-6 Data sheets for hardware used Sensitivity levels of each detection scheme Assembly drawings Wiring diagrams Primary Power System Design Package: 1. High speed circuit breaker: Data sheets 2. Primary voltage fuses: Data sheets for fuses and associated components. 3. Surge arrester: a. Data sheets b. Rating selection design analysis 9-7 Pantograph Design Package: 1. Submit the pantograph dynamic envelope as a dedicated section in the design package 2. Furnish sufficient information to verify that the pantograph does not lose contact with the OCS under normal and abnormal operating conditions identified in these Specifications. 3. Include the following: a. b. c. d. e. 9-8 Data to support ratings of components Data sheets on each component Parts lists Electrical drawings Assembly drawings Shop Power Design Package: 1. Load calculations to support the ratings of the components, if not already submitted previously (“AC and DC Load Calculations”) 2. Transfer switch design documentation LTK Standard Streetcar Specifications Section 9 20 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment 3. Data sheets on each major component, including but not limited to receptacle, receptacle enclosure, mating plug, and components used for interlocking 4. Electrical wiring diagrams and schematics for both power and control wiring showing functionality and interlocking 9-9 AC Auxiliary Power Supply (APS) Design Package: 1. Functional description: Justify selected configuration and confirm compliance with requirements of this Section 2. Load study 3. Data indicating how the equipment operates under extreme conditions and faults 4. Assembly drawings 9-10 Failure Management Design Package: 1. List of critical safety and vehicle operation loads required during failure of an auxiliary inverter to maintain vehicle operation 2. Data sheets on transfer mechanism, if applicable 9-11 Low-Voltage DC Power System Design Package: 1. Low-voltage power supply: a. Data sheets b. Capacity calculations showing ability to carry normal and transfer loads 2. Battery charging: a. Single LVPS (if proposed): Switch-over circuit functional description, data sheets for hardware, and electrical schematics 3. Vehicle battery: a. Battery description and specification b. Recommended charging processes c. Battery circuit breaker, including breaker data sheet, enclosure data sheet, location of enclosure, and electrical schematic d. Load calculations and assumptions e. Mounting location f. Ventilation design g. Battery heat detection system, including component data sheets, electrical schematic, and locations of components h. Battery cut-out switch, including data sheet and location, if required by battery circuit breaker configuration 9-12 Line Filters The following may be provided as part of the respective system CDRLs, if required elsewhere. 1. For each system filter: a. b. c. d. Frequency characteristics Component types, values, manufacturer Calculations demonstrating life expectancies Installation details, if not included within system enclosure LTK Standard Streetcar Specifications Section 9 21 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electrical Equipment e. Filter degradation monitoring methods 2. Simulation results with sufficient information to demonstrate compliance with the Specifications. 3. EMI frequency monitor details, if simulation does not demonstrate compliance with Specifications. 4. Line filters not included with other system submittals: a. Data sheets showing ratings of hardware b. Functional description: Include failure detection c. Wiring diagrams 9-13 Electrical Panels, Components, and Devices Design Package: 1. Manufacturer’s data: Include certification of compliance to specified standards or sufficient data to confirm compliance. 2. Location and application of each product submitted. END OF SECTION LTK Standard Streetcar Specifications Section 9 22 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control Table of Contents 10.1 General ......................................................................................................................................1 10.1.1 Scope .............................................................................................................................................. 1 10.1.2 System Configuration ..................................................................................................................... 1 10.1.3 Propulsion Control Signals ............................................................................................................. 1 10.1.4 Inverter Drive Technology.............................................................................................................. 1 10.1.5 Drive Configuration ........................................................................................................................ 1 10.1.6 Interchangeability .......................................................................................................................... 1 10.1.7 Circuit Protection ........................................................................................................................... 1 10.2 Equipment Thermal Capacities ....................................................................................................2 10.3 Equipment Temperature Management .......................................................................................2 10.4 Transients and EMI .....................................................................................................................2 10.4.1 Switching Line Transients ............................................................................................................... 2 10.4.2 Electromagnetic Interference ........................................................................................................ 2 10.5 Performance Requirements ........................................................................................................2 10.6 Propulsion System Functions ......................................................................................................2 10.6.1 Load Compensation ....................................................................................................................... 2 10.6.2 Braking ........................................................................................................................................... 3 10.6.2.1 Friction Brake Control ............................................................................................................. 3 10.6.2.2 Dynamic Braking ..................................................................................................................... 3 10.6.3 Fault Detection............................................................................................................................... 3 10.6.3.1 General.................................................................................................................................... 3 10.6.3.2 Dynamic Brake Fault ............................................................................................................... 3 10.6.3.3 Fault Annunciation .................................................................................................................. 4 10.6.3.4 Reduced Overspeed Set Point ................................................................................................ 4 10.6.4 Direction Change............................................................................................................................ 4 10.6.5 Rollback Prevention ....................................................................................................................... 4 10.6.6 Cut-Out Control .............................................................................................................................. 4 10.6.7 Wheel Spin/Slide Detection and Correction .................................................................................. 5 10.6.8 Overspeed Protection .................................................................................................................... 5 10.6.9 Adjustments for Wear .................................................................................................................... 5 10.6.10 Distance Signal ............................................................................................................................. 5 10.7 System Components ...................................................................................................................6 10.7.1 Traction Motors ............................................................................................................................. 6 LTK Standard Streetcar Specifications Section 10 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 10.7.2 Gear Drive ...................................................................................................................................... 7 10.7.3 Resistors ......................................................................................................................................... 8 10.7.3.1 Dynamic Brake Resistors......................................................................................................... 8 10.7.3.2 Other Resistors ....................................................................................................................... 9 10.7.4 Contactors ...................................................................................................................................... 9 10.7.5 Propulsion Line Filter ..................................................................................................................... 9 10.7.6 Control Logic .................................................................................................................................. 9 10.7.6.1 General Requirements ............................................................................................................ 9 10.7.6.2 Configuration .......................................................................................................................... 9 10.7.6.3 Monitoring .............................................................................................................................. 9 10.7.6.4 Self-Tests ................................................................................................................................. 9 10.7.7 Static Power Devices .................................................................................................................... 10 10.7.8 Line Contactor .............................................................................................................................. 10 10.7.9 Speed Sensing Devices ................................................................................................................. 10 10.8 Inverter Enclosures ................................................................................................................... 11 10.9 Painting.................................................................................................................................... 11 10.10 Contract Data Requirements List (CDRL) .................................................................................. 11 LTK Standard Streetcar Specifications Section 10 ii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 10.1 General 10.1.1 Scope Provide traction inverters, traction motors, drive gear units, sensors, control logic, friction brake blending logic, wheel spin/slide correction, protection devices, and all accessories necessary to meet the specified requirements of propulsion and dynamic braking. 10.1.2 System Configuration Comply with the following configuration requirements: 1. Configure each propulsion system to function independently, regardless of the condition of other propulsion systems. 2. Sharing of components between propulsion systems shall be minimized, and only as approved. 3. Provide either one inverter per powered truck or one inverter for each motor. 4. Power collection and primary protection equipment (see Section 9, Electrical Equipment) may be shared between the two truck control systems. 10.1.3 Propulsion Control Signals See Section 17, Electronic Controls, Software, and MDS, for propulsion system control signal requirements. 10.1.4 Inverter Drive Technology Comply with the following: 1. Propulsion and dynamic braking: Provide state of the art IGBT (insulated-gate, bipolartransistor) inverters. 2. Brake chopper: Use a high-side IGBT switching device and a freewheeling diode across the brake resistor. 3. Drive control system: Use a modern vector control system, with sufficient accuracy to provide stable operation at any speed down to standstill, including the ability to maintain the vehicle stationary on a grade. 10.1.5 Drive Configuration Comply with the following: 1. Powered trucks: Each motor shall drive one axle or one wheel. 2. Drive configuration: a. Proven in similar service b. Minimizes unsprung weight on the drive axles or wheels 10.1.6 Interchangeability Propulsion system components shall be identical and interchangeable between trucks and all vehicles. 10.1.7 Circuit Protection Refer to Section 9, Electrical Equipment. LTK Standard Streetcar Specifications Section 10 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 10.2 Equipment Thermal Capacities The thermal capacity of the propulsion equipment shall be based on either the normal duty cycle or the abnormal duty specified in Section 2, whichever is worse. 10.3 Equipment Temperature Management Comply with the following: 1. Provide equipment cooling on a per-truck basis such that continued operation is possible via the remaining propulsion system, at proportionally reduced performance, in the event of cooling system failure. 2. Comply with equipment temperature requirements in Section 9, Electrical Equipment. 10.4 Transients and EMI 10.4.1 Switching Line Transients Comply with the following requirements: 1. Suppress switching line transients normally generated by the propulsion system such that the instantaneous voltage complies with IEC 60850 or EN 50163. 2. Vehicle-borne equipment shall withstand vehicle and wayside generated transients without damage or reduction in life (see Section 2, Design and Performance Criteria, for required tolerance to transients and abnormal electrical conditions). 10.4.2 Electromagnetic Interference Comply with the following: 1. Propulsion system shall not exceed electromagnetic interference (EMI) limits, as specified in Section 2, in any mode, including regenerative braking and abnormal operating conditions. See Fault Detection section, below, and also Section 9, for line-filter monitoring. 2. Design propulsion system to operate successfully in an environment of high ambient electrical noise, whether self-generated, generated by other vehicle systems, or generated off-vehicle. 10.5 Performance Requirements Comply with the requirements specified in Section 2, Design and Performance Criteria. 10.6 Propulsion System Functions 10.6.1 Load Compensation Normal Operation: The propulsion control system shall adjust tractive and braking efforts to compensate for varying passenger loads as specified in Section 2, Design and Performance Criteria. See also Section 12, Friction Brake System. Failure Mode: In the event of a failed load compensation signal, the system shall default to the load value of the nearest healthy truck, and notify the operator through the MDS system (see Section 17, Electronic Controls, Software, and MDS). LTK Standard Streetcar Specifications Section 10 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 10.6.2 Braking 10.6.2.1 Friction Brake Control The propulsion control system shall interface directly with the friction brake controls to optimize blending, slide control, and failure management. 10.6.2.2 Dynamic Braking Comply with the following: 1. Type: Combined regenerative and rheostatic braking. 2. Operating range: Continuously available from vehicle design speed down to a vehicle speed of 5 km/h (3 mph) or less. 3. Zero speed: Friction brakes shall be fully blended in to provide a secure zero speed detection. 4. For brake initializations below 5 km/h, the dynamic brake shall be disabled. 5. The dynamic brake control system shall perform the following: a. Continuously monitor line voltage. b. Supply to the line the maximum amount of energy possible within the line-voltage limits prescribed in Section 2. c. Divert to the braking resistors only that generated energy in excess of the energy accepted by the line. 6. No line voltage: Once initiated, dynamic braking shall be available independent of the presence of line voltage. 7. Friction brake coordination: Provide a per-truck dynamic brake effort signal to the friction brake system, indicating achieved dynamic brake effort. Coordinate signal characteristics and values with the friction brake supplier. 8. Regenerative braking: a. Maximum OCS voltage: Per IEC 60850, Table 1, Nominal voltages and their permissible limits in values and duration. b. Possible to cut out by PTU for test purposes. 10.6.3 Fault Detection 10.6.3.1 General Provide a comprehensive fault detection and health monitoring system, on a per-inverter basis: 1. The system shall detect and report the following: a. Actual and pending equipment failures b. Out-of-range voltages or signals c. Loss or reduction of requested efforts or performance; and similar problems 2. Record detected faults in local fault logs, and report to the MDS and TOD. 3. System health monitoring shall identify the potential for excess EMI. See also Section 9, Electrical Equipment, Line Filters section. 10.6.3.2 Dynamic Brake Fault Comply with the following: 1. Design of dynamic brake failure detection and associated interface circuits: LTK Standard Streetcar Specifications Section 10 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control a. Conform to the general safety design requirements specified in Section 2, Design and Performance Criteria. b. Minimize nuisance fault annunciations due to transient events, including momentary loss of primary power when braking is initiated. 2. Performance: When failures in dynamic braking are detected, the system shall perform the following: a. All residual dynamic brake effort shall be disabled b. The dynamic brake signal to friction brake shall be clamped to zero c. A dynamic brake fault shall be indicated for that truck 10.6.3.3 Fault Annunciation Provide visual annunciation in the cab for all propulsion system faults, including but not limited to the following: 1. 2. 3. 4. 5. 6. Cut-out Dynamic brake failure General faults Ventilation failure Overheating Line voltage out of range 10.6.3.4 Reduced Overspeed Set Point Propulsion system faults may impose a reduced overspeed set point, as appropriate (see Overspeed Protection section, below). 10.6.4 Direction Change The inverter control shall perform as follows regarding direction change: 1. Respond to cab reverser switch direction control signals only when no-motion is detected and tractive effort is zero. 2. Monitor correspondence between the control-line command and motor rotation, and if out-ofcorrespondence, apply friction brakes and flag a rollback condition. 3. Comply with additional requirements in Section 5, Operator’s Cab and Controls. 10.6.5 Rollback Prevention The propulsion system shall detect and prevent vehicle motion in a direction opposite to that selected by the cab when a propulsion mode is selected, as specified in Section 2, Design and Performance Criteria. 10.6.6 Cut-Out Control Include provisions for each powered truck to be independently isolated from the propulsion control signals and the OCS supply: 1. With one truck cut out on a single vehicle, it shall be possible to operate the vehicle in either direction over the whole alignment with no damaging effects. 2. If needed, a speed limit may be automatically applied when any truck is cut out (see Overspeed Protection, below). 3. All other systems shall remain operational. LTK Standard Streetcar Specifications Section 10 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 10.6.7 Wheel Spin/Slide Detection and Correction Provide a wheel spin/slide detection and correction system as an integral part of the propulsion control system: 1. It shall meet the requirements of Section 2, Design and Performance Criteria. 2. Coordinate system with friction brake slide control. 10.6.8 Overspeed Protection The propulsion control system shall include overspeed protection that limits vehicle speed to set values by means of tractive effort and brake control. See the Speed Sensing Devices section, below. 1. Overspeed protection shall function as follows: a. As overspeed set point is approached: Limit propulsion effort as a function of speed. b. At overspeed set point: Reduce tractive effort to zero. c. At 6 km/h above overspeed set point: • • Impose a full service brake command. The brake command shall be resettable by moving the Master Controller to the full service brake position at any speed below the overspeed set point. 2. Overspeed set point: a. Initial: Set per values defined in Section 2, Design and Performance Criteria, Speed Requirements section. b. Changes: Setpoints shall be adjustable by the Owner, up to and including the maximum operating speed in Section 2, Speed Requirements section. 3. Abnormal operating conditions: Overspeed set point and reset criteria may vary as deemed necessary to protect equipment in case propulsion or brake equipment is in failure mode or has been cut out, as approved by the Owner. 4. Equipment protection: The propulsion system may impose a separate, non-user-adjustable, overspeed setting for equipment protection, set no lower than the vehicle design speed value in Section 2, in Speed Requirements section. 10.6.9 Adjustments for Wear Adjustments shall not be necessary to compensate for component wear, aging, and similar phenomena: 1. Provide compensation for a reference wheel diameter using software commands from Portable Test Units specified in Section 17, Electronic Controls, Software, and MDS. 2. Adjustments shall be made in 1 mm (0.04 in) increments of wheel diameter, covering the full range between new and fully worn diameters. 3. Other required wheel size compensation shall be automatic. 4. It shall be possible to query actual wheel diameters for each axle/wheel on the TOD. 10.6.10 Distance Signal As required by the system design, provide a distance signal with sufficient accuracy to the following systems specified in Section 13, Vehicle Communication Systems: 1. Automatic passenger information 2. Automatic passenger counting LTK Standard Streetcar Specifications Section 10 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 3. Any other system as required 10.7 System Components 10.7.1 Traction Motors AC traction motors shall have the following basic design features: 1. Motor Type: Three-phase, squirrel cage induction motor, with welded or brazed copper cage and formed stator coils. 2. Ventilation: Forced-ventilated or self-ventilated. 3. Duty: Thermally rated in accordance with the duty-cycle specified in Section 2, Design and Performance Criteria. 4. Load Sharing: The motor characteristics shall allow achievement of all performance requirements with wheel diameter differences of at least 0.6% for motors driven in parallel by the same inverter. 5. Motor Standard: IEC 60349. 6. Insulation: a. Motor insulation: IEC 60085, Class 200 insulation system or better. b. Motor stator coils: Vacuum pressure impregnated in the complete stator frame assembly. 7. Enclosure: Splash-proof or totally enclosed. 8. Mounting: a. Each traction motor shall be resiliently or rigidly mounted to the truck frame. Axle-hung motors are prohibited. b. Unsprung mass of the motor-gear unit assembly shall be kept to a minimum. c. Provide safety straps, tabs, or hangers as required to retain the motor or gear in the event of mount failure. 9. Shaft Coupling: a. Provide a maintenance-free coupling arrangement between traction motor and gear-unit shafts. b. The coupling design and motor-gear unit mounting arrangement will be considered acceptable if no maintenance is required and coupling life exceeds drivetrain overhaul period. 10. Motor Design Speed: a. Equal to the vehicle design speed indicated in Section 2, at fully worn wheels. b. Based on the motor design speed, test the traction motor to the over-speed defined in IEC 60349-2. 11. Bearings: a. Type: Grease lubricated, NFL, antifriction bearings: • • Grease cavities: Large enough to hold a five-year supply of lubricant. Configurations are acceptable that use gear lubricant for the traction motor bearing at the pinion end. b. ABMA L10 rating life: Equivalent to 1,600,000 km (994,200 mi) of service, or greater. c. Inspection or service: None required except periodic lubrication. LTK Standard Streetcar Specifications Section 10 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control d. Prevent induced shaft currents and electrostatic discharges resulting from inverter switching pulses from damaging motor bearings as follows: • • Provide insulated bearings, shaft grounding brushes, microfiber-type shaft grounding rings, or a combination of these measures. Demonstrate that the proposed solution has been used successfully for minimum five years in a similar transit environment. 12. Motor and Rotor Balance: a. Motors shall be dynamically balanced to meet the requirements of IEC 60349-2. b. Balancing shall be accomplished by using metal weights, welded in place; or by drilling the rotor core. 13. Vibration: Meet the requirements of IEC 60349-2. 14. Noise: Motor shall be free of objectionable windage and mechanical noises at all vehicle speeds and under all load conditions. 15. Markings: Terminals, leads, and motor frames shall be clearly marked for positive identification. 16. Traction Motor Wiring and Electrical Connections: a. Cabling shall minimize EMI: • • As a minimum, provide a ground wire connecting inverter ground to traction motor ground, bundled with the three-phase cables. There shall be no other ground connection of this cable between inverter and traction motor. b. Size cables in accordance with NFPA 130, Section 8.6.3, Propulsion Motors. c. Connectors to motor leads and related hardware: • • Quick-disconnect type Rated for the peak voltages and currents present d. See Section 9, Electrical Equipment, for vehicle-to-truck wiring requirements. 10.7.2 Gear Drive Gear units shall have the following basic design features: 1. Bearings: Provide anti-friction bearings throughout: a. Inspection or service: None required before a major gearbox overhaul. b. ABMA L10 rating life: Equivalent to minimum 1,600,000 km (994,200 mi) of service. c. External bearing shaft seals shall be the labyrinth type, with supplemental sliding contact seals, if necessary to keep high velocity splashed water from entering the gear units. 2. Lubrication: a. The gear unit shall be oil lubricated and provided with sufficient baffles, dams, and passages to ensure an adequate flow of lubricant to bearings and gears under all combinations of acceleration, speed, direction, load, and environment. b. The gear unit shall prevent infiltration of moisture into the lubricant from any and all sources. c. Maximum rate of oil replenishment shall be one quart for every 160,000 km (99,400 mi). LTK Standard Streetcar Specifications Section 10 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control d. The gear unit shall have openings with removable plugs located with easy access for filling and draining. Plugs shall be of a type or be located to prevent damage by obstacles on the track and the resultant loss of lubricant. Plugs shall be secured by lock wires, lock tabs, or other approved means to prevent loosening in service. e. The filler plug opening shall be arranged to provide an indication of oil level and also prevent overfilling. Drain plugs shall have magnetic particle collectors. 3. Maintainability and Life: a. Accessibility: Provide inspection covers on the gear housing that are accessible, removable, oiltight, and airtight for visual inspection of the gears. b. Inspection or service before a major overhaul: None requiring disassembly. See Section 2, Scheduled and Preventative Maintenance section, for the minimum operating miles to the first major overhaul. c. Life: Minimum 1,600,000 km (994,200 mi). 10.7.3 Resistors 10.7.3.1 Dynamic Brake Resistors Comply with the following: 1. Capacity: Sufficient to provide full power dissipation by convection cooling during operation at full service brake over the Project alignment up to and including AW3 passenger loading: a. Assume no regeneration into the line. b. Do not consider air speed in estimating resistor cooling for resistor designs. 2. Cooling: Either convection-air ventilated or forced-air ventilated: a. Forced-air cooling is acceptable only if the inverter cooling air is used. b. Standalone resistors shall be convection cooled. c. In either case exhaust air and radiated heat from the resistors shall be routed to prevent damage to nearby equipment and overhead contact wires. 3. Location: Roof mounted. 4. Resistor grid: a. Resistor type: Edge wound ribbon, flat wound ribbon, or stamped sheet metal types. b. Application design: Conform to NFPA 130, Section 8.6.5, Propulsion and Braking System Resistors. c. Design and test per IEC 60322 requirements for double-insulated applications, except both insulation levels shall be rated at the basic insulation level. d. Make provision for grid expansion to prevent warping. e. Maximum active element temperature under specified operating conditions shall be limited to the manufacturer's recommendation. 5. Protection: a. Shield resistors from accumulation of snow and ice. b. Provide screens to protect resistors from persons working on the roof, physical damage (including that resulting from overhead vandalism), and fouling by debris. Screens shall withstand all brake resistor temperatures without damage or distortion. LTK Standard Streetcar Specifications Section 10 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 6. Material: a. Resistor elements, resistor frames, heat shields, screens, enclosures, and hardware shall be stainless steel. b. All resistor components shall be selected both for their thermal and mechanical properties and for corrosion resistance. c. Mounting and grid insulators shall be designed for rail application and withstand weather, heat cycles, and vibration encountered in this application for the design life of the vehicle. 10.7.3.2 Other Resistors Other power resistors shall have power dissipation capability that is 50% greater than the maximum load to which they can be exposed under all specified operating conditions. 10.7.4 Contactors Comply with the following: 1. Minimize the use of contactors for propulsion control to the greatest possible extent. 2. Comply with contactor requirements in Section 9, Electrical Equipment. 3. Propulsion system contactors, in coordination with HSCB, shall be capable of safely interrupting the maximum possible load current in the event of a malfunction. 4. Safe and continued operation shall be possible upon reset after a malfunction. 5. Coordinate contactor rating and operation with circuit protection elements. 10.7.5 Propulsion Line Filter Line filter(s) shall conform to the requirements of Section 9, Electrical Equipment. 10.7.6 Control Logic 10.7.6.1 General Requirements Propulsion system control shall comply with the design requirements of Section 2, Design and Performance Criteria, and with Section 17, Electronic Controls, Software, and MDS. Control logic units shall comply with Section 17 and IEC 60571. 10.7.6.2 Configuration Provide dedicated control logic units and logic power supplies for each propulsion system such that a failed system has no impact on others. 10.7.6.3 Monitoring The control logic units shall provide status and fault recording as part of a comprehensive MDS in accordance with Section 17: 1. Critical parameters: Continuously monitor motor currents, switching device currents, cooling air flow, and component temperatures. 2. Detection and response times: Shall permit detection and corrective action on a per unit basis before other protective devices, including the HSCB, react. 10.7.6.4 Self-Tests The control logic shall support two types of self-tests. The self-tests shall be initiated automatically and manually through the PTU or TOD, as approved by the Owner. LTK Standard Streetcar Specifications Section 10 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 1. Low-voltage test: Checks the integrity of the control logic and the peripheral low-voltage circuits. 2. High-voltage test: Checks all high-voltage components of the propulsion system and identifies malfunctioning high-voltage components or components out of tolerance such as filter capacitor, filter inductor, or resistor. Refer to Section 9, Electrical Equipment, for additional input filter capacitor test result requirements. 10.7.7 Static Power Devices Comply with the following: 1. Apply and install per manufacturer's recommendations. 2. Propulsion power semiconductor assemblies shall be functionally grouped, keyed, and mounted in modular form to facilitate maintenance and easy removal. 3. Ventilation: a. Forced air may be used where required to stabilize heat sink temperature, but shall not be used to ventilate the inside of the equipment cabinets. b. Route cooling air through channels free of high voltage. c. See also Section 9, Electrical Equipment, for equipment temperature management requirements. 10.7.8 Line Contactor Provide a line contactor for each inverter to make and interrupt power during normal or faulted conditions and to isolate the inverter from primary power when the inverter is cut out: 1. 2. 3. 4. Type: Contactor shall comply with Section 9, Electrical Equipment. Operation: Coordinate with the high speed circuit breaker (HSCB) described in Section 9. Protection: Coordinate line contactor rating with inverter protection requirements. Instantaneous inrush currents: a. Provide a charging circuit to limit inrush current to acceptable values. b. The charging circuit shall not interfere with vehicle performance under conditions of intermittent line-voltage availability, as with an icy contact wire or pantograph bouncing. c. See also the Line Filters section in Section 9. 10.7.9 Speed Sensing Devices Provide speed sensors to measure axle or wheel speeds: 1. Location: On the axles or wheel assemblies, or incorporated as integral with traction motor or gearbox if higher resolution is desired. 2. Quantity: Sufficient to continue normal operation with one speed sensor failed on each powered truck. 3. Sensor type: a. Active or passive magnetic pick-up type. b. Optical encoders may be used only with approval of the Owner. 4. Sensor packaging: a. The face of each speed sensor shall be smooth with no protruding elements. b. The sensor shall be hermetically sealed in a stainless steel case. LTK Standard Streetcar Specifications Section 10 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control c. The face shall be encased in a seamless stainless steel cover unless the sensor is guaranteed, and proven in service, to be immune to damage or inaccurate operation caused by continuous exposure to the intended lubricating fluids and temperatures. 5. Interchangeability: Speed sensor types and mountings shall be identical between powered trucks and within the non-powered truck. 6. Mounting: a. Mounting shall not require mechanical adjustments. b. The mounting method shall be selected to guarantee that the speed-measuring device cannot indicate speeds other than the actual axle speed under all conditions except massive drivetrain damage. 7. Accessibility: All speed sensors shall be easily accessible for inspection, adjustment, and replacement both with trucks attached to vehicles over maintenance pits; on jacks; and with trucks sitting by themselves on the floor. 8. Wiring: a. Speed sensor wiring shall be enclosed in conduit on the vehicle body and shall be run to a terminal box that is located above the speed sensor location on the truck. b. Speed sensors shall be connected to the vehicle body by shielded wires terminated in waterproof multi-pin connectors. See Section 16, Materials and Workmanship, for cable connector requirements. 10.8 Inverter Enclosures Comply with the following: 1. Provide IP65 rated enclosures for inverter system control components, to prevent dirt and moisture from affecting the system performance. 2. Provide ventilation where necessary as follows: a. Semiconductor heat sinks, line filter chokes, brake resistor and contactors, if they are designed to cut power. b. Openings to the atmosphere shall be screened and filter-protected. c. Filter elements shall prevent snow and water from entering the enclosure. d. Filters shall have a replacement interval greater than two years. 10.9 Painting Comply with the following: 1. Traction motors and gear reducers: Same paint as specified for the truck, applied by either the manufacturer or the Contractor. 2. Requirements: See Section 16, Materials and Workmanship. 3. Color: See Section 14, Interior and Exterior Appointments. 10.10 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. Detail drawings: Top level assemblies, and other drawings if requested LTK Standard Streetcar Specifications Section 10 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 2. 3. 4. 5. Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values 10-1 Propulsion System Design Package: 1. 2. 3. 4. 5. 6. 7. 8. 9. Propulsion and drive system configuration High-voltage system and grounding schematics Primary power and traction motor cabling Outline drawings of major components Cooling air requirements, filtering, and blowers Manufacturer, part number, and ratings of power semiconductors Line reactor details Filter capacitor details Overvoltage and overcurrent protection concept 10-2 Propulsion System Performance: 1. Tractive effort curves and line current for motoring from zero to the vehicle design speed, as indicated in Section 2, at AW0, AW1, and AW2, for line voltages of 525, 625, 750, and 900 Vdc. The charts shall include the factors needed to convert effort to torque and speed to rpm. 2. Braking performance curves and brake line-current, including emergency braking, from the vehicle design speed to zero, at AW0, AW1, AW2, and AW3 showing apportionment between dynamic, friction braking, and track brakes for 900 Vdc and 750 Vdc. The charts shall include the factors needed to convert effort to torque and speed to rpm. 3. Speed/time/distance curves for motoring and braking at 525 Vdc and 750 Vdc and at AW0, AW1, AW2, and AW3. 10-3 Run Time Simulations: 1. Perform at AW3 loading over the Project alignment 2. Show traction motor, IGBT, and brake resistor duty cycles 3. All simulations shall use distance as the x-axis and shall indicate, at a minimum, all station stop locations 10-4 Abnormal Duty Run Time Simulation: 1. Selected abnormal duty cycle. 2. Perform run time simulation showing traction motor, IGBT and brake resistor duty cycles for the abnormal duty cycle. 10-5 Inverter Design Package: 1. Data sheets and a layout drawing 10-6 Inverter Control Design Package 1. Hardware and software functional description, including all interfaces and their interdependencies, including propulsion system control logic and friction brake controls 2. Interfaces with the vehicle data bus and hard wired control signals 3. Description of Spin/Slide system 4. Description of EB application LTK Standard Streetcar Specifications Section 10 12 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Propulsion System and Control 5. Description of load compensation 6. Description of the propulsion system fault monitoring scheme and response performance that supplements the MDS CDRL in Section 17, Electronic Controls, Software, and MDS. a. Diagnostic features b. Self-test capabilities 10-7 Traction Motor Design Package: 1. Tractive effort curves as a function of rpm, including as a minimum the following signals: a. b. c. d. e. f. g. Torque Output power Phase voltage Phase current Efficiency Stator frequency Slip frequency 2. Outline drawings of major components 3. Insulation process information 4. Data sheets with sufficient information to confirm that all specified requirements are satisfied, such as the following: a. Nominal values of signals listed in Item 1, above b. Peak values of signals listed in Item 1, above 10-8 Gear Drive Design Package: 1. Outline drawing and data sheets 2. Traction-gear drive coupling 10-9 Brake Resistor Design Package: 1. Data sheets 2. Resistor outline drawing 3. Resistor grid and frame drawing showing electrical isolation and protective screens END OF SECTION LTK Standard Streetcar Specifications Section 10 13 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies Table of Contents 11.1 General ......................................................................................................................................1 11.1.1 Scope .............................................................................................................................................. 1 11.1.2 General Requirements ................................................................................................................... 1 11.2 Design Requirements..................................................................................................................1 11.2.1 Wheelbase ..................................................................................................................................... 1 11.2.2 Interchangeability .......................................................................................................................... 1 11.2.3 Wheel Machines ............................................................................................................................ 1 11.2.4 Clearance Requirements ................................................................................................................ 1 11.2.5 Truck Removal................................................................................................................................ 2 11.3 Suspension System .....................................................................................................................2 11.3.1 General Requirements ................................................................................................................... 2 11.3.2 Primary Suspension........................................................................................................................ 2 11.3.3 Secondary Suspension ................................................................................................................... 3 11.3.4 Dampers ......................................................................................................................................... 3 11.3.5 Suspension Stops ........................................................................................................................... 3 11.3.6 Wear Adjustment ........................................................................................................................... 3 11.3.7 Load Compensation Sensors .......................................................................................................... 3 11.4 Truck Frame and Bolster .............................................................................................................3 11.4.1 General Requirements ................................................................................................................... 3 11.4.2 Connection ..................................................................................................................................... 4 11.5 Journal Bearings .........................................................................................................................4 11.6 Wheels .......................................................................................................................................4 11.6.1 Description ..................................................................................................................................... 4 11.6.2 Conductive Path to Rail .................................................................................................................. 5 11.7 Axles ..........................................................................................................................................5 11.8 Wheel and Axle Assembly ...........................................................................................................5 11.9 Track Brake Support ...................................................................................................................6 11.10 Safety Bars ...............................................................................................................................6 11.11 Flange Lubricators ....................................................................................................................6 11.12 Design Calculations ...................................................................................................................7 11.12.1 Design Loads ................................................................................................................................ 7 11.12.1.1 Maximum Load Variation ..................................................................................................... 7 11.12.1.2 Static Strength Design Condition .......................................................................................... 7 LTK Standard Streetcar Specifications Section 11 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 11.12.1.3 Vertical Load ......................................................................................................................... 7 11.12.1.4 Longitudinal Load.................................................................................................................. 7 11.12.1.5 Lateral Load........................................................................................................................... 7 11.12.1.6 Accessory Loads .................................................................................................................... 7 11.12.2 Maximum Allowable Stresses ...................................................................................................... 7 11.12.3 Fatigue Design .............................................................................................................................. 8 11.12.4 Fatigue Allowable Stress Levels ................................................................................................... 8 11.12.5 Non-U.S. Standards ...................................................................................................................... 8 11.12.6 Stress Analysis .............................................................................................................................. 9 11.12.6.1 Scope..................................................................................................................................... 9 11.12.6.2 Service Proven Design........................................................................................................... 9 11.12.6.3 Testing................................................................................................................................... 9 11.13 Truck Painting...........................................................................................................................9 11.14 Serial Numbers .........................................................................................................................9 11.15 Contract Data Requirements List (CDRL) .................................................................................. 10 LTK Standard Streetcar Specifications Section 11 ii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 11.1 General 11.1.1 Scope This Section specifies the design and functional requirements of the truck assembly, which includes truck frame and suspension components, wheels and axles, and other components defined below. Gear boxes, motors, wiring, and brake system components are physically part of the completed truck assemblies but are not included in this Section, except that mechanical interfaces requiring welding or drilling on the truck frame shall be considered part of the truck. 11.1.2 General Requirements Comply with the following: 1. Supplier experience: The trucks shall be designed, and the truck frames manufactured by a supplier that has designed and manufactured the same trucks previously for the vehicle offered: a. Adaptations are limited to changes in dimensions, materials, or procedures necessary to comply with the Specifications. b. The trucks shall have operated in the same or more unfavorable climatic conditions over track meeting FRA Class 4 requirements, and at the same or higher maximum operating speed. 2. Vibration and noise: The trucks shall minimize resonant vibrations when in operation. Surface contact between truck components, except suspension stops, shall be made through serviceproven, non-metallic materials selected to impede the transmission of vibration and noise. 3. Speeds: Trucks shall operate safely at all speeds from zero up to vehicle design speed, as indicated in Section 2, Design and Performance Criteria, and provide the specified ride quality at all speeds up to the maximum operating speed indicated in Section 2, over the entire range of wheel wear and vehicle loading. 11.2 Design Requirements 11.2.1 Wheelbase Truck wheelbase: 1,780 to 1,910 mm (70 to 75 in). 11.2.2 Interchangeability Powered trucks shall be interchangeable among every vehicle furnished under this Contract, without modification. Non-powered trucks, if provided, shall be interchangeable among every vehicle furnished under this Contract, without modification. 11.2.3 Wheel Machines Wheel truing: Provide suitable adapters and fixtures to permit wheel truing on Owner’s wheel machines. 11.2.4 Clearance Requirements The complete truck assembly shall clear the vehicle body and vehicle-body-mounted equipment by minimum 12 mm (0.5 in). All truck parts, except wheels and track brakes, shall clear the plane of the top-of-rails by minimum 50 mm (2 in). LTK Standard Streetcar Specifications Section 11 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies These clearance limits shall be met when full allowance is made for the most unfavorable combinations of the following: 1. 2. 3. 4. Wheel tread or flange wear Static and dynamic primary and secondary spring deflection Primary and secondary suspension failure Static and dynamic suspension stop deflection, including possible wear of the suspension stops to the condemning limit 5. The full specified range and worst case combination of horizontal and vertical curves 6. Other possible movements of the trucks and associated parts, including those caused by the maximum excursions of truck-mounted parts 11.2.5 Truck Removal Provide a design that allows for the following: 1. There shall be clear and direct access from the side or under the vehicle to all mechanical, electrical, pneumatic, hydraulic, and other connections necessary for trucking and de-trucking. 2. All such connections shall be operable with common hand tools. 11.3 Suspension System 11.3.1 General Requirements Truck suspension shall consist of a primary and secondary suspension system. The vehicle body shall be supported on the secondary suspension. The suspension system shall: 1. Provide stable operation at all defined speeds. 2. Provide specified ride quality. 3. Retain and locate the vehicle body relative to the truck centerline, such that specified clearances and platform interfaces are achieved under all normal conditions. In the case of suspension failure, limit the lateral vehicle-body motion and maximum change in floor height over the loading range from AW0 to AW4, such that the following parameters are satisfied: 1. Safe operating requirements. 2. Clearance requirements. 3. Prevention of interference between the doors and wayside loading platforms during door opening. 11.3.2 Primary Suspension Comply with the following: 1. Primary suspension: Elastomeric elements in compression. 2. Vertical resonance frequency: Maximum 12 Hz. 3. Longitudinal spring rate: a. Maximum 1600 kg/mm (89,595 lb/in). b. Select such that the requirements of the Specifications are met. c. Shall permit the axles to align properly (absent squealing or hunting) in curves. LTK Standard Streetcar Specifications Section 11 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 11.3.3 Secondary Suspension Comply with the following: 1. Secondary suspension system: Coil springs or elastomeric springs, dampers, and related hardware. 2. Design: Shall keep the vehicle body aligned laterally and longitudinally with the truck centerline under all forces expected in rail service. 3. Stable operation and ride quality: Augment springs with dampers and other components as necessary to comply with the Specifications. 11.3.4 Dampers Provide vertical and lateral dampers: 1. Type: Hydraulic 2. Service life: Minimum 10 years 3. Orientation: Comply with manufacturer’s recommendations, as installed on trucks, and detail in the maintenance manuals 11.3.5 Suspension Stops Provide lateral, longitudinal, and vertical suspension stops with replaceable elastomeric cushions: 1. Function: Shall not engage under normal operations, but shall limit maximum vehicle-body and truck motions under maintenance or suspension failure conditions. 2. Performance: Dimensions and developed forces shall limit motion to within clearance requirements. 3. Vertical suspension stops: May be incorporated into vertical dampers or other suspension elements. 11.3.6 Wear Adjustment Make provision in the truck design for vertical mechanical adjustment of the primary or secondary suspension to compensate for maximum wheel wear and wear or settlement of other truck parts: 1. 2. 3. 4. Adjustments shall be made with standard maintenance-shop equipment. Adjustments shall not impair the operation of the truck. Adjustment at any level shall not cause the vehicle to exceed the specified dynamic envelope. Adjustment range: 10% greater than the full range of tolerances plus wear. 11.3.7 Load Compensation Sensors The truck shall incorporate the load sensors and other devices necessary to meet the load compensation requirements specified in this Section and Section 2, Design and Performance Requirements. Transducers shall not be mounted to the truck frame or bolster. 11.4 Truck Frame and Bolster 11.4.1 General Requirements Comply with the following: 1. Truck type: Inboard frame, to facilitate wheel tire replacement. LTK Standard Streetcar Specifications Section 11 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 2. Truck frame and bolster design: a. Service-proven. b. Allow compensation for the expected maximum level of creep or settlement of the primary and secondary suspension springs. 3. Fabrication: By welding, castings, or a combination of the two. 4. Drainage: Provide where pockets or partially enclosed spaces exist so that no moisture collects anywhere within the truck frame and bolster. 5. Accessibility: Threaded fasteners, adjustment points, and structurally-critical locations shall be accessible for inspection and work using conventional means and tools. 11.4.2 Connection Comply with the following requirements for connection between vehicle body and trucks: 1. Positive and safe mechanical connection such that the trucks can be raised with the vehicle body without disengaging any part of the suspension system. 2. Strength of the connection shall comply with Section 3, Vehicle-Body Structure. See Truck Removal section, above. 11.5 Journal Bearings Comply with the following: 1. Type: Grease lubricated, tapered or spherical roller bearings. 2. Application: There shall be no sliding surfaces involved in the method of retaining the journal bearings in their proper positions. 3. Inspection or service: None requiring disassembly before a major truck overhaul. 4. ABMA L10 rating life: Minimum 1,600,000 km (994,194 mi) at AW3 vehicle weight with the shock and impact loads typical of rail vehicle service. 5. Service-proven: For use in a similar rail vehicle. 11.6 Wheels 11.6.1 Description Comply with the following: 1. Type: Resilient wheel with a steel tire and steel center (hub). 2. Tire material: Comply with ASTM A551/A551M Class DHT. 3. Maintainability: Tire shall be replaceable by bolted connections, and shall not require pressing off any axle components. 4. Wheel Assembly Product: SAB/Wabco V-type with noise dampeners, Bochum 84, or other approved design. 5. Rating: The wheel and tire assemblies shall be rated by the manufacturer for continuous operation at vehicle weights up to and including AW4. 6. Wheel Diameter and Wear: See Section 2, Design and Performance Criteria, for requirements. LTK Standard Streetcar Specifications Section 11 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 11.6.2 Conductive Path to Rail Comply with the following: 1. Function: The wheel assembly shall serve as the interface for electrically connecting the vehicle to the running rails for the following purposes: a. Safety ground. b. Return of propulsion and auxiliary current. c. Shunting of signal system track circuits from rail-to-rail. 2. Capacity: Sufficient to conduct specified currents via minimum three external shunts per wheel, between hub and tire. See Section 9, Electrical Equipment, for additional requirements related to return circuits, ground brushes, and safety grounding. 3. Current path: Ensure that journal bearings are isolated from shunting currents. 4. Shunting Resistance: a. Full length axle wheelset: Maximum 0.01 ohm, measured from tire tread to tire tread. b. Stub axle wheelset: Maximum 0.05 ohm, measured from tire tread to tire tread, including wheel, tire, and axle assemblies, ground brushes and cables, and all connections. c. Wheel tread to axle/stub axle: 0.005 ohm. d. Measurement: See Section 15, Testing, for resistance routine tests. 11.7 Axles Comply with the following: 1. Axles shall withstand static and dynamic stresses expected in revenue service: a. Standards: European standards EN 13103 for non-powered axles, EN 13104 for powered axles, or other railway-specific axle design standard as agreed upon with the Owner. b. Dynamic loads for axle design: Minimum in accordance with the Fatigue Design section, below. 2. Axle fatigue life: Meet the minimum service life requirements of Section 2, Design and Performance Criteria. 11.8 Wheel and Axle Assembly Comply with the following: 1. Assembly: a. Fit wheels, bearings, and ground brush ring to the axle by pressing or mounting. b. Fit tolerances and pressing forces shall be as recommended by the equipment manufacturers. 2. Records: a. Furnish pressure graphs of all gear coupling, disc hub, grounding ring, journal bearing, and wheel-to-axle pressings. b. The graphs obtained for the wheel pressing shall meet the requirements described in AAR RP-631 (AAR MSRP, Section G-II), Section 2.3, “Wheel Mounting Press Practices,” subsection 2.3.5, and Standard RP-633, including the following figures: • Figure 4.19, Identification of wheel fit pressure diagram LTK Standard Streetcar Specifications Section 11 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies • • • • • • • • • Figure 4.20, Constructing and using a typical wheel mounting template Figure 4.21, An example of an ideal mount Figure 4.22, Example of an acceptable amount Figure 4.23, Example of an acceptable mount Figure 4.24, Example of a misfit where the final tonnage is not concise Figure 4.25, Example of a misfit whose peak tonnage exceeds the minimum tonnage Figure 4.26, Example of a misfit where tonnage does not build up to the 75% fit line Figure 4.27, Example of a misfit caused by an obstruction or by excessive positive taper Figure 4.28, Example of a misfit indicating an alignment problem 3. Wheel and axle assemblies shall be fully interchangeable, and shall be interchangeable between powered trucks and non-powered trucks, if provided. 11.9 Track Brake Support Comply with the following: 1. Track brakes shall be supported from the journal bearing housings. 2. The track-brake support arrangement shall maintain positive lateral alignment of the track brake with the running rail. 3. Track brake forces shall be transmitted to the truck frame as near to the top-of-rail as practical to minimize moment imposed on the track-brake unit. 11.10 Safety Bars Provide safety bars at the outboard ends of trucks: 1. Dimensions: a. Width: 1700 mm (66 in), or the lateral extent of truck components, whichever is greater b. Height: 150 mm (6 in) 2. Mounted Clearance: a. Maximum: 100 mm (4 in) to top of rail when all truck parts are new. b. Minimum: 50 mm (2 in) for the worst case combination of conditions specified in the Clearance Requirements section, above. 3. Strength: Shall withstand a horizontal force of 2200 kN (500 lbf) applied at the center. 4. Maintainability: Arrange and mount for replacement with common hand tools. 11.11 Flange Lubricators Comply with the following: 1. End trucks: Equip with wheel flange lubricators for wheels on the lead axle, or other configuration as approved by the Owner. 2. Center truck (if provided): Equip with wheel flange lubricators on at least one wheel on both sides of the truck. 3. Location: Install each lubricator such that it provides friction modifier material between the flange of the wheel and the rail. 4. Material: Applicator components shall be stainless steel. 5. Interchangeability: Lubricator sticks and applicators used for the end and center trucks shall be identical. LTK Standard Streetcar Specifications Section 11 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 11.12 Design Calculations 11.12.1 Design Loads 11.12.1.1 Maximum Load Variation The truck frame and all truck parts shall be capable of withstanding the maximum load variation imposed by the forces acting on the frame, in addition to the loads identified elsewhere in the Specifications. Truck parts include the following: 1. Motor 2. Gear unit 3. Friction and track brake equipment supports The basis for determining maximum load variation shall include forces resulting from the following: 1. 2. 3. 4. 5. 6. Passenger load Track shocks and forces Motor torque Friction brakes Track brakes Any possible combination of these forces when operating under all possible conditions on track meeting the minimum requirements of 49 CFR 213 Class 4 track. 11.12.1.2 Static Strength Design Condition The static strength design condition for the truck frame and bolster shall be based on the truck’s share of a design load weight equal to the AW4 weight minus the weight of the truck. 11.12.1.3 Vertical Load The minimum vertical load on the truck shall be the truck's share of the design load, augmented by the weight transfer effects such as tractive effort reactions. 11.12.1.4 Longitudinal Load The minimum longitudinal load, applied at the center of gravity of the vehicle, shall be the maximum possible instantaneous braking effort (friction and dynamic plus track brake) with AW4 loading and 50% adhesion. 11.12.1.5 Lateral Load The minimum lateral load, applied at the center of gravity of the vehicle, shall be that developed at vehicle overturning. 11.12.1.6 Accessory Loads Accessory loads, such as those from brake units, track brakes, and traction motors, shall represent maximum steady state conditions; for example, maximum motor torque and brake unit weight, and maximum brake unit reaction and motor weight, or the worst combination (brake blending) of both. 11.12.2 Maximum Allowable Stresses Under the above load conditions, the maximum stresses at any location in the truck frame and bolster shall not exceed 50% of the yield strength of the material. LTK Standard Streetcar Specifications Section 11 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies Exception: Local zones greater than the allowable will be reviewed on a case-by-case basis as long as it does not affect the overall stability of the truck. Based on this review, the Owner will determine the acceptability of these areas. Alternatives maybe approved, see 11.12.5. 11.12.3 Fatigue Design The fatigue design of the truck frame and bolster shall be based on the above conditions with a design load equal to the AW2 weight minus the weight of the trucks. Loads on the truck shall be as follows: 1. Vertical load: The mean vertical load shall be the truck's share of the design load; the vertical load shall vary about the mean vertical load by plus or minus 25%. 2. Lateral load: Shall vary between 15% of the mean vertical load acting towards one side of the truck and 15% of the mean vertical load acting towards the other side of the truck. 3. Longitudinal load: Shall vary between 15% of the mean vertical load acting towards one end of the truck and 15% of the mean vertical load acting towards the other end of the truck. 4. The lateral and longitudinal loads shall act as if they were applied at the center of gravity of the vehicle body at AW2 with resulting vertical loading applied to the bolster or truck frame as appropriate. 5. Accessory loads: Shall vary between plus or minus 100% of their maximum steady-state values: a. Motor under maximum braking torque; and b. Brake unit tractive effort reaction under full service brake application with minimum 50% adhesion; plus c. Maximum track brake tractive effort load. Loads shall be applied with the phasing to produce the worst possible stress combination. Under these conditions, stresses shall not exceed the allowable fatigue values. 11.12.4 Fatigue Allowable Stress Levels Fatigue allowable stress levels for truck materials shall not exceed the following: 1. Published endurance stress values for smooth, flat, tension-tension specimens; or 2. Recent Contractor tests with sufficient individual tests to establish the endurance stress value for 95% survival at the 84% confidence level, as defined in ISBN: 978-0871700148, ASM Metals Handbook, 9th Edition, Volume 8: Mechanical Testing, “Fatigue and Fracture,” pages 695-720. (Note that this is a description of the statistical treatment of the fatigue data; the Contractor is responsible for finding or developing data to establish the fatigue properties.) Fatigue allowable stress levels for welded connections shall not exceed the following: 1. Requirements of AWS D1.1/D1.1M for dynamic structures; or 2. Contractor tests of the specific connection establishing its endurance stress (load) value for 95% survival at 69% confidence level. Alternatives maybe approved, see 11.12.5. 11.12.5 Non-U.S. Standards Standard EN 13749, or other standards, may be permitted at the discretion of the Owner as a basis for design conditions of the trucks, provided it is shown that the truck design conditions will aim to produce a truck that meets the more severe track conditions, speeds, and truck weights in the U.S. LTK Standard Streetcar Specifications Section 11 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies In no case will the requirements be exempted for strength of the truck-to-vehicle-body connection specified in Section 3, Vehicle-Body Structure. 11.12.6 Stress Analysis 11.12.6.1 Scope 1. As a minimum, the stress analysis shall consist of a finite element analysis (FEA) of the global structure and a classical analysis of all connections, supplemented as necessary by manual or computerized calculations. 2. Perform a stress analysis of the end truck frame and bolster and the center truck assembly. Show the calculated stresses, allowable stresses, and margins of safety for all elements for all specified loading conditions. 3. Update the analysis as the truck design proceeds. Perform a separate analysis of welds and welded connections on the finished truck frame, including welds attaching brackets, studs, and holders for truck accessories. 11.12.6.2 Service Proven Design The Contractor may provide data from previous tests, historical data from operations, or stress analysis, as required above, to satisfy the corresponding portion of these requirements, only for those portions of the proposed designs that meet each of the following conditions: 1. Based on a service-proven truck, as defined in Section 1, General Topics and Definitions. 2. Fabricated by the same manufacturer at the same manufacturing facility. 3. Approved by the Owner. 11.12.6.3 Testing The information derived from the stress analysis shall be used to determine strain gauge locations and other criteria for truck tests (see Section 15, Testing, for details). 11.13 Truck Painting Paint all truck components except components specifically excluded below, in accordance with Section 16, Materials and Workmanship. See Section 14, Interior and Exterior Appointments, for paint color. The following truck-related items shall not be painted: 1. 2. 3. 4. 5. 6. 7. 8. Wheels Axles Elastomeric parts Grease fittings Linkages Threads used for adjustments Electrical equipment Wearing surfaces 11.14 Serial Numbers Provide permanent identification for each component as follows: 1. Truck frame: a. Serial number plate: Permanently attached and located in a conspicuous place. LTK Standard Streetcar Specifications Section 11 9 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies b. Figure size: Minimum 20 mm (0.8 in) high. 2. 3. 4. 5. Wheels: Mark according to ASTM A551/A551M or other approved standards body. Hubs: Mark according to AAR M-107/M-208 or other approved standards body. Axle: Mark with information required by AAR M-101, or other approved standards body. Other truck components: Serialize as required in Section 19, Program Control and Quality Assurance. 11.15 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. Detail drawings: Top level assemblies, and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values 11-1 Truck Clearance Design Package: 1. Drawings showing truck clearances under the specified worst case conditions, with sufficient detail to demonstrate that specified clearances have been achieved. 11-2 Truck-to-Vehicle-Body Connection Design Package: 1. Calculations demonstrating vehicle-body-to-truck connection strength meets requirements of Section 3, Vehicle-Body Structure. 2. Instructions for de-trucking and re-trucking on flat tracks with portable jacks, including diagrams. 3. Details of lifting tools provided for de-trucking and re-trucking, if required by design. 11-3 Journal Bearings Design Package: 1. Data sheet on proposed bearing type. 2. Journal bearing L10 life calculation. 3. Sufficient data to demonstrate that the proposed bearings are service proven. 11-4 Axle Strength Design Package: 1. Submittal shall be furnished by the axle manufacturer. 2. Proposed material specification and manufacturing requirements per AAR M-101, EN 13261, or equivalent standard. 3. Strength calculations for axles: a. Load diagram. b. Static and dynamic stress calculations for the axles that show, at a minimum, the maximum value of stresses to which the axles are expected to be subjected in service. 4. Fatigue life calculations: a. Prediction of axle's fatigue life using cumulative damage (or other approved) calculation method. LTK Standard Streetcar Specifications Section 11 10 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies b. Consideration of effect of bending loads induced by the presence of restraining rails in the axle bending fatigue stress calculations. 11-5 Wheel-Axle Assembly Design Package: 1. Axle press fitting procedures for all components pressed onto the axle. 2. Pressure graphs: a. Gear coupling, disc hub, grounding ring, journal bearing, and wheel-to-axle pressings. b. Before submitting, confirm that graphs are within the limits recommended in the AAR's Wheel and Axle Manual, as required by this Section. 11-6 Flange Lubricator Design Package: 1. Data sheets on lubricator sticks and applicators 11-7 Truck Stress Analysis and Testing Plan: 1. Truck Stress Analysis and Testing Plan must be approved before submittal of Truck Stress Analysis Report. 2. Contractor’s chosen static and fatigue allowable values, whether published or test values. 3. Outline of the procedure to be used to analyze and test the design of the truck. 4. Table of loads to be used for static analysis and test, with load magnitudes and points of application. 5. Derivation of the static loads to be applied. 6. Table of loads to be used for fatigue analysis and test, with load magnitudes, points of application, and phasing. 7. Derivation of the fatigue loads to be applied. 8. Diagrams of load applications. 9. Table of allowable stress levels. 11-8 FEA Model Package: 1. Submit and receive approval of the FEA Model Package before performing the Finite Element Analysis (FEA) and submitting the Truck Stress Analysis Report. 2. FEA input data on electronic media as approved by the Owner. 3. Element grid, assumptions, and input data, such as loads, section properties, boundary conditions and material properties. 4. Boundary reaction forces of the truck under its own weight. 5. Key to symbols and colors. 6. Format: a. Number each page, and clearly label columns of data on each page. b. Define terms, symbols, abbreviations, and units. 11-9 Truck Stress Analysis Report: 1. Submit after receiving approval for the Truck Stress Analysis and Testing Plan and the FEA Model Package. 2. Submit before truck frame static load test and fatigue endurance test (see Section 15, Testing). 3. Format: a. Include a Table of Contents. LTK Standard Streetcar Specifications Section 11 11 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies b. Number each page, and clearly label columns of data on each page using terms defined in the analysis. 4. Include the following as a minimum: a. Structural diagram (layout) of the truck frames and bolster showing member locations and shapes, and indicating the material and thickness of each. • • Completely define the methods of joining, including AWS D1.1/D1.1M weld classifications for fatigue for all welds. Clearly show connections between the truck, bolster, and vehicle body. b. Diagrams displaying external loads and supports applied to the truck frames and bolster. c. Summary of the results of calculations of stresses in all members: • • Show in a separate table the locations where calculated stress levels equal or exceed 85% of the allowable stress criteria approved by the Owner in CDRL 11-8, Truck Stress Analysis and Testing Plan, along with the design or operating conditions (loads) that cause them. Calculated stresses shall be supported, where available, by the results of actual tests of trucks of identical design. d. Analysis of all critical connections of the truck frames and bolster major structural elements under all specified loading conditions. e. For the truck frame and bolster members that are fatigue critical, include a tabulation of the Contractor's selection of allowable truck frame and bolster static and fatigue stresses and assumed applied fatigue stress ranges. Allowable stress levels shall be substantiated by the Contractor's test data or by citing published sources. f. Critical welds including, as a minimum, all welds or portions of welds which, based on the results of the stress analysis and truck tests, are expected to be critical in fatigue. g. Table showing the engineering properties of each grade and temper of each material: • • Include the material designation, yield strength, ultimate strength, elongation, Young's modulus for tension and compression, and shear elastic moduli. In each case, use minimum-guaranteed values from the specifications for the corresponding grade and heat treatment of the material. 5. FEA portion of the report: a. FEA output data on electronic media as approved by the Owner. b. Element grid, all assumptions, and all input data, such as loads, section properties, boundary conditions and material properties. c. Color plots showing the following: • • • • • • Deflections in all three axes separately plotted and imposed over the deflected shape Von Mises, or other approved combination stresses Maximum and minimum principal stresses Direction of maximum and minimum principal stresses Meshing accuracy index Locations of strain gauges, shown on plots of the FEA truck and bolster mesh with dimensions LTK Standard Streetcar Specifications Section 11 12 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Section 11, Truck Assemblies 11-10 FEA Input and Output Data: 1. In addition to submitting FEA input data with the FEA Model Package, submit the input files each time the files are changed, but not more often than monthly. 2. In addition to submitting FEA output data with the Truck Stress Analysis Report, submit the output files each time the files are changed. 3. Submit on electronic media as approved by the Owner. 4. Criteria for final approval of the Truck Stress Analysis Report shall include the submittal of the fully configured input data files. 5. Each revision shall be accompanied by detailed revision notes that explain each change and indicate where changes were made in the report as a result of the change. 11-11 Welding Analysis Report: 1. Fatigue classifications of each weld according to AWS D1.1/D1.1M. 2. Drawings of truck welding locations, or FEM mesh plots with the weld locations indicated, with the AWS classification indicated. 11-12 Service Proven Design: 1. For a service-proven truck, submit data from previous tests, historical data from operations, or stress analysis. 2. Include a summary stating specifically what portions of the submittal requirements are intended to be satisfied by the submitted material. END OF SECTION LTK Standard Streetcar Specifications Section 11 13 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System Table of Contents 12.1 General ......................................................................................................................................1 12.1.1 Scope .............................................................................................................................................. 1 12.1.2 Configuration Options .................................................................................................................... 1 12.1.3 System Description ........................................................................................................................ 1 12.1.4 Performance Requirements ........................................................................................................... 1 12.1.5 Power Sources................................................................................................................................ 1 12.1.6 Audible Noise ................................................................................................................................. 1 12.2 Components ...............................................................................................................................2 12.2.1 Configuration ................................................................................................................................. 2 12.2.2 Disc Brake Rotor and Hub .............................................................................................................. 2 12.2.3 Actuators and Calipers ................................................................................................................... 2 12.2.4 Brake Pads ...................................................................................................................................... 2 12.2.5 Hydraulic Pressure Control Units (HPCU) ...................................................................................... 2 12.2.5.1 General.................................................................................................................................... 2 12.2.5.2 Reservoir and Accumulator .................................................................................................... 3 12.2.5.3 Hydraulic Pump....................................................................................................................... 3 12.2.6 Pressure Transducers ..................................................................................................................... 3 12.2.7 Parking Brake ................................................................................................................................. 3 12.2.8 Disc Brake Cutout ........................................................................................................................... 4 12.2.9 Track Brakes ................................................................................................................................... 4 12.2.10 Electronic Control Unit (ECU) ....................................................................................................... 5 12.3 Controls .....................................................................................................................................5 12.3.1 General ........................................................................................................................................... 5 12.3.2 Dynamic Brake Interface ................................................................................................................ 5 12.3.3 Load Compensation ....................................................................................................................... 5 12.4 Disc Brake - Propulsion System Interlock .....................................................................................6 12.5 Sanding System ..........................................................................................................................6 12.6 Contract Data Requirements List (CDRL) ......................................................................................7 LTK Standard Streetcar Specifications Section 12 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System 12.1 General 12.1.1 Scope Provide a spring-applied, hydraulic-release friction brake system. The friction brake system includes disc brakes, disc brake actuators, calipers, track brakes, sanders, electronic control units, hydraulic pressure control unit, and related components. 12.1.2 Configuration Options Control: Friction brake controls may be independent, or embedded in the propulsion system. Load-Weigh System: The friction brake system may provide the equipment and controls for the loadweigh system. 12.1.3 System Description Friction braking shall be arranged as a physically and functionally independent system for each truck on the vehicle. The friction disc brake system shall perform the following basic functions: 1. 2. 3. 4. Provide service and emergency braking in the event of dynamic brake failure; Provide emergency braking with the assistance of dynamic brakes, track brakes and sand; Act as a parking brake system; Supplement dynamic braking on a per powered-truck basis, to provide the requested service braking efforts in all cases where dynamic braking is not providing the requested efforts. If a non-powered truck is provided, see Section 2, Design and Performance Criteria, for allocation of dynamic and friction braking. 12.1.4 Performance Requirements Comply with the following: 1. See Section 2, Design and Performance Requirements, for brake performance requirements, and performance related to sanding. 2. The friction brake system shall have the thermal capacity to provide continuous operation with the duty cycles specified in Section 2. 3. Complete disc brake release shall be achievable at all vehicle speeds down to zero, and under the worst case combination of LVPS or battery voltage, reservoir fluid level, accumulator charge, and ambient temperatures. 12.1.5 Power Sources All friction brake equipment shall operate from the vehicle’s low-voltage dc power system, except as may be permitted below. 12.1.6 Audible Noise The disc brake rotor, caliper, and pad assembly shall not emit audible squeal, chatter, or other undesirable sounds. LTK Standard Streetcar Specifications Section 12 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System 12.2 Components 12.2.1 Configuration Comply with the following: 1. For through-axles, provide at least one brake disc and caliper per axle. For stub axles, provide one brake disc and caliper per wheel. 2. Provide two track brakes for each truck. 3. Provide sanding on each truck. 12.2.2 Disc Brake Rotor and Hub Comply with the following: 1. Type: Split-disc, retained by bolted connection. 2. Durability: Shall resist warping and cracking due to thermal stress resulting from the specified duty cycle. 3. Wear indication grooves: Provide on both edges of each disc brake rotor to indicate the minimum allowable thickness. 12.2.3 Actuators and Calipers Each disc brake rotor shall be equipped with a spring-applied, hydraulic-release brake actuator: 1. Each caliper shall act as a parking brake by removal of hydraulic pressure. 2. The brake actuator shall include an automatic slack adjustment feature, which shall compensate for brake pad and disc rotor wear as well as assure drag-free running. 3. Brake actuators shall be mounted to floating calipers designed as follows: a. To follow the disc brake rotor regardless of lateral disc brake rotor motion. b. To accommodate all other relative motions between the disc brake rotor and the caliper to maintain full brake pad engagement with the disc brake rotor, and prevent binding, accelerated wear, or damage to truck or brake components. 4. Actuators and calipers shall be interchangeable: a. Powered truck: Among all powered truck axles. b. Non-powered truck: Among all non-powered truck wheel-axle assemblies. 12.2.4 Brake Pads Brake pads and holders shall be designed for quick pad replacement without disassembly of the caliper unit. Brake pads shall be interchangeable among all axles of the same type. 12.2.5 Hydraulic Pressure Control Units (HPCU) 12.2.5.1 General Provide each truck with an independent hydraulic pressure control unit (HPCU): 1. It shall include the following: a. Hydraulic fluid reservoir and accumulator b. Motor-driven pump c. All necessary control valves and pressure transducers LTK Standard Streetcar Specifications Section 12 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System 2. Function: Shall provide hydraulic pressure to the brake calipers in response to commands from the brake control units. 3. Location: Adjacent to their respective trucks, in an area protected from dirt, dust, wheel splash, and unusual heating conditions, such as cooling air outlet from propulsion equipment or radiant heat from brake discs, to prevent damage. 4. Mounting: Onto the vehicle structure, via resilient mounts. 12.2.5.2 Reservoir and Accumulator Provide accumulator hydraulic storage capacity as follows: 1. Sufficient to allow at least three EB applications after loss of hydraulic pump power: a. Assume accumulator hydraulic volume is at its normal minimum level at the time of power loss. b. Brake application and release shall be as follows: • • • FSB level for an AW1 vehicle weight Brakes shall be applied for at least 30 seconds per application and released for 2 minutes between applications Normal brake modulation shall be available 2. The required capacity shall be available under all specified environmental conditions. 12.2.5.3 Hydraulic Pump Comply with the following: 1. Hydraulic pumps may be powered by the low-voltage dc system via brushless dc motors, or via three-phase induction motors powered from auxiliary inverter. 2. See Section 9, Electrical Equipment, for general electrical and failure management requirements. 12.2.6 Pressure Transducers Comply with the following: 1. Provide pressure transducers for control, feedback, testing, and the failure monitoring system. Pressure switches are not permitted, except as necessary to provide system information to the MDS and TOD upon loss of electronic controls. 2. Transducers shall be low drift, temperature compensated devices that operate minimum five years without requiring calibration. 3. Transducers shall be powered from isolated power supplies and shall not interface directly with vehicle battery-level circuits. 12.2.7 Parking Brake Comply with the following: 1. The parking brake shall be inherent in the caliper design. See this Section. Parking brakes shall be controlled by application and release of the service brakes. 2. The parking brake control signal shall be configured to release the parking brakes when energized. 3. A parking brake applied anywhere on a vehicle shall inhibit propulsion and brake release indications. LTK Standard Streetcar Specifications Section 12 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System 12.2.8 Disc Brake Cutout Provide a means for manual release of the brakes from the side of the vehicle, or via other approved methods, as follows: 1. One hydraulic cutout per truck. 2. Individual mechanical cutout for each caliper. 12.2.9 Track Brakes Comply with the following: 1. Performance: The electromagnetic track brake system shall be effective at all speeds from vehicle design speed down to zero speed, over all conditions of curves and grades. 2. Environmental: a. Track brakes shall be fully watertight b. Coils shall be enclosed in a non-magnetic, corrosion-resistant case with coil voids filled to form a hermetically-sealed unit 3. Mounting: a. Track brake forces shall be transmitted to the truck through bonded rubber elements b. The Owner will consider track brake mounting that provides for quiet operation but does not require rubber elements 4. Rail Contact: Wear surfaces shall be smooth and shall not wear grooves or ridges in the rail head throughout the life of the track brake shoe. 5. Maintainability: a. If it is necessary to remove the track brake to renew the rubber elements, they shall be applied to the track brake assembly rather than the truck. b. Track brake shoes and the pole filler material shall be readily replaceable. c. Make provision for adjustment to maintain proper clearances. 6. Clearance: a. Track brakes shall not interfere with track, wayside, or truck components under all normal conditions and combinations of wear. b. In the area between the railhead and 51 mm (2 in) above top of rail, the track brake shall not extend laterally beyond the wheel-tire cross section with fully worn track-brake shoes. 7. De-energized state: a. The track brake shall be suspended above the rail by springs and shall be located laterally by resilient stops. b. Track brake motion while suspended shall not produce audible noise under any normal operating condition. c. Vertical clearance above top of rail, when de-energized, shall be maintained under all loading conditions. 8. Electrical: a. Coils shall be electrically isolated from grounds and shall be terminated in a built-in two-pin connector or other approved connection. b. The track brake shall include a freewheeling diode. LTK Standard Streetcar Specifications Section 12 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System c. Connection to vehicle wiring shall be via flexible cable with waterproof connectors at both ends. d. Provide a separate track brake contactor and circuit breaker for each truck. e. Tripped or open track brake circuit breakers shall cause annunciation of a friction brake fault, and shall be logged in the MDS. 12.2.10 Electronic Control Unit (ECU) Unless control is via the propulsion system, provide an independent friction brake electronic control unit for each truck. Comply with specified electrical requirements and Section 17, Electronic Controls, Software, and MDS. 12.3 Controls 12.3.1 General The friction brake system shall include microprocessor-based controls (Braking Control Unit, or BCU) on a per-truck basis: 1. Each BCU shall independently read master controller and other signals from the controlling cab and the propulsion controls. The BCU shall calculate and apply the requested brake effort. 2. Each BCU shall provide system status and fault logging, and shall connect to the vehicle data network. 3. If friction brake controls are embedded in the propulsion ECU, then similar friction brake status and fault logging shall be provided within the propulsion system design. Emergency braking shall be caused directly by hard-wired signals from the Cab Console to all brake control valves, track brake contactors, and sanding controls, and shall not be processed by the BCU, except for monitoring purposes. 12.3.2 Dynamic Brake Interface A dynamic brake signal from the propulsion system shall be used by each BCU to modulate disc brake effort in response to the dynamic braking effort on that truck, such that the requested brake effort is provided regardless of the status of dynamic braking: 1. The propulsion and friction brake suppliers shall jointly determine the characteristics of this signal. 2. If the disc brake control logic is within the propulsion system, the propulsion control ECU shall calculate the required disc braking effort so as to provide the requested level of effort within specified tolerances. See Section 10, Propulsion System and Control. 12.3.3 Load Compensation Comply with the following: 1. The friction brake system shall use the signals from the load measuring system on each truck to adjust disc brake efforts according to passenger load, on a per truck basis. See Sections 2, Design and Performance Criteria, and 11, Truck Assemblies. 2. In the event the load compensation signal is not within the allowable range, the system shall default to value of the nearest healthy truck and notify the operator through the MDS system (see Section 17, Electronic Controls, Software, and MDS). 3. The friction brake system may provide the equipment and controls for the load measuring system, and may provide processed load signals to the propulsion system. LTK Standard Streetcar Specifications Section 12 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System 12.4 Disc Brake - Propulsion System Interlock Comply with the following: 1. Interlock the disc brake system with the propulsion system such that propulsion is removed if any disc brake remains applied on any truck for more than a designated time period after the application of propulsion. 2. Initial setting: 7 seconds. 3. Time value: Adjustable in software, and optimized during vehicle testing. 12.5 Sanding System Comply with the following: 1. Sander type: a. Pneumatic with integral compressors. Separate compressors may be considered by the City. Compressor shall be oil-less and maintenance-free except for input filter cleaning. b. Gravity-fed systems may be considered, if specified flow rates can be assured under all conditions. 2. Control: a. Automatic application: • • Sand shall be automatically applied during emergency braking and during severe wheel spins or slides. Sanding shall be interlocked with the no-motion detection circuitry and disabled below the no motion detection point. b. Manual application: • • Possible only if a vehicle direction is selected but shall not be interlocked with the nomotion detection point. See Section 5, Operator’s Cab and Controls, for operator manual control of sanding. 3. Electrical: a. Power source: Low-voltage dc system for all sander functions, including heaters and compressors. b. Circuits: Feed sanders for each truck from a separate circuit breaker, which shall also function as the sander cutout switch. c. Friction brake fault: Annunciate on tripped or open breaker. 4. Sand boxes: a. Quantity: EightFour b. Location: Inside vehicle, under seats, suitable to feed sand to each front wheels of powered trucks c. Material: Stainless steel or aluminum d. Capacity: Minimum 20 liters (5.3 gallons) per box e. Configuration: Slope sandbox bottom towards the floor outlet with the slope angle greater than the angle of repose of the sand, such that all sand in the box can be dispensed LTK Standard Streetcar Specifications Section 12 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System f. Environmental protection: • • Seal to prevent moisture and debris ingress Heat to keep sand dry from condensation 5. Filling: a. Sight gauge: Provide one for each sandbox, visible from inside vehicle, to indicate sand level. b. Filling portal: Arrange sandbox to permit easy filling from inside or outside vehicle. 6. Output: a. Through piping or hose selected and arranged to permit the free flow of sand to the nozzles under all conditions of environment and truck motions b. Tees, elbows, or other restrictive fittings shall not be used 7. Sanding nozzles: a. Fastened to the truck frame. b. Shaped and located to deposit sand directly in front of and as close as possible to the wheel/rail contact point of each leading wheel of powered trucks for both directions of operation. c. Designed to reject water caused by wheel splash. d. Shall not clog under any specified environmental conditions. 8. Flow rate: Approximately 0.45 kg/min (1 lb/min), adjustable by shop personnel by minimum +/- 25% of the nominal setting. 12.6 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. Detail drawings: Top level assemblies, and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested 12-1 Friction Brake System Design Package: 1. 2. 3. 4. 5. 6. 7. 8. 9. Description of friction brake system Details of parking brakes Description of EB application Description of load compensation Description of Spin/Slide system Hydraulic fluid specifications Details of truck cut-out and mechanical brake release Outline drawings and mounting of major components Hydraulic system schematics LTK Standard Streetcar Specifications Section 12 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Friction Brake System 12-2 Friction Brake Control Design Package: 1. Hardware and software functional description, including all interfaces and their interdependencies 2. If friction brake control is provided by propulsion equipment, demonstrate that sufficient information from the friction brake supplier is provided on the following: a. b. c. d. Friction brake physical and electrical characteristics Transfer functions Network communications All other aspects necessary to provide specified performance 3. Interfaces with propulsion system 4. Hardware design description 12-3 Simulation and Thermal Capacity Design Package: 1. Abnormal duty cycle report, including simulations component thermal ratings. 2. Normal duty cycle report, including simulations component thermal ratings 3. Emergency brake duty cycle report 12-4 Track Brake Design Package: 1. Data sheets on track brake components with sufficient detail to demonstrate that specified requirements have been satisfied 2. Outline drawings of overall system 3. Illustrations demonstrating how to replace track brake shoes, pole filler material, and bonded rubber elements 4. Illustrations demonstrating how to make adjustments to maintain proper clearances 12-5 Sanding System Design Package: 1. Data sheets on system components 2. Outline drawings of overall system 12-6 Friction brake redistribution scheme: 1. For EB and slide controlled braking 2. During dynamic brake failure (if applicable) END OF SECTION LTK Standard Streetcar Specifications Section 12 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems Table of Contents 13.1 General .......................................................................................................................... 1 13.1.1 Scope .............................................................................................................................................. 1 13.1.2 General Requirements ................................................................................................................... 1 13.1.3 Communication System Integration with MDS.............................................................................. 1 13.1.4 Audio Communications Functional Description............................................................................. 1 13.2 Public Address (PA) System ............................................................................................ 1 13.2.1 General ........................................................................................................................................... 1 13.2.2 Performance................................................................................................................................... 2 13.2.3 Amplifiers ....................................................................................................................................... 2 13.2.4 Automatic Volume Control ............................................................................................................ 2 13.2.5 Cab Microphone............................................................................................................................. 2 13.2.6 Interior Speakers ............................................................................................................................ 3 13.2.7 Exterior Speakers ........................................................................................................................... 3 13.2.8 PA Passenger Alert Tone ................................................................................................................ 3 13.3 Intercom System ............................................................................................................ 3 13.3.1 General ........................................................................................................................................... 3 DRAFT 13.3.2 Passenger Emergency Intercom (PEI) ............................................................................................ 3 13.3.2.1 General.................................................................................................................................... 3 13.3.2.2 PEI Station Quantity and Location .......................................................................................... 4 13.3.2.3 PEI Stations ............................................................................................................................. 4 13.3.2.4 Functional Description ............................................................................................................ 5 13.3.3 Cab-to-Cab Intercom ...................................................................................................................... 5 13.4 Automatic Passenger Information System (APIS) ............................................................ 6 13.4.1 General ........................................................................................................................................... 6 13.4.2 Functional Description ................................................................................................................... 6 13.4.3 Passenger Information ................................................................................................................... 6 13.4.4 Operator Controls .......................................................................................................................... 6 13.4.5 System Initiation ............................................................................................................................ 7 13.4.6 Message Format, Uploading, and Recording ................................................................................. 7 13.4.7 Data Storage and User Programming ............................................................................................ 7 13.4.8 System Capacity ............................................................................................................................. 8 13.4.9 Performance................................................................................................................................... 8 13.4.10 Recording and Programming Equipment..................................................................................... 8 LTK Standard Streetcar Specifications Section 13 i January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.4.11 Information and Destination Signs .............................................................................................. 8 13.4.11.1 General.................................................................................................................................. 8 13.4.11.2 Information Signs .................................................................................................................. 8 13.4.11.3 Destination Signs .................................................................................................................. 9 13.5 Warning Devices ............................................................................................................ 9 13.5.1 General ........................................................................................................................................... 9 13.5.2 Automobile Warning Device (Horn)............................................................................................. 10 13.5.3 Pedestrian Warning Device (Bell) ................................................................................................ 10 13.6 Radio Equipment ......................................................................................................... 10 13.6.1 General ......................................................................................................................................... 10 13.6.2 Radio Power Supply ..................................................................................................................... 10 13.7 CCTV ............................................................................................................................ 11 13.7.1 General ......................................................................................................................................... 11 13.7.2 Cameras ....................................................................................................................................... 11 13.7.3 Camera Enclosures ....................................................................................................................... 12 13.7.4 Interior/Exterior Surveillance CCTV ............................................................................................. 12 13.7.5 Exterior Side View CCTV ............................................................................................................... 12 13.7.5.1 Functional Description .......................................................................................................... 12 DRAFT 13.7.5.2 Exterior Side-View Camera Mounting .................................................................................. 13 13.7.5.3 Exterior Side-View Display Screens....................................................................................... 13 13.7.6 CCTV Controller ............................................................................................................................ 13 13.7.7 Workstation Software and Hardware .......................................................................................... 13 13.7.8 Digital Video Recorder (DVR) ....................................................................................................... 14 13.7.8.1 General.................................................................................................................................. 14 13.7.8.2 Recording .............................................................................................................................. 14 13.7.8.3 Vehicle ID, Date, and Time.................................................................................................... 14 13.7.8.4 Recording Frame Rate and Resolution ................................................................................. 14 13.7.8.5 Recording Triggered by External Events ............................................................................... 14 13.7.8.6 Storage Capacity ................................................................................................................... 15 13.7.8.7 DVR Data Storage.................................................................................................................. 15 13.7.8.8 DVR Data Transfer................................................................................................................. 15 13.8 GPS Receiver ................................................................................................................ 16 13.9 Vehicle Wireless Communication to Wayside ............................................................... 16 13.9.1 General ......................................................................................................................................... 16 LTK Standard Streetcar Specifications Section 13 ii January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.9.2 Wi-Fi IP Router ............................................................................................................................. 16 13.9.3 Vehicle Status and Health Data.................................................................................................... 16 13.10 Event Recorder .......................................................................................................... 17 13.10.1 General ....................................................................................................................................... 17 13.10.2 Functional Requirements ........................................................................................................... 17 13.10.3 Data Storage and Retrieval ........................................................................................................ 18 13.10.4 Construction Requirements ....................................................................................................... 18 13.10.5 Installation Requirements .......................................................................................................... 18 13.11 Automatic Passenger Counting (APC) ......................................................................... 18 13.11.1 General ....................................................................................................................................... 18 13.11.2 System Requirements ................................................................................................................ 18 13.11.3 APC Accuracy.............................................................................................................................. 19 13.11.4 APC Doorway Equipment ........................................................................................................... 19 13.11.5 APC Logic Unit ............................................................................................................................ 19 13.11.6 APC Data Downloading .............................................................................................................. 20 13.12 Automatic Vehicle Locator (AVL) ................................................................................ 20 13.13 Traffic Light Priority.................................................................................................... 20 DRAFT 13.14 Train-to-Wayside Communication System (TWC) ........................................................ 20 13.14.1 General ....................................................................................................................................... 20 13.14.2 System Description .................................................................................................................... 21 13.14.3 Functional Requirements ........................................................................................................... 21 13.14.4 Vehicle-Borne Equipment .......................................................................................................... 22 13.14.4.1 General................................................................................................................................ 22 13.14.4.2 Operator TWC Control Module and Associated Wiring...................................................... 22 13.14.4.3 Transponder........................................................................................................................ 22 13.14.4.4 TWC Logic Unit .................................................................................................................... 23 13.15 Contract Data Requirements List (CDRL) ..................................................................... 23 LTK Standard Streetcar Specifications Section 13 iii January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.1 General 13.1.1 Scope The on-board communication system includes the public address system (PA); intercom system including cab-to-cab intercom and passenger emergency intercom (PEI); automatic passenger information system (APIS); warning devices, radio; video surveillance (CCTV); vehicle position system, vehicle wireless communication to wayside, the event recorder, automatic passenger counting (APC); automatic vehicle locator (AVL); traffic light priority; and train-to-wayside communication (TWC) system. 13.1.2 General Requirements Comply with the following: 1. Power source: Communication equipment shall be powered from the low-voltage dc power system (see Section 9, Electrical Equipment), and shall be rated for continuous duty in the specified environment, as installed. 2. Grounding: Communications equipment circuits shall comply with the safety grounding and return circuit requirements of Section 9. 3. Network: The communications system, and equipment, shall be Ethernet-based. 4. Design requirements: The communication controls shall comply with the design requirements of Section 2, Design and Performance Criteria, and incorporate a Local Diagnostic and Test System (LDTS) that interfaces with the Central Diagnostic System (CDS) and portable test units (PTU), as described in Section 17, Electronic Controls, Software, and MDS. 13.1.3 Communication System Integration with MDS The APIS, Communications, and MDS hardware, wiring, and functions may be integrated to the maximum extent possible. For information on the MDS, see Section 17. DRAFT 13.1.4 Audio Communications Functional Description The communications system shall be configured to allow the following audio communications: 1. 2. 3. 4. From the operator to passengers inside and outside the vehicle. Between cabs in a vehicle, and the cabs of a vehicle being towed. Between passengers inside the vehicle and the operator. From the automatic passenger information system to passengers inside and/or outside the vehicle via pre-recorded announcement sequences and visual displays. 5. From the door system to passengers inside and outside the vehicle, if door warnings are generated by one of the vehicle communication systems. 13.2 Public Address (PA) System 13.2.1 General Comply with the following: 1. The PA system shall permit the operator to make audio announcements to passengers inside or outside the vehicle, and to provide audio announcements from the APIS. 2. Operator initiated PA messages shall override passenger information system and door system messages. See Section 5, Operator’s Cab and Controls, for a functional description. LTK Standard Streetcar Specifications Section 13 1 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems See Section 6, Passenger Doors, for door functions performed by the PA system, if door warnings are generated by the PA system. 13.2.2 Performance Comply with the following: 1. The frequency response, from signal origin to output signal at the speaker, shall be 150 Hz to 10 kHz, plus or minus 1 dB at all power levels. Total harmonic distortion of all circuits, without compression circuits, shall not exceed 1% at 1 kHz, full output. 2. The output volume and audio quality shall be the same from each speaker. Speech peaks shall be limited to approximately 5 dB above the average input level. 3. Messages shall be intelligible and acoustically pleasing under all operating conditions. 4. The PA system, from the input of the microphone, or audio messages from the APIS, to the output of the speakers, shall have a 90% intelligibility rating when tested according to ANSI S3.2. 13.2.3 Amplifiers Comply with the following: 1. Provide network-connected amplifiers driving one or more speakers, with sufficient power to drive all connected speakers at maximum levels, simultaneously, without distortion. 2. The frequency response of power amplifiers below 100 Hz shall fall off at a rate of maximum 6 dB per octave. 13.2.4 Automatic Volume Control The PA system interior and exterior output levels shall be automatically adjusted in accordance with ambient noise levels before each announcement, regardless of origin: DRAFT 1. Range of automatic adjustment: Minimum 10 dB. 2. Maximum output level (interior): Minimum 15 dB above typical worst case ambient noise levels when the vehicle is moving at maximum operating speed. 3. Maximum output level (exterior): Minimum 15 dB above typical worst case ambient noise levels when the vehicle is stationary at a station selected by the Owner. 13.2.5 Cab Microphone Provide a microphone in each cab, usable for PA, cab-to-cab, and PEI modes: 1. Type: Boom-style, gooseneck, or console-mounted, noise-cancelling, dynamic. 2. Durability: Rugged, weatherproof construction, designed and constructed for transportation applications, and vandal resistant. 3. Location: Shall permit a seated operator of the specified size range to speak into the microphone without leaving the normal operating position or losing sight of traffic in front of the vehicle. See Section 14, Interior and Exterior Appointments, Size Range of Operators section. 4. Wiring connector: Quick-disconnect type. 5. Microphone preamplifier: Shall include a compression circuit that maintains output regulation of + 1/- 0.5 dB, no load to full load, measured at the speaker terminals. LTK Standard Streetcar Specifications Section 13 2 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.2.6 Interior Speakers Interior speakers shall meet or exceed the following criteria: 1. Provide a minimum of one speaker for every 1800 mm (71 in) of vehicle length. 2. Select speaker dispersion and other characteristics to provide sound levels within 3 dB, and intelligible audio, at all seating locations, under all vehicle operating conditions. 3. Provide speakers with a continuous power rating of minimum 5 W. 4. Arrange speakers to eliminate feedback from any audio input source. 5. Provide audio fidelity specified in this section at all power levels. 6. Mount speakers in the ceiling, or other approved locations. 7. Grilles shall be flush mounted, finished to match the panel, perforated, removable for access to the speaker, and held in place with tamper-proof screws. 8. Provide a volume adjustment control for the Operator’s cab PA speaker that can be adjusted by the Operator. 13.2.7 Exterior Speakers Exterior speakers shall meet or exceed the following criteria: 1. Provide a minimum of four external speakers per vehicle, two per side. 2. Speakers shall be impervious to environmental conditions specified in Section 2, Design and Performance Criteria. 3. Provide speakers with a continuous power rating of minimum 15 W. 4. Mounting of speakers and routing of speaker wires shall be waterproof. 5. Speaker locations shall not violate the vehicle's dynamic outline. 6. Speakers shall be immune to the chemicals and detergents normally used during vehicle washing, shall not interfere with nor damage mechanical vehicle wash brushes, and shall be designed to withstand forces generated by these brushes. DRAFT 13.2.8 PA Passenger Alert Tone Comply with the following: 1. Preceding any public audio announcement, including automatic announcements, a local tone annunciator shall be energized to alert passengers that an announcement is forthcoming. 2. The tone volume shall be 3 dB above the normal speech level. 3. The annunciator shall possess a pleasant, chime-like quality, and be approved by the Owner. 13.3 Intercom System 13.3.1 General The intercom system shall allow communication between passengers and the operator, and between vehicle cabs. 13.3.2 Passenger Emergency Intercom (PEI) 13.3.2.1 General The passenger emergency intercom shall permit passengers to communicate with the operator. LTK Standard Streetcar Specifications Section 13 3 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.3.2.2 PEI Station Quantity and Location Comply with the following: 1. Provide the quantity of PEI units according to vehicle length: a. Vehicles less than 22 m (72 ft): Minimum two. b. Vehicles 22 m or longer: Minimum four. 2. Location: a. Two stations: Provide one in each of the two dedicated mobility aid parking areas mounted so as to be easily accessible for the use of mobility aid patrons. b. Four stations: Provide one in each of the two dedicated mobility aid parking areas and one near each end of the vehicle, or as directed by the Owner during design review. 13.3.2.3 PEI Stations Comply with the following: 1. Description: Flat-faced, panel-mounted enclosure with microphone, loudspeaker, large pushbutton switch, indicating light (which may be part of the pushbutton switch), and any necessary auxiliary components to make the system function. 2. Enclosure: a. Material: Stainless steel. b. Rating: Splash-proof, and vandal-resistant. c. Front panel: Perforated in front of microphone and loudspeaker with holes as small as possible to provide adequate performance while reducing opportunities for vandalism. DRAFT 3. Microphone: Omni-directional, with external filters to reduce background noise. 4. Loudspeaker: a. Materials: Like the interior PA speakers. b. Continuous power rating: Minimum 3 W. 5. Pushbutton: Arranged to prevent unintended nuisance application during crowded conditions in passenger area. 6. Electrical connections: Use concealed multi-pin connectors. 7. Signage: a. b. c. d. e. Text: English and Braille. Identification: "Emergency Intercom." Instructions: "To Contact Driver Push Button Once", or approved similar language. Unit location: Identify the vehicle and PEI unit location. Provide signage adjacent to unit. Signage regulations: • • Comply with 36 CFR 1191 Appendix D, Section 703, Signs. Provide tactile symbols and characters that comply with 36 CFR 1191 Appendix D, Section 703.2, Raised Characters, in accordance with 36 CFR 1191 Appendix D, Section 407.4.9, Emergency Communication. 8. Installation: Flush mount each unit at a height of 1220 mm (48 in) above the floor. The installation shall comply with 36 CFR 1191 Appendix D, Section 308, Reach Ranges. LTK Standard Streetcar Specifications Section 13 4 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.3.2.4 Functional Description The system shall function as follows: 1. Pressing the call-request button at a PEI station: a. Causes each call request to enter a first-in, first-out queue in the PEI control system. b. Indicates acknowledgement of the call request to the passenger with a light on the PEI station and an audible notification. 2. When the call request comes to the top of the queue: a. The operator is hailed via a tone and indicator lamp at the active Cab Console. b. The operator acknowledges the call by pressing an acknowledge button, which sets up a half-duplex communication channel between the active cab and the PEI station. c. The operator may speak to the passenger when the microphone switch is pressed, and the passenger may speak to the operator when the switch is not pressed. d. Audio from the passenger is heard in the cab speaker. Audio from the operator is heard by the passenger via the speaker in the PEI station. Audio from the PEI shall be heard only in the active cab and at the active PEI station. 3. When the conversation is finished: a. The operator terminates the call by pressing a button on the Cab Console and the active PEI station returns to an inactive state. b. If there are no more calls in the queue, the PEI session is terminated. Otherwise, the next call in the queue hails the operator in the same manner. 4. If the operator activates other audio functions on the Cab Console: DRAFT a. PEI activities are placed on hold and the queue maintained. b. The PEI indicator lamp on the Cab Console shall remain illuminated. c. The operator shall return to the PEI session by pressing a button on the Cab Console. 13.3.3 Cab-to-Cab Intercom Provide a cab-to-cab intercom to allow communication between cabs within the vehicle, and between cabs of vehicles during towing operations: 1. 2. 3. 4. 5. 6. Function: Similar to the PEI (may use the same equipment). Call initiation: From any cab, with or without an active console. Call annunciation: In every cab, by means of a one-time call chime and an indicating light. Call acknowledgment: In any cab. Indicating lights: Shall stay on until the call is completed. Connection between vehicles: Make provisions for connection during towing operations. A separate cable that attaches at either cab end through a weatherproof connector will be acceptable. LTK Standard Streetcar Specifications Section 13 5 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.4 Automatic Passenger Information System (APIS) 13.4.1 General The vehicle shall include equipment for automated broadcast of pre-recorded audible and visual announcements of transit system information as well as destination information to passengers on the wayside: 1. The APIS components shall be fully integrated into a network-connected system, with a controller common to all. 2. The Owner will coordinate with the Contractor to provide the initial data set of messages, station names and physical locations, announcement sign text/images, and other information necessary to commence revenue service. 3. See Section 6, Passenger Doors, for door functions performed by the APIS, if door warnings are generated by the APIS. 13.4.2 Functional Description The APIS system shall function as follows: 1. After the operator selects the route, announcements are triggered automatically without operator assistance or may be triggered manually by the operator: a. Automatically: By vehicle position, determined by a combination of GPS coordinates, distance measurement by wheel revolution count, and door openings. b. Manually: Via the APIS Control Panel in each cab. 2. Destination signs shall automatically be set. 3. Audio announcements shall be broadcast over the PA system, and corresponding visual announcements displayed on the interior information signs. 4. The message database structure shall include instructions to direct audio to the interior, exterior, or both speaker sets. DRAFT 13.4.3 Passenger Information The system shall provide as a minimum the following passenger information: 1. Station arrival announcement: Station identification may include station name, exit locations, and bus or train transfer information 2. Station departure announcement: Broadcast the following information: a. Next station b. Vehicle destination/route information c. Which doors will be opening at the next station 3. End of Line 4. Public Service Announcements 13.4.4 Operator Controls Provide the operator with an APIS Control Panel in each cab: 1. Location: Integrated into the Cab Console in a less-frequently used area, or alternately, integrated into the Train Operator’s Display (TOD) via the vehicle data network. LTK Standard Streetcar Specifications Section 13 6 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 2. Functionality: It shall allow the following: a. b. c. d. e. f. Initiating the system Entering temporary information such as vehicle ID and operator ID Entering route ID Selecting specific messages Altering the normal message sequence, such as skipping stations Display of system status and other relevant information 3. Interface Device: a. It shall include a keypad or similar with function specific keys. Entering commands via codes is prohibited. 4. Display: LED back-lit LCD display or authorized alternative showing the following information: a. b. c. d. e. System states Entered information System diagnostic and fault data Presently announced messages Similar information 13.4.5 System Initiation Comply with the following: 1. Cab keyed On: The system shall initiate itself to the last route ID, or to a default setting if the last active ID is not present. 2. Cab keyed Off: The route ID shall be stored. DRAFT For a functional description of operator initiation of APIS announcements, see Section 5, Operator’s Cab and Controls. 13.4.6 Message Format, Uploading, and Recording Comply with the following: 1. Audio format: Messages shall be encoded and stored in a common, publicly available, digital format such as MP3. 2. Audio sample rates and compression levels: Chosen for excellent human voice and good music fidelity at the speaker. 3. Message, station, and route data: Up-loadable via Ethernet, USB, or as approved. 4. Recorded audio messages: The initial set shall be created in a professional recording studio, using a trained female English speaker, or approved text-to-speech algorithms. 13.4.7 Data Storage and User Programming Comply with the following: 1. The APIS shall use a non-proprietary, publicly available, database structure to store all data. 2. Each audio, text message shall be stored with, or linked to, related information identifying the message type, destination device addresses, distance-on-route for automatic message triggering, and similar parameters. LTK Standard Streetcar Specifications Section 13 7 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 3. Updating, creating, deleting, uploading, and downloading APIS information shall be intuitive, database structured, and contained within one program; recording of audio messages can be performed using different software. 13.4.8 System Capacity Comply with the following: 1. For storage, assume for audio messages at least 30 seconds per message and for text messages 100 characters each. 2. Message capacity shall depend only on available memory; there shall be no inherent limitation built into the control software or algorithms. 3. The system shall have enough capacity to store the following: a. 50 routes, with a minimum of 100 stations for each route; b. 10 audio and 10 text messages per station; and c. Minimum 50 special messages, audio and text. 13.4.9 Performance APIS audio performance shall be the same as for the PA. 13.4.10 Recording and Programming Equipment Furnish to the Owner a complete set of equipment for recording and modifying the visual and audible messages and routes: 1. The system shall be composed of standard commercial off-the-shelf equipment. 2. This equipment shall include everything required to reprogram the on-board systems with new information, such as messages, routes, and stations. DRAFT 13.4.11 Information and Destination Signs 13.4.11.1 General Provide an electronic information and destination sign system on each vehicle: 1. Regulations and Standards: Comply with 49 CFR 38 Subpart D (ADA requirements), IEEE 100, and IEEE 1477. 2. Quantity: Each vehicle shall have a minimum of four information and four destination signs. 3. Environmental protection: Protect signs from the following: a. Vandalism: Provide a clear polycarbonate shield over the display b. Environmental contamination c. Ingress, as appropriate for the operating environment 4. Maintainability: The LCD panel shall be user-replaceable, and of a common design and format available from multiple sources in the U.S. 13.4.11.2 Information Signs Comply with the following: 1. Type: Industrial grade LED backlit color LCD display assembly, with integrated power supplies, display drivers, and announcement controller interface. LTK Standard Streetcar Specifications Section 13 8 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 2. Display and announcement controller configuration: Half the screen area will provide station information in ADA-compliant text formats and sizes, and the other half will be used for other informational text and graphics as programmed by the Owner. 3. Display size: Minimum 21 in diagonal. 4. Resolution: Minimum 1280 x 1024; wide screen formats acceptable. 5. Refresh rate: High, with no detectable flicker. 6. Character size: Comply with ANSI A117.1, except minimum height is not required to exceed 76 mm (3 in) at any viewing distance. 7. Viewing angle: Minimum 120 degrees horizontally. 8. Brightness: Minimum 500 cd/m². 9. Temperature operating range: a. At least 0 to 35 degrees C (32 to 95 degrees F). b. No damage to the monitor in the temperature range as specified in Section 2. 10. Ethernet connected to announcement controller. 11. Power source: Vehicle low-voltage system via local power supplies. 12. Cooling: Configure the enclosure, installation, and LCD panel to use conditioned interior air without forced air cooling. 13. Location: a. Low-floor section: Mount two as a pair, back to back, hung from the ceiling near the center, oriented transversely. b. High-floor sections: Integrate into fixed portion of cab partition. c. Situate to permit any passenger in the vehicle to have a view of at least one sign. d. Coordinate placement with CCTV cameras such that signs do not obscure CCTV field of view. DRAFT 13.4.11.3 Destination Signs Comply with the following: 1. 2. 3. 4. Type: Single-line, dot-matrix LED or back-lit LCD, capable of scrolling a message. Message Color: Yellow or amber on black. Character Height: Minimum 110 102 mm (4.3 in). Location: On each side near a side entry door and above each cab windshield; alternate locations may be submitted to the Owner. 5. Display: Destination or route information. 6. Cab front display: a. Visible at a minimum distance of 150 ft (46 m) in bright sunlight. b. Coordinate with upper lighting fixture design to ensure glare-free visibility under all conditions. 13.5 Warning Devices 13.5.1 General Comply with the following: 1. Provide a horn and bell on each end of the vehicle for alerting automobiles and pedestrians. 2. Horns and bells shall comply with appropriate federal, state, and local regulations. LTK Standard Streetcar Specifications Section 13 9 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.5.2 Automobile Warning Device (Horn) Comply with the following: 1. Horn: Multiple-tone electronic air horn. 2. Audible output: Minimum 95 dBA at 30 m (100 ft) in front of vehicle, adjustable by maintenance personnel. 3. Location: Mount underneath cab floor. 4. Existing vehicles: The sound shall be similar to existing vehicles. 5. Operation: a. Sound shall continue as long as switch is activated. b. When activated, only horn facing the direction of motion shall sound. 13.5.3 Pedestrian Warning Device (Bell) Comply with the following: 1. Bell: Electronic, traditional-sounding trolley bell with repeating sound of approximately two strikes per second. Sound may be produced by amplified, digitally-sampled audio data using heavy-duty weatherproof speakers on each end of the vehicle. 2. Existing vehicles: The sound and repetition rate shall be the same as existing vehicles. 3. Audible output: Provide two volume settings, low and high, adjustable by maintenance personnel. a. High: 75-80 dBA measured 30 m (100 ft) from front of vehicle. b. Low: 50-55 dBA measured 30 m (100 ft) from front of vehicle. 4. Operation: DRAFT a. Sound shall continue as long as switch is activated. b. Sound shall be capable of being activated in pulses by operator. c. When activated, only the bell at the end where it was activated shall sound. 13.6 Radio Equipment 13.6.1 General Install radio equipment furnished by the Owner in each operator’s cab and provide associated wiring and power: 1. Details of the radio will be supplied during Design Review. 2. See Section 5, Operator’s Cab and Controls, for location information. 3. The Contractor shall be responsible for installing and testing the radio equipment. 13.6.2 Radio Power Supply For each set of radio equipment, provide an industrial grade dc-to-dc power converter that complies with Section 9, Electrical Equipment, and includes the following: 1. Characteristics complying with radio manufacturer’s requirements. 2. The following features: a. Transformer-isolation b. Input voltage transient suppression rated for minimum 150 J c. Output overvoltage protection LTK Standard Streetcar Specifications Section 13 10 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems d. Short circuit protection e. Current limiting 3. Output voltage: As recommended by the radio manufacturer. 4. Line and load regulation: 1% or less over the full range of the LVPS input voltage and from noload to rated output. 5. Rating: a. For continuous output current 25% greater than the maximum load current drawn by the radio transceiver and all other relevant loads. b. The converter may be used to power other cab equipment that requires the same dc voltage as the radio, in which case the power rating of the converter shall be selected accordingly. 6. Power the radio equipment via dedicated dc circuit breaker. If the supplied radio is a fixed, nonportable unit, power the radio power supply through a circuit breaker directly connected to the battery, upstream of the battery circuit breaker. 13.7 CCTV 13.7.1 General Provide each vehicle with an Ethernet TCP/IP-based Closed Circuit Television (CCTV) system consisting of color cameras, display screens, DVR, CCTV Controller and other ancillary equipment, as required. Equipment shall be NTSC format. See Section 14, Interior and Exterior Appointments, for CCTV signage requirements. DRAFT 13.7.2 Cameras Comply with the following: 1. Quantity: a. Interior/exterior surveillance: At least eight, to achieve the coverage specified below b. Exterior side view: Four 2. Type: Networked IP digital color cameras recording both video and audio, with pan and tilt adjustments. 3. Maintainability: Use the same camera for all applications. Choose lenses and enclosures as appropriate for each application. 4. Camera characteristics: a. Resolution: Minimum 1280×1024800, with 720p, and lower resolutions available and user selectable. b. Power source: From the CCTV system. Power over Ethernet (PoE) cameras are acceptable. c. Imaging: Automatic WDR. d. Illumination rating (light sensitivity): Maximum 0.2 lux, for low light conditions. Demonstrate that the camera does not “white out” when operating at night. e. Colors: Minimum 16 bit color depth. f. Compression: H.264 or H.265. g. Frame rate: Minimum 30 25 fps, with lower rates available. LTK Standard Streetcar Specifications Section 13 11 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems h. Control: Frame rate and bandwidth for each camera shall be remotely controllable using the CCTV Controller. 13.7.3 Camera Enclosures Comply with the following: 1. Interior Camera Enclosures: Vandal-resistant, industrial grade. 2. Exterior Camera Enclosures: a. Waterproof. b. Heating Elements: Provide for defrosting and de-fogging, with control such that clear view for exterior camera is available within 10 minutes of activation of any cab, and is maintained while any cab is active. c. Non-Snagging: Design shall prevent snagging of carwash brushes or debris. d. View Port: Tempered glass. e. Removable: Without affecting camera adjustments. 13.7.4 Interior/Exterior Surveillance CCTV Provide each vehicle with the following surveillance cameras: 1. Interior Surveillance: a. Enough on the vehicle interior to provide complete coverage of all passenger areas, including all door openings looking out to the platform. b. Active when either cab is active. 2. Exterior Surveillance: DRAFT a. A front-facing camera in each cab to provide a wide-angle front view, covering the area in front of the vehicle. Provide two cab-forward cameras in each cab if deemed necessary by the Owner to cover a 180-degree arc in front of the cab. b. Active when either cab is active. 3. Operator Surveillance: a. Camera in each cab, oriented to view operator activities and audio. b. Active when either cab is active, but only at the end with the active cab. 13.7.5 Exterior Side View CCTV 13.7.5.1 Functional Description In place of side-view mirrors for the vehicle operator, the exterior CCTV shall enable the operator to supervise the loading and unloading of passengers at vehicle doorways, and to verify that the doors on the vehicle are clear of passengers. Each exterior side view camera shall be directly connected to its respective display. If a camera fails, the system shall indicate a failure to the operator and automatically switch to the camera on the opposite cab. LTK Standard Streetcar Specifications Section 13 12 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.7.5.2 Exterior Side-View Camera Mounting Comply with the following: 1. Location: Above the cab side windows to provide a clear view of the side of a vehicle with the doors opened. 2. Field of view: Show passengers entering or exiting the vehicle. 13.7.5.3 Exterior Side-View Display Screens Provide color display screens, two in each cab, connected to the camera for the matching side: 1. Type: LCD TFT, LED backlit 2. Reflection/glare mitigation: Shroud to prevent washout during bright conditions, and provide a filter or coating, if necessary; filter or coating shall not reduce clarity or brightness 3. Orientation: Vertical 4. Size: Minimum 200 mm (8 in), diagonally 5. Resolution and Aspect Ratio: Match the display screen’s camera 6. Controls: Provide for user-adjustable contrast and brightness 7. Operating Environment: Ensure that display functions in all environments, including an enclosed unconditioned cab in worst-case ambient conditions. 8. Location: Each side of the cab as specified in Section 5, Operator’s Cab and Controls 9. Maintainability: The LCD panel shall be user-replaceable, and of a common design and format available from multiple sources in the U.S. 13.7.6 CCTV Controller Provide a network controller to perform the following functions: DRAFT 1. Manage all cameras in the vehicle; 2. Provide network interfaces to the VNC and specified display and recording devices; and 3. Provide an interface to CCTV workstations. 13.7.7 Workstation Software and Hardware Provide CCTV Workstation software for installation on personal computers with current Windows 7OS: 1. Using a network port on the CCTV controller, the software shall permit uploading operating parameters (such as sampling rates), viewing all or selected cameras in real time, downloading and viewing of video data from the DVR, verification of authenticity, image and video enhancement, and similar processes. 2. The software shall be Web-browser based, and compatible with common Internet Web browsers, such as Internet Explorer or Mozilla Firefox. 3. The software shall provide access to recorded video data that has been removed from the vehicle, and is contained in a storage device removed from the vehicle, or has been uploaded to the Owner’s server. 4. The workstation software shall include provision to connect to the Owner’s server, navigate to stored data by vehicle number and date range, and display on the workstation. Provide network-connected equipment that will accept the storage device as a simple plug-in, and allow access to the data. LTK Standard Streetcar Specifications Section 13 13 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.7.8 Digital Video Recorder (DVR) 13.7.8.1 General Provide a DVR in each vehicle: 1. Inputs: Sufficient for the quantity of cameras to be recorded in each vehicle, plus two spare. 2. Capacity: Sufficient to record all cameras in use at one time. 3. Authentication: The recording method shall include a process to detect any alteration of the data after recording. 13.7.8.2 Recording Provide for recording the cameras described above as follows: 1. Interior surveillance cameras 2. Exterior surveillance cameras, both active and inactive cabs 3. Operator surveillance camera (active cab only) 13.7.8.3 Vehicle ID, Date, and Time The DVR shall automatically include the vehicle ID and a date/time stamp on all images: 1. Vehicle ID: Entered by the user into non-volatile memory via the CCTV controller. 2. Camera ID: Provide a unique ID for each camera, such as an IP address, that is consistent in each vehicle. 3. Date and time: Maintained by an internal clock, synchronized by the GPS at agreed intervals. 4. GPS signal: Lack of a signal shall not disrupt or alter the internal clock. 13.7.8.4 Recording Frame Rate and Resolution DRAFT Frame rate and resolution shall be software adjustable, using a PTU via the CCTV controller: 1. Normal recording: a. Speed: 15 fps. b. Resolution: Lower than maximum, as agreed. c. Bandwidth: Lower than maximum, as agreed. 2. High rate recording triggered by external events: a. Speed: 30 fps. b. Resolution and bandwidth: Maximum camera. 13.7.8.5 Recording Triggered by External Events Comply with the following: 1. Triggering events: a. b. c. d. e. Distress signal over the radio, if provided and available for monitoring EB application Passenger emergency intercom activity Manual (emergency) door release Incident Alarm switch activation (see Section 5, Operator Cab) 2. High rate recording: Continue for 10 minutes after an event trigger. LTK Standard Streetcar Specifications Section 13 14 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 3. Storage: Provide protected area that prevents video recording from being overwritten or erased. 13.7.8.6 Storage Capacity Comply with the following: 1. Storage capacity: Minimum 21 15 days of surveillance video, computed using a minimum 20 hours per day, maximum camera resolution and bandwidth, 15 fps, and specified compression. 2. Recording durations: User selectable, from one day to full capacity. 3. Capacity status: Used/unused capacity of the DVR shall be viewable by maintenance personnel and the operator on the Train Operator Display (TOD). Provide a warning on the TOD via the VNC when capacity is near full. 4. Full capacity: When reached, new data shall over-write oldest data. 13.7.8.7 DVR Data Storage Provide the DVR with hot-swappable non-volatile memory storage: 1. Type: a. Solid State Drive (SSD) storage medium, if necessary storage capacity is available with commercial drives, and the Contractor can ensure a minimum 10-year life at the defined recording rates. Provide confirmation of predicted lifespan from the SSD manufacturer. b. Hard disk drive (HDD) if an SSD is determined to be inappropriate: • • Reliability: Propose only HDDs with high reliability in continuous duty. Reliability shall be as determined by independent groups, such as BackBlaze. Installation: Comply with all manufacturer’s recommendation, including ambient temperature and power quality. Provide resilient mounts. DRAFT 2. Security: The memory storage device shall be secured via a keyed lock, or other approved mechanically secure methods. 3. Playback: Provide appropriate adapter hardware and software for the memory device, including a standard Ethernet interface, for playback on a standard Windows-based PC. 13.7.8.8 DVR Data Transfer The CCTV system shall provide automatic and manual, software-adjustable data transfer between the DVR and wayside storage installations using a wireless data link: 1. The wireless data link may be external to the CCTV system. 2. Include Windows-based server software for the vehicle and wayside, and requirements for server equipment on the wayside. 3. The server software shall automatically organize data from each vehicle according to vehicle ID, camera ID, and date/time. 4. Application software shall provide rapid searching of recorded data by any parameter. 5. Include utility software for server diagnostics, storage capacity statistics, and similar. LTK Standard Streetcar Specifications Section 13 15 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.8 GPS Receiver Provide a WAAS-enabled GPS receiver for use by the APIS and CCTV system (see above) and MDS system (see Section 17, Electronic Controls, Software, and MDS), and other systems on the vehicle that require position and/or time information: 1. The GPS shall furnish the primary vehicle time, which shall be passed on to all relevant vehicle control systems via the vehicle network (see Section 17). 2. Provide satellite prediction and recent ephemeris data features for quicker location determination when the GPS is powered on. 3. Provide an interface at the VNC and MDS to GPS data, allowing access by other vehicle systems to vehicle location data and GPS time signals via Ethernet connection. Include appropriate access methods and software techniques for third parties to access such data. 4. The GPS shall remain powered during vehicle layover periods. See Section 5, Operator’s Cab and Controls, and Section 9, Electrical Equipment. 5. Mount the GPS antenna on the roof, or other location, optimized for satellite access. Coordinate the antenna location with other vehicle antennas to avoid interference. 13.9 Vehicle Wireless Communication to Wayside 13.9.1 General Provide wireless communication from the vehicle to the wayside for transmission of data to the vehicle maintenance workstation in the Shop (see Section 17, Electronic Controls, Software, and MDS, sections on Vehicle Data Network, MDS, and Vehicle Software and Systems). 13.9.2 Wi-Fi IP Router DRAFT Provide a high performance COTS mobile access IP router with the following attributes: 1. 2. 3. 4. IEEE 802.11ac compliant Rugged design Specifically optimized for use in vehicles used by public transportation agencies Designed to withstand harsh environments, including high temperature variations, high altitude, intense shock and vibration, and exposure to dampness, moisture, or dust 5. It shall support the following: a. b. c. d. e. Simultaneous usage of UDP/IP and TCP/IP transmission protocols User-configurable data packet transmission priorities based on Quality of Service (QoS) Ethernet Ports with IP67 D-coded M12 Connectors Advanced IP services such as Virtual LAN, Discovery Protocol, Policy Routing, IP Multicast Firewall protection/access rights 13.9.3 Vehicle Status and Health Data Provide a method for a third party system to access vehicle status and health data via an Ethernet port on the MDS: 1. 2. 3. 4. 5. Include appropriate access methods and software techniques to access such data. Provide robust protection against third party access to vehicle controls or other vehicle systems. Ensure that data access has no effect on vehicle network performance. Arrange the data fields to be accessed individually. Place the data in a memory buffer, updated at agreed intervals, for asynchronous retrieval. LTK Standard Streetcar Specifications Section 13 16 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 6. Examples of desired data fields: a. b. c. d. e. f. Vehicle location via GPS Passenger counts, from the APC system Vehicle mileage Vehicle faults, using agreed codes Vehicle incidents, such as passenger emergency door access, and MB/EB applications. Others, as may be requested by the Owner. 13.10 Event Recorder 13.10.1 General Provide each vehicle with a fully electronic data recorder system, independent of the monitoring and diagnostic system described in Section 17, Electronic Controls, Software, and MDS: 1. The primary purpose of this recorder is to furnish documentation in support of accident investigations. 2. It must be a tamper-proof, self-contained design capable of withstanding high shock. The Owner’s operating environment is described in Section 2, Design and Performance Criteria. 3. The event recorder shall be based on a family of service proven designs, with at least five years successful operating history in revenue service on rail vehicles. 4. Unless explicitly stated otherwise, the event recorder shall comply with the requirements of IEEE 1482.1. 13.10.2 Functional Requirements Comply with the following: DRAFT 1. Signal sampling and recording rates shall comply with IEEE 1482.1. 2. The event recorder shall record at least the following information: a. All applicable signals referenced in IEEE 1482.1, Table 1, Required event recorder signals; b. The following signals referenced in IEEE 1482.1, Table 2, Potential additional event recorder signals. Where trainline is referenced in the standard, the requirement applies to control line on a single vehicle: • • • • • • 3. 4. 5. 6. Signal A15, Sanding Signal A36a, A36b, etc., Wheel spin/slide activation (other trucks) (lead axle included in Table 1) Signal A64a, A64b, etc., Door close command (left/right) Signal A65a, A65b, etc., Door open command (left/right) Signal A66a, A66b, etc., Door enable command (left/right) Signal A81, Bell/gong activated Provide minimum six spare digital channels. Provide minimum two spare analog channels. The event recorder time base shall be independent of other vehicle systems. Event recorder functional status and failures shall be reported to the MDS described in Section 17. LTK Standard Streetcar Specifications Section 13 17 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.10.3 Data Storage and Retrieval The recorder shall be able to store a minimum of seven days of data, including signals from the spare channels, in non-volatile memory: 1. This memory shall not require battery backup for data retention and shall remain intact for a period at least one year after removal from the vehicle. 2. Provide the following data retrieval capabilities: a. Event data memory module removal b. Data retrieval via a USB or Ethernet port using a laptop computer 3. Downloaded data shall be capable of being evaluated on an office computer. It shall not be possible to erase the data via the USB or Ethernet port on the recorder. 4. Provide all necessary cabling and software to transfer, evaluate, display, and print the data in tabular and graphic form. 13.10.4 Construction Requirements The event recorder shall be constructed in accordance with the requirements of IEEE 1482.1. These requirements may be met by: 1. 2. 3. 4. Design of the data storage device itself; Placing the device in an enclosure meeting the requirements; Judicious placement of the device within the vehicle body envelope; or A combination of these methods. 13.10.5 Installation Requirements DRAFT Comply with the following: 1. Locate the event recorder in the vehicle interior in an electrical locker that shall require a key for access (see Key Assignment Table in Section 14, Interior and Exterior Appointments). 2. The installation shall be such that the event recorder is tamper resistant and waterproof; however, installation shall be such that the USB or Ethernet port is readily accessible once the recorder is installed. 3. Provide a terminal board with locations for all event recorder signals, including spares. Connections to the event recorder inputs shall be made at this terminal board. 13.11 Automatic Passenger Counting (APC) 13.11.1 General Provide an automatic passenger counting (APC) system, Init Iris IRMA, for each vehicle. The system shall count the passengers that enter and exit the vehicle at each station and record the passenger count, location, time, and vehicle number in an onboard database for remote processing at a later time. 13.11.2 System Requirements Comply with the following general requirements: 1. Memory: Sufficient to hold 45 days of data, assuming 20 round trips per day. LTK Standard Streetcar Specifications Section 13 18 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 2. Software: a. Operating software: Provide what is necessary for the vehicle and wayside. b. PTU software: Provide software to maintain the system and download data and software necessary to analyze the data in the Owner’s offices. c. Licenses: Provide what is necessary for the Owner to use the software for the design life of the vehicles. 13.11.3 APC Accuracy The accumulated count of alighting passengers shall be within 2% for each 1,000 consecutive boarding and alighting passengers, and the accumulated count of boarding passengers shall be within 2% for each 1,000 consecutive boarding and alighting passengers. Use the following formula for generating accurate passenger accumulated count data: Where: 𝑒𝑟𝑒𝑙 = 𝑃𝑎 − 𝑃𝑚 × 100% ≤ 2% 𝑃𝑚 𝑃𝑎 = automatic counted passenger (each separate for in and out) 𝑃𝑚 = manual counted passenger (each separate for in and out) Sample size is minimum 1000 passengers (𝑃𝑚 > 1000) 13.11.4 APC Doorway Equipment DRAFT Each doorway of the vehicle shall be equipped with multiple sensors and associated logic unit to sense passengers entering and exiting the vehicle. 1. The combination of sensors and logic shall properly detect and indicate the correct passenger count regardless of whether single or multiple persons are simultaneously entering or exiting a doorway, or any simultaneous or overlapping combination of entering and exiting persons. 2. The APC doorway equipment shall function accurately regardless of the size of the passenger, from small child to large adult and shall not interfere with operation of the doors. 3. Direct connections shall be used to communicate between APC sensors and the APC doorway logic unit. 4. Communication between the APC doorway logic units and the central logic unit shall be by a network that conforms to the requirements of Section 17, Electronic Controls, Software, and MDS. 13.11.5 APC Logic Unit Provide an APC Logic Unit to collect, process, and store the data from the APC doorway equipment: 1. It shall determine the position of the vehicle by a combination of the following: a. Starting location information from the APIS b. Distance traveled information from the propulsion system, or other approved source with wheel diameter correction c. No-motion as indicated by the vehicle no-motion logic d. Door open status signals from the door control system LTK Standard Streetcar Specifications Section 13 19 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 2. Logic shall process the door and location data and store it in non-volatile memory with sufficient capacity to comply with the specified memory capacity, above. 3. The APC Logic Unit shall contain logic to detect system faults and receive fault data from the APC doorway equipment. a. A fault log shall be maintained in the APC Logic Unit. b. In addition to functioning with the PTU to permit manipulation and display of this data, the system shall communicate with the MDS to transmit the fault log and permit manipulation and display of the passenger count data via the MDS specified in Section 17. 13.11.6 APC Data Downloading Comply with the following: 1. The data shall be available for downloading via PTU and for automatic downloading via wireless communication from the vehicle to the wayside. 2. Provide the equipment with the appropriate interfaces and software to use the vehicle wireless communications equipment to automatically transfer APC data to the wayside when the vehicle is in the maintenance shop and yard via the Wi-Fi IP Router specified in this Section. See also information on remote data management in the MDS section of Section 17. 13.12 Automatic Vehicle Locator (AVL) Provide an Automatic Vehicle Locator system, Nextbus GPS Suites. The AVL is a real-time travelerinformation management and display system, composed of wayside displays, Windows-based message creation and control software, and World Wide Web vehicle location for public use. DRAFT 1. The system shall provide vehicle location, updated at regular intervals, using GPS. 2. The system shall use the vehicle GPS. 3. The GPS antenna shall mount on the roof, or other location, optimized for satellite access. Coordinate the antenna location with other vehicle antennas to avoid interference. 4. The Contractor shall furnish the equipment, and shall provide wiring, installation, and verification of the equipment. 13.13 Traffic Light Priority The Owner will furnish a traffic light priority emitter for the roof of each cab. For each vehicle, perform the following: 1. Furnish and install mounting brackets for emitters. 2. Install Owner-furnished emitters. 3. Furnish, install, and connect wiring, consisting of power and an interlock with active cab. 13.14 Train-to-Wayside Communication System (TWC) 13.14.1 General Provide the vehicle-borne portion of the TWC system in accordance with requirements described in this Section. Provide vehicle TWC equipment completely compatible with the wayside equipment. Each vehicle set of TWC equipment to be provided will consist of at least the following: 1. Two operator TWC control modules, installed in the cab console (one per end), in approved locations LTK Standard Streetcar Specifications Section 13 20 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 2. Two transponder assemblies (one per end) 3. One or two TWC logic units 13.14.2 System Description Provide each end of the vehicle with vehicle-borne components of the TWC system to transmit digital information from the vehicle to the wayside or wayside to vehicle, at certain points along the route. 1. Fixed wayside loop antennas placed in the trackway send out an interrogation signal several times a second. 2. When a vehicle passes over the loop antenna and an activated vehicle-borne TWC transponder receives the interrogation signal it shall transmit a message to the wayside in the form of highspeed serial digital data. 3. Provide vehicle-borne equipment compatible with the Owner's existing and new wayside systems: a. Type: Vecom/Vetag b. Frequencies: Wayside and vehicle-borne TWC signals will be in the 100 kHz range. 13.14.3 Functional Requirements Comply with the following: 1. Furnish and install vehicle TWC equipment such that there is accurate, secure transmission of a data message to/from wayside loop antennas. 2. Transponders shall transmit when properly located over the loop and polled by the wayside interrogator. 3. The format of the data message to be transmitted shall be a function of vehicle status. The vehicle shall be configured to furnish the TWC system with inputs representing active cab status and end-of-vehicle status. 4. Vehicle number (to be transmitted by inactive cabs) shall be encoded via jumpers inside the TWC control module. 5. The TWC system shall transmit the following information from the vehicle to the wayside: DRAFT a. b. c. d. e. f. g. Train Number Route Number Vehicle Number Stationary Preempt/Activation Switch Call (Left or Right) Active Cab (on for active cab) End-of-train After Contract Award: 1. Additional TWC transmission requirements will be covered during system design. 2. The exact assignment of bits, including start/stop bit will be furnished to the Contractor by the Owner after Contract award. LTK Standard Streetcar Specifications Section 13 21 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems 13.14.4 Vehicle-Borne Equipment 13.14.4.1 General Comply with the following: 1. Equipment shall be identical in all cabs. 2. Provide interconnection hardware and cables to mount and connect transponders and TWC control modules. 3. Provide power to the TWC system from the low-voltage dc power system with the voltage range and conditions specified in Section 9, Electrical Equipment. 13.14.4.2 Operator TWC Control Module and Associated Wiring Comply with the following: 1. The TWC control module shall consist of the following: a. A unit of four pushbutton switches; these shall be backlighted when the transponder for the active cab is over a wayside loop and is being interrogated. b. A unit of four thumbwheel switches, each with ten positions. 2. Inputs to the TWC control module: a. b. c. d. Battery positive, through a dedicated circuit breaker Negative Return Cab active signal End-of-train signal 3. Installation: All inputs shall be brought to a terminal board mounted under the console in an appropriate location near the TWC control module, and connected to the TWC control module via a multi-conductor cable and quick-disconnect connector. 4. TWC status: Show on the TOD, as specified in Section 5, Operator’s Cab and Controls. DRAFT 13.14.4.3 Transponder Mount each transponder under the vehicle as follows: 1. Mounting Bracket: a. Fabricate bracket to mount the transponder to the vehicle body b. Material: Follow manufacturer’s requirements for electromagnetic properties. c. Finish: Paint the bracket as under-vehicle equipment. 2. Location and Orientation: a. Locate on the centerline of the vehicle body and approximately 1 m (39 in) from the end of the vehicle. b. Location and orientation shall conform to the TWC manufacturer’s installation guidelines, including proximity to ferrous materials. c. Do not mount to truck frame unless specifically permitted by manufacturer. 3. Cable Connection: a. Provide a multi-conductor cable and connectors suitable for exposure in an under-vehicle environment. b. Attach one end of the cable to the vehicle via a connector at a bulkhead or junction box. LTK Standard Streetcar Specifications Section 13 22 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Vehicle Communication Systems c. Attach the other end of the cable to the transponder by methods appropriate for the transponder design. 13.14.4.4 TWC Logic Unit Comply with the following: 1. Provide dc power to each TWC logic unit via dedicated circuit breakers. 2. Install logic units in equipment lockers/racks with other vehicle control units. 13.15 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Each design package shall include the following, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. 6. Detail drawings: Top level assemblies, and other drawings if requested Functional description Electrical specifications Control schematics Component ratings: Top level components, and ratings of other components if requested Vehicle integration drawings 13-1 Public Address Design Package 13-2 Intercom Design Package 13-3 Automatic Passenger Information System Design Package: 13-4 Warning Devices Design Package: DRAFT 13-5 Radio Design Package 13-6 CCTV Design Package: 13-7 Wi-Fi Router Design Package 13-8 Event Recorder Design Package: 13-9 Automatic Passenger Counting Design Package: 13-10 Automatic Vehicle Locator Design Package 13-11 Traffic Light Priority Design Package 13-12 TWC Design Package END OF SECTION LTK Standard Streetcar Specifications Section 13 23 January 30, 2017June 19, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments Table of Contents 14.1 Scope .........................................................................................................................................1 14.2 Interior Finishing ........................................................................................................................1 14.2.1 Materials ........................................................................................................................................ 1 14.2.2 Design and Workmanship .............................................................................................................. 1 14.2.3 Interior Linings ............................................................................................................................... 1 14.2.3.1 Walls ....................................................................................................................................... 1 14.2.3.2 Ceiling...................................................................................................................................... 2 14.2.3.3 Support and Installation of Interior Linings ............................................................................ 2 14.2.3.4 Access Panels .......................................................................................................................... 2 14.2.3.5 Equipment Supports ............................................................................................................... 3 14.2.4 Interior Finishes ............................................................................................................................. 3 14.2.5 Articulation..................................................................................................................................... 3 14.3 Insulation ...................................................................................................................................3 14.3.1 Acoustical Insulation ...................................................................................................................... 3 14.3.2 Thermal Insulation ......................................................................................................................... 4 14.3.3 Urethane Foam Prohibited ............................................................................................................ 4 14.4 Floor Covering ............................................................................................................................5 14.4.1 General ........................................................................................................................................... 5 14.4.2 Floor Material................................................................................................................................. 5 14.4.3 Specific Applications ...................................................................................................................... 5 14.4.4 Cove and Trim Moldings ................................................................................................................ 5 14.4.5 Floor and Molding Installation ....................................................................................................... 6 14.4.6 Quality Criteria and Repair Methods ............................................................................................. 6 14.4.7 Door Thresholds ............................................................................................................................. 7 14.5 Passenger Seats ..........................................................................................................................7 14.5.1 Description ..................................................................................................................................... 7 14.5.2 Design Criteria ................................................................................................................................ 8 14.5.3 Materials ........................................................................................................................................ 8 14.5.4 Cushion Inserts ............................................................................................................................... 8 14.5.5 Dimensions..................................................................................................................................... 9 14.5.6 Flip-Up Seats .................................................................................................................................. 9 14.6 Mobility Aid Parking Areas..........................................................................................................9 14.7 Interior Equipment .....................................................................................................................9 LTK Standard Streetcar Specifications Section 14 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.7.1 Stanchions, Handrails, and Grab Rails............................................................................................ 9 14.7.2 Windscreens................................................................................................................................. 10 14.7.2.1 Description and Location ...................................................................................................... 10 14.7.2.2 Material and Assembly ......................................................................................................... 11 14.7.3 Bicycle Racks ................................................................................................................................ 11 14.7.4 Provisions for Equipment Specified in Other Sections................................................................. 12 14.8 Keys and Locks ......................................................................................................................... 12 14.9 Windows .................................................................................................................................. 13 14.9.1 General ......................................................................................................................................... 13 14.9.2 Type and Performance ................................................................................................................. 13 14.9.3 Installation ................................................................................................................................... 14 14.9.4 Cab Windshield ............................................................................................................................ 14 14.9.5 Cab Side Windows........................................................................................................................ 14 14.9.6 Passenger Section Side and Door Windows................................................................................. 14 14.10 Operator’s Cab ....................................................................................................................... 15 14.10.1 General ....................................................................................................................................... 15 14.10.2 Size Range of Operators ............................................................................................................. 15 14.10.3 Cab Layout.................................................................................................................................. 15 14.10.4 Visibility Requirements .............................................................................................................. 15 14.10.5 Cab Partition .............................................................................................................................. 15 14.10.6 Cab Door .................................................................................................................................... 16 14.10.7 Cab Console................................................................................................................................ 16 14.10.7.1 Cab Console Design............................................................................................................. 16 14.10.7.2 Cab Console Material and Finish ........................................................................................ 17 14.10.7.3 Cab Console Construction................................................................................................... 17 14.10.7.4 Master Controller Area of Cab Console .............................................................................. 17 14.10.7.5 Operator’s Handhold .......................................................................................................... 17 14.10.8 Cab Furnishings and Equipment ................................................................................................ 18 14.10.8.1 Cab Flooring ........................................................................................................................ 18 14.10.8.2 Operator Seat...................................................................................................................... 18 14.10.8.3 Air Comfort System ............................................................................................................. 18 14.10.8.4 Sunscreens .......................................................................................................................... 18 14.10.8.5 Windshield Wiper and Washer ........................................................................................... 19 14.10.8.6 Convenience Outlets ........................................................................................................... 19 LTK Standard Streetcar Specifications Section 14 ii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.10.8.7 Operator’s Tools ................................................................................................................. 19 14.10.8.8 Interior Mirror..................................................................................................................... 19 14.10.8.9 Fire Extinguisher ................................................................................................................. 20 14.10.9 Operator’s Appurtenances......................................................................................................... 20 14.10.9.1 Coat Hook ........................................................................................................................... 20 14.10.9.2 Operator's Storage Locker .................................................................................................. 20 14.10.9.3 Waste Receptacle ............................................................................................................... 20 14.10.9.4 Cup Holder .......................................................................................................................... 20 14.11 Exterior Finishing .................................................................................................................... 20 14.11.1 Exterior Finishes ......................................................................................................................... 20 14.11.2 Paint Colors and Gloss................................................................................................................ 21 14.11.3 Graphics ..................................................................................................................................... 21 14.12 Rain Gutters and Water Drainage ............................................................................................ 21 14.13 Equipment Enclosures............................................................................................................. 22 14.13.1 General ....................................................................................................................................... 22 14.13.1.1 Standards ............................................................................................................................ 22 14.13.1.2 Construction ....................................................................................................................... 22 14.13.1.3 Hardware ............................................................................................................................ 22 14.13.1.4 Seals and Gaskets................................................................................................................ 22 14.13.1.5 Labels and Warnings ........................................................................................................... 22 14.13.1.6 Paint .................................................................................................................................... 23 14.13.1.7 Location .............................................................................................................................. 23 14.13.2 Exterior Equipment Enclosures .................................................................................................. 23 14.13.2.1 Material and Construction .................................................................................................. 23 14.13.2.2 Covers ................................................................................................................................. 24 14.13.2.3 Equipment Arrangement .................................................................................................... 24 14.13.2.4 Ventilation .......................................................................................................................... 24 14.13.3 Interior Equipment Enclosures .................................................................................................. 25 14.13.3.1 General................................................................................................................................ 25 14.13.3.2 Underseat Type ................................................................................................................... 25 14.13.3.3 Electrical Locker Type ......................................................................................................... 25 14.14 Signage................................................................................................................................... 25 14.14.1 General ....................................................................................................................................... 25 14.14.2 Informational Text and Graphics ............................................................................................... 26 LTK Standard Streetcar Specifications Section 14 iii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.14.3 ADA Accommodation Graphics .................................................................................................. 26 14.14.4 CCTV Notice................................................................................................................................ 26 14.14.5 Vehicle Numbering..................................................................................................................... 27 14.14.6 Safety ......................................................................................................................................... 27 14.15 Owner-Provided Routes, Schedules, and Advertising ............................................................... 27 14.16 Contract Data Requirements List (CDRL) .................................................................................. 27 LTK Standard Streetcar Specifications Section 14 iv January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.1 Scope This Section describes interior finishing, including liners, insulation, floor covering, seats, and windows; layout and design of the operator’s cab and Cab Console; exterior finishing; and other such features and appurtenances. 14.2 Interior Finishing 14.2.1 Materials Provide only the following types of materials: 1. High-durability, low-maintenance, as specified in this Section and in Section 16, Materials and Workmanship, or as approved by the Owner. 2. Conforming to flammability, smoke emission, and toxicity requirements of Section 16. 3. Color shall extend all the way through materials except FRP and melamine (where FRP and melamine are specified). 14.2.2 Design and Workmanship Comply with the following: 1. 2. 3. 4. The vehicle interior shall be free of sharp corners or edges. Surfaces shall be free from tooling marks, gaps, distortions, and other visible defects. Surfaces shall be rigid and supported to prevent sagging, drumming, and vibration. Gaps between apparatus that are not absolutely rigid shall be wide enough to prevent injury when the apparatus moves, or provide rigid spacers to prevent the gap from closing. 14.2.3 Interior Linings 14.2.3.1 Walls Comply with the following: 1. Side Wall Material: a. b. c. d. Balanced melamine, FR Grade, minimum thickness 3.2 mm (0.125 in); Thermoplastic sheet; FRP; or Aluminum sheet with a melamine cover. 2. Side Wall Joints: a. Maximum one joint per wainscot section between side entrance doors and in each passenger compartment level. b. Hide joint from view with seats, where appropriate. 3. End walls, bulkheads, and door pocket panels: Cored construction, to be approved by the Owner. 4. Window masks: Provide at vehicle-body windows, including windshields: a. Slope masks to eliminate dirt collecting areas. b. Support and cover joints with moldings. c. As an alternative, if glued-in windows are not selected, wide glazing strips may be used which extend to and engage the lining panels. LTK Standard Streetcar Specifications Section 14 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 5. Moldings: Colors of moldings on exposed surfaces shall be compatible with the colors of the other materials in the vehicle. 14.2.3.2 Ceiling Ceiling between air diffuser-light fixture assemblies: 1. Material: Melamine-faced panels with an aluminum honeycomb core, minimum thickness 10 mm (3/8 in); or other materials and thicknesses if approved by the Owner during design review. 2. Ceiling panels: Individually removable. Provide trim caps between panels. 3. Joints: a. Transverse joints: Space no closer than 1220 mm (4 ft). b. Longitudinal joints: Not permitted. 4. Support: Ceiling panels may be supported by the air-distributor/light-fixture assemblies and by hinges welded to the roof structure. Hinges shall be no greater than 1015 mm (40 in) apart. Ceiling Cove Area (outboard of light fixtures): 1. Material: a. Melamine-faced aluminum, minimum thickness 2.0 mm (0.08 in). b. Molded fiberglass reinforced composite; or approved equal. 2. Alternatively, panels may be formed by extensions of the window masks, or may be flat diagonal sections, using the above materials. 14.2.3.3 Support and Installation of Interior Linings Mechanically fasten interior linings to their supporting surfaces: 1. Fasteners shall not be exposed to passengers unless specifically approved. 2. Alternatives that bond the interior panel to the exterior wall as a unitized replaceable assembly will be considered. 3. The mounting shall accommodate dynamics of vehicle movement without transmitting stress to the liners. 4. Provide minimum 25 mm (1 in) radius cove at intersecting adjacent surfaces. 5. Provide "anti-squeak" tape between all linings or panels and any structure to which they are attached or with which they come into contact. 14.2.3.4 Access Panels Provide access panels in the vehicle interior lining where required, and as approved by the Owner. Comply with the following: 1. Interchangeability: Manufacture panels, hardware, and their interface to the vehicle body with sufficient tolerances to allow exchange of panels of like size anywhere in the vehicle. 2. Material: Matching the surrounding lining. 3. Latches: Quick-release fasteners, as specified in Section 16, Materials and Workmanship, or as approved by the Owner. 4. Ceiling Access: Panels and grilles shall be hinged and equipped with safety catches. 5. Equipment Enclosures: See Equipment Enclosures section, below. LTK Standard Streetcar Specifications Section 14 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.2.3.5 Equipment Supports Support equipment directly from the vehicle structure or via hangers welded to the vehicle structure. Ceiling panels and wall linings shall not be used to support equipment or equipment lockers. 14.2.4 Interior Finishes Comply with the Interior and Exterior Design Package and the following: 1. Interior metals: Painted, with the following exceptions: a. Exposed stainless steel (except for floor covering): Provide an approved brushed finish with grain direction arranged to be consistent with the decorative scheme. Paint only as required by the approved Interior Design Package. b. Aluminum: For interior applications not exposed to passengers, aluminum may be unpainted, but if unpainted must be anodized. 2. Powder Coat: If the approved Initial Interior and Exterior Design Package permits interior surfaces requiring paint, provide powder coat in accordance with Section 16, Materials and Workmanship. Powder coat may be applied only to items that can be removed for recoating. 3. Durability: Color and finish shall be fade-resistant and shall not change appearance or run when exposed to interior lighting, sunlight, or chemicals typically used to clean vehicles. 4. Graffiti Resistance: Walls and ceilings shall be graffiti resistant to ASTM D6578/D6578M, using cleaning agents agreed by the Owner, with a pass rating of 5, minimum. 5. Gloss: Interior surfaces shall have a low-glare finish with a glossometer reading between 4 and 15, per ASTM D523, machine direction, using a 60 degree glossometer, or as outlined in the approved Initial Interior and Exterior Design Package. 14.2.5 Articulation Comply with the following: 1. Design and construct flooring, walls, and other moving components such that their movement creates no audible noise under all conditions. 2. Design and size gaps between articulation section wall and ceiling panels to prevent injury. Gaps in the articulation portion of the passenger compartment shall not increase or decrease in width, so as to be hazardous to persons, under any conditions. 14.3 Insulation 14.3.1 Acoustical Insulation Provide sound- and vibration-damping insulation as required and as specified below: 1. Material: a. Resistant to dilute acids, alkalis, greases, gasolines, aliphatic oils, and vermin. b. Compliant with flammability, smoke emission, and toxicity requirements in Section 16. 2. Location: a. Provide on inner surfaces of all areas of the structural shell, including sub-floor pans, ends, roof, and side frames, and one side of air duct splitters (if used). b. Provide on articulation close off panels and bellows. LTK Standard Streetcar Specifications Section 14 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 3. Installation: Clean and prime surfaces before installation in accordance with Section 16, Materials and Workmanship. The Owner may consider alternatives that provide insulation between interior panels and the exterior wall as a unitized replaceable assembly. 14.3.2 Thermal Insulation Insulate vehicle to ensure that heating and cooling requirements of Section 7, Heating, Ventilating, and Air Conditioning, are met: 1. Material: a. Fiberglass: Manufactured from long, textile-type glass fibers drawn from a calcium borosilicate mixture to an average diameter of 9 microns. b. Bonding agent: Thermosetting phenolic resin not exceeding 6% by weight. c. High-temperature limit: Minimum 230 degrees C (446 degrees F). d. Alternatives that provide insulation between interior panels and the exterior wall as a unitized replaceable assembly will be considered. 2. Material shall not: a. b. c. d. Mold, rot, or sustain vermin Corrode metals Settle as a result of vehicle vibration Have an odor or be capable of absorbing odors 3. Location: Insulate roof, sides, and ends of the vehicle, including inside faces of posts and structural members. 4. Density: a. Fill entire volume of the available cavity. b. Select density of fiberglass insulation consistent with vehicle-body transmission heat loss/gain calculated in Section 7. 5. Installation: a. Roof: Retain insulation using stainless steel wires or strips. b. Side- and end-walls: Retain insulation using spears or other approved method. Take steps to ensure that sharp, pointed ends are not a hazard to personnel or maintenance equipment. c. Floor: • • • Insulate with two layers of equal thickness of fiberglass separated by a vapor barrier. Place this insulation in the structural floor between the transverse floor beams and fill the entire volume of the available cavity. Floor insulation shall be compatible with the material used at each insulated location in the vehicle structure. 14.3.3 Urethane Foam Prohibited The use of urethane foam insulation is prohibited in the vehicle. See Section 16, Materials and Workmanship, for other prohibited materials. LTK Standard Streetcar Specifications Section 14 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.4 Floor Covering 14.4.1 General Provide floor covering and accessories that provide a durable, watertight, textured covering for the floor panels and other vehicle structures. Flooring color and pattern will be determined by the Owner during the design review process. 14.4.2 Floor Material Comply with the following requirements for floor covering material: 1. Rubber material: a. Water and chemical resistant. b. Fully homogeneous throughout, meeting requirements of ASTM F1344. c. Rubber flooring shall bend around a 20 mm (0.8 in) diameter mandrel without breaking, cracking, crazing, or showing any change in color. 2. Flammability, smoke emission, and toxicity: In accordance with Section 16, Materials and Workmanship. 3. Static coefficient of friction: Minimum 0.6 measured in accordance with ASTM D2047, using leather and rubber shoe materials meeting these requirements: a. Leather shoe material: Federal Specification KK-L-165C b. Rubber shoe material: ASTM D1630 14.4.3 Specific Applications Provide the type of floor material indicated below for the specified locations: 1. 2. 3. 4. Seat areas: Smooth rubber sheets. Aisles and other walking areas: Ribbed or non-slip grit surface, as approved. Mobility aid parking areas: Smooth rubber sheets with an integral non-slip grit surface. Stairs: a. Provide each step with a safety nosing resistant to chipping, peeling, and other forms of preliminary failure. b. Nosing shall extend the full width of the step and contrast visually from the stair tread and riser covering by 70%, as determined by the following formula: Contrast (%) = [(B1-B2)/B1]*100 Where: B1 = Light reflectance value of brighter area B2 = Light reflectance value of darker area 14.4.4 Cove and Trim Moldings Comply with the following for cove molding used for floor covering: 1. Material: Brushed finish stainless steel. 2. Size: Minimum size consistent with maintenance access to dirt in the corners. 3. Corners, Splices, Terminations: Formed pieces that rigidly connect to the cove pieces. LTK Standard Streetcar Specifications Section 14 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 4. Application: Provide between floor covering and vertical surfaces at which, or behind which, the floor covering terminates, such as side walls, end walls, equipment boxes, and floor heaters, including those in the operator's cab. Trim molding: Provide stainless steel or aluminum molding around the periphery of the floor covering at exposed removable floor access panels and at the edge of the articulation section. 14.4.5 Floor and Molding Installation Prepare and install floor as follows: 1. Preparation: a. Before installing the floor covering, fill voids, indentations, fastener heads, and separations between floor panels with an approved flame-retardant leveling compound. b. The floor shall be made smooth and flat within 1.6 mm (0.063 in) measured within any 915 mm (36 in) distance in any direction. 2. Installation: Securely bond floor covering to the floor structure with a waterproof adhesive as recommended by the floor-covering supplier. 3. Seams: Transverse seams shall not be used. All seams shall be longitudinal. Install molding as follows: 1. Form a watertight seal with the floor covering and the vertical surface. 2. Alternate: a. Where floor covering meets walls, curve floor covering upward onto walls, providing support in the curve. Radius shall not be less than recommended by floor covering manufacturer. b. Terminate floor covering with an edge sealant or other method approved by the Owner. 14.4.6 Quality Criteria and Repair Methods Comply with the following quality criteria and repair methods, where permitted, for rubber flooring: 1. Thin-skinned blister: A blister that, when finger-pushed, will collapse upon itself. Thin-skinned blisters larger or more frequent than the indicated maximum size and population shall be repaired as indicated: a. Maximum Size: 0.75 mm (0.03 in) height, 0.500 mm² (0.0008 in²) area with longest dimension of 50 mm (2 in). b. Maximum Population: 3 blisters in a 300 mm by 300 mm (11.8 in by 11.8 in) area. There shall be only one other blister within 1 m (39 in) of this area. c. Repair Method: Using a hypodermic needle, apply just enough Loctite 420 or Bostik 1685 to bring to a flush surface. 2. Thick-skinned blister: A blister that, when finger-pushed, will collapse and then return to its original condition. Thick-skinned blisters larger or more frequent than the indicated maximum size and population are not permitted and may not be repaired: a. Maximum Size: 0.75 mm (0.03 in) height, 0.500 mm² (0.0008 in²) area with longest dimension of 50 mm (2 in). b. Maximum Population: 3 blisters in a 300 mm by 300 mm (11.8 in by 11.8 in) area. There shall be only one other blister within 1 m (39 in) of this area. LTK Standard Streetcar Specifications Section 14 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 3. Lump: A blister without a void, consisting of solid material. Lumps larger or more frequent than the indicated maximum size and population are not permitted and may not be repaired: a. Maximum Size: 0.75 mm (0.03 in) height, 0.500 mm² (0.0008 in²) area with longest dimension of 50 mm (2 in). b. Maximum Population: Three lumps in a 300 mm by 300 mm (11.8 in by 11.8 in) area. There shall be only one other lump within 1 m (39 in) of this area. 4. Hole: A defect that is 100% through the material. No holes are permitted, regardless of size or population. Repair of holes is not permitted. 5. Thin area: A defect where the sheet is below thickness locally. Thin areas of the indicated maximum size and population are permitted but shall be repaired as indicated. Thin areas larger or more frequent than the indicated maximums are not permitted and may not be repaired: a. Maximum Size: 0.75 mm deep at the lowest point, 2000 mm² (3.1 in²) with a longest dimension of 125 mm (5 in). b. Maximum Population: One thin area in a 1 m by 1 m (39 in by 39 in) area, and there shall not be another thin area within 1 m (39 in) of this area. c. Repair Method: Rub with #00 steel wool to blend this area into the normal thickness material and then buff to a normal surface finish. 14.4.7 Door Thresholds Provide a threshold at each doorway: 1. Material: Extruded aluminum, or cast or machined stainless steel. 2. Anti-skid treatment: Provide on top surface, integral to the threshold. 3. Drainage: If the threshold includes longitudinal slots, such as for door tracks, provide drainage to the outside of the vehicle. 4. Installation: a. Fasten threshold to vehicle structure with stainless steel fasteners. b. Provide sealant underneath and around the full periphery of the threshold. c. Fully seal the interface between threshold and mating floor covering. 5. If bridge plates are provided, the threshold may be integral to the bridge plate assembly. 14.5 Passenger Seats 14.5.1 Description Provide passenger seats meeting the following requirements: 1. 2. 3. 4. Type: Heavy-duty, transit-grade, with removable cushion inserts. Color and fabric: To be determined by the Owner during design review. Seat back pans: Sculptured to provide knee room. Manufacturer's logos or markings: Not visible to passengers. LTK Standard Streetcar Specifications Section 14 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.5.2 Design Criteria Incorporate the following requirements in passenger seat design: 1. Standards: Comply with 49 CFR 571.222 or APTA-PR-CS-S-016-99-Rev 2 for seat construction and attachments to vehicle structure, except that seats shall be subjected to a 5g, 250 ms crash pulse rather than the 8g requirement for commuter rail. 2. Comfort and Safety: Use recognized ergonomic and human factors principles to provide a comfortable and safe ride for short distance local patronage: a. Design: Molded one-piece type or backs rigidly attached to each other. b. Pinching: Design gaps between seats and walls or windows or back-to-back seats to prevent injury when the seat moves. 3. Seat Replacement: a. Secure seats with maximum six mounting bolts per seat for easy removal and reinstallation. b. Hide mounting bolts where exposed to passenger view using inconspicuous snap-in covers. 4. Aisle width: a. Minimum 635 mm (25 in) between seating on opposite sides of the vehicle. b. See Section 2, Design and Performance Criteria, for special requirements related to width of Accessible Onboard Circulation Paths for access to mobility aid parking areas. 14.5.3 Materials Materials shall be consistent with intended use and performance requirements: 1. Application considerations: Passenger safety, comfort, and durability; maintainability; and compliance with flammability, smoke emission, and toxicity requirements in Section 16. 2. Visible structural materials: a. Brushed stainless steel, with 180 grit, horizontal finish. b. Formed synthetic frames, such as FRP or thermoplastics, may be considered but must comply with material requirements and flammability, smoke emission, and toxicity requirements in Section 16, Materials and Workmanship. 3. Non-visible internal structures: Powder-coated steel or stainless steel. 14.5.4 Cushion Inserts Provide cushions for both seat and back, with each type completely interchangeable. 1. Material: Low smoke, flexible foam, inherently fire retardant. 2. Covering: Fabric or other approved material, cut resistant, fire resistant, and UV resistant, with colors and patterns as selected by the Owner. 3. Thickness: Minimum 13 mm (0.5 in). 4. Shape: Contoured for maximum comfort. 5. Removal: Inserts shall be detachable by means of a simple, hidden release mechanism so that inserts are easily removable by maintenance staff, but not by a passenger. LTK Standard Streetcar Specifications Section 14 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.5.5 Dimensions Comply with the following dimensions for passenger seats: 1. Total seat cushion depth: Minimum 431 mm (17 in), measured from the seat's forward edge to the forward surface of the seat-back. 2. Seat spacing (knee-to-back seats): Minimum 740 mm (29 in), measured from the same point on each seat. 3. Legroom (longitudinal clear distance tangent to the seat bottom cushion): Minimum 660 mm (26 in), measured from the front of the seat-backrest-cushion to the back of the next seat-backshell. 4. Individual seat width: 457 to 483 mm (18 to 19 in), which may be achieved through the use of spacers placed between individual seats. 14.5.6 Flip-Up Seats Where flip-up seats are provided in mobility aid parking areas, comply with the following: 1. Seat back: Similar in shape and contour to standard seat back, complete with cushion. 2. Seat bottom: Fold-up type to provide space for the mobility aid. When not in use it automatically reverts to the “raised” position. Regardless of the seat bottom position it shall be firmly in place under normal conditions. 3. Supports: Attach to wall and pedestals, or other approved arrangement. 4. Area beneath seat: Leave open for easy cleaning. 5. Strength: Installed seat shall withstand a downward vertical load of 400 lbf (1780 N) applied uniformly along the front edge. A permanent maximum set of 3.2 mm (0.125 in) will be permitted under these conditions. 14.6 Mobility Aid Parking Areas Comply with the following: 1. Quantity: Provide in each vehicle as specified in Section 2, Design and Performance Criteria. 2. Orientation: Design parking areas to locate the mobility aid longitudinally (end facing) in the vehicle. 3. Clear Floor Space: Provide area compliant with 49 CFR 38, Subpart D, for each mobility aid parking area. 4. Maneuvering Circle: Provide area compliant with 49 CFR 38, Subpart D, for each mobility aid parking area. 14.7 Interior Equipment 14.7.1 Stanchions, Handrails, and Grab Rails Provide stanchions, handrails, grab rails, grab handles, and handholds (as defined in Section 1) and related fittings complying with the following requirements: 1. Regulations: Comply with 49 CFR 38, Subpart D. 2. Material: Stainless steel with an approved circumferential finish. Surfaces shall be smooth and free of sharp edges that might injure passengers. 3. Dimensions: a. Diameter: 32 to 38 mm (1.25 to 1.5 in). b. Knuckle Clearance: Minimum 38 mm (1.5 in). LTK Standard Streetcar Specifications Section 14 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 4. Placement: a. Standing passenger positions: Provide stanchions within 760 mm (30 in) of possible standees, but in locations that do not interfere with access by mobility devices. Provide handholds where stanchions are not possible. b. Boarding area: Do not place stanchions between windscreens, except they may be located on the inboard edge of each windscreen. c. Transverse seats: Provide grab handles or grab rails, and at every other seat row provide stanchions, alternating from one side of the aisle to the other. 5. Mounting: a. Fasteners: Tamper-resistant stainless steel. b. Orientation: Select and locate attachment points, including seat attachments, such that there is no visual deviation from vertical or horizontal, as appropriate, from all viewpoints. c. Stanchions: • • • • Rigidly mount to the floor, wall support structure, or seat grab rails. At upper end, mount stanchion only to vehicle structure. Mount such that no rattling or noise is produced during operation. Design such that stanchions provide no support for the ceiling, roof, or any other component, and make no contribution to vehicle-body structural design. d. Grab rails: Design without the need for lateral supports. 6. Strength: Shall withstand applied loads of 1330 N (300 lbs) in any direction without permanent deformation and without transient deformation that would pinch or injure. 7. Mobility aid area: a. Provide at least one horizontal handrail positioned 685 mm (27 in) above the floor. b. Provide stanchions, handrails, or other safety devices to permit safe use of this area by standees when no mobility aids are present. 14.7.2 Windscreens 14.7.2.1 Description and Location Provide windscreens as follows: 1. Purpose: To define the boarding area and minimize drafts of external air onto passengers near the door and outside of the boarding area. 2. Description: Solid lower panel with a transparent upper panel above the level of lower-side window edge, and a stanchion on the inboard side. 3. Location: At each passenger door location. 4. Accessible Boarding: At locations where a windscreen may interfere with accessible boarding, it may be reduced in size or eliminated with the Owner's approval. LTK Standard Streetcar Specifications Section 14 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.7.2.2 Material and Assembly Material and assembly of windscreens shall comply with the following requirements. Glass specified in this section shall conform to all requirements of the Windows section, above, except for UV and solar heat gain requirements: 1. Material: a. Lower panel: Plymetal panels, double sided, melamine faced, minimum thickness 13 mm (0.5 in), or equivalent melamine-faced aluminum. b. Upper panel: • • Clear safety glass, laminated, with an aluminum frame, or tempered, with or without an aluminum frame, minimum thickness 6.4 mm (0.250 in), with Vandal Shield, or approved equal, applied to both surfaces. If the upper panel is without an aluminum frame, the panel edge shall be ground smooth with edges seamed in accordance with SAE J673, Edge No. 4. 2. Assembly: a. Attach the upper panel flush to the top of the lower windscreen panel and to sidewall. b. Attach the upper edge of the frame or tempered glass panel to the windscreen stanchion. 3. Dimensions: a. Top edge of upper panel: Minimum 1830 mm (72 in) above floor. b. Between upper panel and windscreen stanchion: Minimum 64 mm (2.5 in) for hand clearance. c. Lower panels adjacent to high floor areas shall extend to the top of the high floor section wainscot area, with upper panels above. d. Windscreens adjacent to mobility aid parking areas may be of reduced width to provide mobility aid maneuvering room. 14.7.3 Bicycle Racks Provide bicycle stowing racks as specified in Section 2, Design and Performance Criteria: 1. 2. 3. 4. Type: Bracket (hook) for hanging bicycle. Size: For adult size bicycles with large tires. Material: Stainless steel (all visible components). Mounting: As close to the interior sidewall as possible, to minimize bicycles protruding into the passenger aisle. 5. Strength: Each single bicycle bracket and its mountings and supports shall withstand, without permanent deformation, the following loads: a. Horizontal load of 1330 N (300 lbf) applied in any direction on the bracket. b. Vertical load of 1330 N (300 lbf) at the bracket. LTK Standard Streetcar Specifications Section 14 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.7.4 Provisions for Equipment Specified in Other Sections Other sections define equipment that must be accommodated in the design of the vehicle interior. Typical equipment includes the following: Passenger Stop Request Passenger Intercoms Information Signs PA speakers Surveillance cameras Automatic Passenger Counting equipment Section 6, Passenger Doors Section 13, Vehicle Communication Systems Provide mounting space, brackets, wiring, connectors, and related components for all specified equipment. Install and test such equipment, where specified. 14.8 Keys and Locks Comply with the following: 1. Provide keys operable in both existing and new vehicles. 2. Provide the following three types of keys for access to various vehicle equipment or controls: a. Master Controller Key: Seven-pin tumbler tubular key cut to match Owner’s existing vehicles b. Crew Key c. Maintenance Key 3. Keys and locksets shall be readily obtainable from U.S. domestic sources. 4. Keys and locksets shall be assigned as shown in the Key Assignment Table, below, or as agreed during design review. Other locks and keys may be required that are not listed, and they will fall into one of these two categories: a. Crew Key: Access panels or controls intended for operator access or operation. b. Maintenance Key: Access panels or controls intended for maintenance access or operation only. LTK Standard Streetcar Specifications Section 14 12 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments Key Assignment Table What the key operates/opens Name Master Controller Key Crew Key Maintenance Key Master Controller key switch Crew door switch Exterior manual door release Manual door release mechanism reset device Cab electrical lockers with circuit breakers Cab via the cab door Operator’s storage locker Other electrical lockers All overhead access panels Access panels to under-seat equipment requiring operator access Side skirt (for removal) Electrical locker with event recorder All other access panels 14.9 Windows 14.9.1 General Provide only glazing products that are readily available in the U.S. from U.S. suppliers, in the sizes and thicknesses provided on the delivered vehicles. 14.9.2 Type and Performance Comply with the following: 1. Type: Single-glazed, fixed. 2. Glazing: Laminated, tempered safety glass. 3. Standard: Test in accordance with ANSI Z26.1 or approved equivalent standard: a. “Motor vehicle” shall apply to the vehicles in this Contract, although vehicles of this type operated only on a rail line are excluded by the standard. b. Apply requirements in the standard applicable to buses with comparable types of glazing. 4. Identification: In accordance with ANSI Z26.1, and other appropriate designation. 5. Solar Heat Gain Coefficient (SHGC): As defined by the National Fenestration Rating Council and specified in this Section. 6. Visible light transmittance: As defined by the National Fenestration Rating Council and specified in this Section. 7. Distortion: In accordance with ANSI Z26.1 Optical Deviation and Visibility Distortion tests. Test specimens must comply with requirements for both optical deviation and visibility distortion to meet this requirement. 8. Glazing treatments: Permanent, within the glazing and/or in the center membrane. Surface films are not permitted. 9. UV blockage: Minimum 99% for both UVA and UVB. 10. Corners and edges: Ground smooth with edges seamed in accordance with SAE J673, Edge No. 4. LTK Standard Streetcar Specifications Section 14 13 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.9.3 Installation Mount glazing directly to the vehicle structure with service proven bonding methods: 1. Sealant: Commercial product suitable for exposure to carwash, cleaning solvents, UV, and temperature range and other climatic conditions specified in Section 2, Design and Performance Criteria. 2. Installation: a. Prepare glazing per sealant manufacturer’s instructions. b. Finish where visible to a smooth surface flush with surrounding surfaces, with no gaps or blemishes. 3. Removal: Design joint and provide sealant that allow removal with standard hot- or vibratingknife bonded-window tools. 14.9.4 Cab Windshield Provide a windshield in each cab: 1. Tinting: None 2. Parallel luminous transmittance: Minimum 0.70, visible light at normal incidence. 3. Solar heat blocking: Lowest SHGC rating consistent with minimum 0.70 transmittance, using the most technologically advanced low emissivity products. 4. Embedded electrical defrosting: As specified in Section 7, Heating, Ventilating, and Air Conditioning. 5. Design/Installation: Shall minimize external glare, and reflections from inside the vehicle when the vehicle is operated at night with the passenger interior lighting in use. 6. The upper portion of the windshield may cover the end destination sign. Tinting is allowed in that area to cover the surrounding area, if required. 14.9.5 Cab Side Windows Provide side windows in each cab: 1. 2. 3. 4. 5. Type: Horizontal sliding, with latch. Tinting: None. Parallel luminous transmittance: Minimum 0.70, visible light at normal incidence. Solar heat blocking: Maximum 0.4 SHGC. Window frame: Satin finished anodized aluminum, opening, with a latch operable from inside the cab only; weather stripped; reinforced for hard usage; designed to eliminate rattling in all positions. 14.9.6 Passenger Section Side and Door Windows Provide side and door windows in the passenger section: 1. Tinting: None. 2. Solar heat blocking: Maximum 0.4 SHGC. 3. Visible light transmittance: Minimum 0.75. Lower light transmittance may be considered if SHGC values of less than 0.4 can be attained. 4. Protection: Provide Vandal Shield, or approved equal, on window interiors. LTK Standard Streetcar Specifications Section 14 14 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.10 Operator’s Cab 14.10.1 General Provide a full-width, fully-enclosed operator’s cab at each end of the vehicle, as specified in Section 5, Operator’s Cab and Controls. 14.10.2 Size Range of Operators Design cab for use by an operator in the size range of the fifth-percentile female to the ninety-fifthpercentile male of the general population as defined by The Measure of Man and Woman: Human Factors in Design (“Measure of Man and Woman”). 14.10.3 Cab Layout Design cab layout to meet the following criteria: Comply with the design principles of Measure of Man and Woman. Operator's forward view shall not be obstructed while standing or sitting. The cab shall be free of sharp edges, protruding objects, safety hazards and floor obstructions. Areas in which paper and other debris can accumulate are not permitted. Ensure that height to underside of console is sufficient to accommodate largest specified operator, and distance to controls accommodates smallest specified operator. 6. Coordinate seat dimensions, console height, clearances, and footswitch locations and dimensions to comply with design requirements. 1. 2. 3. 4. 5. 14.10.4 Visibility Requirements Design cab to provide maximum possible field of view in all directions and minimize reflection in windows, taking into consideration cab layout and design of windshield, corner posts, cab liner color, and cab side windows. Provide the following operator view as a minimum, allowing for all possible operator seat adjustment positions and an operator within the specified size range: 1. Upward view of minimum 20 degrees. 2. Downward view sufficient to see a 1.0 m (3 ft-3 in) tall person standing 0.5 m (1 ft-8 in) from the front-most surface of the vehicle without the need to bend at the waist. 3. Ability to directly or indirectly locate coupler head while at the same time accessing controls during coupling operation (standing is permitted for this activity). 14.10.5 Cab Partition Provide a full width, transverse partition for the rear wall of the cab enclosure: 1. Material: Melamine faced plymetal, of balanced construction, or approved equal. Aluminum or other materials may be proposed in place of plymetal, subject to the Owner's review and approval. 2. Thickness: 13 mm (1/2 in). 3. Attachment: Fasten securely to vehicle roof structure, floor, and vehicle-body side structure, not to ceiling panels or side lining panels. LTK Standard Streetcar Specifications Section 14 15 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.10.6 Cab Door Comply with the following: 1. Provide a hinged or sliding door in the cab partition: a. Material: Same as cab partition. Aluminum honeycomb material or approved equal may be proposed, subject to the Owner's review and approval. b. Matching: Cut from cab partition panel to maintain proper color and pattern match. c. Hinge (if provided): Full length, stainless steel, piano-type. d. Door swing (if hinged): Into the passenger compartment. Provide a rattle-free latching device to retain against the cab partition. e. Tamper-proof construction: Design and construct door and frame such that passengers cannot gain access when door is locked. 2. Provide door latching and locking hardware as follows: a. Material: Nickel-bronze or stainless steel. b. Inside Cab: Rapid door lock release mechanism that allows the operator to quickly find it under poor lighting conditions, and allows the door to be opened without use of a key. c. Operation: Door shall automatically latch and lock when closed. d. Key: Lock shall be unlockable from passenger side with a key (see Section 14, Interior and Exterior Appointments, for Key Assignment Table). 3. Provide a grille in the lower portion of door for ventilation: Louvered, sight-tight. 4. Provide kick plates along the bottom portion of door on inside and outside face: a. Material: Stainless steel b. Dimensions: Minimum 0.76 mm (1/32 in) thick and 200 mm (8 in) high 5. Provide a sash window to allow operator to look into passenger compartment: a. b. c. d. e. f. g. Location: Align bottom edge of window with bottom edge of side windows Glass: Minimum 6.4 mm (1/4 in) thick laminated safety glass Frame: Aluminum. Fully support frame with cab door panel on all sides Tinting: Adequate to prevent glare on the windshield from passenger area lighting at night Operation: Vertically sliding Latch: Spring latch in the up (closed) position, operable only from within the cab Protection: Provide Vandal Shield, or approved equal, on surface of window facing passenger compartment h. Window curtains: Designed to block light from entering cab from passenger compartment 14.10.7 Cab Console 14.10.7.1 Cab Console Design Design the Cab Console to accommodate all controls and indicators specified in Section 5, Operator’s Cab and Controls, and others as needed per the Contractor’s design: 1. Slope console surfaces toward the Operator at angles suitable for the layout requirements of Section 5. 2. Design materials and orient surfaces to avoid glare on the windshield interior or any other adverse visual distraction. LTK Standard Streetcar Specifications Section 14 16 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 3. Design size and shape taking into consideration the layout of controls and indicators specified in Section 5. 4. Permit easy operator access to both cab side-windows. 5. Design so that liquid spilled on the surface will not pool or collect, and will not damage or interfere with operation of the components or backpanel wiring. 14.10.7.2 Cab Console Material and Finish Comply with the following material and finish requirements: 1. Console Cabinet Material: a. Melamine faced aluminum, integrally colored; b. Fiberglass reinforced polyester resin; or c. Thermoplastic sheet. 2. Console Cabinet Color: Match adjacent cab lining materials. 3. Operating Face Material: a. Anodized aluminum: Corrosion resistant, cigarette burn resistant; or b. Melamine faced aluminum: Integrally colored. 4. Operating Face Finish: a. Black, non-reflective, non-glare. b. Cleanable with soap and water solution. 14.10.7.3 Cab Console Construction Comply with the following: 1. Maintenance Access: a. Provide a piano-type hinge along the lower edge of the console face panel to facilitate replacing switches or repairing wiring. b. Provide wire dress and slack that allows full horizontal opening without wire strain. 2. Fasteners: No fasteners shall be visible on the console face. 14.10.7.4 Master Controller Area of Cab Console Comply with the following: 1. Location: To the left of operator’s seat. 2. Armrest: Adjustable 150 mm (6 inches), upholstered, padded, ergonomically designed for comfort during long periods of use. 14.10.7.5 Operator’s Handhold Provide a formed tubular handle attached to the front edge of the Cab Console to provide support for operators: 1. Material: Stainless steel. 2. Strength: Handle, attachment method, and console structure shall withstand repeated use by the 95% percentile male without loosening or damage to the console over the life of the vehicle. LTK Standard Streetcar Specifications Section 14 17 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.10.8 Cab Furnishings and Equipment 14.10.8.1 Cab Flooring Subfloor: Same as provided in the passenger section. Floor covering: Smooth surface, same as used under the passenger seating. 14.10.8.2 Operator Seat Provide an operator's seat in each cab meeting the following requirements, located on the vehicle's longitudinal centerline: 1. Design principles: Comply with Measure of Man and Woman. 2. Size: Design for the specified size range of operators (see Size Range of Operators section, above). 3. Foot space: Adequate to accommodate the operator's feet. 4. Foot rest: Adjustable, or flip-down type for use by smaller operators. 5. Seat frame: Corrosion-resistant tubular construction, designed for hard vehicular usage. 6. Seat and back cushion: Low-smoke foam; the seat cushion shall be minimum 100 mm (4 in) thick. 7. Seat covering: Transportation-grade fabric-backed vinyl that breathes to minimize perspiration buildup and operator discomfort. 8. Armrests (both sides of seat): Flip-up type. 9. Seat adjustments, with controls easily operable from a seated position: a. b. c. d. Vertical, forward, and backward directions. Seat back angle. Seat back lumbar support. Swivel: Minimum plus or minus 30 degrees from the forward facing position, with a lock that engages automatically in the forward facing position and prevents further turning. 10. Attachment: Through the flooring into the underlying vehicle structure and designed to withstand normal usage without failure or loosening over the life of the vehicle. 14.10.8.3 Air Comfort System Provide each cab with operator controlled heating and cooling, as specified in Section 7, Heating, Ventilating, and Air Conditioning. Provide cab windshield and side window defrosting and demisting as specified in Section 7. 14.10.8.4 Sunscreens Provide adjustable sunscreens as needed to aid the operator in all external light conditions, including simultaneous front and side sunlight: 1. Screens shall be service-proven in a similar transit application with respect to material, mounting, and adjustment. 2. The sunscreen material shall not neutralize the color of traffic control signals. 3. Consider the following design factors: a. Window size and arrangement b. Operator position c. Color LTK Standard Streetcar Specifications Section 14 18 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments d. Light blockage ratio 14.10.8.5 Windshield Wiper and Washer Provide a windshield wiper (or wipers) for each cab windshield: 1. Wiper drives, mechanisms, blades, and controls shall be an integrated system, presently in use in similar applications. 2. Wiper blades and rubbers shall be considered consumables, and commercially available in the U.S. 3. Wipers shall sweep minimum 80% of the width and 60% of the height of the total windshield area over one complete cycle. 4. Wiper controls shall provide variable speed and interval operation to suit a wide range of rainfall conditions. 5. When not active, wipers shall automatically park at a secure and unobtrusive location. Provide fluid-dispensing windshield washers: 1. Washer nozzle: Attached to each wiper blade such that it moves with the blade. 2. Washer fluid reservoir: a. Readily accessible for refilling from vehicle exterior. b. Minimum usable capacity 8 liters (2 gallons). 14.10.8.6 Convenience Outlets Provide one duplex convenience outlet in each cab: 1. Location: As approved by the Owner. 2. Receptacle: Ground fault circuit interrupter (GFCI) protected, rated 120 Vac, 20 A. 3. Circuits: Provide a dedicated circuit breaker for each outlet. 14.10.8.7 Operator’s Tools Provide mounts for operator’s tools: 1. Location: A-end operator’s cab, as approved by the Owner. 2. Tools: a. Switch iron, furnished by the Owner b. Pantograph crank, provided by Contractor. See Section 9, Electrical Equipment. 14.10.8.8 Interior Mirror Provide one or more adjustable interior mirrors in each cab: 1. Locate so operator can view the passenger compartment 2. Mirror: Distortion-free glass with minimum 360 cm² (56 in²) reflecting area 3. Frame: Cover edges LTK Standard Streetcar Specifications Section 14 19 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.10.8.9 Fire Extinguisher Provide fire extinguishers: 1. 2. 3. 4. 5. 6. Type: Marine, with a minimum rating of 4-A:30-B:C, UL listed Capacity: 4.5 kg (10 lb) Quantity: Two total Location: Mount one in each operator’s cab, accessible to the operator Mounting: Use a marine-type mounting bracket Signage: Clearly marked 14.10.9 Operator’s Appurtenances 14.10.9.1 Coat Hook Provide a coat hook of approved design in each cab on the cab rear partition: 1. Hook: Folding, flush, nickel-bronze 2. Strap: Provide to restrain hanging items 14.10.9.2 Operator's Storage Locker Provide an easily accessible storage locker in each cab for storing operator’s personal items while operating the vehicle: 1. Material: Same as that used in construction of the adjacent cab linings. 2. Door: Attached by a stainless steel piano hinge. 3. Lock: Operable with a key (see Section 14, Interior and Exterior Appointments, for Key Assignment Table). 14.10.9.3 Waste Receptacle Provide a detachable waste receptacle in each cab: 1. 2. 3. 4. 5. Location: Within reach of operator when seated; Material: Stainless steel; Design: Leak-proof, designed to accommodate commercially available trash-receptacle liners; Capacity: Approximately 8 liters (2 gallons); Mounting: Secured to prevent rattling when the vehicle is operating. 14.10.9.4 Cup Holder Provide a cup holder in each cab: 1. Location: Within reach of the operator, but not over the console; 2. Size: Designed to hold a 355 ml (12 oz) beverage cup or container. 14.11 Exterior Finishing 14.11.1 Exterior Finishes Comply with Exterior Design Package and the following requirements: 1. Steel and aluminum: Paint in accordance with Section 16, Materials and Workmanship. 2. FRP: Paint in accordance with Section 16 if paint is required by the Exterior Design Package. LTK Standard Streetcar Specifications Section 14 20 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 3. Stainless Steel: a. Exposed to view: Approved brushed finish or paint, as required by the Exterior Design Package. b. Not exposed to view: Need not be painted. 14.11.2 Paint Colors and Gloss The color difference between approved color samples and production components shall have a delta Ecmc of 1 or less. Provide paint colors, gloss, and finish as follows: 1. Exterior sides and ends of the vehicle, and roof shrouds: a. Colors: • • • Six (6) vehicles – PMS 299 Two (2) vehicles – PMS 605 Two (2) vehicles – PMS 021 b. Gloss level: Minimum 85 as measured with a 60-degree glossometer. c. Orange peel: Minimum level 6. 2. Trucks, traction motors, and gear reducers: a. Color: Black b. Gloss level: Semi-gloss 3. All other areas, including roof surfaces and equipment, underfloor surfaces and equipment, and other areas not exposed to view: a. Color: Charcoal gray, or similar b. Gloss level: Semi-gloss 14.11.3 Graphics Where graphics are required as part of vehicle exterior finishing, comply with the approved Exterior Design Package for colors and Section 16, Materials and Workmanship, for material and installation. 14.12 Rain Gutters and Water Drainage Provide rain gutters or other devices to prevent water drainage over the sides of the main body sections and cab ends: 1. Provide concealed gutter-drainage conduits, which shall empty below the floor line of the vehicle. 2. Size gutters and drainage conduits to prevent accumulated water from overloading the system: a. During maximum rainfall rate for the Project area, as provided in Section 2, Design and Performance Criteria b. During vehicle acceleration and braking c. On grades 3. Gutters: Separately form and attach or make integral with the roof structure via roof sheet corrugations or similar configurations. LTK Standard Streetcar Specifications Section 14 21 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 4. Drainage conduits: a. b. c. d. e. Construct with no sharp bends Design for easy clean-out Provide screens at water entry points Fully insulate where inside the vehicle-body structure to prevent condensation or leakage Do not run through equipment lockers except as reviewed and approved by the Owner during design review 14.13 Equipment Enclosures 14.13.1 General 14.13.1.1 Standards Comply with the following standards as applicable to equipment enclosures: 1. NFPA 130, Chapter 8, Vehicles: Comply with requirements of sections on equipment arrangement, flammability and smoke emission, equipment lockers, electrical fire safety, and other sections with requirements applicable to equipment enclosures. 2. NEMA 250: Comply with specified type requirements, except as specified otherwise in this section. Where conflicts exist, comply with this section. 14.13.1.2 Construction Comply with the following: 1. Stiffeners: Provide welded-in-place stiffeners for walls and covers of large boxes; comply with high-quality commercial practice. 2. Cover bearing surface: Provide a flat, NEMA-type formed lip as the bearing surface for the cover seal, minimum 3.2 mm (1/8 in) wide. 3. Gasket compression: When closed and latched, covers shall bear on the frame or a hard stop to control gasket compression. 14.13.1.3 Hardware Latches, hinges, and cover attachment hardware: Stainless steel. 14.13.1.4 Seals and Gaskets Sealing System: 1. 2. 3. 4. 5. Material: Closed cell neoprene foam, minimum thickness 9.5 mm (3/8 in), resilient, watertight. Attachment: Secure in a channel near the periphery of the cover. Minimum life: 10 years. Compression: The seal shall be compressed maximum 50% with the cover securely fastened. Testing: Sealing system shall pass the water test for equipment enclosures in Section 15, Testing. RFI gasketing: Continuously conductive contact strip. Provide on all equipment boxes and covers containing equipment that could produce RF, including auxiliary power supplies and traction inverters. 14.13.1.5 Labels and Warnings Provide labels and warning indicators as specified below in Signs and Graphics section. LTK Standard Streetcar Specifications Section 14 22 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.13.1.6 Paint Comply with the following: 1. Interiors of equipment enclosures shall be primed and painted with white paint. 2. Exteriors and interiors of covers, shall be painted or finished in accordance with this Section and Section 16, Materials and Workmanship. 3. Seals and cover hardware shall not be painted. 14.13.1.7 Location Comply with the following: 1. Locate enclosures for control and other critical equipment to provide protection against environmental contamination and mechanical damage. 2. Locate and orient enclosures and covers such that: a. Covers can be opened at least 90-degrees without interference with other equipment. b. Enclosure openings and space in front of the enclosure provide access to all internal equipment, and allow inspection, repair, and replacement equipment without disassembly or removal of other equipment. 3. No high-voltage dc equipment enclosures may be installed inside the passenger compartment. 14.13.2 Exterior Equipment Enclosures 14.13.2.1 Material and Construction Comply with the requirements of the General section, above, and the following requirements specific to exterior equipment enclosures, which include underfloor- and roof-mounted equipment enclosures: 1. Material: a. High-strength low-alloy (HSLA) steel or, where approved, aluminum, fiberglass reinforced plastic (FRP) or stainless steel. b. Comply with the requirements of Section 16. Enclosures constructed of steel or aluminum shall have continuous welds or approved spot welds with fillers along all seams. 2. Construction: a. Watertight: When subjected to pressure wand cleaning and driving rain, except where equipment must be ventilated; NEMA Type 4. b. Drainage: Provide for discharge of condensation and leakage due to damaged or deteriorated seals. Provide with cotter keys or other approved, simple drain clearing mechanisms. 3. Vents: a. b. c. d. Provide where necessary. Arrange to minimize water entry and deflect direct water spray. Cover vents with stainless steel screens welded to the inside of the enclosure. For underfloor enclosures, provide with external shields or baffles to prevent directed water sources, such as from wheel splash, from entering the enclosure. LTK Standard Streetcar Specifications Section 14 23 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.13.2.2 Covers Comply with the following requirements for exterior equipment enclosure covers: 1. Interchangeable: Provide doors, covers, and access panels that are interchangeable between boxes of the same size and type within a vehicle and between vehicles. 2. Hinged covers: Readily removable, if provided, without the use of tools. 3. Latching: a. Latch Type: Quick-release type with no separable or non-retained parts. b. Latch Clearance: For underfloor enclosures; arrange latches and latch catches so they do not protrude beyond the bottom or edge of the box or cover in latched position and do not violate vehicle dynamic clearance outline in unlatched position. c. Seal Relaxation: Latch shall compensate for seal relaxation considering the worst case condition of hard contact between cover and box. In this extreme case, the latch shall hold the cover firmly to the box without rattling. d. Safety Catch: Spring-loaded. Provide at the center of each underfloor box cover. Design to retain cover within vehicle dynamic clearance envelope at all operating speeds up to vehicle design speed without cover latches engaged. 4. Hold-Open Mechanism: Provide on top-hinged underfloor covers and roof-mounted enclosure covers, internal to enclosure: a. Cover Removal: Mechanism shall not interfere with or impede easy removal or replacement of cover and shall stay with the cover when the cover is removed. b. Mechanism Removal: Easily removable from the cover for replacement. c. Non-Shorting: When the cover is opened or closed, it shall not be possible for the mechanism to short or ground internal electrical parts. 14.13.2.3 Equipment Arrangement Comply with the following requirements for equipment arrangement inside exterior equipment enclosures: 1. Underfloor Equipment Access: Provide ready access from side of vehicle, maintenance pits, and when vehicle is on lifts. 2. Roof-Mounted Equipment Access: Provide from top of enclosure, or other location approved by the Owner. 3. Equipment Mounting: Attach equipment to standoffs or subplates welded to the box. Do not attach equipment directly to enclosure walls, top, or bottom using bolts or other fasteners. 4. Clearance: Provide sufficient clearance to protect internal equipment from damage due to minor impacts; minimum 13 mm (1/2 in), between exposed sides and covers of equipment enclosure and internal equipment. 14.13.2.4 Ventilation Comply with the following requirements: 1. Arrange equipment for maximum ventilation of parts and minimum restriction of cooling air. 2. Divert high-temperature air exhausted from one piece of equipment away from the air intake of other pieces of equipment. 3. Where forced air ventilation is provided, provide a manometer test fitting in an accessible location on each equipment enclosure for measurement of pressurization. LTK Standard Streetcar Specifications Section 14 24 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.13.3 Interior Equipment Enclosures 14.13.3.1 General Comply with the requirements of the General section, above, and the requirements in this section specific to interior equipment enclosures: 1. Use: Requires review and approval by the Owner during the design review process. 2. Construction: Fully enclosed with hinged and latched access covers. Visible enclosures and covers shall match surrounding interior finish and colors, except as specified. 3. Access covers: When closed and latched, prevent access to the enclosure at all locations around the cover periphery. 4. Environmental: Enclosures and covers shall be dustproof. Enclosures in areas subject to water ingress, such as near doorways, in the cab, or under-seat, shall be watertight on all faces potentially exposed to water ingress. 5. Access: Equipment shall be readily accessible and shall be removable through the access cover without removal or alteration of enclosure components. 14.13.3.2 Underseat Type Where approved by the Owner, equipment enclosures may be located under seats: 1. Construction: Stainless steel structural frame faced with sheets of rigidized stainless steel. 2. Access: By removal of the seat or through access panels in windscreens. Seat boxes shall have a removable access cover. 3. Molding: Provide stainless steel cove molding where seat box meets floor covering. 14.13.3.3 Electrical Locker Type Enclosures may be located in the cab, adjacent to the articulation, or in the ceiling cove area: 1. Construction: Rugged and secure, using panel materials specified in Section 16, Materials and Workmanship, or constructed from formed sheet metal coated with an approved thermosetting powder coating, as specified in Section 16. 2. Access Cover: a. Design to be rattle-free during vehicle operation. b. Secure with quarter-turn locks, except as reviewed and approved by the Owner during the design review process. c. Secure with a key as specified above in the Key Assignment Table. d. Access panels may be used for covers if a full dead-front is provided. 3. Ceiling Cove Location: a. Coordinate the design with the need to have card holders above the windows as required by this Section. b. Hinge the panels at the top and secure at the bottom with key-operated latches, as specified in the Key Assignment Table, above. c. Provide “hold open” devices. 14.14 Signage 14.14.1 General Provide signage and graphics in each vehicle as specified in this section. Text shall be in English. LTK Standard Streetcar Specifications Section 14 25 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.14.2 Informational Text and Graphics Provide signs and graphics throughout the vehicle to furnish passengers and operating personnel information regarding operation of the vehicle: 1. Regulations: Comply with 36 CFR 1191 Appendix D, Section 703, Signs (ADA requirements). 2. Operating personnel use only: Clearly label controls and devices with text. 3. For use by passengers: Label equipment both with text and graphical figures or icons in full compliance with ADA requirements, however infrequently the equipment may be used. 4. Passenger interactive devices: Provide identification and instructions, such as for door push buttons, stop request buttons, and passenger emergency stations. Below is a table of typical signage used by the Owner. Signage for this vehicle will be similar, but as defined by the Owner after NTP: Typical Signage Description Priority Seating (Handicapped) Priority Seating (Elderly) Plate-Emergency Exit (Window) Plate-Emergency Exit (Seat) Push For Stop (Horizontal) Fire Extinguisher No Smoking/Eating/Radio (International) Watch Your Step Open Doors Manually Open Emergency Door Passenger Stop Request Switch International mobility aid Don't Forget Your Bike This Streetcar May Be Equipped With Audio Visual Recorders Electrical component locations Location Centered above location Centered above location On all emergency windows On all emergency window location On light panel, center of window above tape Fire extinguisher compartment Centered on bulkhead Centered on all steps and door ways Next to manual door operation Interior, over emergency door handle Interior, at mobility aid location Per ADA requirements At doorway Centered on bulkhead All interior and exterior electrical compartments 14.14.3 ADA Accommodation Graphics Comply with the following requirements for ADA compliant graphics and signs: 1. International symbol of accessibility (ISA): Provide at each required mobility aid parking area and priority seating area. Located 48 inches to 60 inches above the floor or where most logical. 2. Priority Seating: Sign at each mobility aid parking area indicating that the primary use of the area is for mobility aids. Provide instructions for operating the flip-up seats, where provided. 3. Passenger Stop Request: Sign for the mobility aid parking area passenger stop request switch specified in Section 6, Passenger Doors, with instructions for use. 4. Other ADA required signage and information, as they apply to transit applications. 14.14.4 CCTV Notice Provide signage at each entrance indicating that the vehicle has an active surveillance system. LTK Standard Streetcar Specifications Section 14 26 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14.14.5 Vehicle Numbering Provide clearly displayed numbering for each vehicle to aid operating personnel and passengers in reporting vehicle locations or incidents: 1. Number Graphics: a. Material: Graphic film complying with Section 16, Materials and Workmanship. b. Number Font: Helvetica medium type style, or approved equal c. Number Height: • • • Interior: 75 mm (3 in) Exterior: 100 mm (4 in) Roof: 915 mm (36 in) 2. Numbering Scheme: Number vehicles sequentially using numbers with up to four digits, as approved by the Owner, and in the vehicle interior, provide both vehicle number and endidentification letters (A or B). 3. Number Locations: a. Interior: • • Cab: Above left side cab window. Passenger compartment: Upper part of each cab and articulation bulkhead. b. Exterior: • • • Both vehicle ends: Above the windshield. Both vehicle sides: Center section. Roof: Each end, oriented as approved by the Owner. 14.14.6 Safety Provide the following safety warnings and signage: 1. Safety warnings and advisories at doors, articulation sections, and access points to hazardous equipment. 2. Equipment enclosure labels with safety warnings for High Voltage, as appropriate. 14.15 Owner-Provided Routes, Schedules, and Advertising Provide frames or similar fixtures in each vehicle to accommodate Owner-provided printed-sheet material such as route maps, schedules, advertising, and similar materials that are changed periodically: 1. Size of material: Up to 2.3 mm (3/32 in) thick, with dimensions from 300 mm square to 600 mm square (12 in square to 24 in square). Exact dimensions will be defined by the Owner 2. Locations: As defined by the Owner during interior design reviews, but typically on cab or interior walls. 14.16 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. Detail drawings: Top level assemblies, and other drawings if requested LTK Standard Streetcar Specifications Section 14 27 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 2. 3. 4. 5. Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values 14-1 Initial Interior and Exterior Design Package: 1. Submit within 60 days after NTP. 2. Initial submittals may be in the form of accurately colored renderings and models. 3. Include the following: a. b. c. d. e. f. Interior and exterior color scheme Finishing General appearance Seat cushion material and color/patterns Seating arrangement Samples of all finishing materials and the material specifications 14-2 Interior Design Package: 1. After approval of the Initial Interior and Exterior Design Package, submit a comprehensive interior design package. 2. Include everything related to the interior that was included in the Initial Interior and Exterior Design Package, but in final form. 3. Sample of each paint color (if paint is approved for interior): a. Apply the same number of coats of primer and final paint as specified for the vehicle. b. Use the same base material to which paint will be applied on the vehicle. 4. Corresponding CIE Lch tristimulus values for each paint sample, as measured using D65 (sunlight) light source. 14-3 Walls and Ceiling Design Package: 1. Materials specifications 2. Thermoplastic (if used): Laboratory test certificates stating that thermoplastic sheet complies with standards and strength requirements specified in Section 16, Materials and Workmanship. 3. Application Instructions 4. Drawings showing application locations 14-4 Acoustical Insulation Design Package: 1. Data sheets demonstrating that specified requirements are met. 14-5 Thermal Insulation Design Package: 1. Data sheets demonstrating that all specified requirements are met. 2. Details of method of retention for roof insulation and side and end wall insulation. 3. Details of the vapor barrier required for the floor insulation. 14-6 Floor Covering Design Package: 1. Propose the material manufacturer and model. LTK Standard Streetcar Specifications Section 14 28 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 14-7 Passenger Seat Design Package: 1. Details of seat materials, including sufficient information to verify compliance with the Specifications. 2. Dimensioned drawings of seats and seat layout. 3. Mounting details. 14-8 Mobility Aid Parking Area Design Package: 1. Dimensioned drawings for mobility aid parking areas showing required clearances. 14-9 Stanchions, Handrails, and Windscreens Design Package: 1. Stanchion and handrail spacing and placement. 2. Details of finish. 14-10 Bicycle Racks Design Package: 1. Calculations demonstrating that strength requirements are satisfied. 14-11 Key Design Package: 1. Key Assignment Table similar to the table in this Section, with final key and lockset assignments. 2. Samples 14-12 Windows Design Package: 1. 2. 3. 4. Data sheets demonstrating that specified requirements are met. Details of how windows are replaced. Details of U.S. suppliers. Windshield: a. Details of embedded defrosting with sufficient information to demonstrate that the requirements of Section 7, Heating, Ventilating, and Air Conditioning, are satisfied. b. Details of how external and internal glare are minimized for the cab windshield. 14-13 Operator's Cab Design Package: 1. General arrangement drawings of the cab, depicting all features required in the cab: a. Plan, profile, and front elevation drawings of the interior, showing all visible features, with dimensions. b. Plan and elevation views of Cab Console, including operator's seat and side windows. c. Drawings showing operator's range of visibility out the windshield, and views of interior and exterior via display screens: • • • • • Include cab features affecting visibility, such as vehicle structure, sunscreens, shades, window masks, and display screens Show the specified size range of operators, while seated Show the seated operator’s whole body accurately in relation to the console and cab seat, with height adjustment of the operator’s seat according to both head and knee height Show the seated operator’s relationship to the Master Controller Show the actual sitting position of the operator, to the extent possible LTK Standard Streetcar Specifications Section 14 29 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments • Show the operator standing to confirm visibility of the coupler with left hand on the master controller, over the size range of operators d. Foot switch location. e. Panelboard locations. f. Convenience outlet locations. 2. Manufacturer’s literature or detailed drawings of the following, as appropriate: a. Mounts for switch iron and pantograph crank. b. Coat hook c. Speedometer 3. Parts List 14-14 Windshield Wiper and Washer System Design Package: 1. Drawings showing the following: a. b. c. d. e. Components of the windshield wiper and washer system Windshield wipers in parked position Area swept by the wipers Size and capacity of the washer fluid reservoir Access to the washer fluid reservoir, and location of fill port 2. Narrative describing windshield-wiper controls. 14-15 Exterior Design Package: 1. Drawing showing the final exterior color scheme, with detailed drawings of graphics. 2. Sample of each paint color: a. b. c. d. Apply same number of coats of primer and final paint as specified for vehicle. Use same base material to which paint will be applied on vehicle. Roof: One sample with anti-skid paint and one without. Trucks: Sample demonstrating that paint does not hide structural cracks. 3. Corresponding CIE Lch tristimulus values for each color sample. 4. Graphics: a. Sample of each graphic, for small graphics, or a sample of each color, for large graphics. 14-16 Rain Gutters and Water Drainage Design Package: 1. Detail drawings showing material and dimensions. 2. Calculations confirming size of gutters and drainage conduits is adequate for rainfall rate. 14-17 Equipment Enclosures Design Package: 1. Shop drawings and data sheets demonstrating that all specified requirements are met. 2. Details of stiffeners for large boxes. 14-18 Signage Design Package: 1. Informational and safety graphics: Text and graphic layouts. 2. Vehicle numbering: Numbering locations, font, and size. LTK Standard Streetcar Specifications Section 14 30 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Interior and Exterior Appointments 3. Route maps, schedules, and advertising: Frame materials, retention methods, colors, and related features. END OF SECTION LTK Standard Streetcar Specifications Section 14 31 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing Table of Contents 15.1 General ....................................................................................................................... 1 15.1.1 Scope .............................................................................................................................................. 1 15.1.2 Equivalent Testing .......................................................................................................................... 1 15.1.3 Witnessing and Notification........................................................................................................... 1 15.1.4 Test Classifications ......................................................................................................................... 1 15.1.5 Test Procedures ............................................................................................................................. 2 15.1.6 Test Reports ................................................................................................................................... 2 15.2 Testing and Inspection Requirements ............................................................................. 2 15.2.1 Insulation Testing ........................................................................................................................... 2 15.2.2 Non-Destructive Testing and Inspection........................................................................................ 3 15.3 Component Type Tests ................................................................................................... 3 15.3.1 General ........................................................................................................................................... 3 15.3.2 Flammability, Smoke Emission, and Toxicity Type Test ................................................................. 3 15.3.3 Paint Performance Type Test ......................................................................................................... 4 15.3.4 Fiberglass Reinforced Plastic (FRP) Type Test ................................................................................ 4 15.3.5 EMI/EMC Component Type Tests .................................................................................................. 5 15.3.6 Heater Type Tests .......................................................................................................................... 5 15.3.6.1 Cab Heater(s) .......................................................................................................................... 5 15.3.6.2 Floor Heater ............................................................................................................................ 5 15.3.7 AC Traction Motor Type Test ......................................................................................................... 5 15.3.8 AC Auxiliary Motor Type Test......................................................................................................... 5 15.3.9 Traction Gear Unit Type Test ......................................................................................................... 5 15.3.10 Auxiliary Power Supply Type Test ................................................................................................ 6 15.3.11 Low-Voltage Power Supply and Battery Charger Type Test ........................................................ 6 15.3.12 Truck Frame Type Test ................................................................................................................. 7 15.3.12.1 General.................................................................................................................................. 7 15.3.12.2 Test Set Up ............................................................................................................................ 7 15.3.12.3 Static Load Test ..................................................................................................................... 7 15.3.12.4 Fatigue Test........................................................................................................................... 8 15.3.13 Traction Inverter Type Test .......................................................................................................... 9 15.4 Vehicle-Shell Structural Type Tests ............................................................................... 10 15.4.1 General ......................................................................................................................................... 10 15.4.2 Test Set Up ................................................................................................................................... 10 LTK Standard Streetcar Specifications Section 15 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.4.2.1 General.................................................................................................................................. 10 15.4.2.2 Strain Gauges ........................................................................................................................ 10 15.4.2.3 Deflection Gauges ................................................................................................................. 11 15.4.2.4 Load Cells .............................................................................................................................. 12 15.4.3 Vertical Load Test ......................................................................................................................... 12 15.4.4 Compression Load Test ................................................................................................................ 13 15.4.5 Collision Post and Corner Post Load Tests ................................................................................... 14 15.4.6 Crash Energy Management (CEM) Tests ...................................................................................... 14 15.4.7 Diagonal Jacking Test ................................................................................................................... 15 15.4.8 Validation of Linear Elastic Analysis ............................................................................................. 15 15.4.8.1 Measured vs. Analytical Values in Test Procedures and Test Reports ................................. 15 15.4.8.2 Results ................................................................................................................................... 16 15.5 System Type Tests........................................................................................................ 16 15.5.1 General ......................................................................................................................................... 16 15.5.2 Floor and Roof Assembly Fire Performance Type Test Requirements ........................................ 16 15.5.3 Propulsion Combined Type Test .................................................................................................. 17 15.5.4 Friction Brake System Type Test .................................................................................................. 17 15.5.5 Door System Type Test ................................................................................................................ 17 15.5.6 Bridge Plate System Type Test ..................................................................................................... 17 15.5.7 Unitized HVAC System Type Test ................................................................................................. 17 15.5.7.1 General.................................................................................................................................. 17 15.5.7.2 Air Flow Test ......................................................................................................................... 18 15.5.7.3 Scan Test ............................................................................................................................... 18 15.5.7.4 Control Stability Test............................................................................................................. 19 15.5.7.5 Cooling Capacity.................................................................................................................... 19 15.5.7.6 Maximum Operating Conditions........................................................................................... 19 15.5.7.7 Modulation Pressure Switch Test ......................................................................................... 20 15.5.7.8 High-Pressure Cut-Off Switch Test........................................................................................ 20 15.5.7.9 Low Temperature Operation Test ........................................................................................ 20 15.5.7.10 Insulation Efficiency and Condensate Carry-Over Test ...................................................... 21 15.5.7.11 Refrigerant Sample Test...................................................................................................... 21 15.5.7.12 Abnormal Heating Condition, Restricted Air ...................................................................... 21 15.5.7.13 Abnormal Heating Condition, No Air .................................................................................. 22 15.5.7.14 Back-Up Protection Test ..................................................................................................... 22 LTK Standard Streetcar Specifications Section 15 ii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.5.7.15 Start-up Current Draw ........................................................................................................ 22 15.5.7.16 Shock and Vibration Test .................................................................................................... 23 15.5.7.17 Water Eliminators Test ....................................................................................................... 23 15.5.7.18 HVAC Noise Test ................................................................................................................. 23 15.5.8 Communication System Type Test ............................................................................................... 23 15.6 Vehicle-Level Type Tests at Contractor’s Facilities......................................................... 23 15.6.1 General ......................................................................................................................................... 23 15.6.2 Vehicle-Level Type Static Tests at Contractor’s Facilities ............................................................ 23 15.6.2.1 General.................................................................................................................................. 23 15.6.2.2 Horn and Bell Type Test ........................................................................................................ 23 15.6.2.3 Jacking Type Test .................................................................................................................. 23 15.6.2.4 Ducting Watertightness Type Test........................................................................................ 24 15.6.2.5 Air Balance Type Test ............................................................................................................ 24 15.6.2.6 Vehicle HVAC System Type Test ........................................................................................... 24 15.6.2.7 Door Operation Type Test .................................................................................................... 25 15.6.2.8 Bridge Plate Operation Type Test ......................................................................................... 25 15.6.2.9 Light Intensity Type Test ....................................................................................................... 25 15.6.2.10 Communication Equipment Type Test ............................................................................... 25 15.6.2.11 Vehicle Data Network Type Test......................................................................................... 26 15.6.3 Vehicle-Level Type Dynamic Tests at Contractor’s Facilities ....................................................... 26 15.6.3.1 General.................................................................................................................................. 26 15.6.3.2 Preliminary Vehicle-Level EMI/EMC ..................................................................................... 26 15.7 Component Routine Tests ............................................................................................ 27 15.7.1 General ......................................................................................................................................... 27 15.7.2 Air Conditioning Unit Routine Tests............................................................................................. 27 15.7.3 Motor Routine Test ...................................................................................................................... 27 15.7.4 Traction Gear Unit Routine Test .................................................................................................. 27 15.7.5 Traction Inverter Routine Test ..................................................................................................... 28 15.7.6 AC Auxiliary Power Supply Routine Test ...................................................................................... 28 15.7.7 Low-Voltage Power Supply and Battery Charger Routine Test.................................................... 28 15.7.8 Battery Routine Test .................................................................................................................... 28 15.7.9 Friction Brake Routine Tests ........................................................................................................ 28 15.7.10 Communication System Routine Test ........................................................................................ 28 15.7.11 Truck Frame Welds Routine Test ............................................................................................... 28 LTK Standard Streetcar Specifications Section 15 iii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.7.12 Wheel Back-to-Back Routine Test .............................................................................................. 29 15.7.13 Resistance Routine Tests ........................................................................................................... 29 15.7.14 TWC System Routine Test .......................................................................................................... 29 15.8 Vehicle-Level Routine Static Tests at the Contractor’s Facilities .................................... 29 15.8.1 General ......................................................................................................................................... 29 15.8.2 Vehicle-Level Routine Functional Tests ....................................................................................... 30 15.8.3 Vehicle-Level Routine Wiring Tests.............................................................................................. 30 15.8.4 Watertightness Routine Tests ...................................................................................................... 30 15.8.4.1 General.................................................................................................................................. 30 15.8.4.2 Vehicle .................................................................................................................................. 30 15.8.4.3 HVAC ..................................................................................................................................... 30 15.8.4.4 Equipment Enclosures .......................................................................................................... 30 15.8.4.5 Traction Motor Leads............................................................................................................ 30 15.9 Vehicle-Level Type Dynamic Tests at the Owner’s Facilities .......................................... 31 15.9.1 General ......................................................................................................................................... 31 15.9.2 Setup for Vehicle-Level Type Dynamic Tests ............................................................................... 31 15.9.2.1 Instrumentation .................................................................................................................... 31 15.9.2.2 Channel Assignments ............................................................................................................ 32 15.9.2.3 Measurement of Average Acceleration Rates ...................................................................... 32 15.9.3 Propulsion and Braking Type Tests .............................................................................................. 33 15.9.3.1 Propulsion Tests .................................................................................................................... 33 15.9.3.2 Braking Tests ......................................................................................................................... 33 15.9.3.3 Thermal Capacity Tests ......................................................................................................... 33 15.9.3.4 Wheel Spin/Slide ................................................................................................................... 33 15.9.3.5 Parking Brake ........................................................................................................................ 33 15.9.4 Emergency Towing Type Test ...................................................................................................... 33 15.9.5 Ride Quality Type Test ................................................................................................................. 34 15.9.6 Noise and Vibration Type Test ..................................................................................................... 34 15.9.6.1 General.................................................................................................................................. 34 15.9.6.2 Noise Testing......................................................................................................................... 34 15.9.6.3 Vibration Testing ................................................................................................................... 35 15.9.7 EMI/EMC Vehicle-Level Type Tests .............................................................................................. 35 15.9.8 Equipment Settings for Vehicle-Level Routine Dynamic Test at the Owner’s Facilities .............. 36 15.10 Vehicle-Level Routine Static Tests at the Owner’s Facilities......................................... 36 LTK Standard Streetcar Specifications Section 15 iv January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.10.1 General ....................................................................................................................................... 36 15.10.2 Door, Operators and Controls.................................................................................................... 36 15.10.3 Bridge Plate, Operators and Controls ........................................................................................ 36 15.10.4 Heating ....................................................................................................................................... 37 15.10.5 Air Conditioning ......................................................................................................................... 37 15.10.6 Headlight and Stoplight Adjustments ........................................................................................ 37 15.10.7 Friction Brake ............................................................................................................................. 37 15.10.8 Communication Systems............................................................................................................ 37 15.11 Vehicle-Level Routine Dynamic Tests at the Owner’s Facilities .................................... 38 15.11.1 General ....................................................................................................................................... 38 15.11.2 Joint Inspection .......................................................................................................................... 38 15.11.3 Vehicle Performance Test .......................................................................................................... 38 15.11.4 Burn-In Test ................................................................................................................................ 38 15.12 Cooperation with the Owner and Other Systems ........................................................ 38 15.13 Contract Data Requirements List (CDRL) ..................................................................... 38 15.13.1 General Requirements ............................................................................................................... 38 15.13.2 CDRL Details ............................................................................................................................... 39 15.13.2.1 Component Type Test CDRLs .............................................................................................. 39 15.13.2.2 Vehicle-Shell Structural Type Test CDRL ............................................................................. 43 15.13.2.3 System Type Test CDRLs ..................................................................................................... 44 15.13.2.4 Vehicle-Level Type Static Test CDRLs.................................................................................. 46 15.13.2.5 Component Routine Test CDRLs ......................................................................................... 47 15.13.2.6 Vehicle-Level Routine Test CDRLs (Contractor’s Facilities)................................................. 47 15.13.2.7 Vehicle-Level Type Dynamic Test CDRLs (the Owner’s Facilities)....................................... 48 15.13.2.8 Vehicle-Level Routine Static Tests (the Owner’s Facilities) ................................................ 49 15.13.2.9 Vehicle-Level Routine Dynamic Tests (the Owner’s Facilities) ........................................... 50 LTK Standard Streetcar Specifications Section 15 v January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.1 General 15.1.1 Scope Test the vehicle and all its components to verify compliance with specified design, performance, reliability, and maintainability requirements: 1. 2. 3. 4. Perform tests specified in this Section as indicated unless specifically waived by the Owner. Perform tests on production components without modification or special preparation. Material test requirements may also appear in Section 16, Materials and Workmanship. Other test requirements may appear in other sections of the Specifications. 15.1.2 Equivalent Testing Perform the tests included in this Section on equipment designed specifically for this Contract, unless equipment is accepted by the Owner as an existing, proven design: 1. Evidence of satisfactory completion of prior tests, as determined by the Owner, may be sufficient to meet the requirements of this Section, although certain tests must be performed regardless of prior testing. 2. The following will disqualify existing tests: a. b. c. d. Design or material changes have been made to the items under test. The items are produced in a different facility. The requirements are different. Reports of such equivalent testing are dated earlier than five years before NTP of this Contract with the Owner. 15.1.3 Witnessing and Notification Comply with the following requirements: 1. The Contractor shall be present at each specified test. 2. Minimum 30 days before each test, notify the Owner in writing of the date, time, and location of the test. The Owner may, at its option, witness all tests. 15.1.4 Test Classifications The required tests are categorized as follows: 1. Type Tests shall be conducted to demonstrate compliance with design requirements at operating and environmental extremes, and the Specifications. a. These tests shall be performed on selected production components, systems, and completed vehicles, at the highest level of assembly that will allow demonstration of design compliance. b. Type tests are limited to the number of units needed to demonstrate design compliance, typically one or two. 2. Routine Tests shall be conducted to demonstrate that each unit produced operates within specified limits and is in compliance with the requirements of the Specifications. a. These tests shall be performed on each component, system, or vehicle included in the Contract. LTK Standard Streetcar Specifications Section 15 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing b. Routine test requirements may vary from an inspection and functional demonstration for a simple component to full dynamic tests of a vehicle. c. These tests are performed at ambient conditions unless a specific environmental or operating limit is necessary to demonstrate acceptable operation. 15.1.5 Test Procedures Prepare and submit a detailed test procedure for each test described in the Master Test Plan (MTP), and for other tests conducted by the Contractor in connection with its own Quality Assurance program: 1. For each test procedure, provide the following identifying information: a. The number of the CDRL that will be satisfied by the test. b. Each Specification section number relevant to the system or component under test, including both the section within this Section 15, Testing, and those sections from which the test acceptance criteria were derived. 2. Submit with each test procedure the forms to be used to record data during the test. Include the following: a. b. c. d. Step-by-step format for data reduction Formulae used in deriving the format Criteria for acceptability Justification for the criteria set forth 3. Submit each detailed test procedure minimum 30 working days before the planned date of the test to allow the Owner to review and approve the procedure. 4. No test shall occur, and no results shall be considered valid, until approval of the test procedure by the Owner. 15.1.6 Test Reports Submit test reports that follow the format of the test procedure. 1. Include the following in each test report: a. b. c. d. e. f. The same identifying information required for the test procedure A description of the test All raw data collected in the test All data reduction forms Summary of the results Signature fields for test conductor and witness, if applicable 2. Include test reports of routine tests in the appropriate Vehicle History Book, as specified in Section 19, Program Control and Quality Assurance. 15.2 Testing and Inspection Requirements 15.2.1 Insulation Testing When an insulation test is specified to be performed, comply with the requirements of IEEE Std 16, Section 5.9, Insulation Testing. LTK Standard Streetcar Specifications Section 15 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.2.2 Non-Destructive Testing and Inspection Where specified or required, perform the following: 1. Magnetic Particle Testing: Perform in accordance with ASTM E709, using wet fluorescent particles. Inspections shall be by personnel certified to NAS 410. 2. Dye Penetrant Inspection: Perform in accordance with ASTM E165/E165M, using fluorescent dye. 3. Radiographic Inspection: Perform in accordance with ASTM E94. a. Castings: Use ASTM E446 reference radiographs. b. Cast-weld designs: Use ASTM E390 reference radiographs. 15.3 Component Type Tests 15.3.1 General Comply with the following: 1. Perform type tests at the manufacturer’s facilities unless indicated otherwise. 2. Tests shall demonstrate that the components or set of components are likely to meet specified requirements when installed on the vehicle. 3. To the extent practical, test conditions shall replicate worst case operating conditions of the application, such as ambient temperatures, voltage ranges, and other applicable conditions. 4. Subsequent to the Owner’s approval of a component type test, changes to product, design, production process, materials, or location of manufacture shall be the basis for another type test. The scope of the subsequent type test shall be at the sole discretion of the Owner. 15.3.2 Flammability, Smoke Emission, and Toxicity Type Test Test all materials supplied for this vehicle to verify compliance with the flammability and smoke emission performance requirements of Section 16, Materials and Workmanship: 1. Flammability and smoke emission: Perform testing in accordance with NFPA 130, Chapter 8, Vehicles, and verify that test results meet the performance criteria of NFPA 130, Chapter 8. 2. Toxicity: a. Test all material used in the vehicle construction for toxicity, except materials used in small parts that would not contribute significantly to fire propagation, smoke, or toxic gas generation (such as knobs, rollers, fasteners, clips, grommets, and other small parts). b. Perform tests in accordance with BSS 7239 or Bombardier Specification SMP 800C. c. Materials shall not exceed the toxic gas release limits specified in Section 16. 3. Perform tests within one year from NTP on a production batch of material intended to be used on this Contract. 4. If the quantity of a particular material is such that it would not contribute significantly to a fire, a waiver may be requested from testing for this material. LTK Standard Streetcar Specifications Section 15 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.3.3 Paint Performance Type Test Test the final painted or powder coated surface on the first component of the production run to the following criteria: 1. Hardness: Perform pencil hardness tests according to ASTM D3363. a. The range of acceptance shall be between H and 2H and shall be the average of ten readings taken from typical surface locations. b. To avoid a destructive test of a vehicle's surface that would require the tested surfaces to be repaired, the use of a test structure for this test may be proposed for consideration. 2. Adhesion: Perform test using an Elcometer pull-off adhesion gauge. a. Tested surfaces shall achieve a minimum rating as furnished by the paint manufacturer. b. To avoid a destructive test of a vehicle's surface that would require the tested surfaces to be repaired, the use of a test structure for this test may be proposed for consideration. 3. Thickness: Perform non-destructive testing to verify final dry film thickness. a. The minimum and maximum dry film thickness shall be within the recommended criteria furnished by the paint manufacturer. b. Dry film thickness beyond the manufacturer's recommendations will not be accepted. 4. Paint Cure: Perform a solvent rub test per ASTM D5402. a. The test procedure requires minimum 50 double finger rubs with a cloth wetted in acetone or methyl isobutyl ketone to the painted surface. b. No paint color should transfer to the cloth. c. After 72 hours, the painted surface must retain all original characteristics such as gloss and hardness. 5. Surface Appearance: a. Make a visual inspection of vehicle surfaces for uniform gloss and no visible orange peel effect b. Using a DOI meter, take measurements at multiple locations. c. Verify that average readings comply with specified limits in Section 14, Interior and Exterior Appointments. Repeat tests during production on vehicles randomly chosen by the Owner if it appears that there are quality issues. 15.3.4 Fiberglass Reinforced Plastic (FRP) Type Test Test FRP coupons trimmed from production parts: 1. Perform a visual examination for porosity, voids, and other imperfections visible in the cross section. 2. Verify compliance with the strength requirements specified in Section 16, Materials and Workmanship. Tests shall be performed by an independent laboratory. Condition test specimens in accordance with ASTM D618. LTK Standard Streetcar Specifications Section 15 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.3.5 EMI/EMC Component Type Tests Test each component containing electronics to verify compliance with the Specifications: 1. Testing shall be performed by a qualified test laboratory. 2. Perform tests in accordance with EN 50121-3-2. 3. Perform each individual emissions and immunity test cited in EN 50121-3-2 as applicable to the specific subsystem/component. 4. For immunity tests, develop detailed definitions of IEC 50121-1 Performance Criteria A and B applicable to each individual subsystem/component and include in the respective test procedures, including signals to monitor and acceptable signal change boundaries. 15.3.6 Heater Type Tests 15.3.6.1 Cab Heater(s) Perform a type test demonstrating that heaters meet requirements for heat and defrosting as specified in Section 7, Heating, Ventilating, and Air Conditioning, and do not exceed maximum surface temperature. 15.3.6.2 Floor Heater Comply with the following: 1. Perform a type test demonstrating that heaters provide the required capacity, as calculated, without exceeding maximum specified surface temperature. 2. The test shall mimic the actual vehicle installation, including any limits on airflow, such as seats installed over the heater enclosure. 15.3.7 AC Traction Motor Type Test Perform a type test in accordance with a mutually acceptable method from IEC 60349-2 to determine the characteristics and efficiency of the traction motor. 15.3.8 AC Auxiliary Motor Type Test Perform an IEC 60349 type test for one of each type of ac auxiliary motor to demonstrate its capabilities and power rating: 1. Include a temperature-rise test. 2. Test each model at its continuous rating. 15.3.9 Traction Gear Unit Type Test Subject unit to a 100-hour test, and mount with torque load simulation. Alternatively, submit 100-hour test data and gear tooth contact verification data, previously run on identical gear units: 1. The load cycle for the 100-hour test shall consist of a maximum power motor and brake cycle repeated to simulate a typical load cycle in revenue service on the Project alignment. 2. The test shall subject the units to conditions that are more severe than would occur under the most extreme operating conditions, by increasing the torque by 20%. 3. If two motors are controlled in parallel, the torque load shall include the effects of uneven torque distribution due to wheel diameter differences, as specified in Section 10, Propulsion System and Control, in the Traction Motors section. LTK Standard Streetcar Specifications Section 15 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 4. Include the following as a minimum: a. Check and record gear tooth mesh and tooth pattern before the test. b. Start the test with the unit at a temperature from 15 degrees C to 32 degrees C (59 degrees F to 90 degrees F). A fan or other device may be provided so that in-service air flow conditions in driving direction are simulated. c. Measure temperature rise in the oil sump. Maximum temperature shall not exceed the gear oil supplier's recommendations consistent with the life between oil changes, as stated in the Contractor's maintenance manuals. d. Measure the bearing temperature. e. Reverse the direction of rotation every successive 5 hours until the 100-hour test is completed. 5. During the 100-hour test, perform noise and vibration tests to verify compliance with requirements of Section 2, Design and Performance Criteria: a. Take vibration and sound level readings at such intervals as necessary to verify compliance with the Specifications. b. Monitor for any drippage or seepage from the unit. 6. After completion of the test, perform the following: a. Check the oil for contamination or metal particles. b. Disassemble the gear unit and examine all parts. c. Check and record gear tooth mesh and tooth pattern. 15.3.10 Auxiliary Power Supply Type Test Perform tests based on the type test requirements of IEC 61287-1: 1. Take into account the specified design requirements, environmental ranges, and supply voltages and demonstrate that the equipment complies with the Specifications. 2. The acoustic noise measurement test shall demonstrate compliance with Section 2. 3. The temperature rise test shall be designed to test the system for the worst case heat loadings for the following: a. Maximum rated output current at the lowest operational input voltage. b. Lightest possible load, at the highest operational input voltage. 4. In addition, perform a combined system test demonstrating the capability to start up all ac loads, especially the HVAC compressors, under the worst case loading scenario possible, not including load failures. 15.3.11 Low-Voltage Power Supply and Battery Charger Type Test Perform tests based on the type test requirements of IEC 61287-1: 1. If two LVPS units are used on the vehicle, provide two units for these tests. Run the tests below with both units connected as on the vehicle, and with one unit connected as if the other unit is disabled. 2. Acoustic noise measurement test: Take sufficient noise measurements to demonstrate compliance with Section 2, Design and Performance Criteria. LTK Standard Streetcar Specifications Section 15 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 3. Temperature-rise test: Include the following test conditions in addition to requirements of the standard: a. Sufficient duration to allow all critical elements to stabilize in temperature. b. Input voltage at the upper limit of the specified operating range, and at rated output current and voltage. c. Input voltage at the lower limit of the specified input range for which rated output voltage and current is to be delivered, at rated output voltage and current. d. Cycling OFF and ON by interruption of the source voltage supply external to the unit under test at short durations, when connected to its rated load. e. Starting into an open circuit multiple times in succession. f. Starting into a short circuit multiple times in succession. g. Starting while connected into an overload at 120% of rating. The overload shall then be removed and the unit shall automatically provide rated output voltage. h. Pass Criteria: Temperature rises over ambient shall be within Contractor's limits as stated in the test procedure. 4. In addition, perform a test to demonstrate compliance with specified regulation and ripple requirements, monitor output voltage and output voltage waveforms with an oscilloscope at operating points representing the full range of conditions for delivery of rated output voltage and for routine current limit operation. 5. If more than one LVPS is used in normal operation, demonstrate equal load share and dynamic stability with both units connected during the above tests. 15.3.12 Truck Frame Type Test 15.3.12.1 General Perform a static load test and a fatigue endurance test. Select test loads and conditions that will develop a high level of confidence in the adequacy of the truck design. 15.3.12.2 Test Set Up Set up the static load and fatigue tests as follows: 1. Apply minimum 75 rosette strain gauges to the truck frame and bolster at locations of expected high stress and other areas of interest: a. Type: SR-4 or other approved strain gauges specifically suitable for the application. b. Location: Based on the stress analysis and the Contractor's experience, subject to the direction of the Owner. c. Calibration: In accordance with manufacturer's instructions for material being measured. d. Temperature compensation: Apply to the gauges. 2. Provide a load cell at each point of load application. 3. Use deflection gauges during the static load test to monitor vertical and lateral deflection of the truck frame. 15.3.12.3 Static Load Test Test Purpose: 1. To verify that the maximum allowable static stresses selected by the Contractor are not exceeded under the maximum expected static loads. LTK Standard Streetcar Specifications Section 15 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. To verify the predictions of the finite element analysis. 3. To simulate as closely as possible the actual loading conditions to which the truck will be subjected in service, by using appropriate methods and points of test load application and reaction. Test Steps: 1. Load the truck and bolster twice, with complete release of the load between applications. 2. Apply test loads as follows: a. Vertical load: The truck's share of completed vehicle weight plus an AW4 passenger load minus the weight of the truck. b. Lateral load: Load developed at vehicle overturning. c. Longitudinal load: The maximum possible instantaneous braking effort (friction and dynamic plus track brake) and 50% adhesion at the wheels at AW4 load. d. Lateral and longitudinal loads shall act as if they were applied at the center of gravity of the completed vehicle plus an AW4 passenger load. e. Accessory loads, such as brake units, track brakes, and traction motors shall represent maximum steady state conditions. For example, maximum motor torque and brake unit weight, and maximum brake unit reaction and motor weight. f. All loads shall be applied to produce the worst stress conditions on the truck. Measurements During Test: 1. Re-zero strain gauges after the first load application and record and report the offset from zero. 2. Take all required data during both load applications. 3. Record all load cells simultaneously with all strain gauges. Test Results: 1. The truck will be compliant with the Specifications if all of the following are met: a. Maximum stresses calculated from strain readings in any gauge during the second load application do not exceed 50% of the material's yield stress. b. Indicated residual strains following removal of the second loading do not exceed the maximum error resulting from the accuracy of the instrumentation. c. There are no permanent deformations, fractures, cracks, or separations in the truck. 2. If any of the above criteria are not met, the truck design shall be corrected and the truck retested at the Contractor's expense, and this process shall continue until these criteria are met. 15.3.12.4 Fatigue Test Test Purpose: To demonstrate that the truck has adequate fatigue strength under dynamic loading. Pre-Test Non-Destructive Testing: 1. Perform a magnetic particle test or dye penetrant inspection on the test unit for cracks and other defects that might impair the performance of the truck during the test. 2. Perform test or inspection in accordance with the Non-Destructive Testing and Inspection section, above. 3. Record the defects found, and if required, repair using an approved procedure. 4. Document the type, size, location, and repair of each defect by photographs and drawings. LTK Standard Streetcar Specifications Section 15 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing Test Steps: 1. Subject the truck frame and bolster to minimum 2 million cycles of dynamic loading. 2. Apply the following loads in accordance with the Fatigue Design section in Section 11, Truck Assemblies, except that loads shall be based on the completed vehicle: a. b. c. d. Vertical load Lateral load Longitudinal load Accessory loads 3. Select the phasing of the loads such as to produce the worst case stresses at critical locations. Post-Test Non-Destructive Testing: 1. At the conclusion of 2 million cycles, perform a magnetic particle or dye penetrant inspection for cracks. 2. The post-test inspection procedure shall duplicate the pre-test inspection procedure. Test Results: 1. The truck will be compliant with the Specifications if all of the following are met after 2 million cycles: a. Stresses calculated from strains measured at critical locations do not exceed Contractorselected fatigue allowables included in the test procedure. b. This stress range shall be within the allowable fatigue endurance limit for non-redundant structures obtained from one of the following: • • • AAR M-1001 (AAR MSRP Section C-II), Section 7.4, Material Properties – Fatigue Properties of Members and Details; AWS D1.1/D1.1M; or The Contractor's own tests if more appropriate and conservative. c. Following removal of all loads, indicated residual strains at strain gauges on principal structural elements do not exceed the maximum error resulting from the accuracy of the instrumentation. d. There are no permanent deformations, fractures, cracks, or separations in the truck. 2. If cracks are found during the post-test non-destructive testing that were not present before the test, or cracks have propagated from original recorded dimensions, correct the design and rerun the test from the beginning with a new test specimen. 3. Redesign and retest shall continue until these criteria are met. Test Unit Disposal: The truck and bolster that undergo this test shall not subsequently be used on a production vehicle, and shall be permanently marked or destroyed. 15.3.13 Traction Inverter Type Test Perform traction inverter type tests on a production unit, based on the type test requirements of IEC 61287-1. These tests shall confirm compliance with all aspects of the specified design requirements, environmental ranges, and supply voltages. LTK Standard Streetcar Specifications Section 15 9 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.4 Vehicle-Shell Structural Type Tests 15.4.1 General Test Purpose: To show that the critical portions of the vehicle-body structure comply with the Specification and to validate the stress analysis. Test Specimen: The first vehicle shell. 1. Conduct all structural tests on the same specimen in accordance with approved test procedures. 2. The test shell shall be structurally complete, consisting of all shell sections with the articulation joints installed, but excluding nonstructural items that would obscure structural members from view or interfere with performance of the test. 3. Simulate equipment by equivalent weights at the respective locations and the approved test procedure. 4. Vertical load test only: a. Doors: All side doors on one side of the vehicle shall be installed: • • Doors shall be complete with operators, thresholds, sealing, and weatherstripping. Door equipment shall be production equipment installed in accordance with production drawings and procedures. b. Bridge Plate: Installed on one side of the vehicle. • • Bridge plate shall be complete with operators and thresholds. Bridge plate equipment shall be production equipment installed in accordance with production drawings and procedures. Test Schedule: Tests shall not begin until the drawings, stress analyses, and test procedures have been approved (see Section 3, Vehicle-Body Structure). Failures: Broken welds shall be jointly inspected by the Contractor and the Owner to determine if the failure is the result of weld quality or stress. Areas exhibiting buckling shall also be examined to confirm elastic behavior, as appropriate. 15.4.2 Test Set Up 15.4.2.1 General At a minimum, the procedures shall describe the following: 1. The general test setup, fixtures, tooling and method of loading. 2. All load application points including dimensions for the position and distribution of loads, where appropriate. 3. Details of the supports and boundary conditions. 4. Load cell, gauge locations, including locational dimensioning of gauges. 15.4.2.2 Strain Gauges Apply calibrated strain gauges to the vehicle structure: 1. Quantity: a. Vertical load tests: Minimum 300 b. End-compression load tests: Minimum 300 LTK Standard Streetcar Specifications Section 15 10 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing c. Collision and corner post load tests: Minimum 100 d. Diagonal jacking tests: Minimum 300 2. Type: a. Rosette, bonded resistance, SR-4; or other approved gauges suitable for the application. b. Linear gauges may be used instead of rosettes where it can be shown that the stress is in one direction only and that direction has been identified and approved by the Owner. c. Gauges used on FRP shall be appropriate for that material. 3. Location: a. Based on the Contractor's experience, the stress analysis, and the Owner’s recommendations. b. Place half the gauges in areas where the stress may be critical and the other half in locations to validate the stress analysis. c. Gauges may be used for more than one test if located on the structure appropriate to more than one test, but the required number of readings must be taken for each test. 4. Calibration and temperature compensation: In accordance with manufacturer's instructions for material being measured. 15.4.2.3 Deflection Gauges Apply calibrated deflection gauges to the vehicle structure: 1. Quantity: a. For each section, five gauges to measure the side sill vertical deflection, except for the post test on the cab section must have these gauges. b. At both ends of the vehicle shell, two total, one at each side sill corner to measure longitudinal deflection. c. Between each section, four total, one at each corner to measure longitudinal deflections. d. For each section, four gauges total, one at each corner on the side sills to measure transverse deflections. e. For the collision and corner post load tests additional gauges to measure the longitudinal deflection of the posts at five locations on the post. f. For the diagonal jacking test additional gauges to measure the vertical deflection at the jacking pads. 2. Type: Displacement transducers with enough stroke to measure 1.25 times the deflection predicted by the FEA. 3. Measurements: Shall be taken to the nearest 0.25 mm (0.01 in). 4. Location: a. As noted above. b. Based on the Contractor's experience, the stress analysis, the Owner's recommendations and verification that the loading condition remains safe. 5. Calibration and temperature compensation: In accordance with manufacturer's instructions. LTK Standard Streetcar Specifications Section 15 11 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.4.2.4 Load Cells Apply calibrated load cells: 1. 2. 3. 4. Quantity: Sufficient to measure the input load and the reaction loads. Type: Load range of 1.25 times the applied load or expected reaction load. Location: At all load and reaction points. Calibration and temperature compensation: In accordance with manufacturer's instructions. 15.4.3 Vertical Load Test Test Purpose: To confirm the ability of the vehicle-body structure and articulation joints to resist the static and fatigue loads specified in Section 3, Vehicle-Body Structure, Vertical Design Load Strength Requirements section. Test Setup: Comply with the approved test procedure. Test Load: See Vertical Design Load Strength Requirements section in Section 3, Vehicle-Body Structure. Test Steps: 1. Apply test load to the specimen in four increments: a. Increment one: Equal to the complete, ready-to-run vehicle-body weight (complete vehicle minus trucks). b. Increment two: Add load such that total load is equal to AW2 passenger load. c. Increment three: Add load such that total load is equal to AW3 passenger load. d. Increment four: Add load such that total load is equal to AW4 passenger load. 2. Unload the specimen in the same increments that it was loaded, in reverse order. 3. Door operation during test: a. At each increment of test load, open and close doors electrically by means of the operators. b. In case of failure to operate at the prescribed speed or any indication of binding, take corrective action to the vehicle structure, or door arrangement, and repeat the vertical load test in its entirety. 4. Bridge plate operation during test: a. At each increment of test load, extend and retract bridge plate electrically by means of the operators. b. In case of failure to operate at the prescribed speed or any indication of binding, take corrective action to the vehicle structure or bridge plate, and repeat the vertical load test in its entirety. Measurements During Test: 1. Measure and record vehicle-body vertical and longitudinal deflection, load cell readings, strains, and flatness of side skin on the vehicle-body shell with each test load applied: a. Plot vertical deflections to verify linearity. b. Plot 10 highest strain values to verify linearity. c. Visually inspect for deformation. 2. Measure and record the opening and closing time of each door leaf. 3. Measure and record the extend and retract time of bridge plate. LTK Standard Streetcar Specifications Section 15 12 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 4. Compare gauge reading to predicted values. Test Results: The vehicle will comply with the Specifications if results comply with ASME RT-1 Test Criteria and approved test procedure criteria for this test with the following exceptions and additions: 1. 2. 3. 4. 5. 6. 7. 8. Referenced loads are in accordance with Section 3, Vehicle-Body Structure. Vertical deflection: Variance not more than +/- 5%. Strain readings: Variance not more than +/- 5%. Maximum stresses calculated from strain readings in any structural element do not exceed the allowable stresses approved as part of the stress analysis before starting the test program. Vehicle-body side-sill deflection is maximum 9 mm (0.4 in) under a load equal to the passenger load of AW4, as measured from the datum line drawn from the transverse center line of the vehicle-body bolster at the truck through the transverse centerline of the articulation joint. Vehicle-body vertical and longitudinal deflections measured at the side sill during the test at AW2, AW3, and AW4 agree with the analysis calculated deflection within +/- 10%. The side doors open and close at all test loads at speeds and operating force levels as required without binding. The bridge plate must extend and retract at all test loads at speeds and operating force levels as required without binding. 15.4.4 Compression Load Test Test Purpose: To confirm the ability of the vehicle-body structure and articulation joints to resist the compression loads specified in Section 3, Vehicle-Body Structure, in the End Sill Compression Load section. Test Setup: In accordance with ASME RT-1 or the approved test procedure. Test Load: See End Sill Compression Load section in Section 3, Vehicle-Body Structure. Test Steps: 1. In accordance with the approved test procedure: a. Apply the load in increments of 25, 50, 75, 87.5, and 100% of specified full load. b. Reduce the load to minimum 2% of full load after each step, but not less than necessary to hold the test article firmly in the fixture. Measurements DuringTest: 1. Measure applied and reaction forces using independent load cells. 2. Take strain gauge and deflection readings at each load increment and at each relaxation of load. a. b. c. d. Plot vertical deflections to verify linearity. Plot 10 highest strain values to verify linearity. Visually inspect for deformation. Compare gauge reading to predicted values. Test Results: The vehicle will comply with the Specifications if all of the following are met: 1. The vertical deflection of each side of the test structure is within plus or minus 10% of the value determined by the analysis. 2. Vertical deflection readings plotted against load do not vary by more than plus or minus 5% from a straight line (linear) deflection curve, with one end point at the origin (no load) and the other at the point that represents the measured deflection at maximum load. LTK Standard Streetcar Specifications Section 15 13 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 3. Strain readings plotted against load do not vary by more than plus or minus 5% from a straight line (linear) deflection curve, with one end point at the origin (no load) and the other at the point that represents the measured deflection at maximum load. 4. Maximum stresses calculated from strain readings in any structural element do not exceed the allowable stresses approved as part of the stress analysis before starting the test program. 5. Following removal of the maximum test load: a. Residual vertical deflection between bolsters does not exceed 1.0 mm (0.04 in). b. Residual horizontal deflection between ends does not exceed 1.0 mm (0.04 in). c. Indicated residual strains at strain gauges on principal structural elements do not exceed the maximum error resulting from the accuracy of the instrumentation. 6. There are no permanent deformations, fractures, cracks, or separations in the vehicle structure or in the vehicle-body sheathing. 15.4.5 Collision Post and Corner Post Load Tests Test Purpose: To confirm the ability of the collision posts, corner posts, and associated supporting structures to resist the elastic design loads specified in Section 3.. Test Steps: In accordance with the approved test procedure.Measurements During Test: 1. Measure applied and reaction forces using independent load cells. 2. Take strain gauge and deflection readings at each load increment and at each relaxation of load. a. Plot vertical deflections to verify linearity. b. Plot 10 highest strain values to verify linearity. c. Visually inspect for deformation. d. Compare gauge reading to predicted values. Test Results: 1. Deflection readings plotted against load do not vary by more than +/- 5% from a straight line (linear) deflection curve, with one end point at the origin (no load) and the other near the point which represents the measured deflection at maximum load. 2. Strain readings plotted against load do not vary by more than +/- 5% from a straight line (linear) deflection curve, with one end point at the origin (no load) and the other near the point which represents the measured deflection at maximum load. 3. Maximum stresses calculated from strain readings in any structural element do not exceed the allowable stresses approved as part of the stress analysis. 4. Indicated residual strains at strain gauges on principal structural elements following removal of the maximum loading do not exceed 50 microinch/in. 5. There is no permanent deformation, fractures, cracks, or separations in the vehicle structure. Failures: Broken welds shall be jointly inspected by the Contractor and Sound Transit to determine if the failure is the result of weld quality or stress. 15.4.6 Crash Energy Management (CEM) Tests Conduct CEM tests in accordance with the recommendations of ASME RT-1, Section 10.4, Crash Energy Management Tests, and as agreed by the Owner to validate the CEM design and verify the Crashworthiness Analysis simulations of Section 3, Vehicle-Body Structure. LTK Standard Streetcar Specifications Section 15 14 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing Include the CEM testing plan, or waiver justifications, as part of the CEM and Collision Survivability Plan CDRL, specified in Section 3. 15.4.7 Diagonal Jacking Test Test Setup: 1. Load the vehicle shell to its AW0 weight. 2. Hang trucks (or an equivalent weight) from the body bolsters. 3. Support the vehicle shell symmetrically at the minimum number of jack pads and placement necessary to support the vehicle safely. Test Steps: 1. Lower the jack that, when lowered, subjects the vehicle-body structure to worst-case diagonal loading: 2. Lower in five equal increments until the load on the jack is 10% of its original value. 3. Reverse the procedure until the load on the jack is returned to its original level. 4. Repeat the test using the vehicle jack socket adapters. Measurements during Test: 1. Record all gauge and load cell readings at each increment of jack position. 2. Measure reaction forces using independent load cells. 3. Take strain gauge and deflection readings at each load increment and at each relaxation of load. a. Plot vertical deflections to verify linearity. b. Plot 10 highest strain values to verify linearity. c. Visually inspect for deformation. d. Compare gauge reading to predicted values. Test Results: The vehicle will comply with the Specifications if all of the following are met: 1. Maximum stresses calculated from strain readings in any structural element do not exceed the allowable stresses approved as part of the stress analysis before the start of the test program. 2. Strain readings plotted against load do not vary by more than plus or minus 5% from a straight line (linear) deflection curve, with one end point at the origin (no load) and the other at the point that represents the measured deflection at maximum load. 3. The vertical deflection of each side of the test structure is within plus or minus 10% of the value determined by the analysis. 4. Following return to original level, indicated residual strains at strain gauges do not exceed the maximum error resulting from the accuracy of the instrumentation. 5. There are no permanent deformation, fractures, cracks or separations in the vehicle structure. 15.4.8 Validation of Linear Elastic Analysis 15.4.8.1 Measured vs. Analytical Values in Test Procedures and Test Reports Test Procedures and Test Reports: For detailed requirements, see the Contract Data Requirements List (CDRL) section, below. Test Procedures: For analytical strain (or stress) values at all strain and displacement gauge locations insert values obtained from the stress analyses required in Section 3, Vehicle-Body Structure. For the vertical load test, values at each step are to be included. LTK Standard Streetcar Specifications Section 15 15 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing To further clarify, the validation requirements in Section 3 also strongly relate to the necessary accuracy of the test setup and procedure. The accuracy of the test setup is to be included in the test procedure. Test Reports: For test report tables that require calculated percent difference between analytical and measured values, it is defined as follows: Percent Difference = where 𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 − 𝐴𝑛𝑎𝑙𝑦𝑡𝑖𝑐𝑎𝑙 × 100 𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 Measured = the value obtained from strain gauges or other instruments during testing Analytical = the value obtained through calculation, as specified in Section 3 15.4.8.2 Results The percent difference between the measured and analytical values shall be as stated in Section 3.5.7 Validation of Linear Elastic Analysis: 1. Where the percent difference is greater than that required in section 3prepare a detailed explanation of the reasons for the excessive variance. 2. Percent difference not within the above-specified tolerance shall be reviewed. For locations where consensus as to the cause or impact of the out-of-tolerance values cannot be found: • • • • • Revise the stress analyses, update the finite element model, and re-run all finite element analyses (see Section 3, Vehicle-Body Structure). Repeat the process until the percent difference is within the specified tolerance. Recalculate all manual analyses using data from the finite element analysis using the corrected values. Revise and resubmit the stress analysis report in accordance with Section 3. All results from re-analysis shall meet the requirements of the Specifications and, if they do not, the design shall be corrected. 15.5 System Type Tests 15.5.1 General The following system type tests shall be performed by the Contractor, or under its direction, to demonstrate conformance to the requirements of the Specifications. 15.5.2 Floor and Roof Assembly Fire Performance Type Test Requirements Test the floor and roof assemblies (structural): 1. 2. 3. 4. Test Setup: In accordance with NFPA 130 Section 8.5, Fire Performance Test Steps: In accordance with ASTM E119 Fire Exposure Duration: 30 minutes Test Results: In accordance with NFPA 130 Section 8.5, Fire Performance LTK Standard Streetcar Specifications Section 15 16 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.5.3 Propulsion Combined Type Test Perform a laboratory test on one set (truck) of propulsion equipment: 1. Scope: Include motors, inverter, brake resistor, protection devices (i.e. HSCB), logic, controls, and master controller. 2. Test Setup: a. The physical layout of vehicle components and cabling for this test shall simulate actual vehicle conditions as much as possible, and shall be approved by the Owner. b. Simulate vehicle inertia with a dynamometer that uses flywheels or programming of a motor generator. c. Simulate vehicle resistance by means of a motor-generator. 3. Test Results: a. Demonstrate that the propulsion functions properly and meets specified requirements before installation on the vehicle. b. Demonstrate compliance with the conductive emission requirements in Section 2, Design and Performance Criteria. 15.5.4 Friction Brake System Type Test Perform a type test on the complete friction brake system and all components: 1. These tests may be included with the propulsion system laboratory tests. 2. Use a dynamometer to confirm braking capability, thermal capacity, response, and wear rates. 3. Testing shall include hot and cold retardation, wet and dry retardation, actuation energy storage, and control response. 15.5.5 Door System Type Test Perform a type test on one door, door operator, control, and sensitive edge of each type of door: 1. Door shall be assembled as a unit for the test. 2. The test fixture used shall accurately represent the actual vehicle body and installation. 3. Include an accelerated life test of 1.5 million cycles for one complete set of door equipment. 15.5.6 Bridge Plate System Type Test Comply with the following, in addition to requirements for the Door System Type Test, above: 1. Perform a type test on one bridge plate and bridge plate operator, and controls. 2. Door and bridge plate equipment shall be assembled as a unit for the test. 3. In addition to the accelerated life test of doors, include 250,000 cycles for the bridge plate equipment. 15.5.7 Unitized HVAC System Type Test 15.5.7.1 General Perform a type test on one self-contained HVAC unit of each type, complete with all controls: 1. The test shall confirm air flow, water elimination, heating capacity, cooling capacity, controls, extreme operating conditions, unit noise, vibration, and power consumption. 2. Test setup shall be according to ANSI/ASHRAE Standard 37, including instrumentation accuracy and tolerances requirements. LTK Standard Streetcar Specifications Section 15 17 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 3. Record all data required by ANSI/ASHRAE Standard 37 using an appropriate data acquisition system. 15.5.7.2 Air Flow Test Test Conditions: 1. Ambient room temperature of 20 degrees C. 2. Interior room temperature of 20 degrees C. 3. "Dry" evaporator coil. Test Steps: 1. Adjust the fresh air flow to comply with the requirements of Section 7, Heating, Ventilating, and Air Conditioning. 2. Adjust the return air flow such that total air flow is in accordance with the required design value. Measurements During the Test: 1. Use the flow measurement device described in ANSI/ASHRAE Standard 37 and related standards for measurements of the total/supply air. 2. Use the flow-hood type instrument for measurements of the fresh air. Test Results: The fresh air flow and total air flow shall comply with the requirements of Section 7 and manufacturer's design parameters. 15.5.7.3 Scan Test Test Conditions: 1. Expose temperature control components to the temperature environments they will experience on the vehicle. 2. The use of test switches or potentiometers to control the unit independent of the temperature sensors is not permitted. Test Steps: 1. Simulate actual operation to the extent possible by slowly varying the temperature in the test rooms, as appropriate for the control system, to reflect natural temperature lags. 2. Cycle the simulated vehicle interior and ambient temperatures through the operating range of the temperature sensors. 3. Verify all points of temperature control on temperature rising and temperature falling. Measurements During the Test: 1. Instrument the simulated vehicle interior and ambient rooms with temperature measuring devices to determine when various control switching points are reached. 2. Connect the contactor coils to the event recorder or other suitable recording instrumentation to determine which contactors are picked up to verify control response. Test Results: Malfunction of the system or components at any temperature shall constitute a failure of the test. LTK Standard Streetcar Specifications Section 15 18 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.5.7.4 Control Stability Test Comply with the following testing requirements: 1. Under steady state operation at design conditions, vary the low-voltage power supply voltage between the limits allowed by Section 9, Electrical Equipment, to show the effect of such change. 2. Shut down and restart the system while the control voltage is at its minimum value. 15.5.7.5 Cooling Capacity Verify cooling capacity at the design criteria conditions specified in Section 7, Heating, Ventilating, and Air Conditioning, using the methodology of ANSI/ASHRAE Standard 37: 1. In addition to test "A", select one of the secondary applicable test methods "B" from Table 1 of the Standard. 2. Verify the efficiency of the unit’s mixed air plenum design: a. Perform the cooling capacity verification test using the normal multi-streamed airflow configuration with the outside air (fresh air) intakes open to the design exterior ambient air condition and the return air stream open to the design interior air condition, balanced to provide the design air proportions. b. No significant degradation of performance shall be present when operating in this actual configuration. c. Verify and finalize the design of the mixing plenum before proceeding with the remaining sections of the unit type test. d. Record the data, after conditions are stabilized, in 10 minute intervals for 1 hour. 15.5.7.6 Maximum Operating Conditions Perform a system functional test as follows: 1. Test Conditions: a. Conduct test with the following temperatures: • • Ambient condition: DB and WB Maximum Operating Conditions temperatures, as found in Section 7, Heating, Ventilating, and Air Conditioning, in the Cooling Design Criteria section. Recirculated air to evaporator: 24 degrees C (75 degrees F) DB and 60% relative humidity. b. Conduct test at nominal supply voltage. 2. Test Steps: a. Operate the unit under the conditions above. b. At the end of one hour of operation, momentarily stop the system and then restart. c. The system shall continue to function properly with all components safe from malfunction. There is no capacity to be met. 3. Measurements During Test: a. Record all data every five minutes during steady state operation. LTK Standard Streetcar Specifications Section 15 19 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing b. Record each condenser motor’s temperature rise during the test and verify that it is within the motor manufacturer’s motor-winding insulation and heat rise and overheat-protection design ratings. 4. Test Results: a. Successful test: Continuous operation of the system at these conditions for one hour without shutdown due to high pressure, modulation, circuit breaker trip, compressor motor overload, or any device failure. b. Test Failure: A shutdown or capacity modulation for any reason while operating at these conditions. 15.5.7.7 Modulation Pressure Switch Test Demonstrate capacity modulation capability as follows: 1. Test Conditions: Perform the test at ambient temperatures above Maximum Operating Conditions, as specified in Section 7, Heating, Ventilating, and Air Conditioning, in the Cooling Design Criteria section. 2. Test Steps: As the condenser outlet air dry bulb temperature rises, allow the system to cycle by pressure transducer or modulation pressure switch. 3. Measurements During Test: a. Record the frequency of pressure switch cycling. b. Record all system pressures and temperatures. 4. Test Results: A successful test shall consist of one hour of continuous operation of the system without shutdown due to high pressure, cutoff, circuit breaker tripping, compressor motor overload, or any device malfunction. 15.5.7.8 High-Pressure Cut-Off Switch Test Test Steps: 1. Upon conclusion of the modulation-pressure switch test, slowly increase the condenser air temperature above the Maximum Operating Conditions DB temperature, as specified in Section 7, in the Cooling Design Criteria section, to achieve a discharge pressure slightly below the high pressure switch trip point. 2. The system shall operate minimum one hour continuously at this condition without operation of the high-pressure cut-off device, while maintaining the interior mixture conditions defined in the section above, Maximum Operating Conditions. 3. Following this, slowly raise the condenser/fresh air ambient to the point when the high-pressure cutoff switch activates and shuts off the system. 4. Repeat this test four times. Measurements During Test: Record pressures and temperatures of the pressure-switch cutoff and reset conditions. 15.5.7.9 Low Temperature Operation Test Test Conditions: Perform the test at air temperature entering evaporator coil based on the following mixture: 1. Recirculated air at 22 degrees C (72 degrees F) DB and 50% relative humidity. LTK Standard Streetcar Specifications Section 15 20 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. Ambient conditions determined from the control chart to be 1 K (1.8 degree F) higher than the compressor lock-out point. Test Steps: After attainment of the specified temperature conditions, operate the unit continuously for a period of four hours. Measurements During Test: Record the data every 10 minutes (or more frequently) during steady state operation. Test Results: During the test, the unitized air cooling system shall operate without damage to the equipment and without the formation of ice or frost on the evaporator coil or piping. 15.5.7.10 Insulation Efficiency and Condensate Carry-Over Test Test Conditions: Ambient and evaporator entering air temperature at 27 degrees C (81 degrees F) DB, 24 degrees C (75 degrees F) WB. Test Steps: 1. Operate the unit continuously for a period of four hours at the specified conditions. 2. Verify that the condensate drains function properly. Test Results: During the test, there shall be no condensate carry-over downstream of the condensate collection system. 15.5.7.11 Refrigerant Sample Test Have a sample of refrigerant analyzed for contaminants by an approved laboratory in accordance with AHRI Standard 700: 1. The sample shall be taken from the air conditioning system of the tested unit. 2. Maximum allowable levels of contaminants shall comply with AHRI Standard 700 with the following exceptions: a. Moisture level of up to 45 ppm maximum. b. High boiling residue may be as high as 5%. 15.5.7.12 Abnormal Heating Condition, Restricted Air Test Conditions: Maintain ambient temperature at approximately 21 degrees C (70 degrees F) with the following conditions: 1. System heaters activated independent of the thermostat 2. Air conditioning compressor not operating 3. Air flow switch bypassed Test Steps: 1. Slowly restrict the mixed air inlet so that heater unit temperature rises 1 K (2 degrees F) per minute (not faster) until the high-limit switch cycles off. 2. Ease the restriction to the point where the high-limit switch stays closed. 3. Continue the heating test to simulate a dirty filter condition. 4. Operate the system until a steady condition is reached. Test Results: The test will be considered successful when the following criteria are met: 1. The back-up protection did not activate during the test. LTK Standard Streetcar Specifications Section 15 21 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. The temperature inside the unit did not cause damage to the equipment and components. 3. There was an absence of smoke and odors. 4. The high-limit switch opened at the design set point +/- 6 K (11 degrees F). 15.5.7.13 Abnormal Heating Condition, No Air Test Conditions: 1. Maintain ambient temperature at approximately 21 degrees C (70 degrees F). 2. The air conditioning compressor shall not be operating and the air flow switch shall be bypassed. Test Steps: 1. Apply power to the heaters with no air blowing over the heaters. 2. The system shall operate as the high-limit switch cycles. Test Results: The test will be considered successful when the following criteria are met: 1. 2. 3. 4. The back-up protection did not activate during the test. The temperature inside the unit did not cause damage to the equipment and components. There was an absence of smoke and odors. The high-limit switch opened at the design set point +/- 6 K (11 degrees F) 15.5.7.14 Back-Up Protection Test Test Conditions: 1. Maintain ambient temperature at approximately 21 degrees C (70 degrees F). 2. The air conditioning compressor shall not be operating. 3. Bypass the high-limit switch and air-flow switch before applying power to the heaters. Test Steps: 1. Energize the heaters and observe the activation temperature of the back-up protection device. Measurements During Test: Measure and record the equipment interior temperatures minimum once per minute from the start until recorded temperatures start decreasing. Test Results: The test will be considered successful when the following criteria are met: 1. The temperature inside the unit did not cause damage to wiring, electrical components, motor, or unit insulation. 2. There was no visible smoke. 3. There was no detectable odor. 4. The back-up protection device opened at the design set point +/- 6 K (11 degrees F). 15.5.7.15 Start-up Current Draw Record the start-up current-draw profile (current versus time) characteristics of the unit under the following conditions: 1. Design cooling conditions 2. Maximum operating cooling conditions For these tests the data-sampling rate shall be maximum 10 ms. LTK Standard Streetcar Specifications Section 15 22 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.5.7.16 Shock and Vibration Test Perform random vibration, simulated long life vibration, and shock type testing of the HVAC equipment under test, in accordance with IEC 61373: 1. Perform routine tests prior to and following the shock and vibration testing to verify that there is no degradation in HVAC equipment performance due to the testing. 2. Evaluate damage that occurs during any portion of the test for potential design changes, if required, and then correct. Following the appropriate corrective action, repeat the test prior to performing the subsequent test/s. 15.5.7.17 Water Eliminators Test Test Steps: Conduct the water test of the HVAC unit per requirements of Watertightness Routine Tests section, with the design air flow, including required fresh air. Test Results: At the conclusion of the test, there shall be no evidence of moisture in the ducts downstream of the water excluding features and fresh air filters shall be dry. 15.5.7.18 HVAC Noise Test Noise test the HVAC equipment to verify compliance with the specified noise limits of Section 2, Design and Performance Criteria. Comply with applicable noise testing requirements in this Section. 15.5.8 Communication System Type Test Before shipping the first vehicle's communication equipment, perform a functional laboratory test: 1. The test shall include one complete vehicle set of equipment. 2. The testing shall verify compliance with the Specifications and design. 15.6 Vehicle-Level Type Tests at Contractor’s Facilities 15.6.1 General Perform vehicle-level static and dynamic type tests on the first fully assembled vehicle to confirm that the overall vehicle design complies with the Specifications: 1. In general, perform static tests at the Contractor's facilities or at other specified facilities and dynamic tests at the Owner’s facilities. The Owner will consider allowing some tests, or subsets of these tests to be performed at the Contractor’s facilities. 2. Perform a complete, orderly, and comprehensive test of each vehicle system to verify systems integration and the proper operation of each system, whether specifically described below or not. 15.6.2 Vehicle-Level Type Static Tests at Contractor’s Facilities 15.6.2.1 General 15.6.2.2 Horn and Bell Type Test Test the horn and bell, as mounted on a completed vehicle, to demonstrate compliance with specified requirements. Test horn and bell at both ends of the vehicle. 15.6.2.3 Jacking Type Test Perform a jacking test to demonstrate compliance with the specified jacking requirements. LTK Standard Streetcar Specifications Section 15 23 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.6.2.4 Ducting Watertightness Type Test Water test the fresh air and electric equipment ventilation intake ducts in the vehicle roof to determine the effectiveness of the water-excluding features of the duct work: 1. Run ventilating fans at full speed. 2. At the conclusion of the test, there shall be no evidence of moisture in the ducts downstream of the water excluding features. 15.6.2.5 Air Balance Type Test Perform an air balance test to verify conformance with the requirements of Section 7: 1. Perform with "dry" evaporator coil condition. 2. Measure and record the volumes of fresh, recirculated, and exhaust air, and the total volume of air delivered by the circulating blowers. 3. Measure and record the conditions of the air (degrees C DB, degrees C WB, and barometric pressure). 4. The blower motor current, voltage, power consumption, and speed shall conform to the HVAC manufacturer's design data and motor specifications. 5. Measure and record interior pressurization. Make adjustments as necessary to conform to the requirements of Section 7. 15.6.2.6 Vehicle HVAC System Type Test Test the vehicle HVAC system to verify compliance with the requirements of Section 7, with assistance from the HVAC unit manufacturer. Test Setup: 1. This test may be conducted in a climate room, or in an enclosed facility, such as a paint booth, where the "ambient" temperature and humidity requirements specified in Section 7 can be achieved. 2. Use electric baseboard heaters and humidifiers to simulate the passenger, sensible and latent, and solar loads inside the vehicle. Test Steps: 1. Expose the vehicle to high ambient temperature condition specified in Section 7 for minimum six hours, without HVAC system operation (“soaking period”). 2. Following the soaking period, perform a pull-down test, and measure the time required to reach the required vehicle interior temperatures and stabilize, for information. 3. Include a cooling test at the design conditions of Section 7 and the cooling tests required in the Unitized HVAC System Type Test section, above, except simulate actual interior passenger and solar loads inside the vehicle, instead of regulating the return air temperature. 4. After stabilizing for each test condition, record the temperatures every minute for 30 consecutive minutes in order to determine temperature swing as the HVAC equipment cycles. 5. The test shall also verify proper operation of HVAC equipment during cooling and heating operation. LTK Standard Streetcar Specifications Section 15 24 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing Measurements During and After Tests: 1. Use data logging equipment to record temperature at a minimum of 30 locations throughout the vehicle, representative of seating and standing passengers, including operator's cab and articulation section. 2. Record all significant events and data (such as refrigeration and heating equipment cycling), with corresponding temperatures and pressures as applicable for each test. 3. After all tests have been completed, take samples of the refrigerant for analysis for contaminants by an approved laboratory. Test Results: 1. Vehicle interior temperatures shall not exceed the temperature variation specified in Section 7. 2. Refrigerant and compressor crankcase oil test results shall conform to the requirements of AHRI Standard 700 with the following exceptions: a. Moisture level of up to 45 ppm maximum. b. High boiling residue may be as high as 5%. 15.6.2.7 Door Operation Type Test Test the door system on the first vehicle to verify compliance with the requirements of Section 6, Passenger Doors: 1. Operate each door for 1,000 continuous, trouble-free cycles. If a door or door control fails before the test is completed, correct the fault and start the test over from the beginning. 2. Independently test each door obstruction system, door sensitive edge, and additional approved method to verify compliance with door obstruction detection requirements in Section 6. 3. Measure door closing stall force during door closing at 50 mm (6 in) intervals along the width of the door opening, to verify compliance with Section 6. 15.6.2.8 Bridge Plate Operation Type Test Comply with the following, in addition to requirements for the Door Operation Type Test, above: 1. Test bridge plate system to verify compliance with the requirements of Section 6, Passenger Doors. 2. Operate each bridge plate for 1,000 continuous, trouble-free cycles. If a bridge plate, or bridge plate control fails before the test is completed, correct the fault and start the test over from the beginning. 3. Independently test each bridge plate obstruction system to verify compliance with bridge plate obstruction detection requirements in Section 6, Passenger Doors. 15.6.2.9 Light Intensity Type Test Take light intensity readings (without light from other sources) to verify conformance with the requirements in Section 8, Lighting. 15.6.2.10 Communication Equipment Type Test PA System and Automatic Passenger Information System: 1. Verify that the PA and APIS systems comply with requirements of Section 13, Vehicle Communication Systems. LTK Standard Streetcar Specifications Section 15 25 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. Perform the following tests as a minimum: a. Test the intelligibility of the PA and APIS systems in accordance with ANSI S3.2. b. Test the PA automatic volume control. c. Test the accuracy of the distance calculation of the APIS over the Project alignment. Intercom: 1. Verify that intercom systems comply with requirements of Section 13. 2. Test both cab-to-cab and passenger emergency intercom intelligibility and functional requirements. CCTV: 1. Verify that CCTV complies with requirements of Section 13. 2. Verify viewable areas within the interior and exterior, storage capacity, and functional requirements. Event Recorder: 1. Verify that the event recorder complies with requirements of Section 13. 2. Test functional requirements and data storage and retrieval. Automatic Passenger Counting (APC): 1. Verify that the APC system complies with requirements of Section 13. 2. Test accuracy for simulated unloading and loading of passengers. TWC: 1. Verify that the TWC system complies with requirements of Section 13. 2. Test functional requirements, TWC Cab Control Panel, and transponder. 15.6.2.11 Vehicle Data Network Type Test Conduct a test to verify that there is sufficient bandwidth in the vehicle network and communication systems network (communications and CCTV): 1. Activate all systems connected to the vehicle data network system. 2. Measure actual peak and average traffic levels. 3. Verify compliance with specified traffic level requirements in Section 17, Electronic Controls, Software, and MDS. 15.6.3 Vehicle-Level Type Dynamic Tests at Contractor’s Facilities 15.6.3.1 General Vehicle Type Dynamic Tests will generally be performed at the Owner’s facilities. However, if the Owner’s track facilities are not adequate to perform all required dynamic tests, perform those that require an alternate location at the Contractor’s facilities or other facilities, as agreed with the Owner. 15.6.3.2 Preliminary Vehicle-Level EMI/EMC Perform preliminary EMI/EMC testing on the first vehicle to demonstrate compliance with the emission limits specified in Section 2, Design and Performance Criteria. Use the test procedure prepared for the vehicle-level type test of EMI/EMC at the Owner’s facilities and perform portions of the test as suitable for the Contractor’s test track. LTK Standard Streetcar Specifications Section 15 26 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.7 Component Routine Tests 15.7.1 General Each component shall be routine tested by its manufacturer during production before installation at the vehicle manufacturing site. Each test of electrical equipment shall include an insulation test. 15.7.2 Air Conditioning Unit Routine Tests Perform the following tests: 1. Leak testing: Confirm compliance with refrigerant leak test requirements specified in Section 7, Heating, Ventilating, and Air Conditioning. 2. Evacuation testing: Confirm compliance with evacuation test requirements specified in Section 7. 3. Air conditioning unit test: a. Apply a heat load to both the evaporator and condenser coils. b. Perform a complete functional test to verify capacity modulation, control points of pressure transducers or switches, and return air and fresh air thermostatic control points. c. Record the following: • • • • • • Power consumption of motors Evaporator and condenser fan motor speeds System pressures and temperatures Applied loads to the evaporator and condenser System refrigerant charge Refrigerant condition (wet or dry) d. Correct abnormal conditions and repeat the associated test. 4. Unit heat staging and function of overheat protection devices: Verify performance as specified in Section 7. 5. Insulation resistance and dielectric (high potential) tests: Performed by the manufacturer on each unit in accordance with the Insulation Testing section, above. 15.7.3 Motor Routine Test Perform a routine test on each traction motor, ac auxiliary motor, and dc motor: 1. Perform in accordance with IEC 60349, as appropriate. 2. Dynamically test motor balance in accordance with IEC 60349. 15.7.4 Traction Gear Unit Routine Test Each traction gear unit shall be given the manufacturer’s routine test. The test shall include the following as a minimum: 1. Check gear tooth mesh alignment, backlash, and shaft endplay to verify that it is within the manufacturer's tolerances before the gear unit is operated. 2. No load operation at maximum operating speed equivalent vehicle speed for 10 minutes in each direction. Continuously monitor vibration produced by each gear unit and gear sump oil temperature. Gear units that produce abnormal oil temperature or noise shall be rejected. LTK Standard Streetcar Specifications Section 15 27 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.7.5 Traction Inverter Routine Test Perform a routine test on each traction inverter: 1. Test in accordance with IEC 61287-1 to verify compliance with the Specifications. 2. Test insulation per the Insulation Testing section, above. 15.7.6 AC Auxiliary Power Supply Routine Test Perform a routine test on each auxiliary power supply: 1. Test in accordance with IEC 61287-1 to verify compliance with the Specifications. 2. Test insulation per the Insulation Testing section, above. 15.7.7 Low-Voltage Power Supply and Battery Charger Routine Test Perform a routine test on each low-voltage power supply: 1. Test in accordance with IEC 61287-1 to verify compliance with the Specifications. 2. Test insulation per the Insulation Testing section, above. 15.7.8 Battery Routine Test Perform a capacity test on 5% of the batteries supplied at the point of manufacture: 1. Test in accordance with IEC 60623, Section 4.2.1, Discharge Performance at 20 °C. 2. The test shall be at the 5-hour rate, at 20 degrees C (68 degrees F) ambient temperature. 15.7.9 Friction Brake Routine Tests Test each component and system that is part of the friction brake system. Perform the following tests: 1. Electrical and electronic assemblies: a. Test insulation per the Insulation Testing section, above. b. Perform functional test and certify for performance in accordance with manufacturer's specifications and test codes. 2. Hydraulic pump unit: Perform a functional test and a capacity test. 3. Valves: Perform functional test and certify for performance in accordance with manufacturer's specifications and test codes. 15.7.10 Communication System Routine Test Test each electrical and electronic assembly that is part of the communication system. 1. Test insulation per the Insulation Testing section, above. 2. Perform a functional test and certify for performance in accordance with manufacturer's specifications and test codes. 15.7.11 Truck Frame Welds Routine Test Perform the following inspections in accordance with the Non-Destructive Testing and Inspection section, above: 1. Each production truck weld: a. Perform magnetic particle or dye penetrant inspection. b. Includes welds on the frame, bolster, and other primary structural members. LTK Standard Streetcar Specifications Section 15 28 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. Critical welds: a. Inspect by radiography or by section and etch. b. Perform on the first and fifth production trucks, and thereafter 5% of the trucks chosen at random. 3. Cast trucks: Perform magnetic particle inspection on 100%. If defects are found during sampling inspection, positively locate the beginning of such defects in previous truck frames and apply appropriate corrective action. 15.7.12 Wheel Back-to-Back Routine Test Measure each wheel-axle assembly to verify conformance with back-to-back distance requirements. 15.7.13 Resistance Routine Tests Perform test for each truck, isolating the other trucks during the test. Test must be performed by sending current through the circuit, not by using an ohmmeter. 1. Vehicle-Structure to Wheels Resistance Routine Test: Measure grounding system resistance between vehicle structure and wheels. 2. Propulsion System to Wheels Resistance Routine Test: a. Measure grounding system resistance between the propulsion system return bus and wheels. b. Test shall be via the ground brushes separate from the safety ground system. 3. Wheel Shunt Resistance Routine Test: a. Measure wheel-axle-wheel and wheel-axle-ground brush assembly to verify conformance to shunt resistance values specified in Section 11, Truck Assemblies. b. Measure values for each wheelset with other wheelsets isolated from the measurement. c. Measure wheel tread to stub axle before installation, or with ground brush disconnected. 15.7.14 TWC System Routine Test Perform the following tests: 1. Insulation test: Perform on electrical and electronic assemblies per the Insulation Testing section, above. 2. Functional test: Certify for performance in accordance with manufacturer's specifications and test codes. 15.8 Vehicle-Level Routine Static Tests at the Contractor’s Facilities 15.8.1 General After installation of components and systems on the vehicle, perform routine tests to verify that equipment functions as expected within the vehicle’s nominal mechanical, electrical, and physical environments, and interacts with other systems correctly: 1. Perform tests for all equipment and systems on each vehicle at the Contractor's facilities prior to shipment, whether listed in this section or not. 2. Each test shall be in accordance with the specified standards or an approved test plan. 3. Where insulation testing is specified, perform in accordance with the Insulation Testing section, above. LTK Standard Streetcar Specifications Section 15 29 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 4. Include test reports in each Vehicle History Book as specified in Section 19, Program Control and Quality Assurance. 15.8.2 Vehicle-Level Routine Functional Tests Perform a functional test on each vehicle system to verify correct operation and integration with other vehicle systems. This is not intended to repeat component manufacturer’s routine tests. 15.8.3 Vehicle-Level Routine Wiring Tests Perform each test listed below after the wiring and equipment installation is complete. Confirm integrity of electrical insulation and connections: 1. Wiring Continuity Checks: a. Test each circuit to ensure continuity and correct polarity of equipment and devices. b. Check each frame ground and terminal connection for tightness. 2. Insulation Resistance Test: Conduct in accordance with the Insulation Testing section, above. 3. Dielectric (High Potential) Test: Conduct on each circuit in accordance with the Insulation Testing section, above. 15.8.4 Watertightness Routine Tests 15.8.4.1 General Perform watertightness tests specified below on each vehicle. Perform tests before installation of sound deadening material, thermal insulation, and interior finish. 15.8.4.2 Vehicle Perform a complete watertightness test on all areas of the vehicle sides, ends, and roof, including doors and windows: 1. Spray water from nozzles maximum 1 meter from, and aimed directly at the surface being tested. 2. Deliver minimum 26 liters per minute to each square meter of surface being tested, with minimum nozzle velocity of 45 meters per second. 3. Continue spray applications for 10 minutes before inspection for leaks begins, and run continuously during the inspection. 15.8.4.3 HVAC Conduct HVAC watertightness test as part of the vehicle watertightness test, with blowers operating. 15.8.4.4 Equipment Enclosures During the test of the vehicle body, conduct the enclosure watertightness test on individual underfloor and roof-mounted enclosures required to be watertight: 1. Direct spray at the exposed sides and ends of the boxes as would normally occur during vehicle washing operations. 2. Direct spray as appropriate to simulate water spray from the wheels. 15.8.4.5 Traction Motor Leads Water test traction motor lead connections. Water flow rate and velocity shall be the same as for the vehicle water test. LTK Standard Streetcar Specifications Section 15 30 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.9 Vehicle-Level Type Dynamic Tests at the Owner’s Facilities 15.9.1 General Perform these tests on the Project alignment or at other facilities, as directed by the Owner. 1. Perform tests on the first or second vehicle. 2. Demonstrate compliance with performance specified in Section 2, Design and Performance Criteria, and other sections of the Specifications for a fully assembled vehicle. 3. Make two runs in each direction for each dynamic test, as a minimum. 4. Select, with the Owner's concurrence, a suitable test segment: a. Determine where each test will start, based upon right-of-way restrictions, grades, speeds, clearances, safety considerations, and other limitations at the Owner’s facilities. b. Locations shall be such that the opposite direction test run shall be run over the same portion of the alignment. c. Mark the start location for each test. 5. If the vehicle or apparatus fails to satisfy the specified performance and design criteria, redesign the vehicle and retest. If modifications are necessary, they shall be made on a fleetwide basis. 15.9.2 Setup for Vehicle-Level Type Dynamic Tests 15.9.2.1 Instrumentation Comply with the following for instrumentation: 1. Furnish proof of calibration for each instrument, traceable to a master at the national standards organization of the applicable country. All testing equipment used must be calibrated. 2. Provide personnel familiar with the setup and function of instrumentation and equipped to handle troubleshooting the test setup in the field, to limit testing delays. 3. For vehicle type tests, instrument each vehicle with a Contractor-furnished multi-channel data acquisition system, which shall produce a permanent test record (both electronically and hard copy): a. The data acquisition system shall be capable of interfacing with all major systems through a serial bus. b. Wherever possible, applicable signals needed to verify vehicle performance shall be obtained from the serial interface with the equipment in question instead of hardwiring to obtain the desired signals. 4. Provide all recorders, sensors, transducers, pickups, equipment racks, test wiring termination panels, calibration equipment, wiring, and inverters necessary to operate this instrumentation. a. Test wiring termination panels shall include test jacks and switching for each channel to permit calibration signals to be injected into each recorder channel without requiring wiring or connectors to be disconnected. Arrange so that calibration signals cannot be fed back into the monitored equipment. b. Provide isolation amplifiers and voltage dividers to isolate the inside vehicle instrumentation wiring and equipment from high voltages. No exposed terminals with potential differences greater than 50 V will be permitted. LTK Standard Streetcar Specifications Section 15 31 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 5. Instrumentation shall be powered from the vehicle low-voltage dc power system. a. The equipment shall function over the specified low-voltage dc power system voltage range specified in Section 9, Electrical Equipment. b. Internal combustion engines driving a generator or use of the vehicle inverter power will not be permitted. 6. The accuracy and response of the instrumentation shall be sufficient to determine compliance with the Specifications. 15.9.2.2 Channel Assignments For each test, permanently record the following channel assignments simultaneously: 1. Acceleration (positive and negative): The signal shall be provided by an independent accelerometer: a. Type: Inertial b. Range: +/- 1g c. Acceleration/deceleration rates calculated by the propulsion or friction brake system will not be considered acceptable for this requirement 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Tractive effort: Each truck Spin/slide system operation: Each truck Brake cylinder pressure: Each truck Brake disc temperature: On one powered-truck axle using thermocouples embedded in the brake pads OCS voltage Total OCS current drawn by each vehicle Speed Propulsion and braking trainline command signals (or multiplexed to a single analog channel) Auxiliary inverter voltage and frequency outputs An independent time base with one-second time intervals Such channels as the Contractor feels necessary to record voltage transients Five spare analog and ten spare digital channels for additional signals that may be requested by the Owner 15.9.2.3 Measurement of Average Acceleration Rates Where performance requirements specify average acceleration rates, measure as follows: 1. Use the accelerometer and speed channels. 2. Determine the 90% point on the acceleration trace where the acceleration achieves its response time. (See definition of Time, Response, in Section 1, General Topics and Definitions.) Record the vehicle speed at that point. This is the entry speed. 3. Determine the elapsed time from the entry speed to the end speed (typically zero) of the test. 4. Calculate average accelerations: (Entry speed - End speed) / Elapsed Time. 5. Disputes over interpretation of recorded values and calculations will be resolved by the Owner. LTK Standard Streetcar Specifications Section 15 32 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.9.3 Propulsion and Braking Type Tests 15.9.3.1 Propulsion Tests Perform the following tests as a minimum: 1. Acceleration rates and balancing speed for five evenly-spaced tractive effort commands, accelerating from a stop. 2. Time to travel 1 km (0.6 mi) from a standing start with a maximum power command. 3. Acceleration performance during the AW3 braking tests required in the following section. Run the tests at AW0 and a second series of tests at AW2. Monitor braking during tests. 15.9.3.2 Braking Tests Perform the following tests as a minimum: 1. 2. 3. 4. 5. 6. Full service brake stops from 70, 50, and 25 km/h (43, 31, and 16 mph) Minimum brake stops from 15 km/h (9 mph) All-friction full service brake stops from 70, 50, and 25 km/h All-friction minimum service brake stops from 15 km/h Emergency stops from 70, 50, and 25 km/h Tests designed to determine compliance of the track brake system with the Specifications Run three series of tests: 1. At AW0 2. At AW2 3. At AW3 Before initiation of each friction-stop test, cool brake discs to a maximum of 120 degrees C (248 degrees F) as measured by thermocouples. 15.9.3.3 Thermal Capacity Tests Demonstrate compliance with the specified duty cycle requirements. 15.9.3.4 Wheel Spin/Slide Demonstrate compliance with wheel spin/slide requirements using all power and braking modes. Monitor the following signals during spin/slide testing: 1. Tractive effort command and effort delivered per inverter 2. Pressure signals per truck 3. All wheel (or axle) speed signals on the spin/slide test vehicle 15.9.3.5 Parking Brake Perform a parking brake system test. Demonstrate compliance with performance requirements by measuring the force required to move the vehicle with the parking brake applied. 15.9.4 Emergency Towing Type Test Demonstrate that an operational vehicle can tow an inoperative vehicle over the entire Project alignment. LTK Standard Streetcar Specifications Section 15 33 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.9.5 Ride Quality Type Test Perform ride quality tests according to ISO 2631 to demonstrate compliance with the specified ride quality in Section 2, Design and Performance Criteria: 1. As a minimum, ride quality tests shall consist of operating the vehicle at speeds of 40 and 70 km/h (25 and 43 mph) over track selected by the Owner under two load conditions: AW0 and AW1. Weights used to simulate AW1 shall be provided by the Contractor. 2. Provide and monitor instrumentation capable of measuring and recording the expected magnitude of vertical, longitudinal, and lateral shocks and vibrations concurrently, with speed and event marker. 3. Locate sensing units that measure in the three translation directions on the vehicle floor above the intersection of the vehicle longitudinal center line and the following: a. b. c. d. e. An end truck transverse center line A center truck transverse center line The center of one section of the vehicle between trucks At three seat locations at the bottom of the seat, as determined by the Owner Clearly identify locations for acceleration measurements in the test procedures and obtain final approval from the Owner before starting testing 4. Measure acceleration data over the frequency range of 0.5 Hz to 80 Hz. 5. Make ride quality measurements with fully functioning suspension systems with normal acceleration and braking levels in a simulated revenue service operation. 6. Acceptability of the ride quality will be determined by an analysis of the recorded root-meansquare accelerations and shall meet the requirements of Section 2. 15.9.6 Noise and Vibration Type Test 15.9.6.1 General Perform sound level and vibration tests at AW0 vehicle weight, to demonstrate compliance with the specified limits in Section 2. 15.9.6.2 Noise Testing Provide noise test equipment necessary to perform tests to verify compliance with Section 2. Perform sound measurement per the following: 1. Take sound measurements on welded rail at-grade, newly-ground, and where reflections from nearby walls, floor, or other equipment will not influence the directly radiated sound by more than 2 dB. 2. Ambient sound level shall be minimum 10 dB below the sound level produced by the equipment being measured, when evaluated using the same scale or octave band. 3. Perform sound measurements using Type 1 sound level meters meeting current IEC or ANSI standards. Measure sound levels on the A scale (dBA), with slow meter response for stationary vehicle measurements, and with fast meter response for moving vehicle measurements. 4. Measure interior noise levels in accordance with ISO 3381. 5. Measure exterior noise levels in accordance with ISO 3095, with microphones placed 7.5 m (25 ft) from the track centerline, and 1.5 m (5 ft) above top-of-rail. 6. Test for each condition specified in Section 2, Design and Performance Criteria. LTK Standard Streetcar Specifications Section 15 34 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing Record the following: 1. Description of sound level or vibration source being measured, including pertinent statistical information 2. Description of the environment where sound level or vibration source is measured, including a sketch showing source position 3. Operating conditions of sound level or vibration source during measurements 4. Pertinent meteorological data 5. Locations and orientations of microphones with respect to sound level source 6. Equipment used for making measurements 7. Description and measurements of ambient sound levels 8. Data obtained, including range of variation 9. Instrument settings, corrections, and calibration records 15.9.6.3 Vibration Testing Perform vibration testing to demonstrate compliance with Section 2, as follows: 1. Provide test equipment necessary to perform the tests. 2. Test in accordance with IEC 61373 to verify compliance with the specified limits. 3. Confirm that the vehicle can operate without degradation of performance when subject to vibration and impacts encountered during normal service. 15.9.7 EMI/EMC Vehicle-Level Type Tests Perform EMI/EMC testing on the Project alignment: 1. Conduct tests with all wayside systems functioning, including but not limited to signals and TWC. 2. Demonstrate compliance with EMI limits specified in Section 2, Design and Performance Criteria. a. Validate results considering worst-case conditions to comply with the EMI monitor requirements specified in Section 9, Electrical Equipment. b. Worst case conditions shall include all tolerances of the input filter, such as, but not limited to, loss of capacitance due to aging and worst case location on the alignment. 3. Radiated Emission Testing: Perform in accordance with ENEN 50121-3-1, with the following qualifications: a. Extend measurement range up to 6 GHz, with limits in the range 1 GHz to 6 GHz measured in accordance with EN 50121-3-2, Table 3, Emission - Enclosure port, at 10 m, with limits decreased according to this distance. b. Conduct measurements in the range 10 kHz to 150 kHz as cited in EN 50121-3-1 Annex C, Emission values for lower frequency range. In order to minimize impact of near-field effects and increase measurement certainty, Contractor may propose to carry out these measurements from a greater distance than that prescribed in EN 50121-3-1, with limits recalculated accordingly. 4. Conductive Emission Testing: Perform in accordance with UMTA-MA-06-0153-85-6 (NTIS PB88136932), Method RT/CE02A, Conductive Emission Test, Vehicle, or approved equal, with the following addition for the TWC system: a. Test for electromagnetic compatibility with the TWC system, operating at frequencies specified in Section 13 or as provided by the Owner. LTK Standard Streetcar Specifications Section 15 35 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 5. Inductive Emission Testing: Perform in accordance with UMTA-MA-06-0153-85-8, (NTIS PB87194379) Method RT/IE01A, or approved equal, with the following addition for the TWC system: a. Test for electromagnetic compatibility with the TWC system, operating at frequencies specified in Section 13 or as provided by the Owner. 15.9.8 Equipment Settings for Vehicle-Level Routine Dynamic Test at the Owner’s Facilities Use vehicle-level type dynamic tests to determine equipment settings and calibrations for vehicle routine tests at the Owner’s facilities: 1. Develop the following for a continuous range of passenger loadings from empty to fully loaded: a. Torque vs. passenger load state, per powered truck b. Brake cylinder pressure vs. passenger load state, per each unique truck braking configuration 2. Reference these relationships to evaluate vehicle-level routine testing of all other vehicles, which may then be tested without load during vehicle-level routine testing. 15.10 Vehicle-Level Routine Static Tests at the Owner’s Facilities 15.10.1 General Perform the vehicle-level routine static tests listed below on each assembled vehicle prior to the vehiclelevel routine dynamic testing. In addition to the tests listed, repeat other vehicle-level routine static tests performed at the Contractor’s facilities if requested by the Owner. 15.10.2 Door, Operators and Controls Test and adjust each door and its operating equipment: 1. Check the obstruction detection features for proper operation and adjust before the start of the cycling test. This feature shall operate properly, without the need for readjustment, at the end of the cycling tests. 2. Operate each door a minimum of 100 consecutive, successful cycles. Initiate cycling through the control line. 3. Before and after the above cycling, verify proper forces for opening and closing on each door. 4. If a door or controls fail before completion of the test, document correction of the failure and restart the test from the beginning. 5. Make any necessary adjustments to ensure smooth functioning, attainment of the required speed of operation, and specified operation of controls, signals and interlocks. 15.10.3 Bridge Plate, Operators and Controls Comply with the following, in addition to requirements for the Door, Operators and Controls Routine Test, above: 1. Test and adjust each bridge plate and its operating equipment. 2. Check the obstruction detection features for proper operation and adjust before the start of the cycling test. This feature shall operate properly, without the need for readjustment, at the end of the cycling tests. 3. Operate each bridge plate a minimum of 100 consecutive, successful cycles. Initiate cycling through the control line. LTK Standard Streetcar Specifications Section 15 36 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 4. Before and after the above cycling, verify proper forces for extending and retracting for each bridge plate. 5. If a bridge plate or control fails before completion of the test, document correction of the failure and restart the test from the beginning. 6. Make any necessary adjustments to ensure smooth functioning, attainment of the required speed of operation, and specified operation of controls, signals and interlocks. 15.10.4 Heating Perform a functional test of the heating system by simulation of inputs with the PTU: 1. Demonstrate operation of the thermostatic control system by using the PTU. 2. Apply heat to the overhead heaters without air flow and cycle the high-limit control switch three times. 3. During the test, record power consumption and verify proper operation of all controls. 4. The test shall be successful when the backup protection device is not activated. 15.10.5 Air Conditioning Test the air conditioning system by simulating inputs with the Portable Test Unit (PTU): 1. Demonstrate operation of the thermostatic control system by using the PTU. 2. Verify the sequence of capacity modulation, as applicable, and system pump-down. 3. Record the system refrigerant charge and the refrigerant condition (wet or dry) in liquid sight glasses. 4. Correct abnormal conditions and repeat the associated test. 15.10.6 Headlight and Stoplight Adjustments Aim and adjust the headlights and stop lights on each vehicle to meet the specified requirements. 15.10.7 Friction Brake Perform a functional test of the friction brake system. Tests shall include the following, as a minimum: 1. 2. 3. 4. 5. Verification of brake cylinder pressure settings Control and indicator verification System leakage tests Response to dynamic brake feedback signals Functional test of the brake fault detection system 15.10.8 Communication Systems Functionally test communication equipment and systems to verify conformance with specified requirements. In addition, perform the following tests: 1. Test the PA system, APIS and each PEI for clarity (intelligibility) of voice transmission and reception. 2. Test APC to verify accuracy of the system. 3. Test the CCTV and exterior side view CCTV to verify proper positioning of cameras. 4. Test communication systems not tested at the Contractor’s Facilities: a. Radio b. GPS c. Vehicle Wireless Communication to Wayside LTK Standard Streetcar Specifications Section 15 37 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing d. Automatic Vehicle Locator e. Traffic Light Priority 15.11 Vehicle-Level Routine Dynamic Tests at the Owner’s Facilities 15.11.1 General After completion of all vehicle-level routine static tests and vehicle-level type tests conducted at the Owner’s facilities, perform the following vehicle-level routine dynamic tests on each vehicle at the Owner’s facilities and on the Project alignment. 1. Successful completion of testing is a condition of Acceptance of each vehicle. 2. Instrumentation for the vehicle-level routine dynamic tests shall be as specified for vehicle-level type dynamic tests, as specified above. 15.11.2 Joint Inspection Before starting dynamic routine testing, jointly inspect the vehicle with the Owner. Make adjustments, repairs, or replacements as required for proper operation or as deemed necessary by the Owner. 15.11.3 Vehicle Performance Test Demonstrate, by dynamic testing on the Project alignment, that each vehicle’s tractive power, dynamic braking, friction braking, and track braking systems meet the criteria used for the Vehicle Dynamic Type Tests. 1. Test the vehicles only at AW0. 2. If adjustments are required to obtain values corresponding to the required performance levels, make adjustments before formal delivery and note in the vehicle's history book. 15.11.4 Burn-In Test Perform burn-in test: 1. Sequence: Perform after successful completion of the vehicle performance test. 2. Test: Operate each vehicle a minimum 1000 km (621 mi) on the Project alignment in mixed traffic. During the last 100 km (62 mi), there shall be no failures, using the same criteria as that used for Reliability in Section 2, Design and Performance Criteria. 3. Retest: If a failure occurs in the last 100 km, correct the problem and restart the 100 km portion of the test. 4. Successful completion is a condition of Conditional Acceptance. 15.12 Cooperation with the Owner and Other Systems Assist the Owner as necessary in operation of the vehicle(s) for systems integration testing, including but not limited to interface with maintenance facility, OCS, substations, signal system, track, and wayside. 15.13 Contract Data Requirements List (CDRL) 15.13.1 General Requirements Comply with the following: 1. Type tests: Submit a test procedure and test report for each. LTK Standard Streetcar Specifications Section 15 38 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. Component routine tests: Submit the manufacturer’s routine test procedure for each. Include routine test reports with the shipping documents or furnish separately to verify that the tests were performed successfully. 3. Vehicle level routine test: Submit a test procedure and test report. 4. For CDRLs for which both a test procedure and a test report is required, submit test procedures and test reports using the appropriate CDRL number followed by "P" for procedure and "R" for test report, such as CDRL 15-12.P and CDRL 15-12.R. 5. For test reports where multiple vehicles are tested, submit a separate test report for each vehicle, and include the vehicle designator in the CDRL number, such as CDRL 15-41.R/302. Submit the following in accordance with Section 19, Program Control and Quality Assurance. 15.13.2 CDRL Details 15-1 Master Test Plan: 1. Submit within 180 days after NTP. 2. Include each test, whether specifically referenced in this Section or located in another section of the Specifications. 3. Include a proposed schedule and location for each test. 15.13.2.1 Component Type Test CDRLs 15-2 Flammability, Smoke Emission, and Toxicity (FST) Type Test: A. FST Type Test Procedures: 1. Assemble and submit materials and test procedures for all materials as one package. 2. Include a list of each material included in the package with description of where each type material is used. 3. For each material, include a list of the tests to be performed with the name of applicable testing standards. 4. Include pass/fail criteria for each material B. FST Type Test Reports: 1. Assemble and submit test reports for all materials as one package. 2. Include sufficient test result data to demonstrate compliance with toxic gas release limits of Section 16, Materials and Workmanship, and requirements of this Section. 3. State explicitly whether each material passed or failed each test 15-3 Waiver of FST Type Testing: 1. Submit in writing as one package, including each type material for which a waiver is requested. 2. Include the total weight of the material to be used, the location of the material and its distribution in the vehicle. 3. Furnish flammability, smoke emission, and toxicity test reports for each material. LTK Standard Streetcar Specifications Section 15 39 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15-4 Paint Performance Type Test: A. Paint Performance Type Test Procedure: 1. Include a list of each type of paint and powder used on the vehicle with its location on the vehicle and sufficient identifying information so that it can be cross referenced with the paint design package specified in Section 16, Materials and Workmanship. 2. Include specified test criteria 3. Include step-by-step test procedures for each specified test B. Paint Performance Type Test Report: 1. Submit as one package including test results for each type of paint and powder used on the vehicle. 2. Include sufficient test data to demonstrate compliance with the Specifications. 3. Indicate whether each type of paint or powder passed or failed each test. 15-5 FRP Type Test Certificates: 1. For each FRP item, furnish an independent laboratory test certificate stating that the production FRP material complies with the specified strength requirements when tested in accordance with the standards specified in Section 16, Materials and Workmanship. 15-6 EMI/EMC Component Type Tests: A. EMI/EMC Component Type Tests Procedure: 1. Furnish a test procedure prepared by the qualified test laboratory conducting the test. 2. Procedure shall include the testing standards used for each test. B. EMI/EMC Component Type Tests Report: 1. Group all test reports into one submittal. 2. For each test, furnish the test report prepared by the qualified test laboratory conducting the test. 3. Test report shall include sufficient test data to demonstrate compliance with the Specifications. 15-7 Cab and Floor Heater Type Tests: A. Cab and Floor Heater Type Tests Procedure: 1. Include separate procedures for each type of heater. 2. Include step-by-step test procedures for each test necessary to demonstrate compliance with the Specifications. B. Cab and Floor Heater Type Tests Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-8 AC Traction Motor Type Test: A. AC Traction Motor Type Test Procedure: 1. Include the agreed to IEC 60349-2 method for determination of the characteristics and efficiency and describe adaptations required for compliance with the Specifications. LTK Standard Streetcar Specifications Section 15 40 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 2. Include step-by-step test procedures for each test necessary to demonstrate compliance with the Specifications. B. AC Traction Motor Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-9 AC Auxiliary Motor Type Test: A. AC Auxiliary Motor Type Test Procedure: 1. Include a list of motors to be tested. 2. Include a list of each test to be conducted. 3. Include step-by-step procedures complying with the specified standard. B. AC Auxiliary Motor Type Test Report: 1. Include test data and a statement of pass or fail for each test in accordance with the specified standard. 15-10 Traction Gear Unit Type Test: A. Traction Gear Unit Type Test Procedure: 1. Include the criteria and calculations used to determine the conditions to which the unit will be subjected during the test. 2. Include step-by-step test procedures for the test, including measurements to be taken. 3. Include a checklist for the specified post-test examination of all parts. B. Traction Gear Unit Type Test Report: 1. Include gear tooth mesh and tooth pattern from before and after the test. 2. Include test records of running time and oil temperatures. 3. Include vibration and sound level readings recorded during the test. 15-11 Auxiliary Power Supply (APS) Type Test: A. Auxiliary Power Supply Type Test Procedure: 1. Include the following as a minimum: a. b. c. d. e. Applicable specified design requirements, environmental ranges, and supply voltages. Applicable tests from the specified standard. Details of combined system test demonstrating the capability to start up all ac loads. Details of temperature-rise test. Details of planned noise measurements. 2. If low-voltage power supply (LVPS) and battery charger are part of the APS unit, submit as a combined test procedure under this CDRL. B. Auxiliary Power Supply Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. LTK Standard Streetcar Specifications Section 15 41 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15-12 Low-Voltage Power Supply and Battery Charger Type Test: A. Low-Voltage Power Supply and Battery Charger Type Test Procedure: 1. Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. 2. Include procedures for demonstrating that the battery charger complies with the Specifications. B. Low-Voltage Power Supply and Battery Charger Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-13 Truck Frame Type Test: A. Truck Frame Type Test Procedure: 1. Combine test procedures for all truck tests and submit minimum 90 days before the test date. 2. Approval of the test procedure and stress analysis are necessary prerequisites for testing. 3. The test procedure shall include, but not be limited to the following: a. b. c. d. e. f. g. h. i. A description of the test The purpose Clear description as to how the test specimen is to be loaded The load increments Description of the equipment to be used to load the specimen Type and location of strain gauges Location of deflection gauges Complete description of all instruments Details of the data acquisition system 4. Include the following drawings and sketches: a. Drawings and sketches as needed to clarify the text b. Drawings showing the test fixture, the specimen installed in the fixture, and location of load application points c. Drawings and sketches showing the location of every strain gauge 5. Include a list of the steps to be performed. 6. Include a copy of the current calibration for each instrument and gauge to be used during the test. 7. Include the calculation of the accuracy of the test system. 8. Include typical logging sheets, print-outs, plotting forms, and examples of other data sheets that will be used during the test or in the final report. 9. Include the following tables: a. Table showing the maximum allowable gauge reading for each gauge and loading condition. b. Table listing, for each strain gauge, the strains calculated by the FEA at the gauge location, so that the output of the strain gauge reading is readily comparable to the information in the table. LTK Standard Streetcar Specifications Section 15 42 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing c. Other tables, showing the acceptable criteria for all other test results, shall be included in the test procedure. 10. For the fatigue test include the following: a. Critical locations and fatigue allowables selected by the Contractor. B. Truck Frame Type Test Report: 1. Include tables prepared for the test procedure with test results entered for comparison. 2. Include copies of original data sheets, data plots, and other means used for gathering data during the test. 3. Include a summary of the results indicating whether or not the truck is compliant with the Specifications. If not compliant, indicate what corrections will be made and the schedule for the truck retest. 4. For the pre-fatigue-test magnetic particle and dye penetrant inspection, if defects are found, include the specified documentation of defects, and if required, repairs. 15-14 Traction Inverter Type Test: A. Traction Inverter Type Test Procedure: 1. Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. B. Traction Inverter Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15.13.2.2 Vehicle-Shell Structural Type Test CDRL 15-15 Vehicle-Shell Structural Type Tests: A. Vehicle-Shell Structural Type Tests Procedure: 1. Combine the test procedures for all vehicle-body structural tests. 2. Submit minimum 90 days in advance of the test date. 3. Include the following. Annotated copies of catalogue cuts may be used to provide some of this description: a. A description of the test b. The purpose c. How and with what equipment the specimen is to be loaded and in what load increments d. The type and location of strain gauges e. The location of deflection gauges f. Complete description of all instruments and gauges g. Details of the data acquisition system h. An explanation of the accuracy of the instrumentation 4. Include the following drawings and sketches: a. Drawings and sketches to clarify the text LTK Standard Streetcar Specifications Section 15 43 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing b. Plots of the finite element mesh showing the location of every strain gauge. Dimension the location of each gauge showing the distance from edges, connections and bends. Note the location on upper or lower, inner or outer surface. 5. Include step-by-step instructions for the following: a. b. c. d. Description of how load is applied The load at each step When to record data The place where authorization to proceed is to be obtained from the Owner’s representative 6. Include a copy of the current certification for every instrument and gauge to be used during the test. 7. Include a calculation of the accuracy of the test system for each test 8. Include typical logging sheets, print-outs, plotting forms, and examples of other data sheets that will be used during the test or in the final report. 9. Include the following tables: a. Tables showing the maximum allowable gauge reading for each gauge and loading condition b. Tables showing the requirements for all other test criteria c. A table of analytical strain (or stress) values at selected strain gauge locations. This table shall list the following: • • • • • • Strain gauge number Analytical strain (or stress) from the stress analysis The location of the strain A space to enter the measured strain (or stress) A space to enter the calculated percent difference A space for annotation B. Vehicle-Shell Structural Type Tests Report: 1. Fill in the comparison table that was included in the test procedure with values for measured strain (or stress) and the calculated percent difference between the analytical and measured values. 2. Approval of the Test Report will depend, in part, on the adequacy of the analyses of excessive variance between analytical and measured stress values. 3. Where the percent difference between the actual and analytical values of stress for the 25% exceeds the specified values, include the specified detailed explanation of the reasons for the excessive variance. 15.13.2.3 System Type Test CDRLs 15-16 Floor Assembly Fire Performance Type Test: A. Floor Assembly Fire Performance Type Test Procedure: 1. Include the following as a minimum: a. Drawing of the section of floor to be tested showing location on vehicle, dimensions, loading, penetrations, and thermocouples LTK Standard Streetcar Specifications Section 15 44 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing b. Test facility 2. Include step-by-step procedure that incorporates criteria from the specified standards. 3. Include minimum fire exposure duration B. Floor Assembly Fire Performance Type Test Report: 1. Furnish test report prepared by the test facility, including temperatures, performance, and a test summary indicating pass or fail. 15-17 Roof Assembly Fire Performance Type Test: A. Roof Assembly Fire Performance Type Test Procedure: 1. Include the following as a minimum: a. Drawing of the section of roof to be tested showing dimensions, penetrations, and thermocouples b. Proposed test facility 2. Include step-by-step procedure that incorporates criteria from the specified standards. 3. Include minimum fire exposure duration. B. Roof Assembly Fire Performance Type Test Report: 1. Furnish test report prepared by the test facility, including temperatures, performance, and a test summary indicating pass or fail. 15-18 Propulsion Combined Type Test: A. Propulsion Combined Type Test Procedure: 1. Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. B. Propulsion Combined Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-19 Friction Brake System Type Test: A. Friction Brake System Type Test Procedure: 1. Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. B. Friction Brake System Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-20 Door System Type Test: A. Door System Type Test Procedure: 1. Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. LTK Standard Streetcar Specifications Section 15 45 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing B. Door System Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-21 Bridge Plate System Type Test: A. Bridge Plate System Type Test Procedure: 1. Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. B. Bridge Plate System Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. 15-22 Unitized HVAC System Type Test: A. Unitized HVAC System Type Test Procedure: 1. Submit one test procedure and include each individual test specified. 2. Include step-by-step procedures for each individual test B. Unitized HVAC System Type Test Report: 1. Submit as one test report after each individual test is completed. 15-23 Communication Systems Type Test: A. Communication Systems Type Test Procedure: 1. Include step-by-step procedures for each subsystem being tested. B. Communication Systems Type Test Report: 1. Submit as one test report after each individual test is completed. 15.13.2.4 Vehicle-Level Type Static Test CDRLs 15-24 Vehicle-Level Type Static Tests: A. Vehicle-Level Type Static Test Procedures: 1. Include a description of instrumentation and channel assignments. 2. Include step-by-step test procedures for the following tests as a minimum: a. b. c. d. e. f. g. h. i. j. k. Horn and bell type test Jacking type test Ducting watertightness type test Air leakage type test Air balance type test HVAC system type test Door operation type test Bridge plate operation type test Lighting intensity type test Communication equipment type tests Vehicle data network type test LTK Standard Streetcar Specifications Section 15 46 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 3. Include each specified test requirement. B. Vehicle-Level Type Static Test Reports: 1. Submit as one test report after each individual test is completed. 15.13.2.5 Component Routine Test CDRLs 15-25 Air Conditioning Unit Routine Test Procedure 15-26 Motor Routine Test Procedure 15-27 Traction Gear Unit Routine Test Procedure 15-28 Traction Inverter Routine Test Procedure 15-29 AC Auxiliary Power Supply Routine Test Procedure 15-30 Low-Voltage Power Supply and Battery Charger Routine Test Procedure 15-31 Battery Routine Test Procedure 15-32 Friction Brake Routine Test Procedure 15-33 Communication System Routine Tests Procedure 15-34 Truck Frame Welds Routine Test Procedure 15-35 Wheel Back-to-Back Routine Test Procedure 15-36 Resistance Routine Test Procedure: 1. Wheel shunt resistance 2. Vehicle-structure to wheels resistance 3. Propulsion system to wheels resistance 15-37 TWC System Routine Test Procedure 15.13.2.6 Vehicle-Level Routine Test CDRLs (Contractor’s Facilities) 15-38 Vehicle-Level Systems Routine Functional Tests: A. Vehicle-Level Systems Routine Functional Tests Procedure: 1. Include a list of systems to be tested 2. Include step-by-step procedures used for each system 3. Include pass/fail criteria for each test B. Vehicle-Level Systems Routine Functional Test Report: 1. Submit as one test report after each individual test is completed. 15-39 Vehicle Wiring Routine Tests: A. Vehicle Wiring Routine Test Procedure: 1. Include test methods and voltages applied 2. Include instruments used with calibration dates 3. Include step-by-step procedures for each of the following: a. Wiring Continuity Checks b. Insulation Resistance Test c. Dielectric (High Potential) Test B. Vehicle Wiring Routine Test Report LTK Standard Streetcar Specifications Section 15 47 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15-40 Watertightness Routine Tests: A. Watertightness Routine Tests Procedure: 1. Include details of the spray equipment 2. Include a sketch of the test setup 3. Include step-by-step procedures for each of the following watertightness tests: a. b. c. d. Vehicle HVAC Equipment Enclosures Traction Motor Leads B. Watertightness Routine Tests Report 15.13.2.7 Vehicle-Level Type Dynamic Test CDRLs (the Owner’s Facilities) 15-41 Vehicle-Level Type Dynamic Tests: A. Vehicle-Level Type Dynamic Test Procedure: 1. Include the following: a. Type Testing Instrument Calibration Certification: • • Include each instrument to be used during vehicle type testing. Verify that calibration is current such that recalibration will not be required during the scheduled duration of testing. b. Step-by-step procedures for the following tests as a minimum: • • • Auxiliary inverter type test Propulsion and braking type tests Emergency towing type test 2. Include each specified test requirement for each system. B. Vehicle-Level Type Dynamic Test Report: 1. Auxiliary Inverter: Include representative samples of chart recordings of inverter operating characteristics taken during the auxiliary inverter component type test and the vehicle type tests. 2. Propulsion and Braking: a. Present test results with specified performance criteria in a clear and organized fashion. b. Include results of each type of test, including the following as a minimum: • • • • • Each specified run and series specified for propulsion and dynamic and friction braking Track brake system test Thermal capacity test Wheel spin/slide Parking brake LTK Standard Streetcar Specifications Section 15 48 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 3. Strip charts and recordings taken during the vehicle level type testing shall become the property of the Owner. 15-42 Ride Quality Type Test: A. Ride Quality Type Test Procedure: 1. Include a sketch and description of instrumentation. 2. Include a sketch and description of weights used to simulate loading. B. Ride Quality Type Test Report: 1. Include raw data. 2. Include analysis of data and calculations. 15-43 Noise and Vibration Type Test: A. Noise and Vibration Type Test Procedure: 1. Include a sketch and description of instrumentation setups. 2. Include forms for recording data. 3. Indicate section of alignment where measurements will be taken. B. Noise and Vibration Type Test Report: 1. Include raw data. 2. Include summary clearly showing whether the specified levels have been achieved. 15-44 EMI/EMC Type Test: A. EMI/EMC Type Test Procedure: 1. Include a sketch and description of instrumentation setups. 2. Include forms for recording data. B. EMI/EMC Type Test Report: 1. Include raw data. 2. Include summary clearly showing whether the specified levels have been achieved. 15.13.2.8 Vehicle-Level Routine Static Tests (the Owner’s Facilities) 15-45 Vehicle-Level Routine Static Tests at the Owner’s Facilities: A. Vehicle-Level Routine Static Tests at the Owner’s Facilities Test Procedure: 1. Include step-by-step test procedures for the following tests as a minimum: a. b. c. d. e. f. Door, Operators and Controls Bridge Plate, Operators and Controls Air Conditioning Heating Headlight and Stoplight Adjustments Friction Brake 2. Communication System B. Vehicle-Level Routine Static Tests at the Owner’s Facilities Test Report LTK Standard Streetcar Specifications Section 15 49 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Testing 15.13.2.9 Vehicle-Level Routine Dynamic Tests (the Owner’s Facilities) 15-46 Vehicle Performance Test on Project Alignment: A. Vehicle Performance Test on Project Alignment Test Procedure: 1. Include a description of instrumentation and channel assignments. 2. Include step-by-step test procedures for the following tests as a minimum: a. b. c. d. Tractive power system Dynamic braking system Friction braking system Track braking system B. Vehicle Performance Test on Project Alignment Test Report 15-47 Burn-In Test: A. Burn-In Test Procedure: 1. Include samples of forms used for recording mileage and equipment failures. B. Burn-In Test Report END OF SECTION LTK Standard Streetcar Specifications Section 15 50 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship Table of Contents 16.1 General ......................................................................................................................................1 16.1.1 Scope .............................................................................................................................................. 1 16.1.2 Quality ............................................................................................................................................ 1 16.1.3 Standards ....................................................................................................................................... 1 16.1.4 Material Availability in the U.S....................................................................................................... 1 16.1.4.1 Cleaning Agents ...................................................................................................................... 1 16.1.4.2 Maintenance Materials ........................................................................................................... 1 16.1.5 Storage of Material ........................................................................................................................ 1 16.1.6 Prohibited Materials ...................................................................................................................... 2 16.1.7 Material Reporting Requirements ................................................................................................. 2 16.1.8 Dissimilar Materials........................................................................................................................ 2 16.2 Standards of Workmanship.........................................................................................................3 16.2.1 Workers .......................................................................................................................................... 3 16.2.2 Use of Drawings and Procedures ................................................................................................... 3 16.2.3 Use of Manufacturing Tools and Interchangeability...................................................................... 3 16.2.4 Prohibited Practices ....................................................................................................................... 3 16.2.5 Metal Fabrication ........................................................................................................................... 4 16.2.6 Machining....................................................................................................................................... 4 16.3 Fasteners ...................................................................................................................................4 16.3.1 General ........................................................................................................................................... 4 16.3.1.1 Scope....................................................................................................................................... 4 16.3.1.2 Design ..................................................................................................................................... 4 16.3.1.3 Material................................................................................................................................... 5 16.3.1.4 Plating ..................................................................................................................................... 5 16.3.1.5 Prohibited ............................................................................................................................... 5 16.3.2 General Requirements for Threaded Fasteners............................................................................. 5 16.3.2.1 Head Types.............................................................................................................................. 5 16.3.2.2 Identification ........................................................................................................................... 5 16.3.2.3 Maintenance Access ............................................................................................................... 6 16.3.2.4 Thread Projection ................................................................................................................... 6 16.3.2.5 Bolt Hole Size .......................................................................................................................... 6 16.3.2.6 Tapping Plates ......................................................................................................................... 6 16.3.3 Special Requirements for Structural Fasteners ............................................................................. 6 LTK Standard Streetcar Specifications Section 16 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.3.3.1 Scope....................................................................................................................................... 6 16.3.3.2 Material and Property Class (or Grade) .................................................................................. 6 16.3.3.3 Minimum Size ......................................................................................................................... 7 16.3.3.4 Required Documentation ....................................................................................................... 7 16.3.3.5 Additional Requirements for Safety-Related Fasteners ......................................................... 7 16.3.4 Coatings other than Zinc ................................................................................................................ 8 16.3.5 Self-Locking Nuts and Washers ...................................................................................................... 8 16.3.5.1 Self-Locking Nuts..................................................................................................................... 8 16.3.5.2 Washers .................................................................................................................................. 9 16.3.6 Torquing ......................................................................................................................................... 9 16.3.7 Other Fasteners............................................................................................................................ 10 16.3.7.1 Quick-Release Fasteners ....................................................................................................... 10 16.3.7.2 Rivets and Lock Pins .............................................................................................................. 10 16.3.8 Location- and Application-Specific Requirements ....................................................................... 10 16.3.8.1 Interior – Exposed to Passengers.......................................................................................... 10 16.3.8.2 Exterior – Exposed to Passengers ......................................................................................... 11 16.3.8.3 Access Required .................................................................................................................... 11 16.3.8.4 Heat Producing Equipment ................................................................................................... 11 16.4 Joining ..................................................................................................................................... 11 16.4.1 Joint Fitting................................................................................................................................... 11 16.4.2 Metal-to-Metal Connections........................................................................................................ 11 16.4.3 Wood-to-Metal Connections ....................................................................................................... 11 16.4.4 Wood-to-Wood Connections ....................................................................................................... 12 16.5 Metal ....................................................................................................................................... 12 16.5.1 Stainless Steel .............................................................................................................................. 12 16.5.1.1 Austenitic Stainless Steel ...................................................................................................... 12 16.5.1.2 Ferritic Stainless Steel ........................................................................................................... 12 16.5.1.3 Other Stainless Steel ............................................................................................................. 13 16.5.1.4 Testing................................................................................................................................... 13 16.5.2 High-Strength Low-Alloy Steel (HSLA).......................................................................................... 13 16.5.3 Steel Castings ............................................................................................................................... 13 16.5.3.1 General.................................................................................................................................. 13 16.5.3.2 Design Qualification .............................................................................................................. 14 16.5.3.3 Quality................................................................................................................................... 14 LTK Standard Streetcar Specifications Section 16 ii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.5.3.4 Specific Applications ............................................................................................................. 15 16.5.4 Aluminum ..................................................................................................................................... 15 16.5.4.1 General Requirements .......................................................................................................... 15 16.5.4.2 Design Stresses ..................................................................................................................... 16 16.5.4.3 Connections to Aluminum .................................................................................................... 16 16.6 Welding and Brazing ................................................................................................................. 17 16.6.1 General ......................................................................................................................................... 17 16.6.1.1 Scope..................................................................................................................................... 17 16.6.1.2 Quality................................................................................................................................... 17 16.6.2 Welding and Brazing Prohibitions ................................................................................................ 17 16.6.3 Welding ........................................................................................................................................ 17 16.6.3.1 Structural Welding ................................................................................................................ 17 16.6.3.2 Welding Procedure Qualification.......................................................................................... 18 16.6.3.3 Welder Qualification and Identification ............................................................................... 18 16.6.3.4 Weld Type Requirements ..................................................................................................... 19 16.6.3.5 Weld Inspection .................................................................................................................... 19 16.6.3.6 Weld Cleaning Requirements ............................................................................................... 19 16.6.3.7 Welding Rod or Wire ............................................................................................................ 20 16.6.3.8 Special Welding ..................................................................................................................... 20 16.6.3.9 Resistance Welding ............................................................................................................... 20 16.6.3.10 Resistance, Spot Weld and Intermittent Weld Spacing ...................................................... 20 16.6.3.11 Toughness of Welded Assemblies ...................................................................................... 21 16.6.4 Torch Brazing ............................................................................................................................... 21 16.6.5 Torch Soldering ............................................................................................................................ 21 16.7 Elastomers ............................................................................................................................... 22 16.7.1 General ......................................................................................................................................... 22 16.7.2 Applications.................................................................................................................................. 22 16.8 Piping and Tubing (other than Air Conditioning) ........................................................................ 22 16.8.1 General ......................................................................................................................................... 22 16.8.2 Hydraulic Piping, Tubing, Hose, and Fittings ................................................................................ 23 16.9 Paints, Graphics, and Coatings .................................................................................................. 24 16.9.1 General ......................................................................................................................................... 24 16.9.2 Materials Not to be Painted ......................................................................................................... 24 16.9.3 Paint and Powder Coat Materials ................................................................................................ 24 LTK Standard Streetcar Specifications Section 16 iii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.9.3.1 General.................................................................................................................................. 24 16.9.3.2 Primers .................................................................................................................................. 25 16.9.3.3 Top coats ............................................................................................................................... 25 16.9.3.4 Powder Coat ......................................................................................................................... 25 16.9.4 Preparation and Paint or Powder Application ............................................................................. 25 16.9.4.1 General.................................................................................................................................. 25 16.9.4.2 Applicator Qualifications ...................................................................................................... 25 16.9.4.3 Vehicle Body ......................................................................................................................... 25 16.9.4.4 Exterior Not Visible to Passengers ........................................................................................ 26 16.9.4.5 Trucks .................................................................................................................................... 26 16.9.4.6 Exterior Visible to Passengers ............................................................................................... 27 16.9.4.7 Stainless Steel and FRP ......................................................................................................... 27 16.9.5 Graphics ....................................................................................................................................... 27 16.9.6 Other Coatings ............................................................................................................................. 27 16.10 Flammability, Smoke Emission, and Toxicity Requirements ...................................................... 28 16.11 Wood and Panels .................................................................................................................... 28 16.11.1 Lumber ....................................................................................................................................... 28 16.11.2 Plywood...................................................................................................................................... 28 16.11.3 Plymetal ..................................................................................................................................... 28 16.11.4 Honeycomb Panels..................................................................................................................... 29 16.11.5 Melamine-Faced Aluminum ....................................................................................................... 29 16.11.6 Phenolic Composite Floor Panels ............................................................................................... 30 16.11.6.1 Panels .................................................................................................................................. 30 16.11.6.2 Physical Test Requirements ................................................................................................ 30 16.11.7 Flatness ...................................................................................................................................... 32 16.12 Fiberglass Reinforced Plastic (FRP) .......................................................................................... 32 16.12.1 General ....................................................................................................................................... 32 16.12.2 Composition ............................................................................................................................... 32 16.12.3 Gel Coat ...................................................................................................................................... 32 16.12.4 Manufacturing ........................................................................................................................... 33 16.12.5 Strength Requirements .............................................................................................................. 33 16.12.5.1 General................................................................................................................................ 33 16.12.5.2 Non-Structural (No load) .................................................................................................... 33 16.12.5.3 Structural (Load) ................................................................................................................. 33 LTK Standard Streetcar Specifications Section 16 iv January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.12.6 Shipping and Handling ............................................................................................................... 34 16.12.7 Installation of FRP Front End...................................................................................................... 34 16.13 Thermoplastic Sheet ............................................................................................................... 34 16.13.1 General ....................................................................................................................................... 34 16.13.2 Product Requirements ............................................................................................................... 34 16.13.3 Strength Requirements .............................................................................................................. 35 16.14 Raceways and Junction Boxes ................................................................................................. 35 16.14.1 Scope .......................................................................................................................................... 35 16.14.2 General Requirements ............................................................................................................... 35 16.14.3 Conduit ....................................................................................................................................... 36 16.14.3.1 Permitted Conduit Types .................................................................................................... 36 16.14.3.2 Conduit Fill .......................................................................................................................... 36 16.14.3.3 Conduit Installation............................................................................................................. 37 16.14.3.4 Conduit Connections to Boxes and Enclosures................................................................... 37 16.14.4 Wireway ..................................................................................................................................... 37 16.14.4.1 Scope................................................................................................................................... 37 16.14.4.2 General Requirements ........................................................................................................ 37 16.14.4.3 Interior ................................................................................................................................ 38 16.14.4.4 Exterior................................................................................................................................ 38 16.14.5 Junction Boxes ........................................................................................................................... 38 16.14.5.1 General................................................................................................................................ 38 16.14.5.2 Exterior Junction Boxes....................................................................................................... 38 16.14.6 Bonding and Grounding Metallic Raceway and Junction Boxes ................................................ 39 16.15 Wire and Cable ....................................................................................................................... 39 16.15.1 General ....................................................................................................................................... 39 16.15.2 Wire and Cable Type Requirements .......................................................................................... 39 16.15.2.1 Conductors .......................................................................................................................... 39 16.15.2.2 Insulation ............................................................................................................................ 39 16.15.2.3 Multi-Conductor Cables ...................................................................................................... 40 16.15.2.4 Ethernet Cable .................................................................................................................... 41 16.15.3 Wire and Cable Application and Installation Requirements ...................................................... 41 16.15.3.1 General................................................................................................................................ 41 16.15.3.2 Wire Sizes ............................................................................................................................ 42 16.15.3.3 Insulation Level ................................................................................................................... 42 LTK Standard Streetcar Specifications Section 16 v January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.15.3.4 High-Temperature Wire ...................................................................................................... 42 16.15.3.5 Circuit Separation ............................................................................................................... 42 16.15.3.6 Spare Wires ......................................................................................................................... 43 16.15.3.7 Wire Handling ..................................................................................................................... 43 16.15.3.8 Wiring Location Requirements ........................................................................................... 43 16.15.3.9 Wiring Methods .................................................................................................................. 43 16.15.3.10 Wire and Cable Installation in Conduit ............................................................................. 44 16.15.3.11 Wire and Cable Installation in Wireway ........................................................................... 44 16.15.3.12 Wire and Cable Installation by Cleating ............................................................................ 45 16.15.3.13 Wiring Within Enclosures.................................................................................................. 45 16.15.3.14 Identification..................................................................................................................... 46 16.15.3.15 Wire Ties, Clamps, and Anchors ....................................................................................... 46 16.16 Wire Terminations .................................................................................................................. 47 16.16.1 General ....................................................................................................................................... 47 16.16.2 Terminal Boards ......................................................................................................................... 47 16.16.3 Non-Power Wiring Terminations ............................................................................................... 47 16.16.4 Power Wiring Terminations ....................................................................................................... 48 16.17 Cable Terminations ................................................................................................................. 48 16.17.1 Multi-Pin Cable Connectors ....................................................................................................... 48 16.17.2 Cable Connectors ....................................................................................................................... 49 16.17.3 Ethernet Cable Connectors ........................................................................................................ 49 16.17.4 Cable Connections to Boxes and Enclosures.............................................................................. 49 16.18 Contract Data Requirements List (CDRL) .................................................................................. 49 LTK Standard Streetcar Specifications Section 16 vi January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.1 General 16.1.1 Scope This Section defines the minimum performance requirements for materials to be used in the construction of vehicles, 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 may be considered by the Owner, if proposed. Inclusion of a material or product in this section does not imply approval of its use in a particular application. Refer to other Sections for detailed requirements for specific vehicle systems. 16.1.2 Quality Ensure that equipment, materials, manufacturing, assembly, and installation processes and practices are in full conformance with the requirements and the intent of the Specifications as well as with proven and recognized industry practices and recommendations. 16.1.3 Standards Materials and workmanship shall conform to the appropriate industry standards for use on rail transit equipment: 1. These standards include Federal or Military specifications or standards, the specifications and standards of the Aluminum Association, AAR, ANSI, ASME, ASNT, ASTM, AWS, FRA, IEEE, IEC, EN, NACE, NFPA, SSPC, or other requirements as specified in this Section. 2. Foreign or international standards may be proposed as alternatives. Submit proposed standards in English for review by the Owner. A service history of equipment built to these standards may be included to demonstrate the applicability of the standard. 16.1.4 Material Availability in the U.S. 16.1.4.1 Cleaning Agents For each part of the vehicle that is normally cleaned, materials proposed for use in that area must have a manufacturer-recommended cleaning agent available and not prohibited in the U.S. 16.1.4.2 Maintenance Materials Fasteners, paint, lubricants, and other materials required for maintenance of the vehicles must be available and not prohibited in the U.S. 16.1.5 Storage of Material Ship and store equipment and material intended for use in these vehicles such that damage and reduction in life are prevented: 1. These requirements apply to equipment and material at the Contractor’s facilities, at the Owner’s facilities, and to capital spare parts. 2. At a minimum, comply with the following: a. Protect stored material subject to corrosion by waterproof covers or coatings. Store materials and equipment under cover and off the floor or ground. LTK Standard Streetcar Specifications Section 16 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship b. Store equipment with ports, covers, and other enclosure openings closed to prevent entrance of dirt or moisture. c. Clearly mark dated material with the expiration date; material shall not be used beyond this date. d. Handle and store material with special handling or storage requirements according to the manufacturer's requirements. • • • For equipment with special storage requirements, include storage and handling instructions with the equipment. Clearly mark and store material with appropriate nomenclature to prevent misapplication. Include instructions on how to prepare equipment for use after long periods of storage, where applicable. 3. Clearly mark rejected material as such and store in a separate area specifically designated for that purpose. 16.1.6 Prohibited Materials The following materials shall be prohibited from use on the vehicles: 1. 2. 3. 4. 5. 6. PVC Asbestos Cadmium (except for battery) Lead, all applications, including in paint and coatings, except for electronics solder PCBs Carcinogenic materials as listed by current Publication of the American Conference of Governmental Industrial Hygienists (ACGIH) 7. CFC and HCFC compounds, including R-22 refrigerant 8. Urethane foam 9. Materials in the List of Highly Hazardous Chemicals, Toxics and Reactives, 29 CFR 1910.119, Appendix A 16.1.7 Material Reporting Requirements Comply with the following: 1. Whenever a proposed commercial material is not covered by a specification or standard, it is considered a contract deliverable, in accordance with Section 1, General Topics and Definitions, and must be submitted in accordance with Section 19, Program Control and Quality Assurance. 2. Keep on file Safety Data Sheets (SDSs) for chemical materials (paints, solvents, adhesives, etc.) used in the manufacture of the vehicle, and furnish SDS information as requested by the Owner for any questionable material. SDSs shall comply with 29 CFR 1910.1200 (g). 3. Maintain records that trace all materials to their manufacturers and production lots, and help verify compliance with quality standards specified or cited in this Section. 16.1.8 Dissimilar Materials Dissimilar materials are materials that corrode or otherwise become damaged when in contact with each other. 1. Connection of dissimilar materials is permitted only at permanent connections and with approved electrochemical isolation. LTK Standard Streetcar Specifications Section 16 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Electrochemical isolation treatments shall be permanent and not require maintenance or replacement for the life of the vehicle. 3. Dissimilar materials are not permitted at electrical connections or connections requiring disassembly for maintenance or for removal and replacement of equipment. 16.2 Standards of Workmanship 16.2.1 Workers Comply with the following: 1. Vehicle components shall be constructed by workers experienced in the appropriate trades. 2. Comply with worker training and supervision requirements included in the manufacturing control requirements specified in Section 19, Program Control and Quality Assurance. 16.2.2 Use of Drawings and Procedures Comply with the following: 1. Design and/or construction drawings and procedures shall be readily available where manufacturing is occurring, and shall be used by workers to accomplish and verify their tasks. 2. Comply with requirements in the Manufacturing section of Section 19, Program Control and Quality Assurance, to ensure that workers are always using the current revision. 3. Use tooling as defined by the design and/or construction drawings. 4. Work not expressly detailed on the Contractor's drawings, such as internal standards or documents, shall conform to the minimum standards of workmanship in this Section, and are subject to the same review and approval standards as the drawings. 16.2.3 Use of Manufacturing Tools and Interchangeability Comply with the following: 1. Attachment points in the vehicle and on subassemblies shall be located by jigs, fixtures, laser levels, and similar methods, unless waived by the Owner, to ensure accurate placement and perdesign tolerances. 2. Like components shall be constructed to the same dimensions and tolerances, hole and subassembly locations, materials and finishes, and shall be interchangeable in the vehicle and between vehicles without modification. 16.2.4 Prohibited Practices The following are strictly prohibited: 1. Cut-to-fit, match drilling, filing, and other hand-fitting practices, unless specifically approved by the Owner. Where such practices appear necessary in construction, perform a prompt review of design and construction methods and implement corrections to avoid these practices, in accordance with manufacturing control requirements specified in Section 19. 2. Modification of OEM or subcontractor equipment, including minor modifications such as replacement of wire terminations. 3. Modification of Contractor equipment without following the approved Modification and Configuration Control Manual procedure, as specified in Section 19, Program Control and Quality Assurance. LTK Standard Streetcar Specifications Section 16 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.2.5 Metal Fabrication Comply with the following: 1. In rolled-steel members, camber and sweep, as received, shall not exceed AISC specifications. 2. Flat plates shall be sheared or cut using modern metal-cutting technology such as laser cutting or waterjet cutting. 3. Structural shapes, pipe, and tube shall be cut to length using band saw or cold cut blade saw. Cut to length by hand held torch is not permitted. 4. Holes shall be drilled or die punched. Bolt holes shall not be burned by hand torch. Holes 38 mm (1.5 in) and larger may be cut by modern metal-cutting technology such as laser cutting or waterjet cutting. 5. Spacing of holes on connection plates shall have a tolerance of maximum 0.8 mm (1/32 in). 16.2.6 Machining Comply with the following: 1. Machine fits shall adhere to ASME B4.1. 2. Surfaces receiving power machine cutting or profiling shall have a surface finish of maximum 0.003 mm (125 microinches) RMS. 3. Shafting shall have the ends squared by face off in an engine lathe. 4. Chamfers shall be machined on shaft edges and at edge of bore of press on parts. 5. Cut edges shall be de-burred. 16.3 Fasteners 16.3.1 General 16.3.1.1 Scope Fasteners include threaded fasteners, associated nuts, tapping plates, and washers; quick-release fasteners; rivets; and locking pins. 16.3.1.2 Design Take note of the Owner’s preferences, and comply with requirements: 1. The Owner’s preference is that fasteners conform to ISO metric standards. However, use of inch-standard fasteners will be permitted for U.S. suppliers for which using metric fasteners would require a redesign of products. In the Specifications, metric units and standards are followed by inch units and standards in parentheses. 2. The Owner has a strong preference for the following: a. Fasteners used to mount equipment to the vehicle: Metric. b. Fasteners used internal to equipment: Metric- or inch-standard, but not mixed. 3. The Contractor shall be responsible for selecting fastener types, sizes, styles, lengths, materials, grades, and finishes that will satisfy the requirements of the design and meet the requirements of the Specifications. 4. Minimize the number of different sizes and styles of fasteners used. LTK Standard Streetcar Specifications Section 16 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.3.1.3 Material Comply with the following: 1. Bolts, screws, nuts, washers, and other related fastening devices shall be plated steel or stainless steel. 2. Aluminum fasteners are generally prohibited except where specified. 3. Except for fasteners internal to electrical or electronic components, plastic screws, bolts, nuts, or other plastic fastening components shall not be used unless specifically approved. 16.3.1.4 Plating Comply with the following: 1. Carbon steel, alloy steel, and martensitic stainless steel fasteners shall be plated with zinc, unless specifically waived by the Owner. Zinc plating shall conform to ASTM B633, Type II, and SC2, SC3, or SC4. 2. Plating materials other than zinc, and plating of any type on high strength fasteners, are subject to approval by the Owner. 3. Cadmium plated fasteners are not permitted. 16.3.1.5 Prohibited The following are prohibited: 1. Protruding screws, mounting bolts or similar items on the vehicle interior or exterior, except for those appointments that cannot be built into the structure in any other manner. 2. Self-drilling and self-tapping screws, except where specifically approved. 3. Tapped holes in structure, brackets, and other vehicle assemblies. Tapping plates shall be used when installing fasteners into vehicle structure or subassemblies. 4. Fasteners installed into blind holes, unless specifically approved. 5. Thread-sealing compounds, except for anti-vibration treatments (such as Loctite) where approved. 6. Use of elastic stop nuts for electrical connections. 16.3.2 General Requirements for Threaded Fasteners 16.3.2.1 Head Types Comply with the following: 1. General: Hex heads or hex socket-heads. 2. Where specified: Anti-tamper designs, of the same design throughout. 3. Prohibited: Philips, flat head, or other designs, except in small electronic assemblies or where specifically approved. 16.3.2.2 Identification Comply with the following: 1. Metric fasteners: Shall be identified as required by applicable ISO standards. 2. Inch fasteners: Shall be identified as required by applicable U.S. standards. LTK Standard Streetcar Specifications Section 16 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.3.2.3 Maintenance Access Provide access for maintenance or replacement of threaded fasteners and nuts. When bolts are used to secure apparatus where the bolt head is inaccessible, provide a reusable mechanical locking device to prevent the bolt head from turning when the nut is being turned. 16.3.2.4 Thread Projection Comply with the following requirements for bolt thread projection: 1. Minimum projection: 1-1/2 full screw threads beyond the nut, at proper torque. 2. Maximum projection: a. With elastic stop nuts: 6.4 mm (1/4-inch), regardless of bolt diameter. b. Without elastic stop nuts: • • 6.4 mm (1/4 in) diameter or less: 1-1/2 full threads plus 6.4 mm (1/4 in) Greater than 6.4 mm (1/4 in) diameter: Eight full threads, unless otherwise approved by the Owner. 16.3.2.5 Bolt Hole Size Bolt hole clearances shall not exceed the recommendations of ISO 273 (or Industrial Fasteners Institute). 16.3.2.6 Tapping Plates If tapping plates are used, comply with the following requirements: 1. Minimum Thickness: Equal to diameter of the bolt for which the tapping plate is intended. 2. Strength: Same standards as the equivalent nut. 3. Installation: a. Attach to the structure with mechanical fasteners unless otherwise approved. b. Drill a clearance hole in the structure for the bolt. 16.3.3 Special Requirements for Structural Fasteners 16.3.3.1 Scope This section applies to structural and load carrying bolts: 1. It includes structural bolts for undercar and roof equipment. 2. It includes fasteners used on the side sill to attach heavy equipment brackets (these are considered structural fasteners). 16.3.3.2 Material and Property Class (or Grade) Comply with the following: 1. Structural or load-carrying bolts shall be medium carbon steel. 2. Metric (or inch) bolts and nuts shall conform to minimum requirements as indicated in the table below, including markings. Stronger fasteners shall be used if required for the application. 3. Nuts shall have a material proof strength equal to or greater than the material ultimate tensile strength of the fastener with which it is used. For applications where this is not achievable, submit specific calculations showing that the nut is stronger than the bolt to prevent undetected internal thread stripping. LTK Standard Streetcar Specifications Section 16 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship Structural or Load Carrying Bolts: Minimum Grade Bolts Standard ISO 898-1 (SAE J429 or ASTM A449) Property Class (Grade) 8.8 (5) Nuts ISO 898-2 (SAE J995) According to bolt strength 16.3.3.3 Minimum Size Bolt diameter shall be minimum 10 mm (3/8 in), regardless of design load. 16.3.3.4 Required Documentation Structural fasteners shall have documentation available for examination by the Owner at the Contractor's QA department: 1. 2. 3. 4. Identification of manufacturer Purchase specifications Fastener material or grade Finish, including plating material and specifications, when applicable Obtain and hold the documentation for a period not ending before expiration of the last vehicle's warranty period, whether the buyer is a subcontractor, supplier, or the Contractor. 16.3.3.5 Additional Requirements for Safety-Related Fasteners Comply with the following requirements for safety-related fasteners: 1. Scope: a. Safety-related fasteners include, but are not limited to, those applied to trucks, bolsters, brake equipment, couplers, and power collection devices. b. A fastener is safety related if failures cannot be tolerated; that is, if even a single fastener fails, there is a possibility of brake failure, derailment, or accident. c. In the event of a dispute, the Owner will make the final determination of which fasteners are safety related. 2. Testing for Conformance to Purchase Specifications: a. Have a representative sample of each production lot of fasteners tested for conformance to purchase specifications by an independent laboratory accredited by the American Association of Laboratory Accreditation (AALA), or approved equal. b. A production lot is defined as one size of fastener, from one manufacturer, and produced during one continuous production run. Fasteners not meeting this definition of production lot shall be treated as separate lots. c. Testing shall be performed using sample quantities as proposed by the Contractor and approved by the Owner. d. Tests conducted shall confirm that fastener material meets specified chemistry and strength requirements. e. Obtain certified test results from the testing laboratory and hold the documents for a period not ending before expiration of the last vehicle's warranty period. LTK Standard Streetcar Specifications Section 16 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 3. Testing for Hydrogen Embrittlement: a. Safety-related fasteners that are plated or chemically cleaned shall have certification of hydrogen-embrittlement testing. b. The certification shall be based on a representative sample of actual production fasteners that have been tested by the original equipment manufacturer, Contractor, or a supplier for hydrogen embrittlement following SAE USCAR7 procedures. The plating process shall be certified to ASTM F519 procedures. c. An ASTM F606/F606M wedge-test sample may be used in place of the ASTM F519 standard samples. d. Test loads shall be a minimum of 80% of yield strength or proof load and held for a minimum of 168 hours. Any failures shall result in the rejection of the entire lot. e. Obtain certified test results from the testing laboratory and hold the documents for a period not ending before expiration of the last vehicle's warranty period. 16.3.4 Coatings other than Zinc Comply with the following requirements for alternate fastener coatings (other than zinc): 1. Alternate fastener coatings are permissible only if approved by the Owner. If approved, they must be qualified by testing per ASTM B117 with no red rust or visible corrosion products after 96 hours of exposure. 2. Test for hydrogen embrittlement in accordance with the Testing for Hydrogen Embrittlement section, above, as specified below: a. Fasteners less than Property Class 8.8 (or Grade 5): If the coating has the possibility of causing hydrogen embrittlement, each lot shall be tested for hydrogen embrittlement. b. Fasteners of Property Class 8.8 (or Grade 5) or higher: Each lot shall be tested for hydrogen embrittlement regardless of the coating's propensity for hydrogen embrittlement, including OEM plated zinc or yellow bolts. 3. If the proposed coating results in a change in the K-value for the plated fastener to outside the range of 0.13-0.15, as defined by IFI-543, comply with the following: a. Use the alternate coating on all fasteners within the particular LRU. b. Provide an indelible label identifying the coating type used within the LRU and the required torque values for each size fastener used. c. Fasteners internal to a subcomponent within an LRU may use the standard coating system if they are not subject to removal during maintenance activities. 16.3.5 Self-Locking Nuts and Washers 16.3.5.1 Self-Locking Nuts Self-Locking Nut Requirements: 1. Type: Prevailing-torque, nylon-insert type, regular-height, self-locking ESNA stop nuts, or approved equal. 2. Alternate type: All-metal; use only where there is insufficient clearance to install ESNA type locknuts, or where the locknut is exposed to temperatures above manufacturer's recommended maximum temperature. 3. Standard: Conform to IFI ISO Standards Handbook (or inch fastener standards found in the IFI Inch Fastener Standards Book) or NASM21044. LTK Standard Streetcar Specifications Section 16 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 4. High Temperature: Nylon insert lock nuts shall not be used near heat sources that will exceed the locknut manufacturer's recommended maximum temperature. Use Requirements: 1. Self-locking nuts (locknuts): Use throughout, where appropriate for the application. 2. Non-self-locking nuts with lock washers: Use only in non-structural applications upon approval by the Owner, or where required by the Specifications. 16.3.5.2 Washers Washers Requirements: 1. Suitable for the application and matched with the property class (or grade) of the bolt with which it is used. 2. Where high-strength fasteners (above Class 8.8/Grade 5) are applied, washers shall be hardened. 3. Washers shall comply with ISO standards found in the Industrial Fasteners Institute (IFI) ISO Standards Handbook (or inch fastener standards found in the IFI Inch Fastener Standards Book). 4. If used, lock washers, shall conform to IFI standards. Use Requirements: Provide washers under the heads of bolts and under nuts. Use Restrictions: 1. Split-ring lock washers are prohibited except where specifically approved. 2. Lock washers shall not be used in structural applications or in fatigue applications where the fastener must be torqued and marked. If applicable, prevailing torque nuts shall be used for these applications. 3. Other types of washers, including Belleville washers, may be used for special applications with approval by the Owner. 16.3.6 Torquing Comply with the following requirements for torquing: 1. Specify fastener torque value on the Shop Assembly Drawing. 2. Torque threaded fasteners to the value assigned by the designer or to standard torque values recommended by the fastener manufacturer as appropriate to the application. 3. Torque safety-related fasteners, including truck and brake equipment bolts and all fasteners exposed to fatigue loads, to a minimum preload equal to 75% of their proof load and “torque stripe” after torquing by paint or other approved means. 4. Calculate fastener installation torque for standard oiled or waxed bolts with standard or heavy hex nuts from Industrial Fasteners Institute equations in “Torque Book for Fasteners.” Use the following values for coefficient of friction, “K”, unless another coefficient of friction was established during qualification of an alternate thread plating or coating: a. Unplated threads: K = 0.18 b. Plated threads: K = 0.15 5. Torque self-locking nuts in accordance with their manufacturer’s recommendations, or conduct tests to determine the proper installation torque. 6. Perform torquing only by torque wrench. LTK Standard Streetcar Specifications Section 16 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship For those nuts or bolts requiring “torque striping,” the Owner may require bolt torque-tension tests to verify that installed preload is equivalent to 75% of proof loads. 16.3.7 Other Fasteners 16.3.7.1 Quick-Release Fasteners Quick release fasteners may be quarter-turn type or other types, as approved by the Owner: 1. Quarter-turn fasteners: a. Shank diameter: Minimum 6.35 mm (1/4 inch) b. Strength: Adequate for the application c. Manufacturer: Southco, or approved equal 2. Head type: Philips, tamper proof, hex socket, or hex head. 16.3.7.2 Rivets and Lock Pins Rivets and lock pins shall meet the following requirements: 1. Exposed to passengers: Austenitic stainless steel or aluminum as appropriate to the materials being joined. 2. Exposed heads: Concentric with the shank and free from rings, fins, pits, and burrs. 3. Structural steel rivets: Conform to ASTM A502. 4. Swage-locking (Huckbolt-type) fasteners: Conform to MIL-P-23469. Installation: 1. Rivets: a. Driven hot: May be hand driven and shall completely fill the rivet holes. b. Driven cold: Shall be mechanically driven. c. Removed and replaced: Ream holes to the size required such that the next larger rivet may be driven securely. 2. Huckbolt-type fasteners: a. Machine or grind smooth rough surfaces of the collar end where accessible to passengers, crew, or maintenance personnel performing routine maintenance functions. b. The Owner will make the final determination whether an application is hazardous to maintenance personnel. 16.3.8 Location- and Application-Specific Requirements 16.3.8.1 Interior – Exposed to Passengers Comply with the following requirements: 1. Install such that the fastener head is flush with the mating surface. 2. Match the surfaces being joined using bright or finished fasteners: a. General use: Austenitic or plated martensitic stainless steel. b. For stanchions: Austenitic grade stainless steel. 3. Use screws, bolts, and nuts only if specifically approved. LTK Standard Streetcar Specifications Section 16 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.3.8.2 Exterior – Exposed to Passengers Comply with the following requirements: 1. Stainless steel vehicle body: Austenitic stainless steel. 2. Aluminum vehicle body: Austenitic stainless steel or aluminum alloy fasteners, as appropriate to the design and appearance requirements. 16.3.8.3 Access Required For access panels, equipment box covers, or other areas requiring access, comply with the following: 1. Fasteners shall be captive to the panel or cover in which they are used. 2. Where operator or maintenance access is expected more often than every five years, provide quarter-turn fasteners or similar quick-release fastener. Where greater clamping force is required, such as for EMI containment, alternate fasteners may be proposed. 3. Where accessible to passengers, provide tamper-resistant type fasteners of a single style. 16.3.8.4 Heat Producing Equipment When making connections to heat producing apparatus, take into consideration the thermal expansion of the components for selection of fastener materials: 1. If the joined components are high-expansion alloys such as copper or austenitic stainless steel, use austenitic stainless steel fasteners. 2. If the joined components are low-expansion materials such as carbon steel or ferritic stainless steel, use zinc plated carbon steel fasteners of minimum Class 8.8 (or Grade 5). 3. Cadmium plated fasteners are not permitted. 4. Use only fasteners rated by fastener manufacturer for maximum ambient temperatures. 16.4 Joining 16.4.1 Joint Fitting Comply with the following: 1. Joints shall be properly fitted, whether exposed or concealed. 2. Gaps between joints shall be held to a minimum and be uniform in width. 3. The edges of panels shall have a smooth, finished appearance. 16.4.2 Metal-to-Metal Connections Comply with the following: 1. Metal riveted or bolted to metal: a. Contact surfaces shall be free of dirt, grease, rust, and scale. b. Coat with an epoxy primer as specified below in the Paints, Graphics, and Coatings section. 2. Aluminum: Metal-to-metal connections shall be as specified below in the Aluminum section. 16.4.3 Wood-to-Metal Connections Comply with the following: 1. Wood and ferrous metal surfaces joined: a. Coat wood with two coats of epoxy paint. LTK Standard Streetcar Specifications Section 16 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship b. Coat metal with primer, as specified below in the Paints, Graphics, and Coatings section. 2. Bolts or rods passing through wood: Coat with primer. 3. Aluminum: Wood-to-metal connections shall be as specified below in the Aluminum section. 16.4.4 Wood-to-Wood Connections Wood and wood joined: Coat both abutting surfaces with two coats of epoxy. 16.5 Metal 16.5.1 Stainless Steel 16.5.1.1 Austenitic Stainless Steel Comply with the following: 1. General requirements for delivery: a. As required by the Certification Provisions of ASTM A666. b. Structural applications: Test for susceptibility to intergranular corrosion in accordance with ASTM A262: • • Practice A: Use to accept material only Practice E: Required for final determination of acceptance or rejection of material that is not acceptable by Practice A. 2. Structural components assembled by fusion or resistance welding: a. Specification and composition: • • AISI type 201L, 301L, 301LN or SUS301L (with Nitrogen), 316L Conform to the requirements of ASTM A666 except that the carbon content shall not exceed 0.03 percent and type 301LN and SUS301L (with Nitrogen) shall not exceed 0.25 percent nitrogen. b. Conform to paragraph (f) from Section 2 of AAR "Specifications for the Construction of New Passenger Equipment Cars." 16.5.1.2 Ferritic Stainless Steel Comply with the following: 1. General requirements: As specified in ASTM A480/A480M. 3. Used in welded construction: a. May be used only with the specific written approval of the Owner. b. Shall contain stabilizing element(s) to prevent sensitization during welding. c. When specified, ferritic stainless steel conforming to ASTM A240/A240M may be used for sheeting up to 5 mm (0.2 in) thickness. d. Shall have a ductile-to-brittle transition temperature (DBTT) or nil-ductility temperature (NDT) below -18 degrees C (0 degrees F). e. Weld heat-affected-zones shall also have a DBTT or NDT below -18 degrees C (0 degrees F). f. Shall have a balanced composition (low carbon and/or suitable titanium content) that will, for all conditions of fabrication and assembly into the vehicle body, inhibit formation of LTK Standard Streetcar Specifications Section 16 12 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship martensite and limit chromium depletion in weld heat-affected-zones, such that material meets ASTM A763 requirements for resistance to inter-granular corrosion. g. Where ferritic stainless steels are welded to other structural steels, the less-noble steel shall be painted with weld-through primer. 16.5.1.3 Other Stainless Steel Other stainless steels, non-welded applications: ASTM A666 is acceptable. 16.5.1.4 Testing Before purchasing stainless steel to be used in welded applications, submit a test and inspection plan that verifies that the stainless steel conforms to specified requirements, as described in the Contract Data Requirements List (CDRL), below. 16.5.2 High-Strength Low-Alloy Steel (HSLA) Comply with the following: 1. Structural shapes, plates and bars: a. Minimum standard: ASTM A588/A588M. b. Plate steel: May alternatively conform to ASTM A710, Grade A, Class 1, 2 or 3. c. Delivery: General requirements per ASTM A6/A6M. 2. Cold and hot rolled HSLA sheet and strip: a. Minimum standard: ASTM A606/A606M, Type 4. b. Delivery: General requirements per ASTM A568/A568M. 3. Welded HSLA steel: Shall develop 27 J (20 ft-lbs) Charpy V Notch impact strength in the CGHAZ (Coarse grain heat affected zone 1 mm from fusion area) at -18 degrees C (0 degrees F). 4. Application: a. HSLA steels shall be applied according to their specification properties. b. Hot rolled or formed structural shapes conforming to ASTM A36/A36M may be used for non-structural applications, including equipment supports, jack pads, and clip angles. 5. Testing: Before purchasing structural steel, submit a test and inspection plan that verifies that the stainless steel conforms to specified requirements, as described in the Contract Data Requirements List (CDRL), below. 16.5.3 Steel Castings 16.5.3.1 General Comply with the following: 1. Select for composition, heat treatment, and design best suited for the intended application. 2. Marking: Apply pattern and serial numbers in a manner that does not impair their strength. 3. Disposal of Non-Conforming Castings: If castings are found to be non-conforming to requirements determined by the design qualification castings, the material shall be repaired, retested, and re-inspected or destroyed at the Contractor's expense. 4. Welding of castings: Permitted, provided the casting supplier performs repair welds in accordance with an approved written procedure and uses welders qualified to ASTM A488/A488M. LTK Standard Streetcar Specifications Section 16 13 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.5.3.2 Design Qualification Comply with the following: 1. Before castings are produced: Select acceptance levels for the design qualification radiographic examinations as appropriate for the service intended, subject to approval by the Owner. 2. Qualification Test: a. Conduct on one casting, selected by the Owner from the first lot of production castings, to test the casting design: • • • Perform radiographic examination to determine material soundness using reference radiographs to ASTM E446, and mechanical testing, as required. Radiographs shall meet the requirements of ASTM E94 and E1030 and the quality level in the area of inspection shall be at least 2% (2-2T). Radiographs resulting from the Qualification Test shall be made available to the Owner for review. b. Submit a Qualification Test report as specified in the Contract Data Requirements List (CDRL) section, below. Obtain approval before production of castings. 3. After Qualification: Once a design is qualified and accepted by the Owner, no changes shall be made in the casting patter, technique, heat treatment, or material composition without requalification in accordance with the requirements of this Section. 16.5.3.3 Quality Comply with the following: 1. Structural castings: Equal to or better than the design qualification castings in all respects. 2. Test, inspect, and accept castings in accordance with procedures described in AAR M-201. Perform the inspections below and submit a test report for each lot of castings produced: 1. Magnetic particle inspections: a. Conduct on all surfaces of each casting according to ASTM E709. Testing personnel shall be certified to NAS410. b. Structural castings, including coupler castings: Maximum permissible magnetic particle indications shall be 6 mm (1/4 in) in the direction transverse to the usual direction of loading, and 19 mm (3/4 in) in the direction parallel to the usual direction of loading. 2. Radiographic inspection: a. Conduct according to ASTM E94 and ASTM E1030/E1030M, using reference radiographs to ASTM E446. b. Propose a sampling frequency and submit for approval. 3. Radiographic inspection of structural castings: a. Shall not exceed Severity Level 3 of ASTM E446 in critical areas and shall not exceed Severity Level 5 in other areas of the castings. b. During demonstration that the stated severity level requirements of ASTM E446 have been met, re-inspect successively-produced castings by radiography in the defective areas shown in the prior radiographic inspection. LTK Standard Streetcar Specifications Section 16 14 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship c. Sampling frequency: • • • • After severity levels have been proved, 1 casting out of each 10 produced. If no castings are rejected by radiographic inspection, 1 casting in 25. Unacceptable castings found during sampling shall require 100% inspection of other castings from the lot/heat, or before and after in sequence (if sequentially cast) until the extent of the unacceptable condition(s) is determined. If the reason for the failure has been isolated, based upon Owner review, sampling may return to 1 casting in 10, and then, if no failures are found, to 1 in 25. 16.5.3.4 Specific Applications Comply with the following in the specified application: 1. Truck and vehicle-body structures: a. Meet AAR M-201, Grade "B", plus 2% nickel, minimum. b. Heat-treat castings to develop the following: • • • • Minimum tensile strength: 517 MPa (75 ksi) Minimum yield strength: 331 MPa (48 ksi) Elongation: Minimum 25% in 50.4 mm (2 in) Reduction of area: Minimum 50% 2. Truck side frames and bolsters: a. Comply with applicable standards: • • Bolsters: AAR M-202 Side frames: AAR M-203 3. Coupler, drawbars, and anchors: Meet AAR Specification M-201, Grade "C", quenched and tempered. 16.5.4 Aluminum 16.5.4.1 General Requirements Comply with the following: 1. Aluminum-alloy mill products: a. Identify by designations prescribed by the Aluminum Association. b. Conform to specifications contained in the Aluminum Association's publication "Aluminum Standards and Data." 2. Castings: a. Sand castings: Conform to ASTM B26/B26M. b. Die castings: Conform to ASTM B85/B85M. c. Permanent mold castings: Conform to ASTM B108/B108M. 3. Aluminum alloy forgings: Conform to ASTM B247. LTK Standard Streetcar Specifications Section 16 15 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.5.4.2 Design Stresses Design aluminum structural members such that calculated stresses under the maximum load do not exceed allowable stresses listed in the Aluminum Association's "Aluminum Design Manual." Make proper allowance for the effects of fatigue, for column and plate stability effects, and for strength reduction at welded regions. 16.5.4.3 Connections to Aluminum Take specific measures, based on a suitable method that can be adapted to the design involved, to prevent the risk of direct metal-to-metal contact and resultant possible galvanic or electrolytic corrosion. The measures shall be approved by the Owner. Comply with the following requirements for connections to aluminum unless they conflict with recommendations by the aluminum manufacturer or by ALCOA Technical Report No. 524, "Specifications Covering Use of Aluminum in Passenger Carrying Railway Vehicles": 1. Provide protection at the contact surface of connections to aluminum. 2. Metal-to-aluminum: Comply with ALCOA Technical Report No. 524. 3. Wood-to-aluminum: Comply with ALCOA Technical Report No. 524. The wood shall be thoroughly dried, then coated with varnish or other comparable sealant, as approved. 4. Aluminum alloy to aluminum alloy: Etch or anodize contact surfaces before securing. 5. Carbon steel fasteners (including washers and nuts): a. Zinc plated. b. The head and unthreaded portion of the shank of the bolt shall be in contact with the aluminum part when secured in place, where possible. Suitable bushings may be used. Comply with the follow requirements for connections to aluminum alloy: 1. Surfaces shall not be secured to, nor make direct contact with the surfaces of a. Wood; or b. The following metals: • • • • • • Copper or copper bearing aluminum alloy Brass or bronze Silver Nickel and nickel plated parts or nickel alloys Tin Ferrous materials 2. Aluminum alloy to aluminum alloy: Protect surfaces of parts by painting with zinc chromate primer or approved equal. 3. Aluminum alloy to steel: Protect surfaces of parts as follows: a. With a one-part polysulphide sealant. b. Alternatively, use an approved insulation joint material that completely covers the fayed surfaces: • • The material shall be non-hygroscopic and, if fibrous, shall be impregnated with bitumen or some other approved water and moisture-repellant substance. Prime and paint fasteners with red oxide or aluminum paint after installation. LTK Standard Streetcar Specifications Section 16 16 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship c. 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. 4. Aluminum alloy with zinc plated stainless or carbon steel fasteners: Protect surfaces as follows: a. Coat with zinc chromate paste or approved equal before installation. b. Where possible, only the head and shank of the bolt shall be in contact with the aluminum part when secured in place. c. Suitable bushings approved by the Owner may be used in place of the zinc-chromate paste. 16.6 Welding and Brazing 16.6.1 General 16.6.1.1 Scope This section applies both to welding and brazing performed on vehicle structural elements and on equipment and systems provided for use on the vehicle, unless waived by the Owner. 16.6.1.2 Quality Comply with the following: 1. Control the quality of welding and brazing, including that performed by subcontractors. 2. Before performing work under this Contract, welders shall be tested to confirm their ability to operate the welding equipment and to make the types of welds required by the design or this document. 16.6.2 Welding and Brazing Prohibitions The following weld process and material restrictions shall apply in vehicle structure welding: 1. High-iron-powder flux-type rods such as E6024, E7024 and rods known as "jet rod" may not be used. 2. Short-arc MIG welding using hardwire with argon, or argon/CO₂ shielding may be used only on sheet metal, gauges 12 and thinner. Weld sheet steel in accordance with AWS D1.3/D1.3M. 3. Galvanized steel shall not be welded to stainless steel. 4. Brazing shall not be used to join stainless steel to itself or to other metals unless specifically permitted by the Owner. 16.6.3 Welding 16.6.3.1 Structural Welding Comply with the following: 1. Structural welding practices not specifically covered in other sections of the Specifications shall be in accordance with the following AWS standards. Requirements for cyclically loaded structures shall be applied: a. b. c. d. e. AWS D1.1/D1.1M, for steel 3.2 mm (1/8 in) and thicker AWS D1.2/D1.2M AWS D1.3/D1.3M, for steel thinner than 3.2 mm (1/8 in) AWS D1.6/D1.6M AWS D15.1/D15.1M LTK Standard Streetcar Specifications Section 16 17 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship f. AWS Welding Handbook g. AWS D17.2/D17.2M, for resistance welding 2. As an alternate, structural welding may be in accordance with EN ISO 9606-1 for steel and EN ISO 9606-2 for aluminum, except that the Owner may enforce AWS requirements at its discretion if the alternate standards are more permissive. 3. Structural welding of stainless steel by the fusion-arc process shall be governed by the following standards: a. AWS D1.6/D1.6M b. ASME BPVC, Section IX, “Welding and Brazing Qualifications” c. ASME BPVC, Section VIII, “Rules for Construction of Pressure Vessels,” Part UHA, “Requirements for Pressure Vessels Constructed of High Alloy Steel” 4. Other requirements: a. AISI 201L and 301LN stainless steels shall be treated as P-No. 8, Group-No. 3 category for reference to ASME BPVC requirements. b. Weld heat-affected zones (HAZ) and weld metal shall be limited to maximum allowable stress values in ASME BPVC, 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. c. Ferrite number for welds shall be between WRC 4 and WRC 10, or as proposed by the Contractor and approved by the Owner. 5. Additional information on definitions, processes or other questions pertaining to welding shall be referred to the AWS Welding Handbook. 16.6.3.2 Welding Procedure Qualification Comply with the following: 1. Welding procedures (WPSs) shall be qualified by the Contractor, accompanied by procedure qualification records (PQRs) containing welding test results, and subject to approval by the Owner. 2. Use of prequalified WPSs is prohibited unless reviewed and specifically permitted by the Owner. Weld procedure and qualification shall be identified on shop drawings specifically for that purpose. 3. Perform general welding, not specified elsewhere, in accordance with the standards of AWS D1.1/D1.1M. 16.6.3.3 Welder Qualification and Identification Comply with the following: 1. Welders shall make only those welds for which they have been qualified in accordance with the following: a. Requirements of the AWS or ASME BPVC, Section IX, qualifying procedures. b. As an alternate, the requirements of the applicable standards in the ISO 156xx series, except that the Owner may enforce AWS or ASME requirements at its discretion if the alternate standards are more permissive. 2. Make available records of welder qualification tests for review upon the Owner's request. LTK Standard Streetcar Specifications Section 16 18 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 3. Stamp critical strength welds with an identifying symbol that can be traced to the welder who performed the work. 16.6.3.4 Weld Type Requirements Comply with the following: 1. Full penetration welds: a. Required for structural welds unless otherwise approved by the Owner. b. If made from one side without backup they shall be considered partial penetration welds. 2. Partial penetration welds: a. May be used for structural connections only with approval of a formal detailed proposal: • • Furnish design calculations supporting the penetration required Conduct tests to prove that production welding achieves this required penetration with a margin of safety suited to the design application b. Shall not be used where subject to alternating tensile or bending loads at the weld root. 3. Fillet welds: May be used only to carry shear loads between statically loaded members. 16.6.3.5 Weld Inspection Comply with the following: 1. Visually inspect each structural weld in accordance with the applicable AWS requirements: 2. First production welds: a. Inspect visually in accordance with the specified AWS welding code requirements b. Inspect by nondestructive surface inspection methods (dye penetrant or magnetic particle, as appropriate; see Section 15, Testing, for requirements), regardless of whether the assembly was presented for First Article Inspection 3. Specify additional nondestructive inspection requirements for subsequent welds. 4. For full penetration welds, comply with the following: a. On the first structure, inspect nondestructively, volumetrically all full penetration welds (ultrasonic or radiographic methods), according to the applicable code or standard. b. For subsequent full penetration welds, propose a random sampling plan for volumetric inspection for approval: • • • The minimum acceptable inspection plan shall require inspection of one foot of a full penetration weld for every 200 feet of production welds made. The proposed test welds shall be selected from among welds that are most critically loaded as decided by calculations or load test results. With approval, destructive sectioning and metallurgical examination may be substituted for some or all of the required volumetric inspection requirements for production welding. 16.6.3.6 Weld Cleaning Requirements All welds, regardless of their location, shall be cleaned and free of flux residue, spatter, slag or other debris that may impair the function or appearance of the welded area. LTK Standard Streetcar Specifications Section 16 19 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship Heat tint on stainless steel welds not exposed to passenger view need not be removed. 16.6.3.7 Welding Rod or Wire Comply with the following: 1. Purchase to AWS specifications. 2. Where special materials are required that are not covered by these or other applicable AWS welding material specifications, submit the purchase specifications for approval. 3. Purchase welding filler materials in packages of convenient size, marked with the manufacturer's name and the specification, diameter, and net weight of the material. 4. Store the material in accordance with applicable AWS recommendations to protect it from damage, and so that it can be easily identified. 5. Issue and handle material in such a way as to prevent it from being mixed with that of another filler metal type and specification. 16.6.3.8 Special Welding Comply with the following: 1. Submit procedures for structural welding of stainless steel to HSLA, or other combinations of metals or conditions not covered by AWS specifications or codes, for approval. 2. Use austenitic stainless steel electrodes or wire to join carbon or HSLA steels to stainless steels. 16.6.3.9 Resistance Welding Comply with the following: 1. Weld stainless or carbon steels in accordance with AWS D17.2/D17.2M: a. Structural applications: Class B b. Non-structural applications: Class C 2. Obtain approval for desired deviations from AWS D17.2/D17.2M including, but not limited to weld nugget diameter, tension shear strength, and minimum spacing, before inclusion in the design or in production procedures. 3. Control current, time, electrode size, shape, and tip force to produce uniform welds of specified strength that are not subject to intergranular stress-corrosion cracking. 4. Arrange welds to avoid tension or "peeling" forces on the welds under anticipated loading condition. 5. Surface indentation: a. Not exposed to passenger view: Maximum 20% of material thickness (t) or 0.25 mm (0.01 in), whichever is greater b. Exterior areas exposed to passenger view: Maximum 10% of t or 0.13 mm (0.005 in), whichever is greater 6. Remove surface burn and discoloration by an approved method. 16.6.3.10 Resistance, Spot Weld and Intermittent Weld Spacing Spacing of resistance and spot welds shall be appropriate to the design: 1. Spacing shall not exceed 50 mm (2 in) plus twice the weld nugget diameter for any structural application, including vehicle-body side sheets. LTK Standard Streetcar Specifications Section 16 20 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Intermittent weld spacing shall not exceed 125 mm (5 in) for 50 mm (2 in) weld length (40% minimum). Exceptions to avoid warping in thin sheets will be considered, but must be reviewed and approved by the Owner. 16.6.3.11 Toughness of Welded Assemblies Prove that all safety-related welded structures have adequate toughness for the specified environmental exposure, including, but not limited to end underframes, fabricated truck frames and bolsters, and welded coupler components: 1. Weld heat affected zone (HAZ) and base metal shall resist service impact loads at the lowest specified operating temperature. 2. Criteria for acceptance shall be shown by the Contractor to be adequate. 3. Charpy V-notch specimen impact value: Minimum 20 J (15 ft-lbf) of absorbed energy at the lowest specified operating temperature, in the absence of prior operating history, and if no analysis requires greater toughness. 16.6.4 Torch Brazing Comply with the following requirements for brazing (above 450 degrees C (840 degrees F)): 1. 2. 3. 4. Follow the recommendations in AWS Welding Handbook, Volume 2. Qualify procedures and personnel in accordance with AWS B2.2/B2.2M. Brazed joints shall present a workmanlike appearance in accordance with AWS C3.4M/C3.4. Protect inner surfaces of air conditioning tubing from oxidizing contaminants during and after brazing operations. 16.6.5 Torch Soldering Comply with the following requirements for soldering (below 450 degrees C (840 degrees F)): 1. Follow the recommendations in the AWS Welding Handbook, Volume 2. 2. Qualify procedures and personnel through preparation and testing of samples, as follows: a. Copper Piping into Fittings: • • • Each worker designated to perform this work shall prepare three copper piping connections in the vertical position. The sample joints shall present a smooth, workmanlike appearance, without excess solder reinforcement. Each joint shall be pressure tested using a water or air system to confirm that it is leakfree. b. Stainless Steel Lap Joints (Trim Seams): • • • • Each worker designated to perform this work shall prepare one typical trim seam sample, using the same stainless steel materials, finish, and thicknesses as used on the actual vehicle. The seam for evaluation shall be minimum 915 mm (36 in) in length, and shall be set up in the horizontal 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 four pieces so that eight cross-sections of the joint may be examined. LTK Standard Streetcar Specifications Section 16 21 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship • Exposed solder surfaces shall display a uniform, smooth contour and shall meet or exceed all applicable AWS quality standards. 16.7 Elastomers 16.7.1 General Comply with the following: 1. Material: Neoprene unless otherwise specified or approved. 2. Compound and cure: Suitable for the Project environment specified in Section 2, Design and Performance Criteria. 3. Quality: Free of defects of material and workmanship. 4. Performance: a. Highly resistant to ultraviolet, other solar radiation, and vehicle washing fluids. b. Resistant to ozone, oxidation, heat, oil, grease, and acid. 5. Design life of resilient parts: Minimum 10 years. 16.7.2 Applications Comply with the following: 1. Parts made by vulcanizing an elastomer to metal: a. Premature failure: • • Definition: Failure in less than five years after acceptance of the vehicle. Considered a defect of materials or workmanship when the failure occurs between the metal and elastomer or in the elastomer and the parts are used in normal service and according to the provisions of the Specifications. 2. Metal parts to which neoprene or other such material is cured: a. Material: SAE 1020 or 1045 hot-rolled steel or approved equal, suitable for brass plating after pickling. 3. Door mating edges, door and window seals, and glazing strips: a. Material: Neoprene or ethylene propylene diene (EPDM) rubber. b. Durometer hardness: 70 plus or minus 5 at a temperature between 20 degrees C and 30 degrees C (68 degrees F and 86 degrees F) when measured with a Shore Type "A" durometer. 16.8 Piping and Tubing (other than Air Conditioning) 16.8.1 General Comply with the following general requirements for piping and tubing: 1. 2. 3. 4. Furnish, install, and test piping, valves, and fittings in accordance with ASME B31.1. Straight runs of pipe: Continuous and without fittings unless otherwise approved. Truck piping: Shall not be run on the bottom of truck side frames, transom, or bolster. Connections to resiliently mounted or moving equipment: a. Via hose or other resilient device, as appropriate. LTK Standard Streetcar Specifications Section 16 22 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship b. Clamp piping within 50 mm (2 in) of the resilient connection. 5. Piping passing through holes in fixed members: a. Rigidly clamp piping to support structure. Cantilevered or other flimsy piping supports are prohibited. b. Clamps shall not be welded, brazed, or otherwise permanently fastened to piping. c. Clamps shall be insulated with an approved elastomeric or woven mineral fabric tape to protect and acoustically insulate the piping from structure. 6. After installation: a. Clean piping systems by flushing with an approved cleaning solution b. Pressure test in accordance with ASME B31.1 c. Repair leaks and retest the system until leak free 16.8.2 Hydraulic Piping, Tubing, Hose, and Fittings Comply with the following requirements for hydraulic piping, tubing, hose, and fittings: 1. Tubing: a. Type: Seamless cold drawn steel, SAE 1010 or as approved, designed for hydraulic applications. b. Wall thickness: • • Truck mounted: Schedule 80, and sufficient to maintain a safety factor of 6 at the maximum system pressure. Other locations: Sufficient to maintain a safety factor of 6 at the maximum system pressure. c. Bending: Tubing may be bent using a bending tool designed specifically for bending of the tubing to be used, instead of elbows. 2. Piping: a. b. c. d. Use of tapered pipe threads on fluid carrying system component is prohibited. Deburr piping after cutting. Clean piping and pipe sub-assemblies. Cap openings after fabrication. Caps shall remain in place until just before incorporation into the final assembly. 3. Tubing or Piping Connections: a. Steel or stainless steel fittings, either JIC 37-degree flare or flareless. b. Piping and tubing connections shall use the same type of fitting. 4. Hose: a. Rating: Shall withstand four times the maximum operating pressure without bursting. b. Temperature: Hose shall not be used in locations where the temperature may exceed 100 degrees C (212 degrees F). c. Fittings: Permanently fitted to the hose. d. Openings: Cap immediately after fabrication and cleaning. 5. Joints: Keep to a minimum; inaccessible joints are not permitted. LTK Standard Streetcar Specifications Section 16 23 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 6. Connections: a. To manifold ports, valve bodies, and other hydraulic system components: Use straight thread fittings with separate O-ring seals, unless otherwise approved. b. Quick connect couplings: • • Double shutoff with valves built into both of the mating parts. Shall conform to MIL-DTL-25427, or be Owner-approved commercial couplings providing equivalent performance. 7. Cutout cocks: Designed to automatically depressurize the portion of the system that is being isolated by the cutout cock. 16.9 Paints, Graphics, and Coatings 16.9.1 General Comply with the following: 1. Furnish and apply paint and coatings in accordance with local, state, and federal requirements that apply at the location where paint and coatings are applied. 2. Paint, graphics, and coatings shall be repairable by the Owner with materials and processes conforming to local, state, and federal requirements that apply to the Project. 3. Test paint performance in accordance with Section 15, Testing. 16.9.2 Materials Not to be Painted Equipment or parts of equipment that would be damaged or suffer impaired operation from painting shall not be painted, including but not limited to the following: 1. 2. 3. 4. 5. 6. 7. 8. Flexible conduit and fittings Copper tubing, piping, and fittings Wire and cable Power resistors Heat transfer surfaces Electrical insulators Elastomeric devices Grounding pads 16.9.3 Paint and Powder Coat Materials 16.9.3.1 General Comply with the following: 1. Paint and powder coat materials shall be from a high-quality finishing system, resistant to corrosion, chipping, and fading, and shall retain the gloss level specified in Section 14. 2. Paint and filler materials that are to be superimposed to form a finish system shall be mutually compatible and shall be warranted for use as a system by the manufacturer of the components. 3. The Contractor and its liquid paint or powder coat supplier shall ensure that a continuing supply of touch-up paints in the proper colors used on the vehicle, suitable for touch-up and repair by spray, roller, or brush, will continue to be available in the United States. LTK Standard Streetcar Specifications Section 16 24 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.9.3.2 Primers Where specified, primers shall comply with the following requirements: 1. Wash (etch) primer: A primer with anti-corrosion properties for application as a first coat on metal surfaces, as recommended by the manufacturer of subsequent primer and top coat. 2. Epoxy primer: Compatible with the polyurethane top coat. 3. Truck primer: Compatible with truck paint. 16.9.3.3 Top coats Where specified, top coats shall comply with the following requirements: 1. Polyurethane: Two-part, high solids, low VOC, polyurethane paint system; gloss or semi-gloss, as specified in Section 14. 2. Anti-skid: For surfaces requiring anti-skid paint, mix a non-skid additive into the paint, such as fine glass or plastic beads. 3. Truck paint: Select truck paint that will not hide structural cracks. 16.9.3.4 Powder Coat Where specified, powder coat shall comply with the following requirements: 1. Interior applications: Thermosetting, resin based, polyester or epoxy powder tailored to the individual application. 2. Exterior applications: Not approved for use. 16.9.4 Preparation and Paint or Powder Application 16.9.4.1 General Comply with the following: 1. Prepare the substrate surface in accordance with the paint or powder manufacturer's recommendations. 2. Prepare and apply paint and powder materials according to the manufacturer's recommendations, including environmental conditions (clean, dry atmosphere at specified ambient temperature and humidity). 3. Paint materials shall be used at the consistency recommended by the paint manufacturer. If thinners are necessary, they shall be approved by the paint manufacturer and shall be used only to the extent recommended. 4. Paint and powder coating shall be uniformly applied over all surfaces to be covered and shall be free from foreign matter, runs, sags, orange peel, fisheyes, or other application defects. 16.9.4.2 Applicator Qualifications Painting and powder coating shall be done by experienced labor, using proper equipment under competent supervision. 16.9.4.3 Vehicle Body After fabricating metal portions of the vehicle body not constructed of stainless steel, prepare and prime by one of the following methods: 1. Grit blast, then immediately after grit blasting, apply epoxy primer. LTK Standard Streetcar Specifications Section 16 25 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Wash with an alkaline solution and properly rinse; apply a coat of phosphate or a coat of wash primer; and then coat with epoxy primer. 3. As recommended by the manufacturer and approved by the Owner, if the manufacturer does not recommend the specified methods. In addition, comply with the following requirements for the locations indicated: 1. Enclosed surfaces capable of rusting or oxidation: After cleaning and applying epoxy primer, paint with polyurethane or other approved coating suitable for the vehicle design life. 2. Arc welds between stainless steel and other materials: De-scale the joint, clean, apply wash primer, apply epoxy primer, and apply polyurethane top coat. 3. Concealed aluminum: Apply one coat of primer and one coat of an approved sealer, except to framing structures. 16.9.4.4 Exterior Not Visible to Passengers Surfaces that are on the exterior of the vehicle but not visible to passengers shall be prepared as specified above for the vehicle body, and painted as follows: 1. Under-vehicle: a. Exposed portion of the underframe: Apply epoxy primer and one polyurethane top coat. b. Metal structures (except stainless steel), including welded brackets and appurtenances: After erecting the framing structure and body sheets, apply epoxy primer and two polyurethane top coats. c. Apparatus and Equipment Enclosures (applies to interior and exterior surfaces): • • • • Carbon steel: Apply epoxy primer and one polyurethane top coat. Plastic or fiberglass: Apply epoxy primer and one polyurethane top coat. Verify that the paint system is compatible with the plastic used. Paint apparatus and enclosures only after metal working activities are completed. Apparatus from suppliers shall be painted by the suppliers before installation on the vehicle, under the Contractor's direction and according to the Specifications and approved color scheme. 2. Roof: Apply one polyurethane top coat. Use anti-skid paint on roof surfaces on which a person can walk. 3. Other parts of the vehicle not exposed to view: Apply one polyurethane top coat. 16.9.4.5 Trucks Paint truck frames before assembly and complete painting of truck components before installation on the vehicle: 1. Before painting, clean trucks by blowing with compressed air and wiping with solvent to remove dirt and grease. 2. After cleaning, spray truck components with one coat of primer and one coat of paint and air dry. LTK Standard Streetcar Specifications Section 16 26 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.9.4.6 Exterior Visible to Passengers Comply with the following: 1. Preparation: Before painting vehicle surface that is exposed to view, rectify dents, gashes, nicks, roughness, and other surface imperfections: a. Remove imperfections so far as possible by straightening. b. After straightening, wash prime the surface, fill remaining imperfections with an approved epoxy-based filler, and sand smooth. • • Filler thickness: Maximum 3 mm (0.125 in); or As recommended by the filler manufacturer for the environment and service to which it is to be exposed, whichever is less. 2. Painting: Apply epoxy primer and two polyurethane top coats. 3. Surface appearance: The finished exterior shall present a high-quality appearance free from sags, drips, scratches, variations in gloss, and other imperfections. a. Comply with requirements for gloss and surface appearance in Section 14, Interior and Exterior Appointments. b. Test surface appearance in accordance with Section 15, Testing. 16.9.4.7 Stainless Steel and FRP Comply with the following: 1. Painted stainless steel: Where required to be painted, the painting procedures shall be as recommended by the paint manufacturer for that application. 2. Unpainted exterior stainless steel: Clean with an approved alkaline cleaning solution that will not damage other painted surfaces. 3. FRP: Where required to be painted, apply one coat of epoxy primer and top coat with polyurethane, using the number of coats recommended for the application. 16.9.5 Graphics Comply with the following requirements for graphics, such as stripes, logos, or vehicle numbers: 1. Material: 3M vinyl graphic film or approved equivalent. 2. Installation: In accordance with manufacturer’s recommendations using manufacturer recommended tools. 16.9.6 Other Coatings Comply with the following: 1. Apply undercoatings and other coatings, where required, and acoustical insulating materials (see Section 14, Interior and Exterior Appointments) to cleaned and primed surfaces and members, according to the material manufacturer's recommendations. 2. These materials shall be resistant to dilute acids, alcohols, grease, gasoline, aliphatic oils, and vermin. LTK Standard Streetcar Specifications Section 16 27 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.10 Flammability, Smoke Emission, and Toxicity Requirements Combustible material used in the construction of the vehicle shall satisfy the flammability, smoke emission, and toxicity requirements cited in this Section: 1. As a minimum, materials used in the construction of the vehicle shall meet the requirements of NFPA 130 Chapter 8, Vehicles. 2. Those materials and products generally recognized to have highly toxic products of combustions shall not be used. 3. Material tested in accordance with NFPA 130, Chapter 8, Vehicles, shall meet the following toxic gas release limits (ppm) as determined per BSS 7239 or Bombardier SMP 800C: Carbon Monoxide (CO) Hydrogen Fluoride (HF) Nitrogen Dioxide (NO₂) Hydrogen Chloride (HCl) Hydrogen Cyanide (HCN) Sulfur Dioxide (SO₂) 3,500 ppm 200 ppm 100 ppm 500 ppm 150 ppm 100 ppm 16.11 Wood and Panels 16.11.1 Lumber Comply with the following: 1. Lumber shall be thoroughly air seasoned or kiln dried before using and shall be dressed on all surfaces to full dimensions. 2. Lumber shall be straight grained, free from dry rot, knots, checks, and other defects that may impair its strength and durability or mar its appearance. 3. The use of wood in the vehicle, except where specified, shall be limited to specifically approved applications. 16.11.2 Plywood Comply with the following: 1. Type: NIST PS 1, panel grade Structural I. 2. Storage: Store under cover. 3. Plywood panels: Formed from one piece and sealed with two coats of epoxy paint on all edges and cutouts as soon as possible after fabrication. 4. Exposed edges of panels: Treat joints between panels, fastener heads, and openings of panels used in areas accessible to moisture, before installing in the vehicle, as follows: a. Before sealing edges, plug splits showing on edges with wooden wedges dipped in adhesive conforming to Federal Specification MMM-A-181. b. Seal the exposed edges with an approved epoxy or polyurethane moisture barrier coating. c. Allow minimum 24 hours drying time between each coat. 16.11.3 Plymetal Comply with the following: 1. Plymetal shall be metal-faced plywood conforming to the table below. LTK Standard Streetcar Specifications Section 16 28 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Plymetal faced with melamine shall have the melamine bonded to the metal sheet, and the melamine-faced metal sheet then laminated to the plywood core. Plymetal Requirements Test Conditions Minimum Metal to Wood Average Shear Value (or 80% Wood Failure) Dry shear 1.7 MPa (250 lbf/in²) Boil shear, 3 hour boil, tested wet at room 1 MPa (150 lbf/in²) temperature Soak shear, 48 hour soak wet at room 1 MPa (150 lbf/in²) temperature Creep or cold flow, under static load for 48 1.7 MPa (250 lbf/in²) hour, at room temperature 16.11.4 Honeycomb Panels Honeycomb panels shall be an assembly of honeycomb material bonded to melamine-faced metal panels or to metal panels: 1. Honeycomb Core Materials: a. Aluminum: Commercial grade, complying with SAE AMS-C-7438. b. Aramid Fiber Composite: High strength, Kevlar® N636 or equivalent, para-aramid fiber paper impregnated with a heat-resistant phenolic resin, conforming to specified flammability, smoke emission, and toxicity requirements, for non-structural applications where specifically approved for use. 2. Panel Skin Materials: Melamine-faced metal or metal. 3. Bonding: Sufficient to develop the full strength of the honeycomb material. 16.11.5 Melamine-Faced Aluminum Melamine-faced aluminum panels shall be constructed by laminating melamine impregnated papers to aluminum sheets using heat and pressure. Use of adhesives for bonding is not permitted: 1. Temperature: Minimum 132 degrees C (270 degrees F ) 2. Pressure: Minimum 6.9 MPa (1000 psi) 3. Minimum Thicknesses: a. Melamine and required binder sheets: 0.51 +/- 0.13 mm (0.020 +/- 0.005 in) b. Aluminum sheets, used on plywood substrate: 0.64 mm (0.025 in) c. Aluminum sheets, not laminated to substrate: 2 mm (0.08 in) 4. Flammability, Smoke, and Toxicity: See Flammability, Smoke Emission, and Toxicity Requirements section, above. 5. Preparation: Properly clean aluminum sheets by etching, sanding, or other approved process to ensure full, permanent, acceptable adhesion. 6. Quality Tests: a. Bond between melamine and aluminum sheets: Meet requirements of the table below. b. Surface characteristics, after manufacture: Comply with NEMA LD 3 type GP (General Purpose). LTK Standard Streetcar Specifications Section 16 29 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship Melamine to Aluminum Bond Requirements Mechanical Properties ASTM Condition Value Method Internal bond ASTM D952 17.9 MPa (2,600 lbf/in²) Flexural strength - (S) ASTM D790 with grain 183 MPa (26,500 lbf/in²) with grain cross grain 174 MPa (25,300 lbf/in²) Modulus of elasticity - (E) ASTM D790 with grain 19.3 GPa (2.8 x 106 lbf/in²) cross grain 21.4 GPa (3.1 x 106 lbf/in²) Tensile strength ASTM D638 with grain 154 MPa (22,300 lbf/in²) cross grain 140 MPa (20,300 lbf/in²) 16.11.6 Phenolic Composite Floor Panels 16.11.6.1 Panels Phenolic composite floor panels shall be a wood core faced on the entire top and bottom surface with a skin consisting of fiberglass fabric impregnated with resin. 1. Wood Core: End-grain balsa. 2. Skin: Bi-axial fiberglass fabric impregnated with phenolic thermosetting resin. 3. Bond: Skin shall be permanently bonded to core by a compression molding process, co-curing the wet resin-impregnated skin directly against the core. 4. Minimum Thicknesses: a. Panel: 19 mm (0.75 in) b. Fiberglass fabric: • • Panels supported more than 914 mm (36 in) apart: 2.5 mm (0.1 in) Panels supported minimum 914 mm (36 in) apart: 1.4 mm (0.055 in) 5. Flammability, Smoke, and Toxicity: See Flammability, Smoke Emission, and Toxicity Requirements section, above. 16.11.6.2 Physical Test Requirements Phenolic composite floor panels shall withstand the physical tests in this section with none of the following results: 1. 2. 3. 4. Visible or audible indications of delamination of the panel skin from the core. Puncture or damage to fibers of the top surface. Separation of internal core from the top or bottom skin. Fracture of balsa core. Phenolic composite floor panels shall comply with the following physical test requirements: 1. Static Load Test, Average Loading: a. Test setup: Support a representative sample section of floor panel (without floor covering) on beams spaced at the maximum spacing used on the vehicle, using production bonding and fastening techniques. b. Load: In accordance with crush loading requirements of Section 2, Design and Performance Criteria. LTK Standard Streetcar Specifications Section 16 30 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship c. Test: Apply uniformly distributed load to both sides of joint (butt and/or shiplap). d. Maximum deflection: 2.2 mm (0.088 in). 2. Static Load Test, Maximum Loading: a. Test setup: Same setup used for Average Loading, above. b. Load: 976 kg/m² (200 lb/ft²). c. Test: Apply uniformly distributed load to both sides of joint (butt or shiplap). 3. Small Area Static Load Test: a. Test setup: Same setup used for Average Loading, above. b. Load: 136 kg (300 lb) c. Contact device: Footprint 25 mm by 75 mm (1.0 in by 3.0 in), machined flat within 0.25 mm (0.010 in) and edges radiused maximum 3.2 mm (0.125 in). d. Test: Apply load to the contact device located directly over midspan, 150 mm (6 in) from outer vehicle-body sidewall edge. e. Maximum deflection: 5 mm (0.20 in). 4. Indentation Resistance: a. Test setup: Representative sample section of floor panel laid on a level surface. b. Load: Test dowel with the following characteristics: • • Overall surface area: 242 sq mm² (0.375-sq in²) Radius on bottom edge: 1.6 mm (0.0625-in) c. Test: Apply a concentrated load of 136 kg (300 lbs) to test dowel. d. Maximum permanent deformation of top surface: 0.25 mm (0.010 in). 5. Small Object Impact Test: a. Test setup: Same setup used for Average Loading, above. b. Load: 7.26 kg (16 lb) standard bowling ball. c. Test: Drop load from height of 1500 mm (60 in) directly over mid-span, 610 mm (24 in ) from edge of panel. d. Maximum permanent deformation of top surface: 1.587 mm (0.0625 in). 6. Large Object Impact Test: a. Test setup: Same setup used for Average Loading, above. b. Load: 68 kg (150 lb) c. Contact device: Footprint 75 mm by 200 mm (3.0 in by 8.0 in), with rubber pad on the downside surface having the following characteristics: • • • Minimum Shore D 70 Thickness: 25.4 mm (1 in) Machined flat within 1.524 mm (0.060 in) with edges having a radius of not more than 0.8 mm (0.030 in) d. Test: Drop load from height of 300 mm (12 in) onto contact device located directly over midspan, 610 mm (24 in) from edge of panel. e. Maximum permanent deformation of top surface: 0.8 mm (0.030 in). Some damage to top phenolic composite skin will be allowed. LTK Standard Streetcar Specifications Section 16 31 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 7. Rolling Load Test: a. Test setup: Same setup used for Average Loading, above. b. Load: Four-wheeled cart with load of 91 kg (200 lbs) per wheel. Wheels shall have the following characteristics: • • • • Diameter: 75 mm (3 in) Width: 25 mm (1 in) Radius: 3 mm (0.125-in) on each edge Material: Shore A durometer of 80 c. Test: Roll load onto panels laterally, longitudinally, and in a circular path with radius 610 mm (24 in). d. Maximum permanent deformation of top surface: 0.25 mm (0.010 in). 16.11.7 Flatness Comply with the following: 1. Surfaces exposed to passengers shall deviate from the specified contour by maximum 2.5 mm (0.1 in) in any 1 m (39 in) distance. 2. The slope of any such deviation shall be maximum 2 mm (0.08 in) in 100 mm (4 in). 16.12 Fiberglass Reinforced Plastic (FRP) 16.12.1 General Comply with the following: 1. Material: Polymeric-reinforced, laminated material, composed of a gel-coated surface, fiberglass reinforcement, and a polyester, vinyl ester or other approved resin. 2. Chemical resistance: FRP shall be resistant to acids, mild alkaline solutions, and those cleaning solutions recommended by the Contractor. 3. Environmental resistance: FRP shall withstand, without any physical deformation, structural damage, or reduction in life, the environmental conditions in Section 2, Design and Performance Criteria. 16.12.2 Composition Comply with the following: 1. 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. 2. Mineral filler shall not exceed 28% of finished weight for any preformed matched die molding process. 16.12.3 Gel Coat Comply with the following: 1. The gel coat shall be weatherproof, provide the approved color and gloss as specified and approved in Section 14, Interior and Exterior Appointments, and contain UV inhibitors to protect the FRP from ultraviolet radiation. 2. If a low gloss finish is required, paint the FRP in accordance with this Section. LTK Standard Streetcar Specifications Section 16 32 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.12.4 Manufacturing Comply with the following: 1. Qualifications: FRP suppliers shall be experienced with manufacturing FRP structures of similar sizes and complexities, with materials and standards as defined in this Section. 2. Manufacturing Techniques: a. FRP shall be manufactured by hand-laminated open molding, or as appropriate for the part and approved by the Owner. b. Production techniques shall ensure that the glass fiber reinforcement is uniformly distributed throughout the final product in such a manner as to avoid resin-rich or resinstarved sections. 3. FRP parts: a. Thickness: Minimum 3 mm (0.120 in) b. Thickness at attachment points and edges: Greater than minimum thickness. c. Exposed sharp edges: Not permitted on any parts. 4. Quality: a. Inspect FRP materials at the point of manufacture for voids, density variations, and other internal defects, thickness variations, finish, and other defects. b. Except for minor surface defects, repairs to FRP are not permitted. c. Defective material shall be discarded. 16.12.5 Strength Requirements 16.12.5.1 General Perform independent laboratory tests in accordance with Section 15, Testing, to confirm that products comply with the strength requirements below. 16.12.5.2 Non-Structural (No load) Minimum strength requirements are defined below for items that are non-structural or will not be exposed to any loads, such as window masks, destination sign shrouds, ceiling cove panels, and ceiling headers: Non-Structural (No Load) Strength Requirements ASTM Mechanical Property Required Value Test Tensile Strength D638 69 MPa (10,000 lbf/in²) Compressive Strength D695 124 MPa (18,000 lbf/in²) Flexural Strength D790 103 MPa (15,000 lbf/in²) Impact Strength D256 5.3 J/cm (10 ft-lb/in) of notch Hardness D2583 45 Barcol 16.12.5.3 Structural (Load) Minimum strength requirements are defined in the table below for items that are structural or will be exposed to loads from passengers or impacts, such as end bonnets, side skin, under floor equipment enclosures, door pocket panels, wainscot panels, passenger seat back shrouds, and windscreens: LTK Standard Streetcar Specifications Section 16 33 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship Structural (Load) Strength Requirements ASTM Mechanical Property Required Value Test Tensile Strength D638 124 MPa (18,000 lbf/in²) Compressive Strength D695 165 MPa (24,000 lbf/in²) Flexural Strength D790 206 MPa (30,000 lbf/in²) Impact Strength D256 6.9 J/cm (13 ft-lbs/in) of notch Hardness D2583 45 Barcol 16.12.6 Shipping and Handling Provide special handling for any large, complex FRP parts such as the front end, including enclosing parts in custom frames or crates. Conduct a detailed receiving inspection for each such part. 16.12.7 Installation of FRP Front End Comply with the following installation requirements for FRP vehicle front end: 1. Where FRP is used for the vehicle front end, excessive force shall not be used during assembly onto the vehicle structure. 2. Minor trimming to fit will be permitted only at the discretion of the Owner. 3. After assembly of the front end onto the vehicle, notify the Owner of any cracks, voids, or defects. a. The defective front end shall be removed and replaced unless the Owner approves a repair. b. The determination to remove and replace or repair the defective part shall be solely at the discretion of the Owner with no additional costs to be borne by the Owner. 16.13 Thermoplastic Sheet 16.13.1 General Thermoplastic sheet shall: 1. Withstand the environmental conditions in Section 2 without physical deformation or structural damage. 2. Be resistant to all recommended cleaning agents. 3. Meet the relevant requirements in the Flammability, Smoke Emission, and Toxicity section, above. Thermoplastic sheet shall be used as extruded or pressure-formed, or as approved by the Owner. 16.13.2 Product Requirements Thermoplastic sheet: Homogeneous and extruded from virgin stock, which shall not include any regrind of vacuum formed parts. Thermoplastic in final form: 1. Surface finish gloss: Level shall not vary by more than 5 points, as measured using a 60° glossometer. 2. Surface texture: Shall not fade out at or near part contours. 3. Color, texture, and gloss: Exposed surface shall conform to Section 14, Interior and Exterior Appointments. Only UV stabilized pigments shall be used to create the specified color. LTK Standard Streetcar Specifications Section 16 34 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 4. Anti-graffiti coating: Provide on exposed surfaces. 5. Quality: Free of waves and quilting on both sides. 6. Defects: Following shall be cause for rejection of the piece: a. Degraded polymer. b. Voids, lumps, and contamination if the defects are larger than 0.25 mm (0.010 in) and the population is greater than one defect in 0.37 m² (4 ft²). 16.13.3 Strength Requirements Thermoplastic sheet shall comply with the requirements of the standards listed in the table below. Use extruded sheet in the specified surface finish for testing. Thermoplastic Sheet Strength Requirements Mechanical Properties Specific Gravity Tensile Strength Flexural Strength Flexural Modulus Hardness Rockwell Heat Shrinkage ASTM Method D792 D638 D790 D790 D785 Heat Deflection (annealed) D648 Impact Strength Gardener Dart Drop, 13 mm (0.5 in) diameter ball: @ 23 degrees C (73 degrees F) @ -29 degrees C (-20 degrees F) D5420 Value 1.20 to 1.45 48 N/mm² (7,000 lbf/in²) minimum 69 N/mm² (10,000 lbf/in²) minimum 3100 N/mm² (4.5 x 105 lbf/in²) 90 to 120 “R” Scale 10% maximum 15 minutes at 177 degrees C (350 degrees F) 88 degrees C (190 degrees F) minimum @ 182 N/cm² (264 lbf/in²) 369 kg-cm (320 in-lb) minimum 92 kg-cm (80 in-lb) minimum 16.14 Raceways and Junction Boxes 16.14.1 Scope This section applies as follows: 1. Raceways include conduit and wireway, both non-metallic and metallic. 2. Junction boxes are boxes that are part of the raceway system, and include both pull boxes and boxes for electrical connections. 3. Equipment enclosures and electrical lockers are specified in Section 14, Interior and Exterior Appointments. 16.14.2 General Requirements Comply with the following: 1. Locate raceways and junction boxes to avoid mechanical damage. 2. If the installation of raceways or junction boxes causes the connection of dissimilar materials, the installation shall comply with the requirements for dissimilar materials in this Section. LTK Standard Streetcar Specifications Section 16 35 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.14.3 Conduit 16.14.3.1 Permitted Conduit Types Comply with the following: 1. Flexible Non-Metallic Conduit: a. Use: May be used where flexibility is required but not where subject to physical damage. b. Conduit: Material meeting the flammability, smoke emission, and toxicity requirements of this Section. • • Interior use: Rated IP64 with fittings Exterior use: UV resistant and rated IP66 with fittings c. Terminations: Manufactured by the conduit manufacturer for the conduit selected and suitable for the application. d. Fittings to secure conduit: • • For corrugated-exterior-wall type: Clips manufactured for the purpose by the conduit manufacturer and designed to restrain longitudinal motion. For smooth-exterior-wall type: Two-hole, heavy-duty galvanized steel straps, manufactured for the size of conduit they are used to secure. 2. Liquidtight Flexible Metal Conduit: a. Use: May be used in the same locations as flexible non-metallic conduit, except where exposed to accidental impact damage, such as under the vehicle ends. b. Core: Flexible galvanized steel with a continuous copper bonding conductor spiral wound between the convolutions. c. Jacket: Extruded liquid-tight plastic or neoprene meeting the flammability, smoke emission, and toxicity requirements of this Section; moisture- and oil-proof. If used in exterior locations, jacket shall be UV resistant and rated IP66 with fittings. d. Terminations: Zinc-coated steel. e. Fittings to secure conduit: Two-hole, heavy-duty galvanized steel straps, manufactured for the size of conduit they are used to secure. 3. Rigid Metal Conduit: a. Use: May be used where flexibility is not required. b. Conduit, elbows, nipples: Steel, hot-dip galvanized inside and out after threading, UL listed, complying with ANSI C80.1. c. Couplings and Terminations: Steel, galvanized, threaded type. d. Bushings: Nylon insulated, metallic. e. Fittings to secure conduit: Two-hole, heavy-duty galvanized steel straps, manufactured for the size of conduit they are used to secure. 16.14.3.2 Conduit Fill Conduit fill shall not exceed the maximum fill permitted by NFPA 70, Chapter 9, Tables, Table 1, Percent of Cross Section of Conduit and Tubing for Conductors and Cables. LTK Standard Streetcar Specifications Section 16 36 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.14.3.3 Conduit Installation Comply with the following: 1. General: a. Install conduit to prevent moisture traps and arrange to gravity-drain toward control boxes or an open end. b. Install conduit such that wire and cable may be installed after conduit installation without using power equipment and without exceeding the allowed wire or cable pulling tension or sidewall tension. 2. Flexible Non-Metallic Conduit: Install conduit in accordance with the requirements of NFPA 70, Article 356, Liquidtight Flexible Nonmetallic Conduit, including but not limited to the number of bends in one run, bend radii, and securing and supporting conduit. 3. Liquidtight Flexible Metal Conduit: Install conduit in accordance with the requirements of NFPA 70, Article 350, Liquidtight Flexible Metal Conduit, including but not limited to the number of bends in one run, bend radii, and securing and supporting conduit. 4. Rigid Metal Conduit: a. Install conduit in accordance with NFPA 70, Article 344, Rigid Metal Conduit, including but not limited to how bends are made, the number of bends in one run, bend radii, reaming and threading, securing and supporting conduit, and use of bushings. b. After threading, clean to remove threading oil and protect from corrosion with minimum two coats of brushed on cold galvanizing compound. c. If conduit is terminated at floor level, extend minimum 25 mm (1 in) about the floor to prevent entrance of liquid. d. Clean conduit after installation by pulling through a brush or swab. 16.14.3.4 Conduit Connections to Boxes and Enclosures Comply with the following requirements: 1. Configure conduit connections to boxes and enclosures as follows: a. So that structural, electrical, and environmental integrity is maintained. b. To facilitate removal and replacement of the equipment enclosure. Conduit entries into removable equipment boxes shall be secured by means of a bolt-on watertight access panel. 2. Connect conduit to underfloor and roof equipment enclosures using watertight connectors. The entrance of conduit into the top and bottom of equipment boxes is prohibited. 16.14.4 Wireway 16.14.4.1 Scope Wireway includes wire duct, trough, channel, or other means, not including conduit, used to contain electrical wire, electrical cable, or communications cable. 16.14.4.2 General Requirements Comply with the following: 1. Use restrictions: Use only where it will remain permanently accessible, such as where installed in electrical lockers or behind removable panels. LTK Standard Streetcar Specifications Section 16 37 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Design and installation: Ensure that wire and cable can be installed without damage: a. Surfaces and edges: Designed to prevent damage to wire and cable insulation. b. Wire entry and exit points: Provide additional wire protection and support. 3. Wire management: Provide means to securely fasten wire and cable within wireways to prevent movement and chafing, but allow changes to be made throughout the lifetime of the vehicle. 4. Barriers: If used for conductors of different voltages, provide circuit separation as specified in the Circuit Separation section, below. 16.14.4.3 Interior Interior wireway may be non-metallic or metallic, as appropriate for the application: 1. Non-metallic wireway: a. Material shall be low-smoke, halogen-free, complying with requirements for flammability, smoke emission, and toxicity in this Section. b. Wireway shall be designed for the intended purpose and may be solid or slotted. c. Provide a removable cover. d. Attach securely to the vehicle structure using specified fasteners; adhesive fasteners are not permitted. Secure at intervals complying with NFPA 70, Article 378, Nonmetallic Wireways. 2. Metallic wireway: Meet the requirements for exterior metal wireway. 16.14.4.4 Exterior Exterior wireway shall be metallic, unless otherwise approved, and shall comply with the following: 1. Material: Stainless steel, or steel primed and painted in accordance with the requirements of this Section. 2. Drains: Provide to prevent accumulation of water, unless made with perforated material. 3. Covers: Removable. 4. Installation: Attach securely to the vehicle structure using specified fasteners. Secure at intervals complying with NFPA 70, Article 376, Metal Wireways. 16.14.5 Junction Boxes 16.14.5.1 General Comply with the following general requirements for interior and exterior junction boxes: 1. Manufacturer: The Contractor or a regular manufacturer of electrical junction boxes. 2. Interior finish: Primed and painted white. 3. Covers: Gasketed and retained by spring-type latches or captive screws as agreed by the Owner on a location-by-location basis. Fasteners shall be stainless steel. 16.14.5.2 Exterior Junction Boxes Exterior junction boxes shall meet the general requirements for junction boxes. In addition, they shall be minimum 14-gauge steel and weatherproof. LTK Standard Streetcar Specifications Section 16 38 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.14.6 Bonding and Grounding Metallic Raceway and Junction Boxes Metallic raceway and junction box installations shall comply with the following: 1. Provide appropriate fittings such that raceways and connected junction boxes are mechanically and electrically continuous. 2. Provide additional bonding jumpers or internal grounding wires if necessary to provide electrical continuity. 3. Safety ground raceway and junction boxes to the vehicle structure in accordance with Section 9, Electrical Equipment. 16.15 Wire and Cable 16.15.1 General Comply with the following general requirements for all wire and cable used on the vehicle: 1. Limit the number of wire types and sizes to the extent possible. 2. Comply with the flammability, smoke emission, and toxicity requirements of this Section, AAR RP-585, and NFPA 130. 3. Provide wire and cable suitable for the application. 16.15.2 Wire and Cable Type Requirements 16.15.2.1 Conductors Comply with the following: 1. Material: Soft (annealed) copper. 2. Plating: As indicated in standards referenced for wire types in the Insulation section, below, or if not indicated, in accordance with temperatures below: a. 150 degrees C or less: Tinned; ASTM B33. b. 250 degrees C or less: Silver-plated; ASTM B298. c. 450 degrees C or less: Nickel-plated; ASTM B355. 3. Stranding: Suitable for the application. Provide extra-fine wire stranding for applications subject to repetitive motion, where superior flexibility is necessary for proper installation, or as specified elsewhere. 16.15.2.2 Insulation Comply with the following: 1. Flexibility: For wire sizes No. 6 AWG and larger, the insulation material shall be formulated for extra flexibility. 2. Voltage Rating: a. Nominal voltages 300 V or less: Insulation shall be rated 600 V, ac and dc. b. Nominal voltages greater than 300 V: Insulation shall be rated 2000 V, ac and dc. 3. General Vehicle-Body Wiring: a. Sizes No. 12 to No. 28 AWG: Teflon®, mineral-filled, abrasion-resistant insulation; or LTK Standard Streetcar Specifications Section 16 39 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship b. All sizes: Flame retardant, flexible, cross-linked polyolefin complying with ICEA S-95-658, having a continuous temperature rating of 110 degrees C (230 degrees F) or 125 degrees C (257 degrees F), as appropriate for the application. c. Flammability, Smoke Emission, and Toxicity Standards: • • • • • • NFPA 130 49 CFR 238 ASTM E662 in flaming and non-flaming modes BSS 7239 or Bombardier SMP 800C IEEE 1202 UL 1685 4. High Temperature Applications: a. Sizes No. 16 AWG and Larger: • • Abrasion resistant Teflon® polytetrafluorethylene (PTFE) complying with SAE AS 22759/6 or tetrafluorethylene (TFE) complying with SAE AS 22759/10, as appropriate for the voltage level; or Silicone rubber complying with AAR RP-587 and suitable for the application. b. Sizes No. 18 AWG and Smaller: • Abrasion resistant Teflon® polytetrafluorethylene (PTFE) complying with SAE AS 22759/6 or tetrafluorethylene (TFE) complying with SAE AS 22759/10, as appropriate for the voltage level. c. When used for interconnecting pieces of apparatus, wire used in high-temperature applications shall be in bundles with a high-temperature rated, low-smoke generating, insulated protective covering. 5. In Equipment: Wiring within replacement modular units, electronic apparatus such as cards and card racks, and other equipment, as approved, shall be one of the following: a. Tefzel® ethylene tetrafluoroethylene (ETFE) per ASTM D3159 (material standard) and insulation construction per SAE AS 22759/16. b. Teflon® polytetrafluoroethylene (PTFE) type EE per NEMA HP 3. c. Cross-linked polyolefin insulated wire, as described for general vehicle-body wiring, above. 6. Crowded Locations (Cab Console or similar locations): a. Tefzel® ETFE per ASTM D3159 and insulation construction per SAE AS 22759/16. b. When used for this application, bundle these type wires with a protective covering of crosslinked modified polyolefin or similar high-temperature rated, low-smoke generating insulation. 16.15.2.3 Multi-Conductor Cables Where multi-conductor cable is approved, comply with the following: 1. Conductors and insulation: As described above. 2. Fillers: Where required to obtain a circular cross-section, fillers shall be made of nonhygroscopic materials compatible with the wire insulation and jacket, and shall be of the same or of a higher temperature rating than the wire insulation. LTK Standard Streetcar Specifications Section 16 40 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 3. Binder Tape: Non-hygroscopic, of the same (or better) temperature class as the wire insulation, and of a compatible material. Apply if needed to assist in cable manufacture, or as required to permit the cable to function as intended in its application. 4. Shield (if required): Either tin-plated copper braid, concentrically-served copper, or aluminum/polyester tape with a drain wire, as appropriate for the application. Tape shields shall be permitted for fixed installations only. 5. Overall jacket: Flame-retardant, cross-linked, modified polyolefin, Tefzel® (ETFE), or Teflon® (PTFE), fully compatible with the wire insulation and application. 6. Identification: a. Individual conductors in multi-conductor cables shall be color coded or otherwise permanently identified as approved. b. Overall jacket shall be permanently marked at maximum 1 m (3 ft) intervals with the following information, as a minimum: • • • • Conductor size Number of conductors Voltage rating Jacket type 16.15.2.4 Ethernet Cable For network cabling provide industrial-grade Ethernet cable designed for reliable performance in a transit environment: 1. Conductors: Tinned copper, solid or stranded as required for the application and specified performance. 2. Shielding: Provide if required to obtain specified performance. 3. Jacket: Abrasion-resistant. 4. Construction: a. Suitable for the intended installation method. b. In compliance with flammability, smoke emission, and toxicity requirements of this Section. c. Minimum IP65 rated in accordance with IEC 60529 when mated with specified connectors. 5. Identification: Cable shall be permanently marked at maximum 1 m (3 ft) intervals with the following information, as a minimum: a. Electrical performance rating (e.g. Cat 5e) b. Number of pairs and size (AWG) 16.15.3 Wire and Cable Application and Installation Requirements 16.15.3.1 General Comply with the following: 1. Wire and cable shall be applied and installed as indicated in NFPA 70, Chapter 3, Wiring Methods and Materials, APTA PR-E-RP-002-98, NFPA 130, and IEEE Std 16, except where otherwise specified, and except that wire shall be as specified. 2. Vehicle wiring shall have circuit protection conforming to NFPA 70, Article 240, Overcurrent Protection, or the Specifications. LTK Standard Streetcar Specifications Section 16 41 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.15.3.2 Wire Sizes Comply with the following: 1. Size wiring for the intended load, voltage drop, application, and installation method. 2. Wire and cable ampacity shall comply with NFPA 70, Section 310.15, Ampacities for Conductors Rated 0-2000 Volts. Where the temperature rating of the approved wire or cable is not included in Section 310.15 tables, manufacturer’s ratings may be used, provided that the rating method is consistent with NFPA 70 Section 310.15. 3. Regardless of load, minimum wire sizes shall be as follows: a. Wire pulled through conduit: No. 14 AWG b. Wire on electronic units, cards, and card racks: No. 28 AWG c. Wire laid in, rather than pulled through, wire ducts: No. 16 AWG 4. Wires sizes other than the above shall be only as approved. 16.15.3.3 Insulation Level Wiring within enclosures shall be insulated for the highest voltage in the enclosure, unless approved otherwise. 16.15.3.4 High-Temperature Wire Comply with the following: 1. If used for interconnecting pieces of apparatus, high-temperature wire shall be in bundles with a high-temperature rated protective covering. 2. High-temperature insulated wire shall not be used in conduit or raceways without specific approval. 16.15.3.5 Circuit Separation Comply with the following: 1. Circuits shall be physically separated to reduce the possibility of unsafe conditions, interference, or equipment damage. 2. 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: a. b. c. d. e. High-voltage circuits AC circuits Communication circuits Battery voltage level circuits Semiconductor voltage level circuits 3. Wiring operating at potentials differing by 50 V or more shall be separated as follows: a. Shall not be harnessed or cabled together b. Shall not be run in conduit together c. In wireway, junction boxes, or other wire routing devices shall be separated by a rigid physical barrier d. Within equipment enclosures shall be separated, routed, and secured such that contact between wiring is not possible LTK Standard Streetcar Specifications Section 16 42 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 4. Provide separation and/or electromagnetic shielding 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. 16.15.3.6 Spare Wires Comply with the following: 1. Provide a minimum of 10% spare wires in each harness or group of wires between equipment enclosures, but no fewer than two spares for each wire size. 2. Unless specifically approved by the Owner, no spare wiring shall be used by the Contractor. 3. Install spares in connectors on terminal boards or other means as approved by the Owner. 16.15.3.7 Wire Handling Comply with the following: 1. Wiring shall be installed by qualified and experienced wiring personnel: a. Use appropriate tools for work such as stripping insulation, cutting, tinning, soldering, harness making, and attaching terminals. b. Use wiring tools and equipment as recommended by the tool and equipment manufacturer. 2. Wire shall be protected from damage during all phases of equipment manufacture. a. Wire shall not be walked on, dragged across sharp or abrasive objects, kinked or twisted, or otherwise mishandled. b. 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. 3. When removing insulation, wire strands shall not be nicked or broken. 16.15.3.8 Wiring Location Requirements Comply with the following restrictions on location: 1. Locate wiring such that heat sources, maintenance access, and the Project environment do not damage or reduce the life of the wiring. 2. Wiring shall not pass through or over the battery compartment, or over heat-generating equipment such as acceleration and braking resistors. 16.15.3.9 Wiring Methods Comply with the following requirements for wiring methods: 1. Wiring Type Requirements: a. Exposed wiring: Keep to a minimum; subject to the Owner’s review and approval. b. Multi-conductor cabling: • • Keep to a minimum; subject to the Owner’s review and approval. Shall not be exposed with the following exceptions: ○ ○ Coupler cables with additional jacketing or armor Wiring to standard small devices, such as speed sensors, that cannot accept conduit fittings LTK Standard Streetcar Specifications Section 16 43 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship c. Under-vehicle and roof wiring: Waterproof, including entrance and exit points from equipment enclosures or wiring devices. 2. Raceway Requirements: a. Wire smaller than No. 6 AWG shall be installed in conduit or wireway unless it is an integral part of equipment or is contained within an enclosure. b. Wiring to resiliently mounted or moving equipment shall be by flexible conduit. c. Wire No. 6 AWG or larger may be cleated in place without conduit or wireway. 3. Securing: a. Wiring shall be secured and protected against movement, chafing, and contact with conductive, sharp, or abrasive objects and surfaces such that normal equipment motion does not damage or reduce the life of the wiring. b. No wiring shall be secured directly to the vehicle structure, equipment enclosures, or any metallic surface. c. Wire ties: May be used only to secure or bundle wire and cable within wireway, where exiting wireway or entering equipment enclosures, and within equipment enclosures. 16.15.3.10 Wire and Cable Installation in Conduit Install wire and cable in conduit without using power equipment and without exceeding the manufacturer’s allowed wire or cable pulling tension or sidewall tension: 1. Clean the conduit just before installation of wire or cable by pulling a brush or swab through. 2. Install all cables to be placed in one duct simultaneously. 3. Use extreme care in installing wire and cables so as to avoid twisting, kinking, scraping, or injuring outer sheath. 4. Use continuous lengths of wire and cable between power source and equipment. Splices are prohibited. 5. Wiring within conduit shall not be bundled or secured. 6. Pulling compound, if used, shall be non-conductive, non-hygroscopic, non-odorous and shall not attract vermin. 16.15.3.11 Wire and Cable Installation in Wireway The installation of wire and cable in wireway shall comply with the requirements of NFPA 70 Article 376, Metal Wireways, or Article 378, Nonmetallic Wireways, including but not limited to the size of conductors, number of conductors, and ampacity of conductors based on wireway fill. Comply with the following: 1. Wire and cable shall be laid into wireway. If pulling is required, prepare a pulling plan documenting the wire or cable manufacturer’s minimum acceptable bend radius and maximum tension during pulling. 2. To the extent possible, install all wire and cable in a wireway at the same time, unless physical separation barriers are provided. 3. Wire and cable shall be installed neatly and fastened securely to eliminate movement and chafing. 4. When wire and cable is in its final position, inspect to ensure that it has sufficient bend radius, and that there is no sagging, pinching, or possibility of chafing that could cause damage over time. LTK Standard Streetcar Specifications Section 16 44 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.15.3.12 Wire and Cable Installation by Cleating Comply with the following: 1. Cleat Type: a. Split-block cleats of fire-retardant neoprene rubber with a durometer of 50 to 60. b. Neoprene blocks shall be clamped together with minimum two bolts with a rigid stiffener on each side of the cleat. c. Stiffeners shall ensure that clamping pressure is evenly distributed over the full length of the cleat. 2. Cleat opening: a. Molded into the material by an experienced manufacturer. b. Sized only for the intended wire size such that it firmly grips the wire without insulation damage or cold flow. Shimming of oversized openings is not permitted. c. Cutting, drilling, or modification of cleat openings during vehicle construction is prohibited. 3. Installation: a. Route and support wiring such that each individual run of wiring cannot contact other wiring or any other part of the vehicle under any circumstances. b. Cleat spacing: Maximum 0.5 m (18 in). c. Drip loop: Provide on exposed wiring to prevent fluid runoff into connected equipment. 16.15.3.13 Wiring Within Enclosures Wiring within enclosures shall be attached to wire supports rigidly fastened to the enclosure structure. Comply with the following requirements: 1. Wiring shall be clear from edges, bolt heads, and similar areas, and shall not interfere with or contact enclosure covers. 2. Wiring shall be located on the top or sides of the enclosure. Wiring shall be a minimum of 25 mm (1 in) above the bottom of the enclosure, including wiring that must connect to the bottom of apparatus. 3. Wiring entering a removable enclosure shall be harnessed and secured to facilitate removal of the enclosure. Wires entering an enclosure from different raceways shall not be harnessed together or with internal wiring. 4. Wiring shall be secured such that there is no strain on wire terminals, multi-pin connector pins, or other wire termination hardware. 5. 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. 6. Provide additional wire length for retermination of wires without excess tension or splicing as follows: a. No. 10 AWG and smaller: Four reterminations b. No. 8 AWG and larger: Three reterminations LTK Standard Streetcar Specifications Section 16 45 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.15.3.14 Identification Devise a wire and terminal designation system that will coordinate each electrical circuit in the vehicle into a unified system: 1. The system shall identify wiring, including circuit return wiring, and terminals according to their respective circuit function(s), and shall accurately correlate with the Integrated Schematic Diagrams. 2. Common designations for return circuits are not permitted. 3. Alternative designations may be used with Owner approval in small standard assemblies, such as PA amplifiers. Clearly identify each terminal and identify each wire with both its circuit designation, and, if attached to a terminal, its terminal designation. 1. Mark wires within 75 mm (3 in) of the end of the wire. 2. Provide white or yellow permanent markers with black printing or continuous wire marking printed on the wire. a. Markers: Oil and grease resistant; shall withstand the worst case combinations of ambient and equipment temperatures. b. Printing: By machine with permanent ink that will not rub off. Hand printing is prohibited. 3. Color coded wires are permitted as an alternative in small standard assemblies such as PA amplifiers. 16.15.3.15 Wire Ties, Clamps, and Anchors Wire ties shall be nylon formulated for resistance to ozone and ultraviolet light, rated for outdoor service. Wire ties: 1. 2. 3. 4. Select width for intended wiring load and minimum insulation indentation. Install with tools with automatic tensioning devices, as supplied by the wire tie manufacturer. Install with sufficient tension to restrain the wiring but without indenting the wire insulation. Install with cut ends flush with the locking mechanism. Wire clamps: 1. Wire clamps shall be either nylon as specified above for wire ties or stainless steel covered with neoprene or silicon rubber, such as Adel clamps as manufactured by Adel Wiggins. 2. Size for each harness such that minimum 90% of the harness circumference is securely clamped. 3. Fasten clamps with bolts and elastic stop nuts. Wire tie anchors (if used): 1. Material: Nylon, as specified above for wire ties. 2. Installation: Fasten to a rigid structure using rivets or screws; adhesive-based wire tie anchors are not permitted. LTK Standard Streetcar Specifications Section 16 46 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16.16 Wire Terminations 16.16.1 General Wiring shall terminate in approved connectors or on terminal boards: 1. Provide junction boxes or equipment enclosures for all wire terminations or circuit branches. 2. Wire splicing is prohibited. 3. Inline connectors and splice packs are prohibited. 16.16.2 Terminal Boards Definition of Terminal Board: Device commonly called terminal block, terminal strip, terminal stud, or similar, to which wires are connected. Comply with the following requirements for terminal boards: 1. Shall be of a series service proven in rail transit. 2. Conducting portion: Plated copper. 3. Insulating portion: a. Strong, high temperature rated, tracking resistant material that is not brittle. b. The material shall be either a filled reinforced thermosetting material or a thermoplastic material. c. Use of general purpose phenolic is prohibited. 4. Clamps, screws, or other hardware: May be plated steel. 5. Jumpers between adjacent terminals: Plated brass or copper. 6. Spare terminal requirements: a. Less than 100 terminals: Minimum 10% spare, but no fewer than one unused terminals. b. 100 terminals or more: Minimum 10 spare, plus 2 for every 50 additional terminals above 100. 7. Number of wires permitted: a. Screw compression-clamp terminal boards: Connect a maximum of two terminals to each binding terminal. b. Other terminations: Only one wire per terminal is permitted. 8. Provide adequate space to permit connecting wire terminals with standard tools. 16.16.3 Non-Power Wiring Terminations Comply with the following: 1. Terminate wires as appropriate for the intended terminal block, as recommended by the terminal block manufacturer. 2. Spring-clamp terminals: Wire may be bare, as recommended by the terminal supplier. 3. Non-spring-clamp terminals: Provide terminations complying with the following requirements: a. Mechanical crimp type terminals such as AMP brand as manufactured by TE Connectivity, or other approved manufacturer with a comprehensive line of terminals, connector pins and application tools. b. Plated copper. c. Ring-type terminals. LTK Standard Streetcar Specifications Section 16 47 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship d. Prohibited: • • • Hook type terminations. Faston-type (receptacle and tab) terminations, unless part of OEM components. Fork (spade) type terminations, unless specifically approved for applications such as relays or other devices with captive screw fasteners. e. Conductor sizes No. 10 AWG or smaller: • • Insulated terminals with metal strain relief device under the insulation that is crimped onto and grips the wire insulation simultaneously with the terminal. The insulation material shall be rated for the expected worst case temperature. 4. Installation: a. Maximum of one wire in each terminal. b. Attach wire terminals and connections to the wiring with crimping tools and dies as recommended by the manufacturer and approved by the Owner: • • Crimping tools shall be ratcheting types that ensure a complete compression. Maintain these tools in proper calibration and ensure that personnel using them are properly trained. 16.16.4 Power Wiring Terminations Comply with the following: 1. General Applications: Bolted compression terminals manufactured by TE Connectivity (AMP brand), Thomas & Betts, or approved equal. 2. Special Applications: a. Locations where rotation of termination could result in contact or unacceptable clearance: Double-bolted terminals. b. Traction motor wire: Terminals shall be as recommended by the motor manufacturer, subject to approval. 3. Installation: a. Procedures: As recommended by the terminal manufacturer. b. Crimping tools: Ratcheting type that ensures a complete compression, and as recommended by the terminal manufacturer. c. Terminations at heat generating devices: At the terminal, peel back insulation from the conductor a sufficient distance to prevent excessive heat from damaging insulation. 16.17 Cable Terminations 16.17.1 Multi-Pin Cable Connectors Provide cable connectors of service proven design by manufacturers such as ITT Veam or Harting. Connectors shall comply with the following: 1. Contacts: a. Removable crimp type, with a positive seating mechanism for each contact so it cannot back out of its location in the connector. b. Sized for the wire, as recommended by the manufacturer. LTK Standard Streetcar Specifications Section 16 48 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Strain relief: Cable clamp at the back of the connector sized for the cable jacket. Clamping on cable wires is prohibited. 3. Extension bodies: Provide where necessary to ensure that there is sufficient room to terminate cable wires while providing the seal and clamp on the cable jacket. Adjacent connectors shall use either different inserts or different insert orientations to prevent erroneous connections. 16.17.2 Cable Connectors Comply with the following: 1. Application: a. Weatherproof interior locations: Non-waterproof or waterproof connectors. b. Under-vehicle and exposed locations: Waterproof connectors. 2. Type: Circular or rectangular metal-shelled, positive-locking, quick disconnect, with the following features: a. Rated for a minimum life of 2,000 couplings before failure. b. Connectors shall give audible, visual, and tactile indications of full coupling. 3. Waterproof connectors shall have the following additional features: a. Watertight b. Furnished with gaskets on the front mating surface and on the back at the cable entry. 4. Installation: Seal unused connector pin positions with either connector contacts or plastic sealing plugs designed for that purpose. 16.17.3 Ethernet Cable Connectors Connectors shall be industrial Ethernet M12 type, complying with IEC 61076-2-101, with the following features: 1. Gold plated contacts. 2. Rated for minimum 500 mating cycles. 3. Connectors and the cable-to-connector attachment IP65 rated per IEC 60529. 16.17.4 Cable Connections to Boxes and Enclosures Comply with the following: 1. Configure cable connections to boxes and enclosures so that structural, electrical, and environmental integrity is maintained, and to facilitate removal and replacement of the box or enclosure. 2. Cable entry shall be by means of watertight sealing glands. Glands and cable terminations shall provide for cable replacement without removal of lugs, terminals, or connectors from the wires. 3. The entrance of cables in the top and bottom of equipment boxes is prohibited. 16.18 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance: 16-1 Recommended Cleaning Agents: 1. Each material exposed to normal cleaning: Manufacturer’s recommended cleaning agent. LTK Standard Streetcar Specifications Section 16 49 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Each cleaning agent: Safety Data Sheet (SDS). 16-2 Certification of No Prohibited Materials: 1. List of prohibited materials, and certification that none are present on vehicles. 16-3 Proposed Materials Not Covered by Specification or Standard: 1. Material, identified by commercial trademark, name, and address of Supplier. 2. Description and technical data specifications of material composition. 16-4 Safety Data Sheets (SDS): 1. Submit as one complete package including an SDS for each chemical material used in the manufacture of the vehicle. 16-5 Fasteners Design Package: 1. Matrix listing each type of fastener used on the vehicle. Furnish the following information: a. b. c. d. e. f. g. h. Fastener type Manufacturer Base material and plating or finish Size(s) Property class, grade, strength Indication of application for structural and safety-related fasteners Indication of location for fasteners used where there are location-specific requirements Indication of application for fasteners used where there are application-specific requirements 2. Manufacturer’s data for each type of fastener, with sufficient information to demonstrate compliance with the Specifications. 3. Plating type used for high strength fasteners. 4. Alternate plating or coating system (if proposed): a. Qualification data for each process used at each Supplier applying proposed coating, including the following: • • • • Coating manufacturer's product data including required thickness ASTM B117 test results from an accredited third party laboratory Documentation of torque/tension characteristics A statement from the coating manufacturer regarding the propensity for the coating process to cause hydrogen embrittlement of the fastener during coating 5. Structural threaded fasteners: Sufficient information to demonstrate compliance with the requirement for coordination of nut strength with bolt strength to prevent undetected internal thread stripping, including calculations if required. 6. Safety-related fasteners: Proposed sample quantities to be used for production lot testing. 16-6 Stainless Steel Test and Inspection Plan: 1. Submit before purchasing stainless steel to be used in welded applications. LTK Standard Streetcar Specifications Section 16 50 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 2. Purpose: For acceptance of stainless steel. a. Austenitic stainless steels: Include frequency of submittal of certifications in accordance with ASTM A666 and frequency of submittal of checks for susceptibility to intergranular corrosion in accordance with ASTM A262. b. Ferritic stainless steels: Include frequency of submittal of checks for susceptibility to intergranular corrosion in accordance with ASTM A763. 16-7 Structural Steel Test and Inspection Plan: 1. Submit before purchasing structural steel. 2. Include provisions for submission of reports and certification to the Owner for each shipment in accordance with the applicable requirements of this Section and specified CGHAZ impact tests. 16-8 Steel Casting Qualification Test Report: 1. If the casting selected for qualification fails to qualify, include a plan of action with details of how failed material will be handled. 16-9 Aluminum Test Reports: 1. Copies of all test reports for sheet, extrusion, and forgings used in the vehicle structure. 16-10 Paints, Graphics, and Coatings Design Package: 1. Manufacturer’s data for each type of painting material with the following information: a. b. c. d. e. Composition Recommended application procedures for substrates on which it will be applied Curing characteristics Recommended minimum and maximum dry film thickness Performance characteristics 2. Detailed paint procedure for all items to be coated. 3. Powder coating (if approved in the Initial Interior and Exterior Design Package submitted under Section 14, Interior and Exterior Appointments): a. Manufacturer’s data on powder coating material. b. Powder coat applicator’s cleaning and application procedures, including certification that the procedure is approved by the power coating material manufacturer. 4. Paint coating and application document containing the following maintenance information: a. Procedures for surface cleaning and preparation, priming, surfacing, and painting for equipment that is painted or powder-coated, whether by itself or by its manufacturers and suppliers. b. Detailed paint schedule showing equipment painted, paint type and manufacturers, recommended thickness, and other pertinent information. c. After approval, include as part of the Maintenance and Servicing Manual specified in Section 18, System Support. LTK Standard Streetcar Specifications Section 16 51 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 16-11 Flammability, Smoke Emission, and Toxicity Design Package: 1. Submit a matrix including the following during detailed design review: a. b. c. d. e. f. g. h. Total weight of all materials Where material is used Flammability, smoke emission, and toxicity test identity Test facility Test requirements Test results Nature and quantity of the products of combustion Supplier's name 2. Submit test reports containing the following information for all materials tested: a. b. c. d. e. Test Performed Date Tested Test Facility Test Results Toxicity 16-12 Conduit and Raceways Design Package: 1. Manufacturer’s data for each type of proposed conduit. 2. Manufacturer’s data for each type of proposed wireway, and indicate where it is proposed for use. 16-13 Wire and Cable Design Package: 1. Matrix showing each type of wire and cable proposed for use on the vehicle, and indicate the application(s) for which it will be used. a. Manufacturer’s data for each type of wire and cable in the matrix. b. Number and name of the standard or standards with which each type of wire or cable complies. 2. Sample of each type of wire and cable proposed, including wire that is part of equipment proposed for use on the vehicle. Samples shall be 30 cm (12 in) long. 3. Three copies of certified type test documentation for each size and type of wire and cable proposed. 4. Proposed wire and terminal designation system: a. Manufacturer’s data for wire, cable, and terminal markers b. Printed samples of wire, cable, and terminal markers 5. Manufacturer’s data for wire ties and clamps 6. Details of proposed spare wires in each harness or group of wires. a. Proposed terminations for spares 16-14 Wire and Cable Connections Design Package: 1. Proposed terminations product line. 2. Manufacturer’s data on termination crimping tools LTK Standard Streetcar Specifications Section 16 52 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Materials and Workmanship 3. Specific application terminations: a. Power wire terminations b. Traction motor wire terminations c. Ethernet terminations 4. Manufacturer’s data for each type of cable connector. END OF SECTION LTK Standard Streetcar Specifications Section 16 53 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS Table of Contents 17.1 General ......................................................................................................................................1 17.1.1 Scope .............................................................................................................................................. 1 17.1.2 Electronic Control Equipment Configuration ................................................................................. 1 17.2 Control Logic Units .....................................................................................................................1 17.2.1 General ........................................................................................................................................... 1 17.2.2 Vehicle Control Unit ....................................................................................................................... 1 17.2.3 Monitoring and Fault Recording Capability ................................................................................... 1 17.3 Control Signals ...........................................................................................................................2 17.3.1 General ........................................................................................................................................... 2 17.3.2 Required Discrete Control and Status Signals ................................................................................ 2 17.3.3 Special Requirements for Door Control and Status ....................................................................... 2 17.4 Vehicle Data Network .................................................................................................................2 17.4.1 General ........................................................................................................................................... 2 17.4.2 Network Standards ........................................................................................................................ 2 17.4.3 Network System Redundancy ........................................................................................................ 3 17.4.4 Network Requirements .................................................................................................................. 3 17.4.5 Vehicle Network Controller ........................................................................................................... 3 17.4.6 Time Synchronization..................................................................................................................... 4 17.4.7 Wireless Access .............................................................................................................................. 4 17.5 Monitoring and Diagnostic System (MDS) ...................................................................................4 17.5.1 General ........................................................................................................................................... 4 17.5.2 Diagnostic Systems......................................................................................................................... 4 17.5.3 Fault Management ......................................................................................................................... 4 17.5.4 Interface with Shop ........................................................................................................................ 5 17.5.5 Train Operator Display (TOD)......................................................................................................... 6 17.5.5.1 General.................................................................................................................................... 6 17.5.5.2 Display Requirements ............................................................................................................. 6 17.5.5.3 Controls ................................................................................................................................... 6 17.5.5.4 Operating Status Screen ......................................................................................................... 6 17.5.5.5 Additional Screens - Vehicle Stopped ..................................................................................... 7 17.5.5.6 Maintenance Mode ................................................................................................................ 7 17.5.6 Portable Test Units (PTUs) and PTU Connection Points ................................................................ 7 17.6 Vehicle Software and Systems ....................................................................................................7 LTK Standard Streetcar Specifications Section 17 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17.6.1 General ........................................................................................................................................... 7 17.6.2 Software Functions ........................................................................................................................ 7 17.7 Contract Data Requirements List (CDRL) ......................................................................................8 LTK Standard Streetcar Specifications Section 17 ii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17.1 General 17.1.1 Scope This Section includes the following: 1. Requirements for the vehicle control system specified in this and other sections. 2. Requirements for the vehicle network and monitoring and diagnostic system. 3. Requirements for software specified in this and other sections. See Section 2, Design and Performance Criteria, Section 9, Electrical Equipment, and Section 13, Vehicle Communication Systems, for additional or related control requirements. 17.1.2 Electronic Control Equipment Configuration Comply with the following: 1. Segregate electronic control equipment both physically and electrically from power equipment. 2. Galvanically isolate control circuitry and control voltage sources from power circuitry and high voltage sources via transformers. 3. Provide dedicated power supplies for control systems, which are transformer isolated and powered from the low-voltage dc system. 17.2 Control Logic Units 17.2.1 General Comply with the following: 1. Each vehicle system shall have dedicated network-connected controls to provide all functionality specified in this Section and other sections of the Specifications. Provide diagnostics and fault logging, connections, and firmware for portable test units. 2. The control logic units shall include user-programmable operating characteristics. Control programs shall be stored in field-updateable, non-volatile memory. 3. All connections to low-voltage dc circuits shall have galvanic isolation. 17.2.2 Vehicle Control Unit Provide a control unit, designated as the vehicle control unit (VCU): 1. Purpose: To manage all communication between vehicle systems, monitor system states, display required information on the TOD, and similar functions. 2. Alternate to VCU: May be proposed to the Owner, such as the propulsion system providing the VCU function. 17.2.3 Monitoring and Fault Recording Capability Comply with the following: 1. Control logic units shall provide self-diagnostics, status, and fault monitoring of internal and external devices and shall continuously monitor critical parameters (Local Diagnostic and Test System (LDTS)). 2. LDTSs shall be integrated into the Monitoring and Diagnostic System (MDS) specified below. 3. The control logic unit and related software and devices shall be sufficiently responsive to detect and remedy erroneous or potentially damaging conditions such that equipment damage is prevented or minimized. LTK Standard Streetcar Specifications Section 17 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17.3 Control Signals 17.3.1 General Comply with the following: 1. Critical vehicle systems shall be controlled via discrete battery-level signals issued directly from the controlling cab, and propagated directly to the controlled systems without intervening electronic systems or other components that could cause false activation. 2. The status of control signals may be monitored by the vehicle network controllers specified below. However, the discrete control signals must predominate and conflicts shall be flagged as errors. 17.3.2 Required Discrete Control and Status Signals The following signals, at a minimum, shall be provided and configured as Type 1 interfaces as defined in IEEE 1475: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cab or Vehicle activation status Emergency brake control Door Interlock (locked and closed) status Door Enable control Door Open control No Motion status Propulsion mode control Brake mode control Track brake control Friction brake released status Forward mode control Reverse mode control Sanding control 17.3.3 Special Requirements for Door Control and Status Configure door control and status signals in a completely separate left/right side of vehicle configuration. 17.4 Vehicle Data Network 17.4.1 General All vehicle system control logic units shall communicate with each other and the main VCU via data networks. 17.4.2 Network Standards The vehicle networks shall conform to TCN (Train Communication Network), in accordance with IEC 61375-1. The following network types are permitted: 1. MVB (Multifunction Vehicle Bus): IEC 61375-3-1 2. CCN (CANOpen Consist Network): IEC 61375-3-3 3. ECN (Ethernet Consist Network): IEC 61375-3-4 The main vehicle network may be MVB, CCN, or ECN. LTK Standard Streetcar Specifications Section 17 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17.4.3 Network System Redundancy Comply with the following: 1. Use a partial mesh topology and other techniques to minimize the effects of single-point network failures on the remaining system. 2. Establish redundant links between managed switches and/or routers using Rapid Spanning Tree Protocol (IEEE 802.1D) or Shortest Path Bridging (IEEE 802.1Q) to provide a convergence time of no more than six seconds after a link failure. 3. Unmanaged switches that do not participate in RSTP or SPB shall not be used to make redundant connections to managed switches or routers. 17.4.4 Network Requirements Comply with the following: 1. The network system shall use an open design that is either non-proprietary or available from multiple sources. Network components and transceivers shall be available from multiple sources. 2. The network protocol shall be structured in a manner similar to the ISO/OSI communication model. All layers other than the application layer shall be transparent to the various vehicle system suppliers. 3. Communication related to real time control, such as propulsion control, shall be prioritized to the extent that anomalies in system stability and operation are prevented. 4. Calculated peak and average traffic levels shall not exceed 60% of the recommended peak and average traffic levels. Actual peak and average traffic levels measured under Section 15, Testing, shall not exceed 70% of the recommended peak and average traffic levels. 5. Protocols shall include error detection and retransmission. Each node on the network shall collect summary statistics regarding current and historical error rates and make that information available through the Monitoring and Diagnostic System specified below. 6. Network wiring shall be physically isolated from sources of EMI. Where redundant networks are employed, they shall not be run in the same conduit, wireway, or other such routing path. 7. The main network shall be fault tolerant, such that loss of connections to systems does not affect the connections of other systems to the network. 8. Safety relevant bus members, such as door controls and friction brake controls, shall continue to operate safely, and as commanded by the operator, even if the network has failed. 17.4.5 Vehicle Network Controller Each vehicle shall include a Vehicle Network Controller (VNC) to manage the local vehicle network(s): 1. Data that does not need to pass between the various networks shall be restricted from so doing. 2. The VNC may be considered as a functional entity and may be physically implemented within a more comprehensive equipment package. 3. The VNC shall automatically identify the vehicle upon which it is installed. 4. The VNC shall act as a router, and shall prevent local vehicle faults from interfering with vehicle operation. LTK Standard Streetcar Specifications Section 17 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17.4.6 Time Synchronization The vehicle data network shall be used to synchronize sub-system clocks within the vehicle with the official time signal, as received by the GPS system specified in Section 13, Vehicle Communication Systems. 17.4.7 Wireless Access The network shall be accessible via the Wi-Fi IP Router, specified in Section 13, to allow protected access to the vehicle network for purposes such as downloading data when the vehicle is in the Yard or Shop. 17.5 Monitoring and Diagnostic System (MDS) 17.5.1 General Comply with the following: 1. The MDS shall be a physically-distributed, functionally-integrated system that monitors signals and events within the vehicle and within selected subsystems on the vehicle and stores the collected subsystem and vehicle data in non-volatile memory located within the selected subsystems and at a central data storage point on the vehicle. 2. Each vehicle system shall provide self-diagnostics, status, and fault monitoring, accessible locally via laptops (portable test units) and via the MDS. 17.5.2 Diagnostic Systems Provide each vehicle with a Central Diagnostic System (CDS) and each specified individual subsystem with a Local Diagnostic and Test System (LDTS). The CDS shall integrate the individual LDTSs of the various subsystems and sensors on the vehicle. Provide an LDTS to subsystems including, but not limited to, the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. AC Auxiliary Power System Low-Voltage DC Power System Propulsion System Friction Brake System Door and Door Control System HVAC System Communications System CCTV System Automatic Passenger Counting System Diagnostic System Event Recorder System Network System 17.5.3 Fault Management Comply with the following: 1. Provide diagnostic and failure reporting at levels of detail appropriate for the operating or maintenance function being supported. 2. Data points shall be associated with fault attributes that can be changed by the Owner’s personnel. 3. System faults shall be time stamped and stored in memory. LTK Standard Streetcar Specifications Section 17 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 4. Operating and maintenance functions that shall be considered include the following: a. Operating Failure Identification and Correction: • • MDS shall provide information concerning failures affecting vehicle operation to the operator and other staff, where appropriate, of which they should be aware. MDS shall indicate if the failure is safety-related, affects operating procedures, and is correctable by the operator or other staff. b. Status Assessment: • MDS shall provide sufficient information to enable maintenance personnel to assess operational readiness and suitability for service of each vehicle, before entry into service. c. Troubleshooting: • • MDS shall provide detailed data to guide maintenance personnel using troubleshooting procedures to isolate and diagnose faults down to the lowest level possible. This capability shall be built into the vehicle-borne MDS hardware and embedded software to the greatest extent practical; however, use of Portable Test Unit (PTU) will be permitted, subject to approval of the Owner. d. Intelligent Failure Screening: • • Each subsystem shall have sufficient diagnostic intelligence to enable it to distinguish between actual subsystem failures and apparent failures caused by failure of another subsystem. For example, auxiliary inverter failures causing loss of three-phase power to an HVAC system shall not be reported as an HVAC system failure. Power-up and shut-down sequencing among subsystems shall not generate failure messages. e. Repeated instances of the same failure shall be handled such that LDTS memory is not filled with multiple occurrences of the same failure. 17.5.4 Interface with Shop Comply with the following: 1. Equip the vehicle MDS with a Wi-Fi IP router to transmit MDS and other specified data to the vehicle maintenance workstation in the Shop. a. The MDS shall automatically transmit fault data to the Shop when a vehicle enters the Yard or Shop. b. Communication shall be secure and encrypted to prevent unauthorized users from accessing the data or system. c. See Section 13, Vehicle Communication Systems, for Wi-Fi IP router requirements. 2. Provide software for the storage, interpretation, and assessment of fault data transmitted to the vehicle maintenance workstation in the Shop. a. Provide software and hardware compatible with the Owner’s computer systems and associated access points to read and display vehicle health data from the onboard Wi-Fi when vehicles are in the Shop and Yard. b. It shall collect and analyze the data from the MDS and other specified systems. LTK Standard Streetcar Specifications Section 17 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 3. Coordinate with the Owner to ensure compatibility. 17.5.5 Train Operator Display (TOD) 17.5.5.1 General Provide a TOD, as part of the vehicle network, in each cab: 1. Activated cab: Automatically activated. 2. Non-activated cab: Possible to activate display manually. See Section 5, Operator’s Cab and Controls, for location of the TOD in the cab and additional TOD requirements. 17.5.5.2 Display Requirements Comply with the following: 1. 2. 3. 4. Type: LED back-lit LCD touch screen color display, ruggedized for industrial applications. Screen size: Minimum 10 inch (diagonal measurement) Resolution: Minimum 1280x720. Brightness: a. Easily readable under adverse lighting conditions including bright sunlight. b. Provide both manual and automatic brightness adjustment. 17.5.5.3 Controls Interface with the TOD shall be by control buttons located directly below or by pressing the appropriate area on the screen. Provide the following controls, as a minimum: 1. 2. 3. 4. 5. Fault Acknowledge Screen Selection Navigate through screens (menus) Select specific items Screen Brightness 17.5.5.4 Operating Status Screen Comply with the following: 1. Activation: Default screen upon power up and while the vehicle is in motion. 2. View: a. Important information such as system status and conditions of each subsystem monitored. b. Other indications specified in Section 5. 3. Failures: Annunciate by highlighting the subsystem shown on the display in which a fault occurred. 4. Urgent items: a. Shall flash to catch the operator's attention. b. Flashing shall be canceled by the operator's activation of the Fault Acknowledge control. LTK Standard Streetcar Specifications Section 17 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17.5.5.5 Additional Screens - Vehicle Stopped Comply with the following: 1. Activation: Possible if the vehicle is at standstill. 2. Additional screens available: a. Fault screens to assist in failure reset or isolation b. Screens to show more detailed information 17.5.5.6 Maintenance Mode Activation: No restrictions on which screens may be activated. 17.5.6 Portable Test Units (PTUs) and PTU Connection Points Comply with the following: 1. PTU type: Laptop computer, Windows 7, or more current. 2. PTU connections: a. Via Ethernet ports using M12 connectors. b. Where other interfaces are approved, provide all necessary interface adapters and interface software. 3. Centralized diagnostic port: Provide to connect a PTU to monitor vehicle bus traffic and to download fault logs from interconnected control units. Provide integrated software to allow access to all connected units. 4. Independent PTU connection points: a. Acceptable to provide at major control units, such as propulsion controls. b. For such equipment it is expected that at least top-level fault information is still made available on the vehicle bus. c. Detailed fault information will then be accessible by the PTU on the local connection. d. PTU connections shall be USB or Ethernet, as available on COTS laptop computers. 5. Additional requirements: See Special Provisions, for the quantity of PTUs required and other requirements. 17.6 Vehicle Software and Systems 17.6.1 General Design software using modern programming techniques and compilers, and formal software design processes and management tools. Implement rigorous and documented testing, QC processes, and version controls. 17.6.2 Software Functions Software shall perform the following basic functions: 1. Implement the desired control scheme such that the specified performance is achieved. 2. Monitor inputs for unsafe, erroneous, or unknown conditions or combinations of conditions. 3. Sample input conditions at rates sufficient to detect and remedy 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. LTK Standard Streetcar Specifications Section 17 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 4. Limit output commands to safe levels regardless of the combination of input conditions. 5. Perform self-diagnostic routines and respond promptly, safely, and predictably to detected faults. 6. Respond safely and predictably when powering up or recovering from power interruptions. Detect power interruptions likely to have corrupted temporary storage and cause the system to re-initialize affected routines and temporary data. Detection of power interruptions may be by hardware. 7. Permit thorough interrogation of input, output, and internal conditions by external diagnostic equipment. 8. Present all user-accessible features in clear English. 17.7 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance. Include the following in each design package, if applicable, in addition to specific items listed below for each CDRL number: 1. 2. 3. 4. 5. Detail drawings: Top level assemblies, and other drawings if requested Functional description Control schematics Component ratings: Top level components, and ratings of other components if requested Software functional descriptions: Include top level control parameters and values 17-1 Vehicle System Functional Description (SFD): 6. Define hardware and software components, the partitioning of the system functions, and the allocation of requirements (including derived requirements) to the individual systems. 7. Use terminology consistent with terminology of the Specifications and define names for subsystems and the interfaces between them to ensure consistent terminology used by all suppliers. 8. Diagram of the complete vehicle system: a. Show individual systems with their interfaces, including network interfaces. b. Show the location of system components within the vehicle and describe function. 2-1 Individual Systems SFDs: 1. Submit for each individual system. If individual systems are not submitted all at one time, comply with the requirements of Section 19, Program Control and Quality Assurance, for numbering and documentation for submittal packages that are submitted in more than one part. 2. Completely describe the system and how it meets the project requirements. 3. Documents shall be consistent with the Vehicle SFD and with the Specifications. 4. Include the following in each individual system SFD: a. Context Diagram: Show the system and external interfaces. Include a description of the functions of the system and the relationships of the system with other systems. LTK Standard Streetcar Specifications Section 17 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS b. Decomposition Diagram and Description: Describe all system components and internal interfaces. Break components down into the hardware components, Software Configuration Items (SCIs), the internal interfaces within the system, and the external interfaces to other vehicle-level systems: • • Hardware Components: Describe each to the level of its major components, LRUs, and LLRUs; the functions to be performed; and the interfaces SCIs: ○ ○ ○ Describe each in its own numbered section Describe the major functions of the item and the relationship to the hardware, including memory and input/output hardware Include version numbers and report upon request c. Software Summary Table: • • Rows: Include one for each software item in the system Columns: Include one for SCI name and ID, Software Requirements Specification (SRS) name and ID, Software Design Description (SDD) name and ID, and section within the SFD where the SCI is described (see Section 17, Electronic Controls, Software, and MDS, for SRS and SDD requirements) d. Programmable Components: Define all specific hardware and programmed functions and the interfaces in a dedicated section e. Data Files loaded to the individual systems (e.g. stop and station data, not programming code): • • f. Include as separate configuration items and describe their content in a dedicated SFD section Include version numbers in the data file and report upon request Power On/Off: • • Normal power on, power off strategy Startup sequences and durations g. Failure Detection and Remedial Action: • • Describe monitoring the correct operation of system components, the failures to be detected, and the system reaction (e.g. shut down, announce) Distinguish between local system self-monitoring (and reporting) and external monitoring by higher level systems 17-2 Vehicle Control System Design Package: 1. Vehicle control system circuit drawings and diagrams including the following: a. Hardwired circuit drawings b. Software diagrams c. Functional descriptions 2. Sneak circuit and single point failure analysis that covers emergency loads, interlocks and safety critical functions. LTK Standard Streetcar Specifications Section 17 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS 17-3 Vehicle Data Network Design Package: 1. Description of vehicle data network, network protocols, and transmission methodology. 2. Calculations of the variations in transmission time, as related to real-time control requirements, with a statement of acceptability by the propulsion and the brake supplier. 3. Detailed calculations of peak and average data traffic levels and calculations of network delays. a. Network delay calculations: Include expected average delays and distribution of delay times. b. Peak and average traffic levels for transmission media, as recommended by protocol Supplier. 4. Describe process whereby problems with networks will be detected, reported, and repaired. 5. Vulnerability assessment of hacking via Wi-Fi or vehicle ports. 17-4 Monitoring and Diagnostic System Design Package: 1. 2. 3. 4. 5. 6. 7. Mechanical specifications of the system Mechanical assembly drawings with weights, dimensions, and parts lists Electrical schematic drawings for system interconnections Electrical schematic drawings for each device and assembly Installation drawings Layout of each screen with descriptions of each screen element and its use and operation TOD: a. b. c. d. Monitor details (size, resolution, colors, etc.) Sample screen displays Description of navigation Listing of available displayed data for each system 17-5 Software Quality Assurance (SQA) Plan: 1. Use IEEE Std 1558 2004 as a guideline. 17-6 Software Requirements Specification (SRS): 1. Use IEEE Std 1558 2004 as a guideline. 17-7 Software Design Description (SDD): 1. Use IEEE Std 1558 2004 as a guideline. 17-8 Software Verification and Validation Plan (SVVP): 1. Use IEEE Std 1558 2004 as a guideline. 17-9 CDRL 17-8, Software Verification and Validation Report (SVVR): 1. Use IEEE Std 1558 2004 as a guideline. 17-10 CDRL 17-9, Software User Manual (SUM): 1. Use IEEE Std 1558 2004 as a guideline. LTK Standard Streetcar Specifications Section 17 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Electronic Controls, Software, and MDS END OF SECTION LTK Standard Streetcar Specifications Section 17 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System Table of Contents 18.1 Manuals and Catalogs .................................................................................................................1 18.1.1 Manual Schedule and Quantities ................................................................................................... 1 18.1.2 Manual General Requirements and Format .................................................................................. 1 18.1.2.1 General Requirements ............................................................................................................ 1 18.1.2.2 Hard Copy Format ................................................................................................................... 2 18.1.2.3 Soft Copy Format .................................................................................................................... 2 18.1.2.4 Content ................................................................................................................................... 2 18.2 Special Tools and Test Equipment ...............................................................................................2 18.2.1 General ........................................................................................................................................... 2 18.2.2 Delivery Schedule ............................................................................ Error! Bookmark not defined. 18.2.3 Special Tools ................................................................................................................................... 3 18.2.4 Portable Test Units (PTUs) ............................................................................................................. 3 18.3 Training ......................................................................................................................................4 18.3.1 General ........................................................................................................................................... 4 18.3.2 Training Program Description ........................................................................................................ 4 18.3.3 Operator Training ........................................................................................................................... 4 18.3.4 Maintenance Training .................................................................................................................... 5 18.3.4.1 Schedule and Duration ........................................................................................................... 5 18.3.4.2 Description .............................................................................................................................. 5 18.3.4.3 Specific Content ...................................................................................................................... 6 18.4 Technical Support Personnel .......................................................................................................7 18.5 Contract Data Requirements List (CDRL) ......................................................................................7 LTK Standard Streetcar Specifications Section 18 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 18.1 Manuals and Catalogs 18.1.1 Manual Schedule and Quantities Furnish manuals for use by vehicle operators and maintenance personnel in accordance with the requirements of this Section: 1. Draft manuals shall be sufficiently complete for the Owner to perform all maintenance and troubleshooting activities. 2. Furnish drafts and final copies of the manuals in accordance with the following schedule: Manual and Catalog Delivery Requirements Manual Type Operator's Instruction and Troubleshooting Manual Maintenance and Servicing Manual Heavy Repair Manual Illustrated Parts Catalog Training Manuals Special Tools and Test Equipment Manuals Integrated Schematic Diagrams for Troubleshooting Labor guide Deliver Two Sets of First Drafts No Later Than: 18 months after NTP Deliver Final Manuals No Later Than: 18 months after NTP 1 year after first vehicle delivery 1 year after first vehicle delivery 1 year after first vehicle delivery 1 year after first vehicle delivery 1 year after first vehicle delivery 1 year after first vehicle delivery 18 months after NTP 18 months after NTP 2 months before start of training 18 months after NTP 18 months after NTP 18 months after NTP 1 year after first vehicle delivery 1 year after first vehicle delivery Quantities of Final Manuals Per Vehicle 10 2 2 1 10 1 3 1 Notes to Table: 1. In the event options are awarded, the specified quantities per vehicle will also apply to option vehicles. 18.1.2 Manual General Requirements and Format 18.1.2.1 General Requirements Comply with the following requirements for each specified manual: 1. Organize the manual such that the vehicle is treated as an integrated system and not as a grouping of disassociated parts. 2. Highlight safety precautions to be taken by operating and service personnel while operating vehicles and performing maintenance and servicing operations. LTK Standard Streetcar Specifications Section 18 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 3. Produce a manual specific to the Owner that accurately represents the completed as-built vehicle, including but not limited to Owner-specific maintenance instructions, parts, wiring schematics, wiring diagrams, and component physical layouts. 4. Furnish in English. Following the issue of each publication, furnish revised pages covering any changes, whether required by change of design or procedures or due to error. Keep these revisions current (revise minimum every 6 months) during the warranty period. 18.1.2.2 Hard Copy Format Professionally produce each specified manual and comply with the following requirements: 1. 2. 3. 4. Furnish as a bound book with cover or in a heavy duty, locking, D-ring-type three-ring binder. Divide and tabulate into logical sections and subsections. Include a table of contents at the front of the manual. Print on quality paper meeting the following requirements: a. b. c. d. Tear-resistant Waterproof Grease, chemical, and stain resistant Polyester based synthetic, such as Revlar, by Relyco, or paper with similar qualities, as approved e. Minimum 5 mil thickness 18.1.2.3 Soft Copy Format Submit each specified manual on electronic media in portable document format (PDF). Comply with the following requirements when creating PDF version of each manual: 1. Create searchable, zoomable PDF directly from native format, not by scanning hard copy documents. 2. Create with sufficient resolution to allow zooming of graphics without loss of quality or resolution. 3. Size PDF the same as hard copy version to allow the Owner to easily print new hard copy versions from electronic media without resizing PDFs. 4. Create a hierarchy of bookmarks, with each major section as a top-level bookmark, and subsections as bookmark subheadings. Bookmarks shall match the structure of the table of contents and include the headings and subheadings in the same hierarchical structure. Revise electronic media versions in accordance with hard copy manual revisions. 18.1.2.4 Content See the Contract Data Requirements section, below, for details of each manual to be submitted. 18.2 Special Tools and Test Equipment 18.2.1 General Special tools and test equipment shall be provided as specified herein and in Special Provisions Section 9. LTK Standard Streetcar Specifications Section 18 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 18.2.2 Special Tools Special tools include, but are not limited to the following tools and equipment that are not commonly available from commercial tool suppliers and are necessary to maintain, repair, overhaul, assemble, and disassemble the vehicle or subsystems: 1. 2. 3. 4. 5. 6. Jigs Fixtures Gauges Equipment Hand tools Power tools Special tools include, as a minimum, the following: 1. 2. 3. 4. Tools to activate tamper proof fasteners and access panels Vehicle jacking adapters (if used) Door System: Gauges and jigs required for door installation and adjustments HVAC System: a. b. c. d. Vacuum pump Refrigeration recovery and charging test manifold Holding fixture Leak tester, electronic 5. Propulsion System: Non-standard wrenches and gauges 6. Truck Assembly: a. b. c. d. e. Tools for gearbox and coupling disassembly and re-assembly Journal-bearing puller Truck assembly stand Truck alignment jigs Wheel tire removal and installation tools 7. Friction Brake System: a. b. c. d. Caliper assembly tools Actuator assembly tools System bleeding & filtering equipment Accumulator servicing gauge and fittings 18.2.3 Portable Test Units (PTUs) PTUs (laptop computers) for on-board diagnostics are specified in Section 17, Electronic Controls, Software, and MDS. Comply with the following additional requirements: 1. Furnish laptop software that is not copy-protected, does not require external validating devices such as “dongles”, and can be freely copied by the Owner onto the Owner’s computers. 2. Furnish software licenses and back-up copies of all PTU software to the Owner. 3. Furnish with each unit all connectors, cables, and adapters necessary to communicate with onboard systems from the PTU. LTK Standard Streetcar Specifications Section 18 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 18.3 Training 18.3.1 General The following requirements apply to all types of training described in this section: 1. The number of training hours and duration and quantities of staff to be trained specified in this Section are the Owner’s estimates only. The Owner shall be the sole judge of the adequacy of the training plan offered. 2. Work closely with the Owner's staff as training materials are being developed to ensure the Owner standards are being met with respect to course organization, content, and overall quality of training materials. 3. All training materials, such as training aids and lesson plans, shall become the property of the Owner at the completion of the training program. 4. The Owner reserves the right to video tape training activities. 18.3.2 Training Program Description Comply with the following general requirements: 1. Location: At the Owner’s facilities 2. Type of training: Classroom and hands-on. 3. Training categories: a. Operator training b. Maintenance training 4. Trainees: Instructors, Supervisors, Vehicle Operators, Mechanics, and Technicians, as selected by the Owner. 5. Training materials: Furnish the following as a minimum: a. Specified training manuals b. Other training aids as required to impart the essential knowledge to trainees c. Accurate and up-to-date reference materials 6. Testing: Design and conduct written and practical tests at suitable points in each course to determine the extent to which trainees have retained the course material and can apply the information. 18.3.3 Operator Training Comply with the following requirements for operator training: 1. Scope: Include basic vehicle operation and how to detect and resolve in-service problems and emergencies. 2. Initial training: a. Within 10 days after delivery of the first vehicle, train Owner’s trainer and one group of five operators. b. This group will come from the core team of operators for the vehicle test program. c. Furnish a vehicle for this purpose and ensure that all applicable systems are properly operating. 3. Additional training: Train a total of 40 operators, including those trained in the initial training. LTK Standard Streetcar Specifications Section 18 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 18.3.4 Maintenance Training 18.3.4.1 Schedule and Duration Provide the following maintenance training: 1. Initial training: Before delivery of the first vehicle, complete training for Owner’s trainer and one group of up to 10 persons. 2. Additional training: After delivery of the first vehicle, train an additional 20 technicians. 3. Refresher training: Conduct one year after delivery of the last vehicle. Time period: 1. Conduct the initial and additional training over a period of maximum 52 weeks. 2. Conduct the refresher training over a period of maximum 52 weeks. Training hours: 1. Initial and additional training: Provide minimum 760 instructor training hours. 2. Refresher training: Provide minimum 240 instructor training hours, 120 classroom and 120 hands-on hours. 3. The Owner may shift these training hours from one training period to another. 18.3.4.2 Description Comply with the following requirements for maintenance training: 1. Scope: Include all systems and sub-systems provided under this Contract. 2. Maintenance types: Include preventive, corrective, and overhaul of components and/or assemblies. 3. Minimum maintenance training outline: a. Introduction to the equipment, including terminology, identification of major components and their location on the vehicle b. Detailed theory of operation c. Preventative maintenance: • • • • • • Lubrication schedules Adjustments Tolerance limits Inspection criteria Recommendation for test frequency Methods for testing, including instruments required d. Troubleshooting: • • • Problem symptoms Troubleshooting techniques Repair procedures e. Removal and replacement of parts and components from the vehicle f. Disassembly and reassembly for the purpose of component familiarity and any special processes g. Instruction in the use of all special tools and processes h. Overhaul of components and assemblies LTK Standard Streetcar Specifications Section 18 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 4. Depth of training: a. Include sufficient detail such that trainees can successfully perform all maintenance and overhaul tasks presented. b. Give trainees the opportunity to perform the more complex maintenance functions on the vehicle and in the Shop. c. Troubleshooting: • • Instruct trainees in how to troubleshoot systems using appropriate subsystem test devices to locate and remedy faults. Artificially introduce faults into equipment as needed to furnish adequate troubleshooting training. 5. Field instruction: Include both on-vehicle demonstrations and demonstrations of basic overhaul procedures using equipment in the Owner’s Shop. 18.3.4.3 Specific Content Provide in-depth instruction addressing the following systems and components as a minimum: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Air conditioning and heating systems, including their controls AC auxiliary power system Low-voltage dc power system, including battery Braking system, including controls Communications system Network controls Train signal and control system Monitoring and diagnostic system Lighting controls Propulsion system, including traction motors and controls Trucks, including bearings, bearing surfaces, gear units, frame, suspensions, and shock absorbers Door and bridge plate operators and controls Removal, replacement, and adjustment of vehicle body materials and equipment, such as the following: a. b. c. d. e. Glazing Seats Doors Underfloor equipment Trucks 14. Removal, replacement, and adjustment, where applicable, of vehicle electrical equipment, such as the following: a. b. c. d. e. Windshield wipers Heaters Circuit breakers Switches and indicators Light fixtures 15. Re-railing procedures LTK Standard Streetcar Specifications Section 18 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 18.4 Technical Support Personnel Comply with the following requirements for technical support personnel: 1. Language: Fluent in English. 2. Availability: Any of three eight-hour shifts, as may be required by the Owner. 3. Purpose: a. Assist during inspection, operation, testing, modification programs, and adjustment of vehicles both before and after Acceptance by the Owner. b. Assist in training that may be required, in addition to the training specified above, both before and after Acceptance by the Owner. 4. Field Service Engineer: a. Quantity: Minimum one. b. Location: At the Owner’s facilities. c. Qualifications: Knowledgeable in each of the vehicle’s systems to the level of competent troubleshooting. d. Availability: Full time. e. Time period: Minimum from one month before arrival of the first vehicle until two years after acceptance of the last vehicle. 5. Suppliers: Ensure that the expert services of equipment suppliers and designers are available, on short notice, during the same period to assist the on-site support personnel in the investigation and resolution of vehicle and equipment malfunctions. 6. Additional on-site technical assistance: If requested by the Owner, furnish as follows: a. Delivery of first vehicle to Final Acceptance of last vehicle: Within 48 hours from receipt of request. b. Warranty Period: Within 72 hours from receipt of request. 18.5 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance: 18-1 Draft Training Plan: 1. Include information detailing the types of training and the number of hours required to train the Owner’s staff. 18-2 Operator’s Instruction and Troubleshooting Manual: 1. This manual shall contain all information needed for optimum operation of the vehicle. 2. Include general vehicle familiarization material, such as the following: a. Description of location, function and operation of controls, gauges, indicators and switches b. Discussion of the trucks, couplers, propulsion, brakes, doors, bridge plates, lights, HVAC control, and other features of the vehicle which the operator may not be able to control or adjust, but of which the operator should have some basic knowledge c. Safe practices and procedures d. Emergency procedures e. Trouble symptoms and diagnosis methods LTK Standard Streetcar Specifications Section 18 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System f. Operator corrective action 3. The manual shall be logically organized with systems and elements considered in descending order of importance. 4. Ensure that all statements are clear, positive, and accurate, with no possibility of incorrect implications or inferences. 5. Size: 5 inches by 7 inches 18-3 Maintenance and Servicing Manual: 1. This manual shall contain all necessary maintenance information for use by the Owner’s maintenance staff for: a. Preventive maintenance inspections b. On-vehicle running maintenance and adjustment c. In-service trouble diagnosis of each system 2. Include safe practices and procedures. 3. Include such data as troubleshooting guides, equipment specifications, and references to the Integrated Schematic Diagrams and Software Functional Description with error code troubleshooting assistance. 4. Include intervals of preventive and required maintenance. List the preventive and required maintenance on a chart that defines the intervals and type of maintenance for the first 10year period of the vehicle. 5. Include forms required for each type of inspection or required maintenance. Each form shall include tasks to be performed and required parts to be used in the inspection or task. 6. Include a detailed analysis and theory of operation for each component of the vehicle so that maintenance staff can effectively service, inspect, maintain, adjust, troubleshoot, repair, replace, and overhaul each component. 7. Include the list of recommended cleaning agents submitted under Section 16, Materials and Workmanship. 8. Include the maintenance information for paints and coatings submitted under Section 16. 9. Size: 8-1/2 inches by 11 inches. 18-4 Heavy Repair Manual (HRM): 1. This manual shall contain the maintenance procedures performed at the Heavy Repair level. 2. Heavy Repair Maintenance is maintenance which requires holding a vehicle out of service due to the longer time required to complete the work, and includes maintenance tasks scheduled for 3-year or greater intervals that are associated with vehicle and equipment overhaul. 3. The opening section of the HRM shall be a table of Heavy Repair tasks, organized by interval, then by subsystem. The table shall refer to subsections of the HRM where procedures for each task may be found. 4. The manual shall be written from a vehicle subsystem and component perspective: a. Each subsystem section shall begin by illustrating the location of components within the subsystem. b. Functional descriptions shall accompany the illustrations to facilitate servicing, repair, overhaul, adjustment, inspection, and test. c. Detail the function of each significant component and circuit within each assembly, rather than furnishing descriptions of subsystem functions within the integrated vehicle system. LTK Standard Streetcar Specifications Section 18 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 5. Furnish maintenance procedures, including inspection, service, test, troubleshooting, adjustment, removal, repair, replacement, and overhaul, as applicable for this specific vehicle or its systems, equipment, or parts. 6. Assembly procedures shall each include pertinent assembly criteria, such as clearances, backlash dimensions, torque values, recommended tools, required supplies, necessary followon tasks (if applicable), and similar data. 7. Procedures shall include detailed instructions for troubleshooting all anticipated failure modes, including the use of necessary special tools, PTUs, and Bench Testers. 8. Furnish a listing of all tools required to perform maintenance on the vehicles and apparatus, including both special and commercially available tools. 9. Include safe practices and procedures. 18-5 Illustrated Parts Catalog: 1. This catalog shall identify each component on the vehicle by part number down to the Lowest Level Replaceable Unit (LLRU). The LLRU is defined as the lowest level of component assembly that consists of a separate, individually fabricated part 2. Enumerate and describe each component with its related parts for the entire vehicle. 3. Incorporate drawings showing exploded views and cutaways of subassemblies and components to permit identification of all parts down to LLRUs. 4. Identify each part with the Contractor’s part number and next higher assembly. Include the supplier’s part number if different from the Contractor’s number. 5. Parts common to different components, such as 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. 6. In addition to identifying each component by the Contractor's number, identify commercially available items such as common fastenings, fuses, lamps, fittings, bearings, and relays by standard hardware nomenclature adequate to allow the Owner to purchase these items through commercial channels. 7. Size: 8-1/2 inches by 11 inches. 18-6 Training Manuals: 1. This manual shall contain material to aid trainees who receive the required training, as specified in the “Training” section. 2. Manuals and other training materials to be used by the Contractor during training shall be furnished to the Owner two months before training is conducted. 3. The manuals shall be complete, and contain an adequate supply of high quality, professionally prepared material of professional quality. 4. Include the final training plan, after approval of the draft training plan. 5. Size: 8-1/2 inches by 11 inches. 18-7 Special Tools and Test Equipment Manuals: 1. Submit manuals for each special device identified in the Special Tools and Test Equipment section. 2. Include setup and testing procedures for each special tool and test device. 3. In a separate section, include all information needed for periodic inspection and servicing requirements of the test equipment, including lubrication, inspection, and adjustment of all apparatus. LTK Standard Streetcar Specifications Section 18 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 4. Size: 8-1/2 inches by 11 inches. 18-8 Integrated Schematic Diagrams for Troubleshooting: 1. Submit diagrams detailing all electrical, electronic, pneumatic and/or hydraulic systems in schematic fashion. These diagrams shall be separate from the schematics and wiring diagrams in the maintenance manuals. 2. These schematics shall be comprehensive, thoroughly detailed, include all components and include the following: a. Electrical systems b. Electronic systems c. Pneumatic and/or hydraulic systems , wiring, and piping on the vehicles 3. Diagrams shall reflect the Owner’s vehicle as-built, and include all circuits on the vehicle. 4. At a minimum, include the following on the schematics: a. Zone gradations around the perimeter of each sheet for location references. b. Alpha-numeric designations for all components. The designations shall be logical and clearly distinguish between different component types, such as CBxxx for circuit breakers. c. All contacts or connections for relays, contactors, connectors, and other devices with multiple contacts or connections, even if unused. d. Numerical designations for all circuit wiring, with logical groupings for power sources, return circuits, and similar. e. Wire sizes and circuit voltages, piping sizes and system pressures, and similar. f. Industry standard device symbols and nomenclature for piping, hydraulic, and pneumatics diagrams, such as defined by ANSI or similar organizations. 5. Number pages numerically and consecutively. 6. In addition to the required quantity of hard copies, submit two copies in an electronic format that is readable and searchable on a PTU screen and formatted to print on 11 inch x 17 inch paper. 7. Hard Copy Size: 11 inches by 17 inches. 18-9 Labor Guide: 1. Submit a guide for use by the Owner to determine vehicle maintenance and repair time. 2. Include standard times for recommended preventative maintenance tasks. 3. Include standard repair times and replacement times for all major components and the associated sub-assemblies. 18-10 Operator training DVDs: 1. Submit two copies. 2. Submit the DVDs minimum 30 days before delivery of the first vehicle. 3. Video training shall include the following: a. Preparing a vehicle for service b. Operating a vehicle under normal conditions c. Emergency procedures for moving a vehicle under fault conditions LTK Standard Streetcar Specifications Section 18 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Support System 18-11 Required Spare Parts: 1. For components that are listed in the Contract as required spare parts but are not applicable to the Contractor’s specific design, indicate “not required.” 2. Include part numbers. 18-12 Recommended Spare Parts: 1. Include spare parts recommended by the Contractor that are in addition to those specified. 2. Include part numbers. END OF SECTION LTK Standard Streetcar Specifications Section 18 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance Table of Contents 19.1 General ......................................................................................................................................1 19.2 Program Management ................................................................................................................1 19.2.1 Project Management ..................................................................................................................... 1 19.2.1.1 Project Management Organization Chart ............................................................................... 1 19.2.1.2 Work Flow Diagram ................................................................................................................ 1 19.2.1.3 Program Schedule ................................................................................................................... 1 19.2.2 Monthly Progress ........................................................................................................................... 2 19.2.3 Document Management ................................................................................................................ 2 19.2.4 Project Meetings ............................................................................................................................ 3 19.2.4.1 General.................................................................................................................................... 3 19.2.4.2 Meeting Minutes .................................................................................................................... 3 19.3 Design Progression .....................................................................................................................3 19.3.1 Specification Review ...................................................................................................................... 3 19.3.2 Vehicle Conceptual Design Definition ............................................................................................ 4 19.3.3 Design Review ................................................................................................................................ 4 19.3.3.1 Design Review Meetings ......................................................................................................... 4 19.3.3.2 Preliminary Design Review (PDR) ........................................................................................... 4 19.3.3.3 In-Process Design Review (IPDR) ............................................................................................ 4 19.3.3.4 Final Design Review (FDR)....................................................................................................... 5 19.4 Documentation and Approval .....................................................................................................5 19.4.1 Contractor’s Submittals ................................................................................................................. 5 19.4.1.1 Format..................................................................................................................................... 5 19.4.1.2 Document Management ......................................................................................................... 5 19.4.1.3 Submittal Packages ................................................................................................................. 6 19.4.1.4 Additional Submittals.............................................................................................................. 6 19.4.2 The Owner’s Review....................................................................................................................... 6 19.4.3 Contractor’s Resubmittals.............................................................................................................. 7 19.4.4 Submittal Approval and Procurement of Materials ....................................................................... 7 19.4.5 Requirements for Drawings, Documents, and Data ...................................................................... 7 19.4.5.1 General.................................................................................................................................... 7 19.4.5.2 Format..................................................................................................................................... 8 19.4.5.3 Content ................................................................................................................................... 8 19.4.5.4 Standards ................................................................................................................................ 8 LTK Standard Streetcar Specifications Section 19 i January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.4.5.5 Final Drawings ......................................................................................................................... 9 19.4.6 Modification and Configuration Control ........................................................................................ 9 19.4.6.1 General.................................................................................................................................... 9 19.4.6.2 Design Changes ....................................................................................................................... 9 19.4.6.3 Component Identification and Serial Numbers ...................................................................... 9 19.4.6.4 Vehicle History Books ........................................................................................................... 10 19.5 Manufacturing Control ............................................................................................................. 11 19.5.1 Communication Between Engineering and Manufacturing ........................................................ 11 19.5.2 Manufacturing.............................................................................................................................. 11 19.5.3 Worker Training ........................................................................................................................... 11 19.5.4 Supervision ................................................................................................................................... 12 19.5.5 Control Samples ........................................................................................................................... 12 19.6 Quality Assurance (QA) and Quality Control (QC)....................................................................... 12 19.6.1 Standards ..................................................................................................................................... 12 19.6.2 Subcontractor/Supplier QA/QC ................................................................................................... 12 19.6.3 QA Organization ........................................................................................................................... 13 19.6.3.1 Scope..................................................................................................................................... 13 19.6.3.2 Responsibilities ..................................................................................................................... 13 19.6.3.3 Authority ............................................................................................................................... 13 19.6.3.4 QA Manager .......................................................................................................................... 13 19.6.3.5 QC Personnel ........................................................................................................................ 13 19.6.4 QA/QC Records ............................................................................................................................ 14 19.6.5 Quality Assurance Plan (QAP) ...................................................................................................... 14 19.6.5.1 Scope..................................................................................................................................... 14 19.6.5.2 Implementation .................................................................................................................... 15 19.6.6 Measuring Equipment and Tools ................................................................................................. 15 19.6.6.1 Measuring and Testing Devices ............................................................................................ 15 19.6.6.2 Control and Calibration......................................................................................................... 15 19.6.6.3 Calibration Records ............................................................................................................... 16 19.7 Quality Control and Inspection.................................................................................................. 16 19.7.1 First Article Inspections ................................................................................................................ 16 19.7.2 Quality Control and Inspection Plan (QCIP) ................................................................................. 17 19.7.2.1 General.................................................................................................................................. 17 19.7.2.2 Inspection Status .................................................................................................................. 17 LTK Standard Streetcar Specifications Section 19 ii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.7.2.3 Control of Non-Conformance ............................................................................................... 17 19.7.2.4 Levels of Inspection .............................................................................................................. 18 19.7.2.5 Receiving Inspection/Pre-Shipment Inspection.................................................................... 18 19.7.2.6 Inspection of Work In-Process .............................................................................................. 18 19.7.2.7 Hold- and Witness-Point Inspections.................................................................................... 19 19.7.2.8 Final Inspection ..................................................................................................................... 20 19.7.2.9 Pre-Shipment Inspection ...................................................................................................... 20 19.7.2.10 Post-Shipment Inspection ................................................................................................... 21 19.7.2.11 Quality Audits ..................................................................................................................... 21 19.7.3 Open Items List ............................................................................................................................ 21 19.7.4 The Owner’s Audit and Inspection ............................................................................................... 21 19.7.4.1 City Inspection Activities ....................................................................................................... 21 19.7.4.2 Contractor Provision of Facilities for the Owner’s Use......................................................... 22 19.8 Contract Data Requirements List (CDRL) .................................................................................... 22 LTK Standard Streetcar Specifications Section 19 iii January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.1 General Control the design and production of vehicles to ensure a high-quality product suitable for long and trouble-free life, and ensure that requirements of the Specifications are met. The Owner may, at its option, monitor Contractor activities regarding this Contract, including subcontractor activities, and inspect and test equipment. The Contractor shall not hinder or limit such activities. 19.2 Program Management 19.2.1 Project Management Designate a project manager and submit a Management Plan, including an organization chart, work flow diagram, and program schedule, as described below. See the CDRL section, below for submittal details. 19.2.1.1 Project Management Organization Chart Develop and submit a project management organization chart for the Contractor’s staff: 1. Include primary personnel involved in this Contract, and key subcontractor personnel. 2. Indicate management personnel responsibilities in relation to engineering, manufacturing, QC, material procurement and other supporting functions. 19.2.1.2 Work Flow Diagram Develop and submit a work flow diagram: 1. Clearly depict the design, manufacturing, testing, and inspection work flow, including Hold and Witness inspections. 2. Indicate responsibilities of the Contractor and each subcontractor or supplier for all systems and major components described in the Specifications. 3. Information furnished shall be consistent with, and expand upon the Contractor's approved Proposal. 4. This Work Flow Diagram and any changes shall be as approved by the Owner and may be modified with the Owner’s approval during the course of the Contract. 19.2.1.3 Program Schedule Develop and submit a Critical Path Method (CPM) schedule: 1. Indicate the reasonability of achieving the milestone dates, including the specified vehicle delivery schedule. 2. Include the following activities as a minimum: a. b. c. d. e. Submittal of general arrangement drawings Each major system subcontractor under contract Type Test of each major system and component First Article Inspection of each major system and component Key design activities, including design completion dates, for both prime contractor and major system suppliers f. Anticipated date of each Preliminary Design Review and Final Design Review for all major systems, as mutually agreed by the Owner and the Contractor. g. Commencement of purchase of parts for Vehicle No. 1 h. Commencement of Vehicle No. 1 parts manufacture LTK Standard Streetcar Specifications Section 19 1 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance i. j. k. l. m. n. o. p. q. r. s. t. u. v. w. x. Commencement of Vehicle No. 1 subassemblies manufacture Commencement of Vehicle No. 1 major assemblies manufacture Completion of Vehicle Shell No. 1 Vehicle Shell No. 1 static load test Commencement of truck manufacture (each type, if more than one type) Completion of first truck (each type, if more than one type) Truck static load test(s) Truck fatigue test(s) Completion of the first vehicle at the Contractor's plant Functional testing of first vehicle Watertightness Testing (if not considered in Functional Testing of each vehicle) First Article Inspection of first vehicle Shipment of first vehicle Completion of the second vehicle at the US assembly facility Arrival, testing (both Type Testing and Routine Testing) Burn-In Test 3. As part of the schedule, furnish a schedule narrative, describing the overall approach to meeting required milestones: a. Follow and describe the CPM schedule activities to the extent practical b. Address each of the following: • • • • Rationale for the given activity durations Rationale for the given activity interconnecting logic Possible work-arounds in the event of delay Identification of areas where delay is most likely, and the mitigation efforts planned to reduce the risk of delay. 19.2.2 Monthly Progress Track actual progress of the work and submit a monthly report: 1. Summarize work accomplished during the month. 2. Include work in progress and work planned for the following month. 3. Include quality activities, with the following as a minimum: a. FAI schedule and status b. Inspection and test status c. Changes issued and their status 4. See the CDRL section, below, for submittal details. 19.2.3 Document Management Comply with the following requirements for document management: 1. Identify correspondence and submittals according to an approved coding scheme: a. Correspondence and submittals shall be numbered separately. b. Propose a scheme suitable for the anticipated quantity of correspondence and submittals. LTK Standard Streetcar Specifications Section 19 2 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance c. If any submittals will be submitted in more than one part, include a scheme for identifying each part of a submittal package such that each part has a unique identifier and it is clear that all parts belong to the same submittal package. d. See the CDRL section, below, for details of the Correspondence and Submittal Coding Scheme submittal. 2. Furnish a consolidated listing of all CDRL submittals required by the Specifications. See the CDRL section, below, for details of the CDRL Report. 3. Drawing and Document Status: a. Maintain a continuous record of Contractor and subcontractor drawing and document status and submit monthly. b. Retain copies of all records and make them available to the Owner for a minimum of 10 years after expiration of all warranty periods, unless otherwise specified. c. See the CDRL section, below, for details of the Submittal Status Report. 19.2.4 Project Meetings 19.2.4.1 General Hold meetings between the Contractor and the Owner on a regular basis for the purpose of reviewing program progress and other program activities that cannot be readily resolved by correspondence. Ensure that persons knowledgeable in the topics to be discussed, including subcontractors, are present or available by teleconference at all meetings. 19.2.4.2 Meeting Minutes Take minutes for each project meeting: 1. Prepare and submit after each meeting. 2. Include an Action Items List with space for projected closure dates for each action item. 3. See the CDRL section, below, for detailed requirements. The level of detail will be evaluated by the Owner after the first submittal. 4. Once approved, use the same format and level of detail for each subsequent report. 5. Confirm meeting minutes before closure of each meeting to ensure agreement on language and content. 6. The Owner will approve the minutes or request revisions within 10 days of receipt of the minutes, or else the minutes shall be considered approved. 19.3 Design Progression 19.3.1 Specification Review Within 30 calendar days of NTP, conduct a Specification Review Meeting. During this meeting the Contractor's Project Manager and technical specialists, major subcontractors and suppliers, and the Owner will populate the Specification Compliance Matrix (SCM) specified in the Contract Data Requirements List (CDRL) section, below. 1. Use the SCM to document the Contractor's compliance with each Specification requirement in spreadsheet format. 2. Update the SCM on a regular basis and submit monthly, as specified in the CDRL section, below. LTK Standard Streetcar Specifications Section 19 3 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.3.2 Vehicle Conceptual Design Definition At the start of the Design Review phase, conduct working sessions with the Owner on the layout and concept of the Vehicle. Submit a System Functional Description (SFD) and Individual Systems SFDs, as specified in Section 2, Design and Performance Criteria. 19.3.3 Design Review 19.3.3.1 Design Review Meetings Conduct a design review meeting for each major system for preliminary, in-process, and final design reviews: 1. Major Systems: As defined in the Commercial Provisions. 2. Submittal Package: 30 days prior to each design review meeting, submit a design review package containing design drawings, SFD, and supplemental information appropriate for the type of meeting. 3. The Owner’s Review: After review of the submitted design review package, the City will provide comments and questions: a. The Owner’s comments and questions will form the basis for the design review meeting agenda. b. Additional review comments may be provided by the Owner at the design review meeting and with transmittal of the design review meeting minutes. 4. Meeting Location: As mutually agreed, including sites of the vehicle manufacturer and any of its sub-contractors or suppliers. 5. Meeting attendees: Representatives of the Contractor, appropriate subcontractors and suppliers, and the Owner or its representative. 6. Meeting Minutes: Will be reviewed before closing the meeting. 7. First design review meeting in each phase shall cover the overall system design as described in the SFD. 8. The Owner may request working sessions at any point in the design progression at mutually agreed times. 19.3.3.2 Preliminary Design Review (PDR) Demonstrate in the PDR that the preliminary design meets all system requirements with acceptable risk and within the schedule constraints, and establish the basis for proceeding with detailed design. Show the following as a minimum: 1. All system requirements have been allocated and the requirements are complete. 2. The proposed design is expected to meet the specified functional and performance requirements. 3. The proposed design approach is ready to proceed to final design. 4. Interfaces have been identified. 5. The design is verifiable and risks have been identified, characterized, and mitigated where appropriate. 19.3.3.3 In-Process Design Review (IPDR) If the Owner determines that an IPDR is necessary, demonstrate that design is progressing as expected by the Owner, based on the PDR. LTK Standard Streetcar Specifications Section 19 4 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.3.3.4 Final Design Review (FDR) Demonstrate in the FDR that the design is essentially complete and ready for production of first article inspection units. Resolve all PDR and IPDR issues before scheduling FDR activities. Show the following as a minimum: 1. The final design fulfills the requirements established at PDR. 2. The production processes and controls are sufficient to proceed to the manufacturing stage. 3. Planned Quality Assurance (QA) activities are sufficient to produce a quality product, and have been submitted for review and disposition. 19.4 Documentation and Approval 19.4.1 Contractor’s Submittals 19.4.1.1 Format Submit documents, data, and assembly and installation drawings as follows: 1. Hardcopy: Four. 2. Electronic copy: a. Documents and drawings shall be PDFs converted directly from the original word processing and CAD vector formats, such that full zooming is possible without a loss of resolution, and text searching is possible. b. Furnish documents and drawings with electronic signatures. c. Final documents shall be in editable form, such as in Microsoft Word, latest version. d. Submit final drawings in an editable form that is fully compatible with AutoCAD, latest version. 19.4.1.2 Document Management Letter of Transmittal: 1. Furnish with submittals of drawings, documents, and data. 2. List drawing and document titles, numbers, and revisions. 3. If more than one drawing or document is submitted at a time, list the drawings and documents in the transmittal in numerical sequence. Attachment Identification: 1. On each attachment to the letter of transmittal (drawings, documents, data), furnish an identification reference including the following information: a. Letter of transmittal number. b. Letter of transmittal date. 2. For drawing packages, or other multiple-sheet attachments, furnish the identification reference on the cover sheet. LTK Standard Streetcar Specifications Section 19 5 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.4.1.3 Submittal Packages Comply with the following requirements for submittal packages: 1. In general, each submittal package shall be submitted complete, as described in the CDRL section at the end of each Specification Section. a. If part of the submittal package is not included (permissible only for parts on which submitted parts do not depend), as a minimum include a complete list of what will comprise the complete submittal package. b. If a submittal package is submitted in more than one part, each part must include the following: • • A number that includes the primary submittal package number and an identifier showing that it is only part of that submittal package, in accordance with the approved Correspondence and Submittal Coding Scheme. A list of previously submitted parts of the package with the letter of transmittal number and date of each. c. If the submittal package does not include all parts required for the Owner’s review, it may be returned without review. 2. Drawings: a. Submit drawings in an orderly and logical sequence to enable the Owner to readily determine and review the interface relationships between all major structural elements and their subassemblies, and between the structural elements and the attached apparatus, equipment, wiring, piping and hardware. b. Submit a drawing tree showing hierarchy and numbering topology. c. When submitting drawings of structural parts or assemblies for the vehicle-body structure, equipment supports, and trucks, also submit stress analyses for these parts or assemblies in summary form. d. Submit subassembly drawings for information to facilitate the review of assembly and installation drawings. 19.4.1.4 Additional Submittals The Owner reserves the right to request additional drawings and other data to support the review of assembly and installation drawings, or when needed to understand the Contractor’s design. 19.4.2 The Owner’s Review The Owner will review and return submittals as follows: 1. Within 30 calendar days after receipt by the Owner, with the following exceptions: a. Due to the Owner's limited resources, and to prevent grouping of drawings into one large package for transmittal, the Owner will not be obligated to review more than 50 drawings, or other mutually agreeable number, in a 30-day period. b. In the event that more than 50 drawings are submitted for review in a 30-day period, the Owner will review them in accordance with priorities as mutually agreed to between the Contractor and the Owner. 2. The Owner will respond to the Contractor at an address designated by the Contractor. LTK Standard Streetcar Specifications Section 19 6 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 3. The Owner's approval or disapproval will be furnished 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/or data for the Owner’s approval c. Disapproved: The Contractor shall revise and resubmit the document, drawing, and/or data for the Owner’s approval before beginning that 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. Limitations of Approval: 1. Approval does not relieve the Contractor of the obligation to meet all of the requirements of the Contract. 2. Approval of documents, drawings, or data that contain deviations from, or violation of the Specifications does not constitute authority for that deviation or violation. Deviations must be specifically submitted to the Owner for approval. 3. Approval is intended to mean that the Owner is aware of the Contractor's intent and there are no objections to the apparent methods, procedures, designs, or calculations expressed in the submitted drawings or documents. It does not imply that all calculations, dimensions, materials, components or other details were checked and verified. 19.4.3 Contractor’s Resubmittals No extension of Contract time will be allowed for revision of Contractor's drawings or documents that have been either "Disapproved" or "Conditionally Approved." 1. 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. 2. Resubmitted drawings shall accrue toward the 50 drawings per month limit. 19.4.4 Submittal Approval and Procurement of Materials Allow adequate time for review and discussion of designs in the procurement schedule. 1. Procurement of materials before City approval of submittals is at the Contractor’s risk and the material shall be identified as not approved for use. 2. Submittal schedules should be timely and consistent with the Contractor’s procurement schedules. 19.4.5 Requirements for Drawings, Documents, and Data 19.4.5.1 General Design documents defining vehicle construction shall be complete with regard to dimensions, tolerances, material properties, fabrication methods, and finishing. 1. Design documents shall be reviewed and approved by the contractor's QA and production departments before submittal to the Owner. 2. Where construction drawings are created for production purposes, all details of the design documents shall be included in the construction drawings. LTK Standard Streetcar Specifications Section 19 7 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.4.5.2 Format Drawings and forms (for example, ECN, FMI, NCR, Deviation Requests) shall be in a format approved by the Owner. 1. Drawings 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. 2. Dimensions shall be expressed in the SI system and U.S. customary units, and wording shall be in the English language. 3. Provide a revision block for documents, drawings, and data. The revision block shall identify the revision letter and date of revision, and shall include the initials of the Contractor's responsible engineer authorizing the revision, a description of the change, and the reason for making the change. 4. Wiring diagrams shall be formatted as both integrated connection diagrams and a wire list in book form ("From/To" list) based on the Integrated Schematic (see Section 18, System Support, for requirements regarding the Integrated Schematic Diagrams). 19.4.5.3 Content Comply with the following requirements: 1. For drawings, especially those showing structural members and outside sheathing, indicate material type and dimensions. 2. Assembly drawings: Include a bill of material. 3. Integrated connection diagrams: Indicate all wiring, raceways, conduits, and connections. 4. Electrical drawings and schematics: As a minimum, provide the following information for each wire segment: a. b. c. d. e. f. g. h. i. Wire code (schematic designation) Origin (FROM device and terminal) Destination (TO device and terminal) Wire size Voltage rating Length Appropriate specifications Jacket color Harness designation 19.4.5.4 Standards Contractor and Subcontractor drawings shall conform to the following standards: 1. ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents 2. IEEE 315, Graphics Symbols for Electrical and Electronic Diagrams 3. IEEE 91, Graphic Symbols for Logic Diagrams The requirements for the specified standard graphic symbols and abbreviations may be waived by the Owner provided a system of standard abbreviations and symbols is used for all drawings submitted and the Contractor provides the Owner with five copies of a bound booklet showing all abbreviations and graphic symbols used on drawings. LTK Standard Streetcar Specifications Section 19 8 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.4.5.5 Final Drawings See the CDRL section, below, for requirements of the complete list of final drawings, and for final drawings of the as-built condition of the vehicle. Include the following in final drawings: 1. Contractor's and suppliers' drawings, details, bills of material, and catalog cuts that are required by the Owner for future installation, maintenance, repair and overhaul purposes. 2. Assemblies, subassemblies, and arrangements of the vehicle as finally furnished, modified and accepted. 3. Electrical schematics, electronic circuits, and wiring diagrams. 4. Interface control drawings down to the lowest level replaceable unit (LLRU). 5. Items that are special purpose or fabricated by the Contractor. 6. Materials furnished by the Contractor and by its suppliers, down to and including the module and circuit board level. Outline drawings shall not be considered acceptable. 19.4.6 Modification and Configuration Control 19.4.6.1 General Develop modification and configuration control plans and procedures. Throughout the Contract, implement and maintain the configuration control system. See the CDRL section, below, for details of modification and configuration control submittals. 19.4.6.2 Design Changes Control changes to approved documents, drawings, and data by processing engineering change requests (ECRs). 1. Submit a proposed standard form and procedure. 2. All changes to approved configuration must be presented to the City for approval prior to implementation. 3. Implementation of a change shall require incorporation into all vehicles, unless otherwise approved by the Owner, and shall require inspection and Owner approval. 4. Maintain an Engineering Change Status Report: a. List all changes, their submittal/approval status, status of implementation, which vehicle or part is affected, parts requiring retrofit including serial numbers, projected completion dates and completion dates. b. Include the Engineering Change Status Report with the Monthly Progress Report. 19.4.6.3 Component Identification and Serial Numbers Permanently identify all vehicle components as mutually agreed between the Contractor and the Owner with a supplier's name, part number, and revision level. 1. 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 or subassembly, including spares, unless otherwise approved by the Owner. 2. Present the serial numbers of components and subassemblies to the Owner as each vehicle arrives on the property or when spare components are received. Track serial number transfers and prepare a list of serial numbered apparatus installed on each vehicle for inclusion in the vehicle history book. LTK Standard Streetcar Specifications Section 19 9 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 3. The list of serialized components and subassemblies shall be agreed to between the Contractor and the Owner and shall include as minimum, the following: a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. HVAC apparatus Converters Inverters Pantographs Master Controller Door operators and controls Motors within equipment All electronic cards and ECUs Principal communications equipment items (not including speakers) Principal items of traction and braking equipment Truck castings or weldments Primary and Secondary Suspension Axles Truck frames Truck gear units Journal bearings Wheels Brake disks Track brakes Front end cab enclosure molding 19.4.6.4 Vehicle History Books Each vehicle shall have a vehicle history book that reflects the configuration and testing status of the vehicle. 1. The vehicle history book shall accompany the vehicle through the production line and be presented to the Owner. 2. As a minimum, each book shall contain the following information: a. Description, completion dates, and approval status of vehicle modifications, and list of modifications pending with expected completion dates b. Hold-point inspection reports, as specified for the QCIP, after all discrepancies have been eliminated. c. List of vehicle defects that were identified by Contractor QA or the Owner’s personnel during construction and the disposition of each as verified by inspection d. List of serial-numbered apparatus e. Results of the pre-shipment inspection, as specified in the QCIP f. Shipping documents g. Results of the post-shipment inspection, as specified in the QCIP h. Results and approval status of each test performed on the vehicle or any part of the vehicle i. A truck section that includes wheels, journal bearings, and gear mounting records, including pressing charts and truck weigh tickets j. A record of any abnormalities that occur during the manufacture of the vehicle or any of its subsystems, including their authorized, validated, repair procedures k. Open item status list l. Vehicle weight and computer generated weigh tickets LTK Standard Streetcar Specifications Section 19 10 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 3. Submit the format and the vehicle history book. See the CDRL section, below, for detailed requirements. 19.5 Manufacturing Control 19.5.1 Communication Between Engineering and Manufacturing Establish a process to provide regular communication between the Contractor’s manufacturing group and its engineering group. Assign specific employees in each group to communicate the following: 1. Engineering changes that affect manufacturing. 2. Manufacturing issues that require engineering input. 3. Engineering solutions to manufacturing issues. 19.5.2 Manufacturing Comply with the following requirements and prohibitions: 1. Documentation: a. All manufacturing activities shall include written procedures, drawings, parts lists, dimensions and tolerances, and explicit criteria defining acceptable results. b. Establish a process to verify that procedures, drawings, and other written material used by workers are always the current revision. 2. Fabrication: a. Establish methods that comply with design documents and use appropriate jigs, fixtures, tooling, and the like to ensure consistent installations. b. Prove the accuracy of production jigs, fixtures, tooling masters, templates, patterns, and similar devices at formally established intervals and adjusted, replaced, or repaired as required to maintain quality and comply with the requirements for standards of workmanship in Section 16, Materials and Workmanship. c. Sufficiently develop design, manufacturing, and QC processes such that all vehicle components are identical, interchangeable, fit without interference, and can be assembled without alterations. 3. Prohibited manufacturing activities include: a. b. c. d. Modification of parts Cut-to-fit assembly Match drilling All other hand-fitting activities 19.5.3 Worker Training Workers shall be trained in the work to which they are assigned, including the following: 1. Specific training related to the standards of workmanship specified in Section 16. 2. Specific training relating to following manufacturing procedures, drawings, and processes. 3. Instruction on correct use of tooling, jigs, and fixtures for control of the work. LTK Standard Streetcar Specifications Section 19 11 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 4. Clear instructions to not proceed if parts do not fit, manufacturing procedures are inadequate, tooling, jigs, and fixtures appear to be poorly maintained or inefficient, or other defects are noted, and to promptly notify QC or manufacturing supervisors. Certify workers that have successfully completed training and demonstrated acceptable work. Uncertified workers shall not perform work on the Owner’s project. 19.5.4 Supervision Provide supervision to ensure that manufacturing complies with manufacturing procedures and good practice. 1. Provide sufficient supervision to detect and retrain, or remove, workers not performing in accordance with the specified standards of workmanship and manufacturing processes. 2. Coordinate manufacturing supervision and QC such that there is consistency in expectations and results. 19.5.5 Control Samples Prepare and submit control samples: 1. Retain copies of signed validation forms with each sample. 2. Furnish approved samples to the subcontractor or supplier, with additional approved samples retained by the Contractor and the Owner. 19.6 Quality Assurance (QA) and Quality Control (QC) 19.6.1 Standards Plan, establish, and maintain a Quality Assurance (QA) and Quality Control (QC) program that complies with the following standards: 1. ANSI/ISO/ASQ Q9001, Quality Management Systems – Requirements (or approved equal) 2. FTA-IT-90-5001-02.1, Quality Assurance and Quality Control Guidelines The Contractor, subcontractors and suppliers shall be in compliance with these standards but Certification to these standards is not mandatory. 19.6.2 Subcontractor/Supplier QA/QC The Contractor's QA/QC program shall be imposed upon all entities within the Contractor's organization and on all subcontractors whenever Contract work is performed. 1. The Contractor may accept established QA/QC plans from its subcontractors and incorporate these plans as part of its overall QA/QC program. 2. The Contractor shall require that each supplier maintains a QA and QC program for the services and supplies that it provides. 3. The Contractor's QA organization shall perform QA activities related to suppliers, including FAI’s, PSI’s, and audits, as detailed in the QAP. 4. Inspect and test materials provided by suppliers for conformance to Specification requirements: a. Identify and document materials that have been inspected, tested, and approved as acceptable to the point of use in the manufacturing or assembly processes. b. Establish controls to prevent inadvertent use of nonconforming materials. LTK Standard Streetcar Specifications Section 19 12 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.6.3 QA Organization 19.6.3.1 Scope The Contractor’s “QA organization” includes the entire QA/QC management structure within the Contractor’s organization, and quality personnel assigned to this Contract. 1. At the Contract level, the QA organization shall include the following: a. b. c. d. e. A dedicated QA Manager A single point of contact for Quality accountability for the entire Contract Each person proposed to conduct QA activities, such as FAI’s, PSI’s, or audits Each person proposed to perform QC activities, such as inspections or tests A Material Review Board, or approved equal 2. The Owner shall have the right to approve or disapprove of each person proposed in the QAP as part of the Contractor’s QA organization at the Contract level. 19.6.3.2 Responsibilities Responsibilities of the QA organization include responsibility for: 1. Establishing processes and activities focused on the prevention of defects in the vehicles through all Contractor and subcontractor/supplier phases from design through manufacture and preparation for delivery. 2. Developing, implementing, and auditing a QC system, including development of a Quality Control and Inspection Plan (QCIP). 19.6.3.3 Authority Comply with the following requirements for authority within the QA organization: 1. Authority for the QA function within the QA organization shall be established such that the quality of products under the terms of this Contract shall not be compromised in order to meet schedule and cost projections. 2. Management responsible for QA shall have sufficient authority and organizational freedom to ensure that a nonconforming or discrepant product will not be delivered to the Owner at any location providing product or services for use on this Contract. 19.6.3.4 QA Manager Select a QA Manager with appropriate training and experience and submit qualifications. 1. Once approved, the QA Manager shall not be removed without the approval of the Owner. 2. The QA Manager shall verify that the Quality Assurance Plan (QAP) and Quality Control and Inspection Plan (QCIP) are fully implemented. 3. The QA Manager shall report to an officer within the Contractor’s organization or a top level manager within the QA organization. 4. The QA Manager shall not report to the Contractor’s Project Manager or Production Manager. 19.6.3.5 QC Personnel Comply with the following requirements for QC personnel: 1. Furnish QC personnel qualified to perform inspections or tests as follows: a. With prior experience and training LTK Standard Streetcar Specifications Section 19 13 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance b. Certified where required, and verified by testing where applicable 2. Maintain records of quality personnel certification and qualifications and make available for the Owner’s review. 3. Contractor’s production personnel may not be used to perform QA or QC activities unless specifically approved by the Owner. 19.6.4 QA/QC Records The QA organization shall maintain its own quality records and data from its QA and QC activities for the effective operation of the QA/QC program. These records and data shall be available for review by the Owner for a minimum of three years after acceptance of the last vehicle. 19.6.5 Quality Assurance Plan (QAP) 19.6.5.1 Scope The QAP shall describe in detail the Contractor's processes for planning, implementing, and maintaining quality in all aspects of both design and construction of the vehicles. Following are minimum requirements: 1. Make specific to this Contract. 2. Include a single point of contact for all Contract Quality activity. 3. Include a company policy statement that clearly defines the authority and responsibilities of each member of the QA organization. 4. Include an organization chart for the QA organization: a. Show roles and reporting relationships of each member of the QA organization engaged in this Contract, b. Show relationship of the QA Manager and QA Department with top management. c. Include a description of the responsibilities of the Contractor’s QA organization that references the quality organization chart. 5. Define the responsibilities and authority of personnel who manage and perform work affecting quality. 6. Include all procedures for implementing the required ANSI/ISO/ASQ Q9001 standard. 7. Describe how the QA organization will maintain and use its own quality records and data from its QA and QC activities for the effective operation of the QA/QC program. 8. Include a list of personnel certification requirements and describe the process for verification. 9. Include provisions for issuance of a Monthly Quality Assurance report. 10. Include QA procedures affecting design, manufacturing, and acceptance site operations: a. Assign the authority and means to implement these procedures. b. Include as a minimum written procedures that control the activities listed below: • • • • Design and drawing production, including technical documentation, engineering changes, deviations, waivers, and FMIs Verification that all applicable Specification requirements are properly included or referenced in purchase orders of articles to be used on vehicles Transmission of all QA requirements to procurement sources Surveillance of subcontractor and supplier quality processes LTK Standard Streetcar Specifications Section 19 14 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance • • • • • • • • • • • • • Special Processes (for example paint operations) Evaluation of procured articles against purchase order requirements Verification of the maintenance and use of approved drawings essential to effective production Verification that basic production operations, as well as all other processing and fabricating, are performed under controlled conditions. Establishment of these controlled conditions shall be based on documented work procedures, adequate production equipment, and special working environments Equipment calibration and certification Production personnel qualifications and certifications Procurement and handling of materials Monitoring the Contractor's system for controlling nonconforming materials, whether furnished by the Contractor or a supplier. The system shall include procedures for identification, segregation, and disposition. Discrepancy reporting Material Review board (MRB) or approved equal QA records Shipping, handling, and storing Internal and external audits 11. See the CDRL section, below, for details of the QAP submittal. 19.6.5.2 Implementation Once approved, the approved QAP shall be implemented throughout the course of the Contract. The Owner-approved QAP and all of the implementing processes, procedures and manuals will be subject to periodic audits by the Owner. 19.6.6 Measuring Equipment and Tools 19.6.6.1 Measuring and Testing Devices Ensure the validity of measurements and tests through the use of suitable inspection, measurement, and test equipment of the range and type necessary to determine conformance with Contract requirements: 1. Furnish and maintain the necessary gauges and other measuring and testing devices to verify that components, systems, and vehicles conform to the approved design. 2. Make available the Contractor's gauges and other measuring and testing devices for use by the Owner to verify that the vehicles conform to all Specification requirements. 3. If necessary, make available Contractor personnel to operate the devices and to verify their condition and accuracy. 4. The Owner shall have the right to approve or disapprove inspection, measurement, and test equipment that is not of the proper range or type required. 19.6.6.2 Control and Calibration Ensure that inspection, measuring, and test equipment is identified, controlled, maintained, and calibrated by an accredited Laboratory approved by the Owner: 1. Establish an effective time-cycled or usage-cycled calibration and certification program. 2. Include tooling, jigs, and fixtures used as media for inspection or manufacture in this program. LTK Standard Streetcar Specifications Section 19 15 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 3. Provide an indication on every verified or calibrated device showing its current status and the date (or other basis) on which inspection or recalibration is next required. 4. Promptly recalibrate devices yielding inconsistent measurements or clearly flawed data before the stated recalibration date. 5. Promptly re-inspect work performed using incorrect, unapproved, or out of calibration equipment. The work is considered invalid, whether delivered to production or to the field. 19.6.6.3 Calibration Records Record calibration certifications and include as part of the QA records. 19.7 Quality Control and Inspection 19.7.1 First Article Inspections Perform a First Article Inspection (FAI) jointly with the Owner on all major components, subassemblies, and the fully assembled vehicle. 1. Owner participation in an FAI shall be at the discretion of the Owner. 2. FAIs may be waived only at the discretion of the Owner. 3. FAI's shall be conducted at the point of manufacture on the first piece, component, assembly, or system constructed using production materials and tooling and conditionally approved or approved design. 4. An FAI will not be conducted until the design drawings, test procedures, inspections, and control samples of the article have been conditionally approved or approved. If conditionally approved drawings are used, the Owner's conditions for approval shall be satisfied at the FAI and represented by the inspection article. 5. Provide an individual notice to the Owner for each FAI a minimum of 30 calendar days before the FAI. 6. Schedule no more than one FAI per day and two FAIs per week without prior written approval by the Owner. 7. When appropriate, display the inspection article on a stand or table in a well-lit work space with skilled labor and all necessary inspection tools and gauges available for any checking or disassembly work required by the Owner. Submittals: See the CDRL section, below, for detailed submittal requirements. 1. FAI List: Submit a list of Contractor and Vendor-supplied equipment that is expected to receive a FAI. 2. FAI Package: Submit for each FAI that identifies product readiness for the FAI. 3. FAI Report: Submit for each FAI performed. After the Owner’s approval of the initial FAI: 1. Equipment shall be shipped from the point of manufacture only after an FAI has been approved or waived by the Owner. 2. Corrections required as a result of the FAI shall be incorporated into all equipment prior to shipment. 3. The approved FAI item shall be retained by the Contractor, subcontractor or supplier for use as a reference production standard, except as approved by the Owner. LTK Standard Streetcar Specifications Section 19 16 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 4. Retained FAI items shall be maintained and upgraded to latest approved design configuration. Shipment of the retained FAI unit with all of its maintenance and upgrade records shall require authorization by the Contractor and the Owner. 5. Changes to product, design, production process, materials, or location of manufacture shall be the basis for another FAI. The scope of the subsequent FAI shall be at the sole discretion of the Owner. 19.7.2 Quality Control and Inspection Plan (QCIP) 19.7.2.1 General Develop, submit, and implement a QCIP: 1. It shall prescribe inspection and testing of materials, work in progress, and complete articles. 2. It shall include references to all formal inspection and test procedures, including Hold and Witness point inspection. 3. It shall ensure that all materials, components, and assemblies are inspected for conformance with the approved drawings, procedures, and the Specifications. 4. See the CDRL section, below, for detailed requirements of the QCIP submittal. As outlined in the QAP, the Contractor's QA organization shall establish, maintain, and periodically audit a fully-documented QCIP: 1. Use a sufficient number of trained inspectors to perform inspections in accordance with the QCIP. 2. Except as otherwise specified or specifically approved by the City, independent testing laboratories shall be located in the United States and shall require City approval. 19.7.2.2 Inspection Status Maintain a system to identify the inspection status of materials and components: 1. Acceptable; 2. Non-conforming; or 3. Not inspected. 19.7.2.3 Control of Non-Conformance Give non-conforming materials and components an inspection status of repair, rework, use-as-is, or scrap. 1. The Owner will evaluate non-conforming article status and determine the final disposition. 2. Plainly mark and control non-conforming material in a bonded hold area pending disposition to prevent installation on the vehicle. 3. Repair, rework, and use-as-is: a. Must have the Owner’s approval before use. b. Repair and rework shall be documented and approved. c. Inspection personnel shall verify all corrective actions and mark the discrepancy record. 4. Scrap: Articles found to be unusable. 5. Control articles that become obsolete as a result of engineering changes or other actions to prevent unauthorized assembly or installation. LTK Standard Streetcar Specifications Section 19 17 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance Enter on a record any non-conformance noted by the Contractor or the Owner during assembly. 1. The record shall accompany the major component, subassembly, assembly, or vehicle from start of assembly through final inspection. 2. Take actions to correct discrepancies or deficiencies in the manufacturing procedures, or other conditions that cause articles to be non-conforming. 3. If non-conformance cannot be corrected by replacing the non-conforming materials, the Owner shall review and approve (or disapprove) the modification, repair, or method of correction to the extent that Contract specifications are affected. 19.7.2.4 Levels of Inspection Perform 100 percent or sampling inspection for discrete items of work if not otherwise required in the Specifications. 1. Develop sampling procedures in accordance with MIL-STD-1916, ANSI/ASQ Z1.9, ANSI/ASQ Z1.4, or other approved approach and submit. 2. Sampling inspection AQL requirements should not exceed an AQL of 1.5 without the Owner’s approval. 3. Submit sampling procedures as part of the QCIP. See the CDRL section, below, for detailed submittal requirements. 19.7.2.5 Receiving Inspection/Pre-Shipment Inspection Perform inspections at source and/or upon receipt to verify conformance to acceptance criteria of specifications and drawings: 1. 2. 3. 4. Perform inspections to Purchase Order requirements, Specifications, and drawing requirements. Retain material certifications and test reports. Specify 100 percent or sampling inspection for all major subsystem equipment to be purchased. Submit procedures as part of the QCIP. See the CDRL section, below, for detailed submittal requirements. 19.7.2.6 Inspection of Work In-Process The Contractor's QA organization shall maintain and direct a force of inspectors to verify that work in its shops is performed in compliance with the approved design drawings, the Specifications, and the approved QCIP: 1. Regularly check dimensions, tolerances, and quality of work against the drawings on each subassembly and vehicle. 2. Record discrepancies in the work in accordance with the approved QCIP and notify departments responsible for the work of the need for corrections. 3. Document and submit corrective actions. 4. After re-inspection in accordance with the QCIP, notify responsible manufacturing supervision of rework that is rejected, if any. 5. Re-inspection acceptance status shall be indicated by the inspectors by their date and stamp or initials on the original of the discrepancy report, prior to offering the inspection to the Owner for consideration. LTK Standard Streetcar Specifications Section 19 18 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.7.2.7 Hold- and Witness-Point Inspections Comply with the following requirements: 1. Hold-Point Inspections: Mandatory inspection points that must be presented for City inspection: a. Inform the Owner of a hold-point inspection with sufficient advance notice to allow City participation. b. Hold points shall be used to inspect completed operations or installations and to inspect items that are about to be concealed by subsequent operations. c. Post the inspection forms at or near the point of inspection for each vehicle and include in the Vehicle History Book when all discrepancies have been eliminated. d. Nonconforming products shall not be released from a hold-point area until all discrepancies have been corrected. e. Vehicle movement beyond any hold point without the Owner’s approval is prohibited. 2. Witness-Point Inspections: Mandatory inspection points that must be presented for City inspection: a. Inform the Owner of a witness-point inspection with sufficient advance notice to allow the City’s participation. b. The Owner’s participation in a Witness Point inspection shall be at the Owner’s discretion. 3. Minimum hold-point inspections: a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u. v. Inbound material requiring Mill Reports Each underframe Each vehicle roof section Each articulation unit after installation Each vehicle shell body section before painting Each vehicle shell body section after painting Each truck frame Each assembled truck, prior to installation under a vehicle Each vehicle roof after equipment installation Vehicle piping Each vehicle floor panels and covering prior to seat installation Each vehicle watertightness test prior to installation of insulation and interior finishings Each vehicle final watertightness test Each vehicle interior wiring, including wiring in electrical cabinets, empty wireway, conduit before being covered by panels Each vehicle interior, including floor heaters, windscreens, seats, interior walls and ceiling, and similar Each vehicle exterior Static and dynamic testing Vehicle complete in all respects Final walk-through prior to shipment Upon arrival on Owner’s property After rework or repairs have been performed on equipment that has completed formal inspection After implementation of design changes and retrofit modifications LTK Standard Streetcar Specifications Section 19 19 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance If work is concealed without conducting a Hold or Witness-point inspection listed in the approved QCIP, the Contractor shall, at no cost to the City, expose the work and demonstrate conformance of the work with Contract requirements. 19.7.2.8 Final Inspection Perform a final inspection and schedule and facilitate final inspection by the Owner: 1. Contractor Final Inspection: a. Perform for each vehicle before the Owner’s final inspection: b. Correct each workmanship item covered by prior inspection reports before the inspection begins. c. Perform after all work is completed according to written procedures. d. Include the following: • • • • Inspection and test Watertightness Vehicle leveling Weighing 2. Owner’s Final Inspection: a. Before scheduling, present all open documentation and action items, including the following: • • • Open discrepancies including missing parts MOC open items Engineering Change/ modification open items, etc. b. Allow one day for the inspection. c. During the inspection, all systems shall be operational with use of approved special equipment or power supplies. d. Provide qualified personnel to accompany the Owner with the authority to act upon issues encountered during the inspection. e. Provide labor and appropriate tools to remove or open and reinstall covers and doors. f. Owner approval is prerequisite to the Contractor shipping the vehicle from the Contractor's plant to the Owner’s facilities 19.7.2.9 Pre-Shipment Inspection After final inspection by the Owner and resolution of any outstanding items, prepare each vehicle so as to preclude damage during shipment. 1. 2. 3. 4. Conduct and document a pre-shipment inspection in accordance with the approved QCIP. The inspection shall be performed for each vehicles scheduled for shipment. The inspection shall confirm that all shipping precautions and checks have been accomplished. The pre-shipment inspection shall also include a walk-through visual inspection to ensure completeness, cleanliness and workmanship. 5. After completion of the pre-shipment inspection, the unit shall be locked and no additional activity allowed on the vehicle prior to departure. LTK Standard Streetcar Specifications Section 19 20 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 19.7.2.10 Post-Shipment Inspection Conduct and document a post-shipment inspection in accordance with the approved QCIP: 1. The inspection shall be for each vehicle upon its arrival on the tracks at the Owner’s facilities. 2. Document the results of this inspection and include in the Vehicle History Book. 19.7.2.11 Quality Audits Submit a comprehensive system of planned and periodic audits: 1. The audits shall be performed by qualified personnel not having direct responsibilities in the areas audited. 2. Audit reports and follow-up action reports shall be available to the Owner for review and approval no later than 10 working days after each audit. 3. Audits of subcontractors and suppliers shall be made by the Contractor and may be witnessed by the Owner. 4. At a minimum, QA audits of subcontractors and suppliers shall be made at the following times: a. As a condition of the subcontract or purchase order, prior to start of work. b. Within 30 calendar days of scheduling First Article Inspections or services being supplied by the subcontractor or supplier. c. When the subcontractor or supplier manufacturing facility or manufacturing process has changed. d. When re-audit is warranted due to unacceptable performance, such as nonconformances, schedule impact, or cost overruns. 5. The Owner reserves the right to conduct independent audits of the Contractor's Quality system, and that of its subcontractors and suppliers, for its effectiveness at any time. 6. At a minimum, QA audits of the Contractor may be made at the following times: a. b. c. d. Prior to start of production of the first vehicle shell. Within 30 days prior to formal presentation of the first vehicle. When the product manufacturing facility has changed. When re-audit is warranted due to unacceptable performance, such as nonconformances, schedule impact, or cost overruns. 19.7.3 Open Items List Throughout the production of the vehicles, develop, maintain and submit an open items list (OIL) of discrepancies, and their status, associated with each vehicle. 1. The Owner will review the details of the OIL and furnish comments or concerns. 2. Correct or remedy all items on the OIL to the satisfaction of the Owner. 19.7.4 The Owner’s Audit and Inspection 19.7.4.1 City Inspection Activities The Owner may, at its discretion, perform its own QA/QC monitoring of work done under this Contract, including monitoring of the Contractor's or Subcontractor's QA and QC activities. 1. Such activities shall not reduce or alter the Contractor's QA and QC responsibilities, nor reduce or alter the Contractor's obligation to meet the requirements of the Specifications. LTK Standard Streetcar Specifications Section 19 21 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 2. Following NTP, the Owner shall have the right of free access to facilities of the Contractor and subcontractors to inspect, examine, and test items during manufacture and shipment, and within a reasonable time after shipment. 19.7.4.2 Contractor Provision of Facilities for the Owner’s Use Provide the following to the Owner’s personnel in the Contractor's manufacturing facility: 1. A heated, cooled, and adequately lighted private office with two desks, chairs, and a work table large enough to view full-sized drawings. 2. Ready access to modern toilet facilities. 3. A private telephone line, a fax line, and a separate dedicated high-speed internet access line not linked to the Contractor's network. 4. Copies of all drawings, diagrams, schedules, changes, deviations, and QA records, upon request. 5. A combination copier/scanner/fax machine dedicated to Owner’s use in the private office space. 19.8 Contract Data Requirements List (CDRL) Submit the following in accordance with this Section: 19-1 Management Plan: 1. Submit within 30 days of NTP. 2. Organization Chart for the Contractor's staff: a. Personnel and responsibilities as listed in the Organization Chart section, above. b. Show lines of both authority and communication. 3. Work Flow Diagram: a. Elements listed in the Work Flow Diagram section, above. b. Include company name, affiliation, principal contact and position, and the location at which the work will be performed. 4. CPM (Critical Path Method) Program Schedule: a. Include, as a minimum, the following elements for each activity listed in the Program Schedule section, above: • • • • • Activity ID Activity duration Early start and early finish dates Late start and late finish dates Activity float b. Include a schedule narrative, describing the overall approach to meeting required milestones and including the elements listed in the Program Schedule section. 19-2 Monthly CPM Schedule Update: 1. 2. 3. 4. Update and resubmit the CPM Program Schedule submitted with the Management Plan Submit at least every month. Submit at the same time as the Monthly Progress Report. The schedule shall comply with the requirements for the CPM schedule in the Management Plan. LTK Standard Streetcar Specifications Section 19 22 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 5. Show actual achieved progress for each activity. 19-3 CPM Schedule – First Vehicle: 1. Separate, stand-alone schedule for the first vehicle 2. Comply with the requirements for the CPM schedule in the Management Plan. 3. Furnish more detail, and show only those activities critical to the delivery of the first vehicle. 19-4 Monthly Progress Report: 1. Submit each month, starting with the first full month after award of contract. 2. Submit the report for each month no later than the 10th day of the following month (e.g., 10 July for the June report). 3. For work accomplished during the month: a. Actual completion dates and start dates. 4. Updated reports, schedules, and other documents: a. b. c. d. e. f. g. CDRL Report Change Status Report On-going or open engineering items Status of correspondence Dates and locations of program review meetings Change Order log Vehicle weight estimate 5. For the following month: a. Estimated remaining durations for activities in progress b. Major work activities planned for the following month c. Estimated start dates 6. Quality breakdown and status, by system as necessary: a. b. c. d. Contractor quality issues, status Vendor quality issues, status Activity related to the closure of discrepancies Projected closure dates for these items 19-5 Correspondence and Submittal Coding Scheme: 1. Submit within 30 days after NTP. 2. Furnish a coding scheme to identify correspondence and submittals. 19-6 CDRL Report: 1. Submit within 30 days after NTP. 2. Update and submit monthly. 3. Include the estimated submittal dates, and their current status. 19-7 Submittal Status Report: 1. Submit monthly. 2. Include the following information: a. Drawing and document numbers LTK Standard Streetcar Specifications Section 19 23 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance b. c. d. e. f. g. Revision letter Drawing title Date submitted Transmittal document Disposition Document number identifying the disposition 19-8 Meeting Minutes Format: 1. Submit the proposed format for minutes of meetings before the first meeting minutes are submitted. 2. Comply with requirements in the Meetings section, above. 19-9 Meeting Minutes: 1. 2. 3. 4. Submit for each meeting between the Contractor and the City. Submit within ten days after the meeting. Comply with the approved meeting minutes format. Include reasonable projected closure dates for each action item. 19-10 Specifications Compliance Matrix (SCM): 1. At least 15 calendar days prior to the Specification Review Meeting, submit an SCM shell in the format that will be used for the completed SCM and monthly updates. 2. Submit the SCM populated during the Specification Review Meeting. 3. Submit monthly SCM updates. 4. Include the following in the SCM and monthly submittals: a. A comprehensive list of Specification requirements extracted from the Specifications. b. Documentation the Contractor intends to submit to demonstrate compliance with each Specification requirement, such as reports, analyses, system descriptions, manuals, drawings, inspection and test procedures, and test reports. c. Approved documents that certify compliance with each requirement. d. An indication for each requirement when it is compliant. 19-11 Construction Photographs: 1. Submit before delivery of the last vehicle. 2. Two sets of color, unmounted progress and finished vehicle photographs, approximately 8-in by 10-in size. 3. Minimum 100 views of the vehicle during stages representative of its complete construction. 4. Record the date each picture was taken, the number of the vehicle pictured, and the location on the vehicle on the back of each print. 5. Insert photographs into a suitable album-type binder with transparent pockets. 6. The album shall contain an index that identifies the photographs enclosed. 7. Provide photographs in standard, high-resolution electronic format on a shared network link, available for download by the Owner. 19-12 List of Final Drawings: 1. Submit within 90 days following shipment of the first vehicle. 2. Identify each drawing that will be submitted as part of the final drawings. LTK Standard Streetcar Specifications Section 19 24 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 3. The list shall identify each item required to be submitted by the Contractor in the Final Drawings submittal. 19-13 Final Drawings: 1. Submit within 90 days following acceptance of the first vehicle. 2. Drawings shall include those listed above in the Final Drawings section. 3. Drawings shall be supplied on electronic media in the form specified above for Contractor Submittals. 4. Update final drawings to as-built configuration and submit within 90 days after Acceptance of the last vehicle. 19-14 Modification and Configuration Control Manual: 1. 2. 3. 4. 5. Submit within 60 days after NTP. Contractor-developed modification and configuration control plans and procedures. Flow chart showing the process of configuration control. Narrative describing the configuration control process. Details and samples showing how drawing revisions are indicated. 19-15 ECR Form and Procedure: 1. Submit within 60 days after award of Contract. 2. Proposed standard form and procedure for controlling changes to approved documents, drawings, and data. 3. The procedure shall include each step required to maintain control of design changes. 4. The form shall include spaces for the following: a. b. c. d. e. f. g. h. A form tracking number Date The vehicle or part affected Quantity affected Serial numbers Corrective and preventive actions Other information appropriate for the proposed procedure Contractor and Owner signature blocks for the change approval and also acceptability of the implemented change 19-16 Vehicle History Books (VHB): 1. Submit for format and content approval in advance of shipment/Acceptance of the first vehicle. 2. Final acceptance of the VHB format and content will be confirmed with review of the VHB for the first vehicle. 3. Material specified in the Vehicle History Books section, above. 4. Submit a VHB for each vehicle when it is Accepted. 19-17 Draft Training Plan for Manufacturing Workers: 1. 2. 3. 4. Instruction on correct use of all manufacturing tools Procedures for addressing manufacturing issues Instruction on specified standards of workmanship Instruction regarding unacceptable practices. LTK Standard Streetcar Specifications Section 19 25 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 5. Description of how workers will be tested at the completion of training to certify that they have understood and retained the instruction. 19-18 Control Samples: 1. Submit four samples for each required item. 2. Include validation forms for Contractor and Owner signature. 3. After approval, retain one sample and furnish one to the appropriate subcontractor or supplier. 19-19 QA Manager Qualifications: 1. Qualifications for the person proposed to be QA manager. 2. Résumé demonstrating appropriate training and experience. 19-20 Quality Assurance Plan (QAP): 1. 2. 3. 4. 5. 6. Submit within 60 days after NTP. Required information as described in the Quality Assurance Plan (QAP) section, above. Organization chart for the QA organization. Organization chart for the Contractor’s staff (see Management Plan submittal) Resumes of each member of the QA organization engaged in this Contract. QA procedures listed in the Quality Assurance Plan (QAP) section, above. 19-21 FAI List: 1. Submit within 120 days of NTP. 19-22 FAI Package: 1. Submit a package for each FAI a minimum of 30 days before the FAI. 2. Include the following as a minimum: a. b. c. d. e. Agenda Event location Schedule of activity All necessary logistics information, including point of contact Pertinent documentation and status reports, including the following: • • • • • • • • • f. Drawings Engineering Changes Modifications lists Complete open items list Mill Certifications (Certificates of Conformance shall not be allowed without approval from the City) Status of required samples Test procedures and reports Contractor pre-FAI results Software documentation, if applicable. Inspection forms and data sheets for the FAI. 19-23 FAI Report: 1. Submit a report for each FAI conducted within 15 working days. LTK Standard Streetcar Specifications Section 19 26 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance 2. The report shall include pertinent information, including photographs. 19-24 Quality Control and Inspection Plan (QCIP): 1. Submit within 120 days after NTP. 2. Flow chart identifying major manufacturing and inspection points including source, receiving point, in-process, hold, witness, and final inspection points. 3. Include a list of all inspection and test procedures used in the manufacture and testing of the vehicle, including those performed at the Acceptance site. 4. Inspection forms: a. Include a list of all forms used in the production or testing of the vehicles b. Include a blank copy of each form on the list 5. Inspection Status: a. Include the method used for identifying inspection status 6. Control of Non-Conformance a. Include a written procedure for control of rejected (non-conforming) material in all of the Contractor’s facilities. The procedure shall include a Material Review Board or approved equal. b. The procedures shall address identification, segregation, and disposition of nonconforming material. 7. Sampling Procedures: a. Include a list of parts and material to be inspected by sampling and indicate the type of sampling to be used. b. Indicate the standard on which sampling procedures are based. 8. Source/pre-shipment inspection for subcontractor and supplier product. Include the documentation/reports that must be captured. 9. Receiving Inspections: a. Include written procedures for documenting how items are inspected at source and/or upon receipt to verify conformance to acceptance criteria of Specifications and drawings. b. Include sample forms or documents for recording receiving inspection results. 10. In-Process Inspections: a. Include written procedures and sample forms or documents for recording in-process inspection results b. Include inspection for conformance to current, approved drawings. c. Include a requirement to submit any corrective actions that must be approved before implementation. d. In addition to steps for initial inspections, include steps for inspection of repairs and corrections for conformance to drawings and the Owner-approved rework procedures, as needed. 11. Hold-Point and Witness-Point Inspection: a. Provide a detailed procedure for each hold-point inspection listed in the Hold-Point and Witness-Point Inspection section, above. LTK Standard Streetcar Specifications Section 19 27 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Program Control and Quality Assurance b. Include sample forms or documents for recording hold point inspection results and discrepancies. c. Include the approach applied to provide notification of a Hold or Witness point inspection to Owner’s representatives. 12. Pre-Shipment Inspection: a. Procedure and sample forms or documents to record this inspection. b. Identify the documentation that must be captured and retained by the Contractor at a pre-shipment inspection. 13. Post-Shipment Inspection: a. Procedure and sample forms or documents to record this inspection. b. Include steps necessary to find any vehicle damage or evidence of anomalous conditions during shipping. 14. QC testing: a. Functional testing b. Subject to the Owner’s approval, performing statistical analysis, tests, and other QC procedures when appropriate in the QA processes 15. List and samples of all forms proposed to be used for the Contractor's QC activities. 16. Steps that the QA organization must take with regard to suppliers, including supplier audits. END OF SECTION LTK Standard Streetcar Specifications Section 19 28 January 30, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) Table of Contents 20.1 General ......................................................................................................................................1 20.1.1 OESS Description ............................................................................................................................ 1 20.1.2 System Capacities........................................................................................................................... 1 20.1.3 Standards Compliance ................................................................................................................... 1 20.1.4 Installation ..................................................................................................................................... 1 20.1.5 Service Life ..................................................................................................................................... 1 20.2 Wireless Segments .....................................................................................................................2 20.2.1 Operating Conditions ..................................................................................................................... 2 20.3 Performance Requirements ........................................................................................................2 20.3.1 Speed.............................................................................................................................................. 2 20.3.2 Acceleration ................................................................................................................................... 2 20.3.3 Braking ........................................................................................................................................... 2 20.3.4 Duty Cycle ...................................................................................................................................... 3 20.3.4.1 Normal Duty............................................................................................................................ 3 20.3.4.2 Thermal Capacity .................................................................................................................... 3 20.4 Charging and Discharging ............................................................................................................3 20.4.1 Voltage Range ................................................................................................................................ 3 20.4.2 Charging ......................................................................................................................................... 3 20.4.3 Discharging ..................................................................................................................................... 3 20.5 Controls and Indications .............................................................................................................4 20.5.1 Interlocks........................................................................................................................................ 4 20.5.2 Automatic Operation ..................................................................................................................... 4 20.5.3 Manual Operation .......................................................................................................................... 4 20.5.3.1 Wireless-Operation Switch ..................................................................................................... 4 20.5.3.2 Pantograph-Down Bypass Switch ........................................................................................... 4 20.5.3.3 Load Shedding Switch ............................................................................................................. 5 20.5.4 Isolation.......................................................................................................................................... 5 20.5.5 Emergency Disconnect Switch ....................................................................................................... 5 20.5.6 Shop Disconnect Switch ................................................................................................................. 5 20.5.7 OESS Cab Controls and Indications ................................................................................................ 5 20.5.8 OESS Load Management Control ................................................................................................... 6 20.6 OESS Components ......................................................................................................................6 20.7 Coordination and Integration with the Vehicle ............................................................................8 LTK Standard Streetcar Specifications Section 20 i January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.7.1 Auxiliary Loads ............................................................................................................................... 8 20.7.2 HVAC System .................................................................................................................................. 8 20.7.3 Dead Battery Operation ................................................................................................................. 9 20.7.4 Shop Power .................................................................................................................................... 9 20.7.5 Auxiliary Inverters .......................................................................................................................... 9 20.7.6 Low-Voltage Power Supply ............................................................................................................ 9 20.7.7 Propulsion System.......................................................................................................................... 9 20.7.8 TWC System ................................................................................................................................... 9 20.7.9 Vehicle Network and MDS ............................................................................................................. 9 20.8 Testing ..................................................................................................................................... 10 20.8.1 General ......................................................................................................................................... 10 20.8.2 Component Type Test - OESS....................................................................................................... 10 20.8.3 System Type Test - Combined Propulsion and OESS ................................................................... 10 20.8.4 Component Routine Test – OESS ................................................................................................. 10 20.8.5 Vehicle-Level Type Dynamic Tests at the Owner’s Facilities ....................................................... 10 20.8.5.1 General.................................................................................................................................. 10 20.8.5.2 Test Setup ............................................................................................................................. 10 20.8.5.3 OESS Type Test...................................................................................................................... 10 20.8.5.4 EMI/EMC - Radiated Emissions Test ..................................................................................... 10 20.9 System Support ........................................................................................................................ 11 20.9.1 Manuals, Catalogs, and Training .................................................................................................. 11 20.9.2 Spare Parts ................................................................................................................................... 11 20.10 Contract Data Requirements List (CDRL) .................................................................................. 11 LTK Standard Streetcar Specifications Section 20 ii January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.1 General 20.1.1 OESS Description Provide onboard power for all vehicle functions and operation during wireless operations. OESS configurations: 1. Provide minimum two independent OESS assemblies with the combined capability of operating the vehicle as specified in this Section. Alternative, functionally independent, redundant, design maybe proposed for review and approval by the owner. a. Provide minimum one OESS assembly per powered truck. b. Split auxiliary loads between the two OESS units. 2. The energy storage device may be composed of capacitors, battery cells, or a combination of the two, arranged to produce a high-voltage storage device. Liquid, flywheel or gaseous fuel-base systems are prohibited. 20.1.2 System Capacities Determine and provide OESS energy storage capacities as follows: 1. Initiate wireless operation at the beginning of each wireless segment described below with an OESS that is no more than 80% fully charged. 2. Provide energy capacity in the OESS equivalent to twice the energy necessary to operate once on each segment under the defined operating conditions, plus sufficient reserve to remain above the recommended minimum state of charge (SoC). 20.1.3 Standards Compliance The OESS shall comply with requirements of NFPA 130, and material, mechanical and electrical requirements specified elsewhere. 20.1.4 Installation Comply with the following: 1. Location: a. OESS assemblies shall be installed on the roof of the vehicle. Consideration may be given to underfloor installations, subject to demonstration of safety under impact with rail vehicles and automobiles or other road vehicles. b. No OESS storage devices, HV components, or HV wiring shall be installed within the passenger or cab compartments. 2. Environment: All installations shall provide protection from damage from worst-case ambient conditions, including heavy wind-blown rains, and the Owner’s vehicle wash facilities and wash materials, as specified in Section 2, Design and Performance Criteria. 3. Structure: Comply with the equipment load requirements in Section 3. 20.1.5 Service Life The OESS energy storage devices shall have a minimum life of eight six years, under the defined operating conditions. LTK Standard Streetcar Specifications Section 20 1 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.2 Wireless Segments The operating alignment will be provided with an OCS except for the segments described in Section 2 as wireless. Assume there will be charging power available from the OCS at both ends of each wireless section, and for sufficient duration to fully recharge the OESS. 20.2.1 Operating Conditions Meet all defined requirements under the following operating conditions: 1. Stops in wireless segments: a. Each traffic light: 20 seconds; assume the vehicle stops at all traffic lights. b. Each station: 30 seconds. 2. Layover at each terminus: 10 minutes, during which time charging of the OESS is available from an OCS wire. 3. Normal vehicle functions and performance in accordance with the Specifications, except as may be altered in this Section. 4. Reduced HVAC performance in passenger areas, as specified below. 5. Worst case ambient conditions. 6. OESS at worst case life condition. 20.3 Performance Requirements When operating under OESS, specific vehicle performance parameters may be modified as indicated. 20.3.1 Speed OESS vehicle design speed: Minimum 48 km/h (30 mph). 20.3.2 Acceleration When operating from the OESS, the instantaneous acceleration rate with the MC in the maximum power position shall be as shown below: 1. Vehicle weights from AW0 to AW2: Acceleration rate at MC Max Power: 1.34 m/s², +/- 5% from 0 to 2014 km/h (12 9 mph) Time to reach 32 km/h (20 mph) from 0 km/h: less than 8 10 seconds Time to reach 48 km/h (30 mph) from 0 km/h: less than 15 20 seconds 2. Vehicle weights greater than AW2: Acceleration may be reduced in direct proportion to the ratio of AW2 weight/actual vehicle weight. 20.3.3 Braking Provide normal service braking and emergency braking in accordance with the Specifications, except that top speed may be limited as specified in the Speed section, above. LTK Standard Streetcar Specifications Section 20 2 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.3.4 Duty Cycle 20.3.4.1 Normal Duty For the normal duty cycle specified in Section 2, Design and Performance Criteria, include energy storage device charging over OCS track segments and OESS operation over wireless track segments. 20.3.4.2 Thermal Capacity The peak and continuous thermal rating of all OESS components shall not be exceeded under all operating conditions defined in this Section, and in Section 2. 20.4 Charging and Discharging 20.4.1 Voltage Range Equipment shall operate over these voltage ranges without damage, failure of the equipment to function as specified, or reduction of required service life. 1. Charging: When connected to an active OCS, the OESS shall operate over the OCS range specified in Section 2, Design and Performance Criteria. 2. Discharging: When the OESS is providing power to the vehicle, the primary input source will be defined by the OESS design but the operating voltages must be within the normal OCS range specified in Section 2. 20.4.2 Charging Comply with the following: 1. The OESS shall charge as follows: a. Connected to the OCS: At all times, including when both cabs are OFF. b. In wireless segments: Whenever the vehicle is in regenerative braking. 2. The OESS shall be capable of being charged within a maximum of 10 minutes, without a reduction in service life, as follows: a. Starting SoC: 80% b. DOD: Vehicle completes a single trip on the defined wireless segments with defined operating conditions. c. OESS charging: To 80% SoC, with all auxiliaries operating, any vehicle mode (stopped, accelerating, or decelerating), and connected to the OCS with a voltage range of 600 Vdc to 925 Vdc. 3. For SoC conditions greater than above and a moving vehicle, recharge times may be extended as approved. 4. For a stationary vehicle, automatically limit pantograph currents to protect the pantograph and OCS contact wire. 20.4.3 Discharging The OESS shall discharge energy only to its local vehicle circuits. Provide equipment to automatically prevent OESS discharge to the OCS when the pantograph is raised, or to the Shop circuits via the Shop connector. LTK Standard Streetcar Specifications Section 20 3 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.5 Controls and Indications 20.5.1 Interlocks Provide a pantograph interlock function that allows off-wire operation only when the pantograph is in a fully stowed position. 20.5.2 Automatic Operation Provide automatic control to transition in and out of wireless segments, at speed, without operator intervention: 1. Communicate with the GPS and/or TWC systems at locations along the right-of-way that define the wireless segment(s). (see Section 13, Vehicle Communication Systems for GPS and TWC requirements). 2. Provide controls to automatically initiate and terminate off-wire operation, including lowering and raising of the pantograph, at speed. 3. Provide controls and interlocks to manage vehicle equipment loads and pantograph currents during on- and off-wire transitions, such that no equipment damage or loss of life occurs. 4. Coordinate with owner for preferred location of wayside TWC loops, and signal coding. 20.5.3 Manual Operation 20.5.3.1 Wireless-Operation Switch Comply with the following: 1. Purpose: To permit manual control of wireless operation by the vehicle operator, in the event that automatic operation malfunctions, or wireless operation is required at other locations. 2. Type: Momentary pushbutton. 3. Location: Cab Console, adjacent to the Pantograph Up/Down switch(es). 4. Function: a. Active at all times when a cab is keyed on. b. Initiates and terminates off-wire operation, including lowering and raising of the pantograph. c. Manages vehicle equipment loads and pantograph currents during on- and off-wire transitions, using controls and interlocks as specified above for automatic operation. 20.5.3.2 Pantograph-Down Bypass Switch Comply with the following: 1. Purpose: To bypass pantograph interlock and allow off-wire operation of the vehicle in the event that the pantograph is damaged and a pantograph-down signal is not present. 2. Type: Momentary pushbutton, sealed. See general requirements for bypass switches in Section 5, Operator’s Cab and Controls. 3. Location: Bypass/Aux Switch control panel (see Section 5). 4. Function: Bypasses the pantograph-down interlock, which prevents wireless operation unless the pantograph is down, and allows wireless operation to be initiated with the manual wireless operation switch. LTK Standard Streetcar Specifications Section 20 4 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.5.3.3 Load Shedding Switch Comply with the following: 1. Purpose: To allow manual load shedding for situations where the vehicle is expected to be stuck in a wireless segment for an extended period of time with passengers on board, such as a serious car accident or traffic jam. 2. Type: Momentary pushbutton, sealed. See general requirements for bypass switches in Section 5, Operator’s Cab and Controls. 3. Location: Bypass control panel (see Section 5). 4. Function: Initiates a pre-defined load shedding scheme as approved by the Owner. 20.5.4 Isolation Comply with the following: 1. Segregate OESS equipment and controls such that failures within one OESS unit can be isolated from, and not affect or prohibit operation of the remaining OESS units. 2. Upon isolating an OESS unit, at least one-half the total installed OESS capacity shall remain available, permitting continued operation with remaining OESS equipment at reduced performance and range. 20.5.5 Emergency Disconnect Switch Provide a switch on the exterior of the vehicle, at ground level, to disconnect all OESS units from vehicle circuits: 1. The switch may control remote circuit breakers, contactors, or similar devices. Rate all such devices to safely interrupt OESS currents and voltages. 2. Location of switch to be determined jointly with the Owner during design reviews. 3. May be integrated into the Vehicle Battery ground level disconnect, such that a single action disconnects both systems. See Section 9, Electrical Equipment. 20.5.6 Shop Disconnect Switch Provide a manually operated two-pole switch at each OESS: 1. Disconnect all energy storage devices, including the Battery Management System from vehicle circuits. 2. Disconnect both positive and negative OESS circuits from vehicle circuits. 3. The positive terminal shall break before the negative terminal. 4. Arrange the switch mechanisms such that the negative terminal cannot be opened without the positive terminal being open. 5. Include provision for tag ID and lock out. 20.5.7 OESS Cab Controls and Indications Provide the following controls and indications on the Cab Console in each cab, in addition to those specified in Section 5, Operator’s Cab and Controls: 1. OESS HSCB Reset Switch: a. Type: Momentary pushbutton b. Purpose: To reset the OESS HSCB, if one is provided separate from the propulsion HSCB. See Section 9, Electrical Equipment, for propulsion HSCB. LTK Standard Streetcar Specifications Section 20 5 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 2. OESS Isolation Switch: a. Type: Sealed rotary or toggle switches, one per OESS unit. b. Purpose: Isolate an OESS unit from vehicle circuits, permitting continued operation with the remaining OESS(s). c. Location: Off the console with other cab cutout switches 3. Indications on the TOD: a. Wayside transition command received. b. Wireless operation mode. In addition, provide a continuous display in the Discrete Indicator Group specified in Section 5, Operator’s Cab and Controls. c. OESS State of Charge: Indicate each OESS capacity as a percentage of maximum capacity. d. OESS Conditions Warnings: Flashing and colors, indicating OESS faults, SoC at unacceptable levels, and similar abnormal conditions. e. OESS HSCB Open/Closed, if one is provided separate from the propulsion HSCB. 4. OESS SoC Low Level Audible Alarm: Include in the audible alarms that are acknowledged by the sealed Audible Alert Bypass switch located in the Bypass Control Panel. See Section 5. 20.5.8 OESS Load Management Control Provide an OESS load management control function to perform the following: 1. Interface with the propulsion and auxiliary loads. 2. SoC Low: Provide load shedding for non-essential loads, with low SoC as defined by the OESS manufacturer and approved by the Owner. The SoC level setting for load shedding shall be user adjustable. 3. SoC Critically Low: Provide load shedding for all loads except those needed to move the vehicle, with critically low SoC as defined by the OESS manufacturer and approved by the Owner. 4. Integrate with the propulsion system logic or the vehicle control unit (VCU) (see Section 10, Propulsion System and Control, or Section 17, Electronic Controls, Software, and MDS). 20.6 OESS Components The OESS shall include the following: 1. Pantograph interlock: Such that high-voltage power draw is terminated, or reduced to safe levels, before the pantograph is lowered. 2. Bi-directional converter: a. To charge the energy storage device and control energy storage power flow to the propulsion system and auxiliary loads. b. May be integral to the propulsion inverter package. c. May be packaged with and share components with the propulsion system. d. Alternative converter designs may be proposed, subject to the Owner’s review and approval. LTK Standard Streetcar Specifications Section 20 6 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 3. Energy Storage Devices: a. Batteries: • • Permitted: No maintenance, nickel metal hydride (NiMH) or lithium-ion (Li-Ion) type, railway or transit quality, service proven in similar applications. Prohibited: Lithium-cobalt-oxide and lithium-sulfur-dioxide type. b. Capacitors: High-current, high-capacity cells, of service proven railway or transit quality. 4. Storage Device Enclosure: a. Type: Sealed, non-combustible enclosure, temperature-controlled with integral or external cooling system. b. Fire Resistance: Designed and constructed to contain battery fire without failure of enclosure. c. Material/Coatings: Selected to withstand spilled battery cell electrolytes. d. Maintenance: Provide access to service the devices and cooling systems e. Cooling Systems: • • Liquid cooling: Use non-leaking quick disconnects to isolate the cooling system from the storage assembly. Air cooling: Use baffles and filters to exclude contamination. Filter shall not require replacement more frequently than 6 months. Loss of air flow shall be detected and announced to the MDS. f. Prohibited: Circuit breakers shall not be installed in OESS battery enclosures, or within assemblies that may enclose the OESS battery enclosures, regardless of ventilation methods. g. Graphics: Provide clear indications of the presence of lethal high voltage; and instructions and warnings on opening the enclosure, and breaking/making electrical and cooling connections. 5. Battery Management System: a. Monitor individual cell states. b. Apply charging regimes as appropriate for cell charge states, providing specified performance and OESS life. c. Provide cell balancing for series-connected cells. d. Prevent damage to cells due to too high or low charge in specific cells. e. Provide state of charge for indication in the cab via the MDS. f. Detect and announce failed cells, and cells with pending failures to the cab, and to MDS. g. Provide remaining life expectancy calculations based on actual usage and duty to the MDS. h. OESS power control switches: Provide high-voltage solid state switches for connecting OESS power to vehicle circuits. High voltage dc contactors may be employed for this function, subject to approval. See Emergency Disconnect Switch section, in this Section, above. 6. HSCB: a. Function may be combined with the propulsion system HSCB. LTK Standard Streetcar Specifications Section 20 7 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) b. If independent of the propulsion system HSCB, install in the high-voltage connection to the energy storage system. c. Automatic reset logic: Coordinate with the primary HSCB in order to maximize vehicle availability and enhance performance and operation capabilities. 7. Circuit protection: a. Provide high-voltage fuses in the positive and negative circuits for each OESS. Arrange circuitry such that fuses can be replaced safely by opening the OESS Shop Disconnect Switch. b. Install in series with both the positive and negative terminals of the energy storage device. 8. Ground fault detection circuits: a. To monitor the OESS for ground faults, including between energy storage cells. b. Upon detection of a fault, open OESS power control switch, as defined above. 9. Cabling and connectors: a. Provide keyed connectors for all external connections into the OESS storage device enclosure. b. Connector and keying design shall not permit cross-polarity connection of OESS power cables. 10. Temperature controls and forced ventilation equipment: a. To control the energy storage device cell temperature. b. To keep the cells at optimum temperature for capacity and long life. 11. Fire alarm system: a. For heat and smoke detection. b. Trip the OESS circuit breaker upon detection of excessive heat or smoke, and announce to the MDS. c. Temperature setting as recommended by the OESS manufacturer. 20.7 Coordination and Integration with the Vehicle 20.7.1 Auxiliary Loads When both cabs are keyed off in OESS mode, shut down all vehicle systems and modify the following modes that may keep the auxiliary system energized: 1. Hotel Load timer: Go immediately to Delayed Off. 2. Auxiliary On/Off switch: Disable. 3. HVAC layover mode: Disable. 20.7.2 HVAC System The following reduced performance is permitted in passenger areas under these specified conditions: 1. Ambient temperatures between 20 – 28 degrees C (68 – 80 degrees F): Maintain interior temperatures as defined in Section 7 Cooling Design Criteria. LTK Standard Streetcar Specifications Section 20 8 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 2. Ambient temperature above 28 degrees C (80 degrees F): Maintain interior temperatures at least 2 K (4 degrees F) below the ambient temperature. 3. Ambient temperature below 20 degrees C (68 degrees F): Maintain interior temperatures between 16 degrees C and 18 degrees C (61 degrees F and 64 degrees F). 20.7.3 Dead Battery Operation All vehicle systems shall start automatically, and function as specified, whenever there is highvoltage dc available at the pantograph or via the OESS, regardless of the charge state of the backup battery. 20.7.4 Shop Power Provide equipment and controls for charging the OESS when under Shop power: 1. Prevent OESS charging when the Shop Switch is in Shop mode (see Section 9, Electrical Equipment). 2. Include a fourth position on the Shop Switch, Shop + OESS, which allows OESS charging in addition to Shop mode vehicle loads. 3. Manage OESS charge rates to conform to Shop power limitations. See Section 9 for Shop power and Shop Switch requirements. 20.7.5 Auxiliary Inverters The inverters may shut down as specified in Section 9, Electrical Equipment, or when the OESS SoC is below the recommended minimum. Indicate all such events to the MDS. 20.7.6 Low-Voltage Power Supply The LVPS and battery charging shall be activated automatically as specified in Section 9, or when OESS voltage is present. 20.7.7 Propulsion System The propulsion system shall allow the vehicle to operate using power provided by the OESS: The OESS may be integrated into the propulsion system and may share control logic and power components as appropriate for the application. 20.7.8 TWC System Provide the following communication regarding the OESS via the TWC system: 1. From vehicle to wayside: Wireless or On-Wire operation. 2. From wayside to vehicle: Wireless segment. 20.7.9 Vehicle Network and MDS Provided interfaces and software to integrate the OESS into the vehicle networks, such that OESS status, diagnostics, failure reporting, and logging function in the same manner as other vehicle systems. Provide local network ports for OESS for diagnostics and data retrieval, as specified in Section 17, Electronic Controls, Software, and MDS. LTK Standard Streetcar Specifications Section 20 9 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.8 Testing 20.8.1 General Comply with the general testing requirements in Section 15, Testing, and perform the tests specified in this Section. 20.8.2 Component Type Test - OESS Perform a type test on a production unit, including all parts of the OESS as specified in this Section. 1. Base the test on the "Type Test" requirements of IEC 61287-1. 2. The test shall confirm compliance with all aspects of the specified design requirements, environmental ranges, and supply voltages. 20.8.3 System Type Test - Combined Propulsion and OESS Perform laboratory test of the OESS combined with the Propulsion System Type Test specified in Section 15: 1. Include OESS with all aspects of the test. 2. The test shall demonstrate that the propulsion and OESS function properly and meet specified requirements before installation on the vehicle. 20.8.4 Component Routine Test – OESS Perform a routine test on each onboard energy storage system in accordance with IEC 61287-1 or IEEE Std 16 to verify compliance with the Specifications. Test insulation per the Insulation Testing section in Section 15. 20.8.5 Vehicle-Level Type Dynamic Tests at the Owner’s Facilities 20.8.5.1 General Test the OESS as part of the vehicle-level type dynamic tests at the Owner’s facilities specified in Section 15, complying with OESS-specific requirements specified below. Submit test procedure and test report under Section 15. 20.8.5.2 Test Setup Include the following channel assignments for OESS: 1. OESS voltage and charge level (percentage of charge) 2. OESS current 20.8.5.3 OESS Type Test Monitor the OESS operation during all vehicle dynamic testing. Conduct additional test runs as needed to confirm compliance with the specified requirements. 20.8.5.4 EMI/EMC - Radiated Emissions Test Include OESS in testing of all onboard systems that may produce radiated emissions. Include OESS charging. LTK Standard Streetcar Specifications Section 20 10 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20.9 System Support 20.9.1 Manuals, Catalogs, and Training Comply with the general requirements for maintenance training in Section 18, System Support, and include OESS in the specified manuals and in-depth instruction. 20.9.2 Spare Parts In addition to the requirements of Section 18, comply with the following OESS-specific requirements: 1. For components or assemblies that cannot be stored at the Owner’s facilities as long term spare parts, provide long term commercial and contractual arrangements, with qualified suppliers, for prompt delivery of 100% compatible replacement units (Buy America issue). 2. Provide, or arrange for, removal and disposal of failed or expired components, in compliance with applicable environmental laws. 20.10 Contract Data Requirements List (CDRL) Submit the following in accordance with Section 19, Program Control and Quality Assurance: 20-1 OESS Design Package: 1. Submit under this Section. 2. Narrative on the overall OESS, including a brief description of each specified component and how it is implemented, with sufficient detail to demonstrate that all specified requirements are satisfied 3. Details of interfaces with propulsion and braking systems 4. Data sheets on specified components, including part numbers and ratings 5. Description of how the equipment operates under extreme conditions and faults 6. Description of how OESS capacities vary between new, and near end of life 7. Recommended minimum SoC, including justification for the recommendation 8. Description and data on reduced vehicle performance characteristics, including tractive effort vs speed vs dc link voltage over the range of OESS voltages 9. Description and data on HVAC reduced performance modes, and anticipated interior temperatures 10. Ratings sheets 11. Software descriptions 12. Design description for raising and lowering the pantograph before and after operation on wireless segments 13. Description of OESS charging strategy. 14. Description of the methods used to validate and confirm the performance of the proposed OESS. 15. Description of prior deployments or bench/road test history with the proposed system. Include the following as a minimum: a. b. c. d. e. Evaluation of ability to meet duty cycle Vehicle efficiency Battery state of charge Vehicle acceleration Length and slope of alignment grades LTK Standard Streetcar Specifications Section 20 11 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 16. Drawings: a. Electrical schematics b. Assembly drawings c. Plan view and cross section drawings of energy storage device and enclosure. 17. Calculations: a. Load analysis, including peak and rms current at ambient temperatures of -10 degrees C (14 degrees F), 25 degrees C (77 degrees F), 40 degrees C (104 degrees F), and 50 degrees C (122 degrees F) while powering the vehicle on the alignment duty cycle. b. Battery state of charge profile while completing the route alignment at AW0, AW1, AW2, amd AW3. c. Worst case maximum charging rates while dwelling in stations or other points where the vehicle is stopped, and while in motion. Submit in a timely manner to allow for coordination with OCS design. 18. Dynamic simulations of the vehicle operating on the indicated alignment: a. Provide speed, time, distance, total vehicle power demands, OESS charge and discharge rates, and OESS charge states and voltage levels. b. Assume worse case ambient conditions, and the end of life OESS characteristics if worse than new. c. Use 1 second or less simulation time steps. 20-2 OESS Thermal Capacity Calculations: 1. Submit with Thermal Capacity Calculations under Section 2, Design and Performance Criteria. 2. Temperature predictions (or actual test results) for OESS energy storage device. 20-3 OESS System Performance: 1. Submit with Propulsion System Performance under Section 10, Propulsion System and Control. 2. Tractive effort curves at minimum, nominal, and maximum energy storage device voltages at AW0, AW1, AW2, and AW3. 3. Speed/time/distance curves and state of charge profile for motoring and braking at the nominal energy storage device voltage at AW0, AW1, AW2, and AW3 for the normal duty cycle. 20-4 Component Type Test – OESS: A. Comply with requirements of Section 15, but submit under this Section. B. OESS Type Test Procedure: 1. Step-by-step procedures that demonstrate compliance with the testing requirements of this Section. 2. Include testing of the proposed energy storage device. C. OESS Type Test Report: 1. Include sufficient test data for each test to demonstrate compliance with the Specifications. LTK Standard Streetcar Specifications Section 20 12 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services Center City Connector Project Onboard Energy Storage System (OESS) 20-5 System Type Test – Combined Propulsion and OESS Type Test: A. Submit test procedure and test report under Section 15 as part of System Type Test titled “Propulsion Type Test,” but revise CDRL title to “Combined Propulsion and OESS Type Test.” B. Test Procedure: Include step-by-step procedures that demonstrate compliance with the testing requirements of this Section. C. Test Report: Include sufficient test data for each test to demonstrate compliance with the Specifications. 20-6 Component Routine Test – OESS: 1. Add testing of each OESS to component routine tests specified in Section 15. 2. Test insulation per the Insulation Testing section in Section 15. 3. See Section 15 for Component Routine Test submittal requirements. 20-7 Vehicle-Level Routine Test – OESS (Contractor’s Facilities): 1. Submit test procedure and test report under Section 15 as part of vehicle-level routine test CDRLs specified in Section 15. 2. Include OESS in vehicle-level systems routine functional tests. 3. Include OESS equipment enclosures in water-tightness routine tests specified in Section 15. 20-8 Vehicle-Level Type Dynamic Test – OESS (Owner’s Facilities): A. Submit test procedure and test report as part of vehicle-level type dynamic test CDRLs specified in Section 15. B. Test Procedure: Add testing of the OESS to vehicle-level type dynamic tests specified in Section 15. C. Test Report: 1. Include results of monitoring performed during dynamic testing. 2. Include results of additional testing done to confirm compliance with specified requirements. 20-9 Vehicle-Level Routine Dynamic Test – OESS (Owner’s Facilities): 1. Submit test procedure and test report as part of Vehicle Performance Test on Project Alignment CDRL specified in Section 15. 2. Add testing of the OESS to test titled “Vehicle Performance Test on Project Alignment” specified in Section 15. END OF SECTION LTK Standard Streetcar Specifications Section 20 13 January 30, 2017June 7, 2017 © 2016-2017 LTK Engineering Services