Regional Connector Transit Corridor Project

SECTION 34 42 16.13

TRAIN CONTROL INTERIOR AND CABLE

PART 1 - GENERAL

1.1 SUMMARY

The Work in this Section consists of furnishing, installing and terminating wire and cable for use inside Train Control rooms and wayside instrument enclosures (bungalows and cases, if provided) installed within the limits of this project. Intra-rack and rack-to-rack wire, cable and terminations shall conform to the requirements of this Section.

1.2 QUALITY CONTROL

A. Comply with Section 01 43 10, Project Quality Program Requirements – Design/Build.

B. The manufacture, test, and installation of wire and cable shall comply with applicable quality assurance provisions of the military and industrial specification referenced for each type of wire.

1.3 REFERENCES Organization Number Title AREMA Part 10 Communications and Signals Manual ASTM A167 Stainless Steel ASTM B3 Soft or Annealed Wire ASTM B33 Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B189 Lead-Coated and Lead-Alloy Coated Soft Copper Wire for Electrical Purposes ASTM D3159 Modified ETFE – Flouropolymer Molding and Extrusion Materials ICEA S-85-625 Polyolefin Insulated Communications Cable - Outdoors IEEE 383 Type Tests of Class 1E Electrical Cables, Field Splices, and Connections for Nuclear Power Generating Stations. DOD MIL-I-45208A Inspection System Requirements

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DOD MIL-STD-202 Test Methods for Electrical and Parts DOD MIL-STD-454 General Requirements for Electronic Equipment DOD MIL-STD-1916 Preferred Methods for Acceptance of Product DOD MIL-W-81044 Wire, Polyalkene Insulation, Crosslinked DOD MIL-W-81822 Solid Conductor Wire NEMA WC 70 Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy

1.4 SUBMITTALS.

For submittal procedures refer to Section 01 33 00 - Submittal Procedures.

A. Cable Qualification Data - Submit technical data describing each type of interior wire and cable that the Contractor proposes. The data shall be sufficient to ensure that the cable complies with the requirements of these Specifications. The submittal shall include evidence that the flame test requirements, specified herein, are satisfied.

B. Connector and Terminal Block Qualification Data - Submit technical data describing each type of terminal block and/or connector to be used. The submittal shall identify the application for which the connector is to be used. Connector technical data shall include: 1. Molded connector blocks 2. Protective shells for blocks 3. Locking and keying devices 4. Strain-relief clamping devices 5. Extractable pin-and-socket contacts (if applicable) 6. Special terminal insertion or extraction tools 7. Manufacturer's part numbers

C. Solderless Wire Terminals - Submit product data for terminals and manufacturer recommended crimping tools to Metro. The submittal shall include a sample board made up of samples of the different types and sizes of terminals.

1.5 DELIVERY AND STORAGE

A. Shipping Lengths - Cable shall be furnished in lengths suited to the installation. All cable shall be shipped on reels, adequately protected from damage in shipment by heavy wrapping or wood lagging.

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B. Reel Design - Each length of cable shall be wound on a separate reel. Reels shall be substantial to withstand reasonable handling and shall be so designed that the inner end of the cable shall be accessible but protected from injury. The diameter of the drum shall be of sufficient diameter to prevent damage to the cable during reeling.

C. Cable Winding on Reels - Both ends of the cable shall be accessible and sealed to prevent the entrance of moisture and securely fastened so that they will not become loose while in transit.

D. Reel and Cable Information - Each reel shall contain on the outside flange, plainly legible and weather resistant, information to show the manufacturer's name, purchase requisition number, lengths of each section of cable, number of conductors, gauge of conductors, and the name and address of the consignee.

E. Each reel of cable shall be inspected by the Contractor at time of delivery to ensure that no physical damage occurred during shipment, and that the reel covering and cable seals are not missing or damaged. A copy of these inspection reports shall be submitted to Metro.

PART 2 - PRODUCTS

2.1 STRANDED WIRE FOR GENERAL USE

A. Design Requirements - Stranded wire shall meet the following requirements: 1. Conductor - Stranded soft annealed copper, ASTM B3-01. 2. Coating - Tin or lead, ASTM B33 or B189. 3. Insulation - Ethylene Tetrafluoroethylene (ETFE) per ASTM D3159-91a, or cross-linked Polyalkene per MIL-W-81044. 4. Construction - see Table 1. 5. Performance - see Table 2.

B. Identification - Mark each stranded wire at maximum intervals of 3 feet with the following information: 1. Manufacturer's name 2. Size of conductor 3. Type of insulation

C. Flame Test – Single Conductors. Single conductor cables and individual conductors of multiconductor cables shall pass the vertical tray flame test in accordance with IEEE Standard 383.

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TABLE 1 STRANDED WIRE CONSTRUCTION DETAILS Conductor Conductor Stranding Max. Diameter Resistance Wire Size (Number of Strands x Stranded Max. @ 20°C (AWG) AWG Gauge of Strands) Conductor (in.) (ohm/1,000 ft) 20 19 x 32 0.041 9.8 18 19 x 30 0.051 6.2 16 19 x 29 0.058 4.8 14 19 x 27 0.073 3.1 12 37 x 28 0.090 2.0 10 37 x 26 0.114 1.3 8 19 x 7/29 0.173 0.70

TABLE 2 PHYSICAL AND ELECTRICAL REQUIREMENTS FOR STRANDED WIRE Per Type of Insulation CROSS-LINKED SPECIFICATION ETFE POLYALKENE NOTES ASTM D3159 MIL-W-81044-12 Nominal Wall Thickness 15 mil 7.5 mil Size 22-12 AWG Nominal Wall Thickness 17 mil 15 mil Size 10-8 AWG Temperature Rating 150°C 150°C Blocking (Qualification) 200°C 200°C Color Contractor Option Flammability Pass Pass per IEEE 383 Identification 36-in. intervals max. Reels per 1.5 D Identification, Striping, or 125 cycles Printing Durability (250 strokes min.) with 500-g weight Life Cycle Oven temp. 200 oC for Dielectric Test 168 hr, 2,200 V rms (60 Hz) Accelerated Aging 7 hr at 210°C 7 hr at 210°C (Quality Conformance Test, Group II; Procedure as in Life Cycle Test)

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CROSS-LINKED SPECIFICATION ETFE POLYALKENE NOTES Physical Properties of Insulation Tensile Strength lb/in.² 5,000 2,500 (minimum) Elongation % (min.) 150 150 Shrinkage at 180±2 oC, in. 0.125 0.125 (max) AWG 30 - 16

Shrinkage at 180±2 oC, in. 0.250 0.250 (max) AWG 14 - 6

Smoke 200°C 200°C Cold Bend -65°C -65°C Wrap Test (Size 20 AWG 2 hr at 200°C - Mandrel diameter 0.125 wire) no cracks in. - no cracks Dynamic Cut Through 90 90 lb (minimum at 23°C with size 20 AWG Abrasion Resistance Same as initial After Immersion Humidity Resistance IR after exposure shall meet initial requirements Voltage Rating 0 - 600 V rms 0 - 600 V rms Impulse Dielectric Test 6.5 kVAC 6.5 kVAC peak (100%) peak

Insulation Resistance 5,000 Mohm per 100 ft (minimum) Surface Resistance 500 500 Mohm/in. (minimum) Initial and Final Wet Dielectric Test 2,500 2,500 V (rms)

* As required by these specifications

2.2 MULTICONDUCTOR CABLE

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Multiconductor cable shall consist of individual or twisted pairs of stranded, insulated conductors bundled in cylindrical form using non-hydroscopic, flame-resistant fillers and tape, with the jacket fitting tightly to form a firm assembly.

A. Assembly - Assembly of multiconductor cables shall conform to the AREMA Signal Manual, Part 10.3, except as otherwise specified herein. Individual conductors or (s) shall be assembled into a tight, cylindrical form. Assemble individual or twisted pairs helically and with adjacent layers wound in opposite directions. The lay of a twisted pair shall be 1-1/2 inches +/- 1/2 inch maximum. Where shielded cable is required, provide braided shields of aluminum or copper.

B. Binder Tape - Helically apply fabric or mylar tape with a minimum of 25 percent lap over the layer to serve as a binder to each layer of two or more . Provide tape of a thickness not less than 0.005 inches and compatible with the other materials in the cable.

C. Conductor Size - Provide a minimum conductor size of 20 AWG.

D. Jacket - Provide jacket with an average thickness not less than the given value. The minimum thickness shall not be less than 80 percent of the value given below. Diameter of Cable Core Jacket Thickness (inches) (inches) Zero to 0.250 0.020 0.251 to 0.425 0.025 0.426 to 0.700 0.030 0.701 and larger 0.045

E. Flame Test - Multiconductor cables shall pass the vertical tray flame test as detailed in IEEE Standard 383. Maintain circuit integrity for five minutes minimum during the test.

F. Identification - Identify each cable conductor with number or color if cables are terminated with connectors. For cables not terminated with connectors, each cable conductor shall be color coded. 1. Color code stranded wires in multiconductor cable in accordance with ICEA S-56-434. 2. Mark the cable outer sheath with the following information repeated at intervals no greater than 36 inches:

a) manufacturer's name b) year of cable manufacture c) number and size of conductors

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d) type of insulation on conductors e) type of jacket insulation f) voltage rating

2.3 SOLID WIRE FOR WIREWRAP

A. General - Use solid wire only for wire wrap applications within modules. Solid wire shall be in accordance with the requirements of MIL-W-81822 where those requirements do not conflict with these specifications.

B. Conductor - Minimum conductor size shall be 26 AWG. Conductors shall be soft annealed copper, ASTM B3 (type A only). Conductors shall be tin coated per ASTM B33.

C. Insulation - Ethylene tetrafluoroethylene (ETFE).

D. Performance - Cable and materials shall meet requirements of Table 3 below.

TABLE 3 PHYSICAL AND ELECTRICAL REQUIREMENTS FOR SOLID WIRE

MIL-Spec MIL-W-81822 Temperature Rating: 200ºC maximum conductor temperature Voltage Rating: 0 - 300 V rms Insulation Tensile Strength: 2,500 lb/in.² (minimum)

Insulation Elongation: 50% (minimum) Color: Contractor Option DC Spark Test 7,000 V dc Insulation DC Resistance: 2,500 Megohm/1,000 ft (minimum) Wet Dielectric Test: 2,000 V rms (60 Hz) Cold Bend Conditioning: 4 hr at -65±2°C Dielectric Test for Cut-Through 500 V rms (60 Hz) and Cold Flow: Insulation Heat Resistance: Conditioning, 120 hr at 275±2ºC; shrinkage, 0.062 in. maximum Dielectric Constant 2.30 maximum at 1 MHz Power Factor 0.005 maximum at 1 MHz Flammability Pass per IEEE 383 Surface Resistance: 500 Megohm (minimum)

2.4 WIRE TERMINATIONS

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Wires shall be terminated with solderless ring tongue terminals for connection to terminal strips or binding posts. Terminals shall be insulated and shall include an insulation grip. Terminals shall be the same as used to terminate exterior wires of the same size. "Flag" terminals may be used in tightly confined areas or crowded terminal blocks. Terminals shall conform to the AREMA Signal Manual, Part 14.1.1.

2.5 CONNECTORS AND TERMINAL BLOCKS

A. Construction - Connector blocks shall be either crimp and insert type or solder type such as AMP M series connector, Amphenol Blue Ribbon, or approved equal. Maximum number of terminal pins per connector shall be 50. Provide connector blocks used for vital circuits with a surface leakage distance of not less than 0.25 inch between the contact and any other contact or metal. Surface leakage distance for non-vital circuits shall not be less than 0.10 inch between the contact and any other contact or metal. Terminal blocks shall be modular with solderless connections of the quick-connect tab, binding post and nut, screw terminal barrier, or wire wrap type. Terminal blocks shall conform to the AREMA Signal Manual, Part 14.1.5.

B. Materials - Metal parts shall be either stainless steel or nickel plated brass.

C. Features - Provide each connector with the following features: 1. Devices for the mechanical locking and keying of the connector halves. 2. A strain relief device for wiring external to a module. When used with a multiconductor cable, it shall grip the cable outer jacket. 3. A shield for each half of the connector which extends beyond the mating surface. 4. Gold plated contacts with a minimum plating thickness of 0.00002 inches. 5. Mechanical devices to allow the connector assemblies to be keyed such that they must be connected in the correct position relative to each other and be connected only to its corresponding receptacle.

D. As an alternate, terminal block for all applications except entrance rack and power bus applications may be channel-mounted type, equipped with spring loaded connectors meeting UL and VDE standards. Terminals of this type shall conform to the AREMA Signal Manual, Part 14.1.2.

PART 3 - EXECUTION

3.1 GENERAL

A. Routing - Install wires and cables according to the following requirements: 1. Lay wires and cables in trays with a minimum amount of crossover in the trays and do not pull tightly around bends.

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2. Protect all exposed wires and cables entering within or leaving equipment racks, equipment, conduit, cable trays or housings from abrasion by sharp metallic edges. Provide grommets or rubber pads where necessary. 3. Wire and cable runs shall be continuous. Splices between wire and cable terminating locations are not allowed. 4. There shall be no point-to-point redundancy of wires for increased current capacity. 5. Leave enough slack in cables and wires at connection points so that the wires or cables can be easily removed, installed or moved at least 6 inches in any direction. Where wire is in a cabinet, provide enough slack so that removable panel or hinged panel can open completely. 6. Group cables and wiring into bundles.

B. Cable Trays - Cables shall be run in cable trays or fastened to struts.

C. Terminations - No more than two wires shall be terminated to connector pins or relay plugboards. Limit terminations on connector posts to three wires per post. Tag all wires according to the requirements of Section 34 42 13.97 – Train Control Marking and Tagging.

D. AC Wiring - Contractor shall provide twisted pair wiring for ac power distribution between racks, rack buses and modules.

E. Wire Size - Contractor shall provide wiring of sufficient size to prevent voltage drop that could affect circuit or equipment operation. The minimum size of the interior wiring shall be as follows:

1. General rack wiring - No. 18 AWG

2. Power distribution wiring - No. 14 AWG

3. Module wiring - No. 26 AWG

4. Track circuits - Multiconductor Twisted Pair (2C) No. 10 AWG minimum, Class C, 1,000 V rated, 5 mil shield, XLPE insulation, ZH-XLPO jacket.. 10 AWG

5. Switch machine power wiring - No. 10 AWG

3.2 RACK WIRING

A. Module Wiring - Wiring to modules shall be terminated by connectors. Power distribution wiring shall be terminated with ring tongue terminals for connection to a terminal post. Track circuit connections shall be terminated with binding post terminals or connectors for vital circuits.

B. Routing - Tie rack wiring into compact bundles. Secure bundles to rack and cable supports to prevent chafing insulation and to prevent wire weight from being supported by the connectors. The arrangement of wire shall not interfere

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with visual inspection of wiring tags, or troubleshooting and repair of rack mounted equipment.

C. Relay Connections - Make wiring terminations to vital relay plugboards using approved crimped or soldered terminals.

3.3 AC POWER WIRING

Use either the 600 Volt cable approved for exterior wiring or use THHW insulated wire for ac power distribution connecting to the electric power panels. Wire size and installation methods shall meet or exceed NEC.

3.4 WALL MOUNTED CONDUIT

AC wiring and ground wiring that requires routing outside the cable tray shall be routed in surface mounted metallic conduits.

END OF SECTION

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