Regional Connector Transit Corridor Project SECTION 34 42 16.13 TRAIN CONTROL INTERIOR WIRE 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 Copper 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 TRAIN CONTROL INTERIOR WIRE AND CABLE ISSUED: 05/22/13 Metro C0980 34 42 16.13 - 1 Regional Connector Transit Corridor Project DOD MIL-STD-202 Test Methods for Electrical and Electronic Component 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. TRAIN CONTROL INTERIOR WIRE AND CABLE ISSUED: 05/22/13 Metro C0980 34 42 16.13 - 2 Regional Connector Transit Corridor Project 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. TRAIN CONTROL INTERIOR WIRE AND CABLE ISSUED: 05/22/13 Metro C0980 34 42 16.13 - 3 Regional Connector Transit Corridor Project 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) TRAIN CONTROL INTERIOR WIRE AND CABLE ISSUED: 05/22/13 Metro C0980 34 42 16.13 - 4 Regional Connector Transit Corridor Project 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 TRAIN CONTROL INTERIOR WIRE AND CABLE ISSUED: 05/22/13 Metro C0980 34 42 16.13 - 5 Regional Connector Transit Corridor Project 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 twisted pair(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 wires. 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.