6-275 SECTION 664 – RAILROAD SIGNALS
664.01 DESCRIPTION . This work includes designing, furnishing and installing new railroad -highway
active warning systems with new metered power services, traffic preemption interconnection where indicated on the Plans, and testing of equipment, material, hardware, and all nece ssary appurtenances specified or required to provide a safe and operating automatic highway crossing warning systems (AHCWS) as specified in this section and as indicated on the Plans.
664.02 MATERIALS . Materials shall meet the requirements of the followi ng subsections:
Sand Borrow and Cushion ................................ ................................ ......................... 703.03 Dense Graded Crushed Stone for Subbase ................................ ................................ 704.06 Electrical Conduit ................................ ................................ ................................ ......752.0 6 Automatic Highway Crossing Warning System (AHCWS) ................................ ......781.03
664.03 Submittals .
(a) Pre-Installation Submittals . The following information shall be prepared and submitted for review and approval by the Engineer . Submittals shall meet the requirements of Subsection 105.0 6. (1) Catalog Cut Sheets . Catalog cut sheets and descriptive literature for all material as specified herein. (2) Working Drawings . Working drawings, including, but not limited to, the following:
a.Fabrication drawings for the assembly of automatic highway crossing warning layout, including detailed bills of material. Fabrication drawings shall include detailed drawings of signal masts, cantilever gates, shelters and cases, and their respective foundations.
b.Design calculations in accordance with the AREMA C&S Manual for signal masts, cantilever gates, and their respective foundations.
c.Detai led installation drawings for each layout indicating the location and sizes of the new wiring.
d.Drawings showing the proposed size and equipment layout of the housing, including rack, lighting, convenience outlet arrangement, and exhaust fan mounting and location. 6-276 e. Drawings showing the location, size, and mounting arrangement of the manual control box.
f.Drawings showing the manual control panel face plate configuration, including types of buttons, plugs, levers, terminals, and lights that have been proposed to be furnished.
g.Drawings of the grounding arrangement.
h.Drawings of the battery trays and racks.
i.Drawings of the sizes and types of internal wire that the Contractor proposes to furnish and install.
j.Design drawings showing the control of the specified equipment for each newly circuited location. Design drawings will be used to generate the as -built drawings. As-built drawings shall meet the requirements specified in Subsection 664.03( b)(2).
k.Drawings of each instrument and entrance rack showing the arrangement and description of the mounted equipment and their proposed method of inter - and intra-rack wiring. (3) Test Documentation . Documentation that all required factory tests of s ystems, subsystems, assemblies, subassemblies, and components supplied under the Contract have been performed. All test records shall be submitted to the Engineer before the equipment is delivered to the site. (4) Training Classes . Outline of training clas ses to be given by the Contractor to familiarize railroad maintenance personnel with the initial setup, troubleshooting, and maintenance procedures for any Style C, motion sensor system, or crossing predictor system furnished under the Contract. (5) Manual s. Six installation and maintenance manuals for each type of AHCWS equipment. (6) Vital Signal Cable Pre -Qualification .
a.General Requirements . All cable manufacturers supplying cable for the Contract shall be pre -qualified by the Engineer. The Contractor shall provide all the data required for the Engineer’s evaluation and shall make the arrangements for any required demonstrations and tests. 6-277 b. Qualifications . Qualifications shall be based on the following criteria:
1.Past Performance and Experience . The cable manufacturers must demonstrate previous successful experience in supplying cable to the railway industry for use as vital signal control cables. A list of such installations shall be provided for each cable manufacturer to be considered.
2.Quality Assurance Program . The manufacturer of cables in accordance with the requirements of this specification shall be in compliance with a quality assurance program that meets the intent of ASQ/ANSI/ISO 9001 . Prime concern must be focused on the necessa ry formal assurance requirements to ensure that cable failure cannot be attributed to actions or lack of actions by the manufacturer.
3.Technical Data . The Contractor shall provide full technical data which demonstrates compliance with the requirements of this specification for each specified cable type the Contractor intends to supply.
4.Warranty . The manufacturer shall certify compliance with the following warranty prior to selection:
i.The manufacturer warrants that the design, material, and workmansh ip incorporated in each item of cable shall be of the highest grade and consistent with the established and generally accepted standards for aerial and underground cable for vital railroad signal, communication, and power circuits; and that each such item and every part and component thereof shall comply with this specification. ii. The manufacturer agrees that this warranty shall commence with the acceptance of each item of the cable, whether the defect is patent or latent, and shall continue for a period of two years after initial satisfactory operation of the item or four years after acceptance of the item, whichever is shorter. 6-278 iii. The warranty covering any length of cable that shall be replaced by the manufacturer under the above conditions shall be reinstated for a period of two years, effective as of the day when said replacement is effected. If the failure is found to be of major importance and affects any other item of cable, the reinstatement of the warranty shall then be extended to cover the item so affected as well, and shall start as of the date of such replacement. The warranty reinstatement provided herein shall apply only to the first replacement or repair of any such item and, in the case of failure of major importance, to the first ext ension of the said warranty to said affected items. iv. The foregoing warranties are exclusive and in lieu of all other warranties, written, oral, implied, or statutory (except as to title and freedom from lien). In no event shall the manufacturer be liabl e by reason of breach of warranty for special or consequential damages. (7) Vital Signal Cable Quality Assurance .
a.The Contractor shall submit the following to the Engineer for approval prior to shipment of the cable:
1.List of the cable manufacturer’s railway signal installations.
2.Each cable manufacturer’s quality assurance program.
3.Full technical data for each type of cable which the cable manufacturer intends to supply.
b.The Contractor shall submit two certified copies of the following to the Engineer for approval:
1.Cable test reports for all factory tests.
2.Test reports of cable tests conducted in the field in accordance with the approved testing procedures.
3.Certification that each cable supplied complies with the requi rements of these specifications. 6-279 4. Information to be supplied by certified cable test reports shall include the following:
i.Report number. ii. Date and location of test. iii. Description of test and test conditions. iv. Complete cable or wire descrip tion.
v.Lot, batch, or reel identification number. vi. Quantitative test results. vii. Summary of test results. viii. Information on the components of the cable tested, to include batch numbers and physical and electrical properties. (b) Post-Installation Submittals . Upon acceptance of the AHCWS , the following information shall be prepared and submitted for review and approval by the Engineer . Submittals shall meet the requirements of Subsection 105.0 6. (1) Documentation that all required specified field tests have been performed and that the installed system and equipment has successfully passed the test. All test records shall be submitted to the Engineer upon acceptance of the AHCWS. (2) As-built drawings meeting the following requiremen ts:
a.Drawings shall be provided to the Contractor which are representative only of the general principles and concepts upon which the Contractor shall base the design and location of the proposed system and equipment.
b.Five copies bound in a protective covering of the as -built drawings for the work shall be provided by the Contractor to the Engineer no more than 10 calendar days after the work is complete and in -service. The Contractor shall furnish to the Engineer a copy of the as -built drawings in Mic roStation DGN and PDF format. 6-280 c. Working drawings shall be in accordance with the industry standards for AHCWS circuit design and detail design. Approval of the working drawings shall be at the discretion of the Engineer. The drawings shall conform to t he following:
1.Use of AREMA standard symbols and nomenclature.
2.Conformance with specifications.
3.Logical grouping and arrangement of subject matter.
4.Drawings shall not be crowded or cluttered but shall be arranged for easy reading for troubleshooting and maintenance .
5.Complete, well described circuits shall be shown on each drawing insofar as possible. A minimum of circuit continuations shall be used . When continuations are used, they shall be clear and specific and shall include the identity of the continuation sheet. Circuitry shall be presented on the drawing with a minimum of crossed or offset lines.
6.The arrangement of circuitry shall be in suc h a manner that no more than two wires shall be shown connected to a single terminal or contact pin. A uniform method of 0.10 inch right or left 45° angle, as drawn in the MicroStation DGN file, shall be used to indicate the actual location of double wire connections. Wires shall be shown at the actual point of termination.
7.Circuits shall not be drawn as schematics but shall be drawn to reflect the actual wiring of the circuits.
8.Circuit drawings shall provide sufficient information by means of contact and terminal numbering to easily enable the tracing and testing of such circuits.
9.A minimum distance of 0.40 inches shall be maintained between lines representing circuit wiring. Lettering or printing shall be at least 0.10 inches high. All spacing sha ll be in multiples of tenths of inches.
10.Circuits shall be arranged to geographically match the track layout. 6-281 11. Relay nomenclature shall appear at the top of the contact and at the top of the coil.
12.Local circuits sh all be drawn with relay coils, timers, motors, or other operated devices shown near the right or left border of the drawing wherever practical. Where there is a choice, the right border shall be favored. Contacts in circuits shall be laid out in geographic al succession insofar as possible and practical.
13.Relay contacts shall line up with the controlling coil and other contacts of the same relay insofar as practicable. Different relay contacts and coils shall not line up. Stick contacts shall line up und er the coil of controlling relay.
14.A cover sheet with the name of the crossing, mile post, and DOT number shall be included.
15.An index sheet listing the sheets included in the working drawings shall be included.
16.Track and cable plan showing the proposed crossing layout and cables to field appurtenances shall be included.
d.As-built drawings shall include fabrication drawings as specified in Subsection 664.03( a).
e.The Contractor shall submit with the as -built drawings a detailed bill of materials. This list shall include the part number of all materials used on th e project.
664.04 Delivery, Storage, and Handling .
(a) All equipment shipped within AHCWS shelters shall be properly fastened and braced to prevent damage duri ng transit. Any equipment damaged during transit shall be replaced at no additional cost to the Agency. (b) Batteries shall be shipped wet, filled to the correct level, and in a fully charged state. Each battery shall be equipped with transit plugs or rubb er stoppers to prevent spillage of the electrolyte. Batteries shall be shipped separately from the housings in which they are to be used. (c) Vital relays shall be shipped separately from the wired racks in which they are to be used. They shall be packaged individually, each in a sturdy corrugated cardboard carton with the drawing number of the relay printed on the outside of the carton. Relays shall be stored in a protected area until tested and installed. 6-282 (d) All cable shall be shipped on reels and adequately protected from damage in shi pment, including the hazard of reels moving obliquely against each other, by heavy wrapping or wood lagging. The manufacturer shall also be responsible for any change in the shape of the cable occurring in normal transit which results in an increase in the maximum diameter beyond that specified. The external protective wrapping on reels shall be secured by at least two steel bands to ensure damage -free shipment. (e) Each length of cable shall be wound on a separate reel. Reels shall be substantial to withs tand handling and shall be so designed that the inner end of the cable will be secured and accessible but protected from injury. If the inner end of the cable projects through the flange of the reel, the inner end shall be protected by a suitable cover of metal having rounded ends and sides and securely fastened in place to protect the cable end. Both ends of cable on reel will be secured in place, to prevent their becoming loose in transit or handling of reel. The diameter of the reel drum shall be at leas t 14 times the cable diameter to prevent damage to the cable during reelings. The arbor hole shall admit a spindle 2 -1/2 inches in diameter without binding. The reels shall be designated and constructed as non -returnable when drum size and cable weight and volume permit. The maximum width of the reel shall not exceed 48 inches unless otherwise specified. (f) After passing factory tests, cable shall be effectively sealed against the entrance of moisture. Both ends of each length of cable shall be protected by wrappings of rubber tape and plastic tape, an effective boot taped or sealed into place, or other suitable means approved by the Engineer. The use of friction tape, other than as external mechanical protection over an adequate rubber or plastic tape, wi ll not be accepted. The cable end protection shall be adequate to protect the cable in shipment and prolonged external storage in the weather if not immediately employed without regard to the position of the reel while so stored. (g) Cable shall be closel y and tightly wound, in a uniform manner, in each layer on reels. An arrow shall be painted on one head of each reel pointing the opposite direction from the outer end of the cable with the words “roll this way” employing letters not less than 3/4 -inch hig h and an arrow not less than 6 inches in length and 1/2 inch in width. (h) LED units shall be packaged separately from flashing light units in which they are to be used.
664.05 Design Criteria .
(a) Fail Safe Design Criteria . (1) Vital circuits shall be designed on fail -safe design principles, which is to say that broken wires, damaged or dirty contacts, a relay failing to respond when energized, or a loss of power supply energy shall not result in unsafe conditions. 6-283 (2) Component or system failures whi ch are not self -detecting shall not cause unsafe conditions. Even if added to other failures, any number of simultaneous component or system failures attributable to the same cause or related causes shall not cause unsafe conditions. Any component or wire becoming grounded or any combination of such grounds shall not cause unsafe conditions. (3) The articles or units submitted by the Contractor must be in production and must have had a previous, satisfactory in -service performance record of at least two years on Class I or Class II railroads. The manufacturer shall provide proof of performance statements upon request. Articles or units that do not meet this requirement shall be made available for type acceptance testing. (4) Type acceptance testing shall be conducted by the Contractor. The Engineer and the Operating Railroad shall be notified prior to testing. (5) All vital circuits shall be double -break, except within a signal instrument house or case, after the entering or leaving circuits are double -broke. (6) All vital repeater relay circuits shall be designed on the cascade principle . The paralleling of vital repeater relays will not be permitted. (7) Repeater relay contacts shall be assigned so that safety will not be compromised by the failure of any repeater relay to energize. (8) Highway crossing warning start circuits shall provide initiation of the warning equipment from both sides of the crossing and shall also include separate island circuits with 5 seconds minimum loss -of-shunt. (9) AHCWS total warning times and approach circuit distance calculations shall be provided on the crossing track plan. Total warning time shall be calculated as follows: 𝑇𝑇𝑊=𝑇𝑀𝑊+𝑇𝐵+𝑇𝐸𝑅+𝑇𝐶+𝑇𝑃 where: TTW = Total warning time (seconds) TMW = Minimum warning t ime (seconds) TB = Buffer time (seconds) 6-284 TER = Equipment response time (seconds) TC = Clearance time (seconds) TP = Preemption time (seconds) The value of each variable shall be determined as follows:
a.The minimum warning time shall be the FRA minimum time of 20 seconds.
b.The buffer time shall be 10 seconds for crossings equipped only with flashing light signals and 15 seconds for crossings equipped with automatic flashing lights and gates.
c.Equipment response time shall be provided per the manufacturer’s recommendation.
d.Clearance time shall be provided for locations with multiple track crossings, skewed angle crossings, or wide travel surfaces. Clearance times for wide crossings are shown on the Plans and shall be verified and submitted t o the Engineer for approval prior to completion of the design.
e.Preemption time shall be added for advanced traffic preemption. (10) Vital relays shall be included for the gate control relay (GCR), emergency control stick relay (ECSR), preemption relay ( PER) and other vital circuits included in the Contractor’s design.
a.The GCR shall be controlled by an output from a vital logic gate delay unit, used to control the gates.
b.The PER shall be driven by an output of the motion sensor unit. The PER relay shall be equipped with heavy duty contacts and shall be a four -wire double break circuit to the traffic controller in advance of the start of the flasher signals.
c.The ECSR will be used to disable the crossing and will include the emergency cutout switch and control of a red LED, indicating that the crossing is out -of- service.
d.The LED shall be located on the side of the shelter. 6-285 (b) Control Circuits . (1) Control circuits shall be in accordance with the AREMA C&S Manual recommended practices where such practices do not conflict with these specifications. (2) Where means are provided for cutting out the warning devices during intervals when trains make regular operating stops or perform switching operations on approach ci rcuits , the following requirements shall be met :
a.Controls shall be designed to ensure that warning devices are operating before the train enters the crossing.
b.Automatic control of the warning devices actuated by approaching trains other than the trai n that has stopped or is performing switch operations shall take precedence over any cut -out features.
c.Hand throw switches equipped with circuit controllers shall not cause the warning devices to operate without trains within the approach circuits when the switch is reversed. (3) Warning devices shall operate until the rear of the train clears the crossing for trains operating in either direction. (c) Modular Design . (1) Modular design shall be used throughout the system. Electrical and mechanical components shall be organized in plug -in assemblies or modules whenever practical and shall be shelf -mounted, unless noted otherwise. (2) Components mounted on printed circuit (PC) cards and weighing more than one -half ounce or with a displacement of more than 1/2 cubic inch shall have a mechanical attachment to the card which is separate from any electrical connection. (3) The Contractor shall organize the printed circuit wiring so that wires serving the same function shall be co nnected to the same terminal of PC cards. PC cards containing the same circuitry shall be interchangeable between subsystems. (4) The design and construction of PC cards of the same subsystem shall be the same. Cards of different subsystems shall be of the same design and construction wherever practicable. 6-286 (5) Adjustable components for electronic equipment shall be avoided wherever possible by the use of appropriate circuitry, stable components, and high -tolerance circuits. Adjustable components, where u sed, shall have locking devices or shall be self -locking to prevent inadvertent operation or drift. Whenever practical, two or more points of adjustment which are required during the same tune -up operation shall be located within 12 inches of each other an d in such a way that they can be operated by one person. Interacting adjustments will not be acceptable. The replacement of a component or PC card with a spare shall not require compensating adjustments to other components or modules. (6) Test points shall be provided for checking essential voltages and wave forms and for injecting test signals. Test points shall permit detection of defective PC boards and equipment modules without the disconnection of wires. All test points shall be readily accessible when the equipment is in the normal operating position and shall be clearly labeled. Test points shall be capable of accepting probes and connectors used with standard test equipment such as voltmeters and oscilloscopes. (7) When built -in indicators or meters are associated with adjustments, the adjustment point shall be sufficiently close to the associated indicator so that the adjustments may be manipulated and the indicator observed simultaneously by one person. Built -in indicators or meters shall be provide d when frequent observation or adjustments are necessary or when portable test equipment will not provide the necessary information or accuracy. (d) Environment . (1) All equipment housed in signal equipment housings or cases shall function in accordance with these specifications and within an operating temperature range of -40°F to +158°F at a relative humidity of 5% to 95% non -condensing, per AREMA C&S Manual, Part 11.5.1 for Class C environment requirements. (2) Signal equipment installed outside of the s ignal housing shall be designed to operate satisfactorily in all weather conditions such as rain, snow, temperature, and humidity variations. This shall be determined by the climatic conditions from data published by NOAA for the Vermont area. In addition, the recommendations of the AREMA C&S Manual, Part 11.5.1 , shall be followed to minimize condensation and frost buildup. (3) The electrical environment that the signal equipment will be exposed to shall be determined by the Contractor. Design, construction , and field application of the signal system shall prevent interference by the site environment from affecting the signal system operation. Possible sources of interference include, but are not limited to, 60 Hz AC electricity , rotating machinery, poor ballast conditions, and lightning. 6-287 (e) Quality Assurance . (1) The design and workmanship of the apparatus will comply in every respect with the requirements of 49 C.F.R. Part 236 . (2) Unless otherwise specified herein, all items furnished or installed shall be in accordance with the applicable standards , practices, and recommendations of the Agency, Operating Railroad, AREMA, NEMA , and the Institute of Electrical and Electronic Engineers , and the requirements of 49 C.F.R. Part 234 and 49 C.F.R. Part 236 . (5) All apparatuses, including the signal junction boxes and all other miscellaneous components that form a complete system, shall be furnished completely factory wired and tested. (6) The Contractor shall verify the testing and inspection of the equipment prior to shipment in accordance with the approved factory test as specified in Subsection 664.07(b) and inspection as specified in Subsection 664.07(a)(3) . (7) All miscellaneous components and products shall be new, free of manufacturing defects, and clearly and permanently labeled with value or type identification. (8) All electrical component s shall be rated to operate at power, voltage, current, and temperature levels exceeding by 20% those which the components will be subject to in service, unless otherwise specified herein. (9) The AHCWS shall be designed to meet the requirements of the MUT CD. (f) AHCWS Materials . (1) The Contractor shall ensure proper integration of components into a complete highway crossing signal layout. In the event the Contractor’s proposed equipment does not fit the vital design specified, it will be the Contractor’s responsibility to modify the design and submit an alternate design for approval. (2) Highway crossing warning equipment shall meet the requirements established by AREMA C&S Manual, Part 3.3.1 and AREMA C&S Manual, Part 3.1.15 , except where such instruction s and requisites conflict with this specification. (3) The active warning system configurations shall be as shown on the Plans. 6-288 664.06 INSTALLATION OF AHCW S. (a) General Requirements . All work shall be accomplished in a manner that will protect the crossing throughout the prosecution of work and ensure the safety of workers, pedestrians, and vehicular traffic. (b) Excavation and Backfill . (1) Excavation of Pavements . Excavation of pavements for the installation of signal conduit shall be performed in accordance with Subsection 203.07 . Cuts in the pavement shall be made with a concrete saw to a minimum depth of 2 inches along the neat lines of the area to be removed. (2) Excavation for Conduit and Buried Cable . Trenches necessary for placin g conduit and buried cable shall be excavated in accordance with Section 204 . The bottom of conduit trench shall be graded to a pitch of not less than 3 inches per 100 feet. (3) Excavation for Signal Foundations . Excavation for signal foundations shall be performed in accordance with Section 204 . (4) Backfill . Backfill shall be placed and compacted as specified in Subsection 204.05 . (5) Buried Cable . All buried cable shall be marked with 6 -inch wide yellow plasti c marking tape as specified in Subsection 781.03(j)(31) . The tape shall be placed in the backfill 12 inches below finished grade. (c) Installation . (1) General Requirements .
a.AHCWS equipment shall be installed in accordance with the approved working draw ings.
b.AHCWS equipment shall be mounted in such a manner as to provide for easy access to test points, indicators, and adjustments.
c.Track termination diodes and shunts shall be installed in accordance with the manufacturer’s standard and at locations shown on the approved working drawings. 6-289 d. Electrical work and materials shall be subject to inspection and approval of the state or municipal electrical inspector, as applicable.
e.All work shall meet the requirements of the National Electrical Code and the National Electrical Safety Code . (2) Foundations and Cribbing .
a.At all locations where precast or cast -in-place concrete foundations are installed, a crushed stone base as specified in Subsection 704.06 shall be placed and compacted on the accepted subgrade to a total depth of not less than 4 inches after compaction.
b.When placing foundations, the Contractor shall exercise care to ensure that anchor bolts are not bent or the threads damaged. All anchor bolt threads, washers, and nuts shall be protected by applying friction tape until such time as the unit to be suppor ted is installed. Anchor bolts requiring leveling nuts shall be of sufficient length and size for the load application and have the necessary concrete coverage to ensure that it does not push out under compression or pull out under tension.
c.Foundations and pads shall be installed level and plumb.
d.Finishing of foundations exposed to view shall be in accordance with Subsection
541.1 4.
e.After backfilling foundations, the Contractor shall ensure that the foundation is plumb and level. The top of foundation shall be at the same elevation as the crown of the roadway and no more than 4 inches above the final top of grade.
f.Cribbing shall be installed as shown on the Plans. Each tier of timber cribbing shall be drift bolted to the one upon which it rests with 3/4 -inch galvanized drift bolts of sufficient length to extend through two tiers and not less than 4 inches into the third tier. Concrete or steel cribbing shall be installed in accordance with the manufacturer’s instructions.
g.The filling of the interior of the crib shall closely follow the erection of the successive tiers and at no time shall the cribbing be laid up higher than 3 feet above the backfilled portion.
h.The cribbing shall be installed so as to have a minimum perimeter walkway ar ound the case or signal of 6 feet. 6-290 (3) Flashing Light Signal Installation .
a.The flashing light signal mast shall be securely fastened within the split base in a manner such as the distance between the split halves of the ba se shall be equal. The heads of the bolts in the base assembly shall be squared with each other and facing oncoming highway traffic.
b.The base shall be securely fastened to the concrete foundation with the hardware provided for that purpose. The mast sha ll be plumb when the base assembly is fastened to the foundation. Shims, spacers, or other filler devices shall not be used to level and plumb flashing light signal equipment.
c.A hole shall be factory -drilled in the mast for the bottom cross -arm. The cen ter line of the hole shall be located so that, when the cross -arm with light unit is attached thereto, the lowest part of the light assembly shall be between 7 -1/2 feet and 9 -1/2 feet above the crown of the roadway. Holes for additional cross -arms, when required, shall be located and drilled in the field after the bottom cross -arm has been secured to the mast. The centerline of the additional light units shall be 23 inches above the centerline of the lower light unit.
d.Electronic bells shall be installed on the top of the mast of the flashing light unit as shown on the Plans. If a bell is not specified, then a pinnacle shall be provided.
e.Underground cables shall be installed in the split base junction box. The cables shall be pot headed, tagged , and t erminated. No. 10 AWG wire shall be run to the cross -arm junction box in a manner as specified in the AREMA C&S Manual, Part 10.4.1 .
1.Wiring for the flashing light units and the bell shall be 37 strand, No. 10 AWG.
2.Where additional light units are use d, wiring for these units shall be run from the corresponding terminals in the next lowest cross -arm junction box.
3.Wiring for bells shall go directly from the bottom cross -arm junction box to the bell.
4.Terminations for flasher unit and bell wiring s hall be solderless compression type terminals as specified in Subsection 781.03(j)(13) . 6-291 f. With AC power off and standby battery in a fully charged condition, the lamp voltage shall be adjusted to 9.5 volts for LED lights (measured at the lamp) by varying the resistor for the flasher unit.
g.The front lights of the flashing light unit shall be focused to provide maximum visibility for oncoming highway traffic. The back lights of the flashing light unit shall be focused to provide close up visibilit y for oncoming highway traffic from the opposite direction. (4) Cantilever -Gate Combination Installation .
a.The base of the cantilever shall be securely fastened to the concrete foundation with the hardware provided for that purpose. The mast shall be plumb when the base assembly is fastened to the foundation. Shims, spacers, or other filler devices shall not be used to level and plumb cantilever layouts. Leveling nuts shall be installed prior to installation of the signal.
b.The railroad crossing sign and ENS sign for the cantilever arm shall be securely fastened with the hardware provided for that purpose as per the manufacturer’s recommendation.
c.Installation of the cantilever shall provide a minimum clearance of 17 -1/2 feet above the roadway.
d.Gate mechanisms and gate arms shall be installed per the manufacturer’s instructions. The Contractor shall install light units, gate arm deflectors, high wind gate arm supports, off set conversions brackets and all equipment required for a complete assembly . (5) Automatic Highway Crossing Warning Gate Installation .
a.The gate arm tip light shall be steadily illuminated and the other gate arm lights shall flash in unison with the mast or cantilever mounted lights.
b.Sidewalk gate tip lights shall be steadil y illuminated.
c.Gate lights shall be adjustable for installations not perpendicular to the tracks. 6-292 d. Gate arm counterweights shall be adjusted in accordance with the manufacturer’s standards for the length of gate arm specified.
e.Ground mount gate masts shall be securely fastened within the junction box base in a manner such that the distance between the split halves of the base shall be equal when tightened.
f.The base shall be securely fastened to the concrete foundation with the hardware provid ed for that purpose.
g.The mast shall be plumb when the base assembly is fastened to the foundation. Shims, spacers, or other fillers shall not be used to level and plumb highway crossing warning gates.
h.Gate operating mechanism, including counterweight arms, shall be securely fastened to the mast with the hardware provided for that purpose.
i.The mechanism shall be located on the pole in a position that shall allow for the gate arms, when in the down position, to be not more than 4 -1/2 feet, nor less t han 3-1/2 feet, above the crown of the roadway.
j.Underground cables shall be installed in the split base junction box. The cables shall be pot headed, tagged, and terminated. (6) Cable Installation .
a.General Requirements .
1.The installation of wire and cable shall conform to AREMA C&S Manual,
Part 10 — .4.1 , except as modified herein.
2.Prior to the installation of underground cables, a sand bed, using material in accordance with Subsection 703.03 , shall be compacted to a depth of not less than 3 inches on the accepted subgrade. Following the installation of the cables, sand backfill shall be placed and compacted with hand tools around and over the cables in 4 -inch to 6 -inch layers, to a uniform depth not less than 8 inches with out damage to the cables.
3.The Contractor shall provide sufficient slack in cable conductors at all terminating posts to enable three re -terminations of the conductor due to broken eyelets without re -servicing or re -pot heading the cable. 6-293 4. Cables sha ll not be bent to a radius less than 10 times the diameter of the cable during installation, or as finally installed.
5.All cable runs shall be continuous without splices between cable terminating locations.
6.Tags to identify cables shall be of plastic material. Tags shall be lettered to correspond with the cable destination and the number of conductors in the cable. The type of tag to be used shall be as specified in Subsection 781.03(j)(14) .
7.All cables shall be terminated in conductor order. Individ ual cable conductors shall be identified at each cable termination with plastic tags as specified herein. All spare conductors in each cable shall be terminated and identified.
8.All cable entrance openings in equipment enclosures and junction boxes shall be sealed with a pliable sealing compound after the cable is in place. Sealing compound shall be used to seal the area around cable where the cable emerges from the end of a conduit, pipe, or duct bank. All spare conduits shall be sealed or plugged in acc ordance with AREMA C&S Manual, Part 15.2.15 .
9.A suitable lubricating medium, non -injurious to the cable insulation, shall be used when pulling cables into conduit or pipe.
10.Wherever multiple conductor cables are terminated, the outer sheath of the cable shall be carefully removed to the point of cable entrance. At the end of the cable sheath or covering, two layers of plastic electrical tape shall be applied.
11.When paralleling the tracks, cable shall be buried at a minimum depth of 30 inches below f inished earth or ballast. Cable shall be laid loosely in the trench with a sand bed and backfill as specified. When passing under tracks, cable that is not protected in conduit shall be buried a minimum depth of 48 inches below the top of tie.
12.Upon req uest, and only under extreme circumstances and because of installation hardship, the Engineer may allow installation of a to a depth of less than 30 inches. The cable shall be protected in a manner as approved by the Engineer. 6-294 13. Whenever any signal cabl e is to pass under pavement or a roadway, if existing conduit is not provided, the cable shall be installed in a 4 -inch galvanized steel conduit, as specified in Subsection 752.0 6, and the conduit shall extend 20 feet beyond the edges of the pavement.
14.Where cable leaves the ground at locations other than buildings or in foundations, it shall be protected by a bootleg or other covering extending above the ground line. The top of such protective coverings shall be filled with a sealing compound in accorda nce with AREMA C&S Manual, Part 15.2.15 .
15.The Contractor shall install polyethylene cable marking tape at a depth of approximately 12 inches below final grade while backfilling each cable trench. This tape shall be as specified in Subsection 664.06(b)(5 ).
16.The pot heading of buried cabled shall be applied whenever cable is terminated in signal equipment and such termination is within 2 feet of the grade level. This neoprene end seal pot head shall be installed in accordance with the manufacturer’s ins tructions. (7) Rail and Turnout Bonding Installation .
a.Non-Insulated Joint Bars . All non -insulated joint bars in the crossing circuited territory shall be bonded with one bond installed on the field side of the joint bars.
b.Turnouts . All turnouts with in the crossing approach shall be furnished with fouling wires and switch heel bonds. Track switch, frog fouling bonds, and track circuit connections shall plug -type rail web bonds.
c.Exothermically Welded Rail Head .
1.The surfaces of the rails where the bond is to be applied shall be ground clean with a reinforced grinding wheel, of a type recommended by the bonding material manufacturer. Vitrified grinding wheels shall not be used. After grinding, the surface shall be cleaned with an approved n on-toxic solvent to remove all traces of grease and dirt. After the surface has been ground and cleaned, it shall be heated to drive out any moisture. The bond wire shall then be welded to the rail in a manner to ensure a thorough mechanical and electrical connection. 6-295 2. The Contractor shall ensure that each bond connection is thoroughly welded to the rail. The Engineer reserves the right to require a test of each weld.
3.The Contractor shall demonstrate that the bonding is in accordance with the require ments of this section and as specified in AREMA C&S Manual, Part 8.1.20 , AREMA C&S Manual, Part 8.1.30 , and AREMA C&S Manual, Part 8.6.40.
d.Plug-Type Rail Web Track Circuit Connections .
1.Track circuit connectors shall be furnished and installed in acco rdance with AREMA C&S Manual, Part 8.1.20 and AREMA C&S Manual, Part 8.1.25 for Type 2 plugs. The opposite end of the connectors shall have a 7 -inch length of turned bond strand with a compression sleeve installed for connection to bond strand wires.
2.Rail shall be drilled in accordance with AREMA C&S Manual, Part 8.6.25 . Rail shall be drilled with an approved 3/8 -inch bonding drill bit and drill normally used for this purpose to permit the application of the bond to the rail web.
3.No hole shall be drilled through the rail brand. Holes shall be drilled within ± 3/16 inch of th e neutral axis of the rail. All holes shall be clean and deburred. Bond wires shall be installed on the same day as the hole is drilled. In the event that bond wires cannot be installed on the same day, the bond hole shall be protected against the elements with a suitable plug.
4.Plugs shall be driven with a hammer approximately three pounds in weight, and when in -place shall be tight to provide the best possible contact throughout the web of the rail.
5.Track circuit connectors shall be furnished and ins talled with insulated bond strand cable. The bond strand shall have a nominal diameter of 0.200 inch and be jacketed with 3/32 -inch rubber compound. The bond strand shall be connected to the solid No. 6 AWG insulated twisted track wire with compression sle eves and taped and insulated to prevent corrosion. The connection between track wire and bond strand shall be housed in rubber water hosing to prevent damage from ballast and frost in the ground. 6-296 6. The underground cable shall be stripped back a suffici ent distance for the exposed conductor to be fully inserted into the compression sleeve. The sleeve shall then be compressed with the type of compression tool designed for that purpose. The sleeve shall then be covered with two layers of vinyl plastic elec trical tape.
7.A 24 -inch piece of hose, as specified in Subsection 781.03(j)(17)b.1. , shall be located beneath the rail base and sealed with sealing compound in accordance with the AREMA C&S Manual, Part 15.2.15 .
8.Any track circuit connection installed by the Contractor that is found to be defective prior to acceptance shall be removed and a new track circuit connection installed at no additional cost to the Agency.
9.Care shall be taken to avoid excessive slack in the bond conductor to prevent vandalis m. A connector sleeve shall be used on the base of the rail.
e.Plug-Type Rail Web Turnout Bonding .
1.Turnout bonding connectors shall be furnished and installed in accordance with AREMA C&S Manual, Part 8.1.20 and AREMA C&S Manual, Part 8.1.25 for Type 2 plugs.
2.Rail shall be drilled in accordance with AREMA C&S Manual, Part 8.6.25 . Rail shall be drilled with an approved 3/8 -inch bonding drill bit and drill normally used for this purpose to permit the application of the bond to the rail web.
3.No hole shall be drilled through the rail brand. Holes shall be drilled within ± 3/16 inch of the neutral axis of the rail. All holes shall be clean and deburred. Bond wires shall be installed on the same day as the hole is drilled. If bond wires cannot be install ed on the same day, the bond hole shall be protected against the elements with a suitable plug.
4.Plugs shall be driven with a hammer approximately three pounds in weight, and when in -place shall be tight to provide the best possible contact throughout th e web of the rail. 6-297 5. Fouling bond wires for all turnouts within the crossing approach shall be installed as close as practicable to the transposition joints. The holes for bond wires shall be located 2 -1/2 inches apart and centered above a tie bay.
6.The fouling wires shall be installed so as to allow for the plug end of the one wire to be placed on the outside of the far rail and the oth er end of the inside of the opposite far rail. The second wire installation shall be the reverse of the first wire.
7.Fouling wire shall be stapled to separate ties, 1 -1/2 inches below the top of tie, opposite each other in the same tie bay. The fouling w ires shall be installed to avoid touching the tie plates. Fouling wires shall be left exposed to allow visual inspection.
8.Any bond, weld, or connection installed by the Contractor that is found to be defective prior to acceptance shall be removed and a new bond installed at no additional cost to the Agency.
f.Existing Bonding . If existing rail bonding is in place on the approach circuits, then the Contractor shall inspect and verify that all such bonding, including track switches, is in accordance with these specifications. If additional rail bonding, or rail bonding corrections, is required then the Contractor shall correct any such deficient existing rail bonding at no cost to the Agency in accordance with these specifications, or as directed by the En gineer. Final determination of bonding requirements shall be approved by the Engineer and Railroad. (8) Installation of AHCWS Shelters and Cases .
a.Each AHCWS shelter shall be mounted level and plumb using the foundation leveling system provided as part o f the shelter.
b.Cable entrance pipes shall be installed through the cable knockout holes provided in the floor of the house behind the terminal boards.
c.The AHCWS shelter or case shall be grounded as specified in Subsection 781.03(g)(9) and Subsection 781.03(j)(22) .
d.Cables shall enter shelters by entrance knockouts and fittings and entrance pipes provided. Cables shall be dressed, pot headed, tagged, and terminated as specified in Subsection 664.06(c)(6) . 6-298 e. Relays shall be installed on the relay plug -boards corresponding to the relay nomenclature and securely fastened in place with the hardware provided.
f.Batteries shall be installed on battery trays. Battery posts shall be coated with approved grease and battery connectors shall be securely fastened to the battery posts.
g.Manual control boxes shall be mounted and wired in accordance with the approved working drawings.
h.Grade crossing predicator, motion sensor, or similar solid -state equipment, as shown on the approved working drawings, shall be shelf mounted with rubber matting under the units.
i.AHCWS shelters and cases, if of sheet steel construction, shall be painted as specified in Subsection 781.03(g)(12) . (9) Metered Power Service Grounding . Power service equipment grounding shall be installed in accordance with the National Electrical Code and the power company’s requirements. (10) Signs . Two signs shall be mounted to the AHCWS masts, one on each side of the crossing on the right -hand side of the driver approaching the crossing. One sign shall be mounted on the signal house or case. All signs shall be mounted in a manner approve d by the Engineer. The signs shall conform to the applicable Standard Drawings. (11) Retirement and Disposal of Existing Equipment . All retired existing AHCWS equipment or passive crossing warning devices shall be removed by the Contractor and transported to a site designated by the Engineer. (12) Protective Service Costs . Following the date of in -service operation, all railroad flagging and related crossing protection expense, during periods that the warning system fails to operate as specified in this sec tion, shall be borne by the Contractor at no additional cost to the Agency until the system is accepted by the Agency.
664.07 Testing of Ahcws .
(a) Quality Assurance Testing Procedures . (1) All test procedures and inspection procedures shall be subject to the approval of the Engineer and shall comply with all FRA rules and regulations. 6-299 (2) Test equipment of the proper type, capacity, range, and accuracy shall be supplied by the Contractor to perform the required tests and inspections. This equipment shal l be in good working order and properly calibrated at the time the tests or inspections are conducted. (3) Each component and unit of the AHCWS shall have an inspection performed at its point of manufacture, and evidence of this inspection and acceptabilit y shall be indicated on the item where practicable. (5) All approved system and subsystem tests to demonstrate that the installation meets these specifications and design requirements shall be completed prior to any operational testing of systems or subsys tems. (6) No more than 3 days prior to placing in service, the Contractor shall adjust all rectifiers and DC power supplies for maximum output for a period of 24 hours. Following this operation, the Contractor shall adjust the output in excess of the load requirements in accordance with the battery manufacturer’s recommendations. (7) The Engineer and the Operating Railroad will have the right to witness any or all field tests conducted. The Engineer and the Operating Railroad shall be notified in writing at least 48 hours prior to each field test. No part of the AHCWS shall be placed in service without an authorized representative of the Agency and the Operating Railroad being present and witnessing the in -service tests, unless otherwise agreed by the Engine er. (8) The work shall include all tests required to ensure the proper and safe operation of all systems and subsystems and to prove the adequacy and acceptability of the total installation specified herein. The tests to be performed shall cause each syste m and subsystem to be sequenced through its required operations, including the imposition of simulated conditions to prove that the installation complies with all specified fail -safe requirements. (9) In the event that the system does not meet the requirem ents of this section, all deficiencies shall be corrected and retested to prove compliance, at no additional cost to the Agency. (b) Factory Test Procedures . (1) Confirmation shall be provided by the Contractor that all required factory tests of systems, subsystems, assemblies, subassemblies, and components supplied under this Contract have been performed. These tests shall verify design and name -plate ratings and adequate and proper performance. 6-300 (2) All vital systems, subsystems, and equipment shall be inspected and tested. (3) Non-vital components, those not related to fail -safe circuits, may be tested on a sampling basis. An approved number of randomly selected components or units from the manufacturing process shall be tested to ensure the adequacy and acceptability of all components and units produced. (4) When test results are not recorded on a test -data plate affixed to the equipment or unit, certified test reports shall be furnished for each item at the time of delivery in a form and format suitable for regular office file record keeping. (c) Factory Tests and Instructions . (1) Vital Relay Tests . All DC vital relays shall be factory tested and inspected in accordance with the AREMA C&S Manual, Part 6.4.1 . (2) Wired AHCWS Shelters and Case s.
a.Operational and Wiring Verification Test . Each AHCWS shelter and case shall be wired complete at the point of assembly, with all equipment installed. An operational and wiring verification test shall be made in accordance with the approved design dra wings. Functions external to the housing shall be simulated where required.
b.Energy Distribution Tests . Energy distribution tests shall include, but not be limited to, the following:
1.All fuses shall be removed and circuit breakers placed in the open p osition.
2.All over -current devices shall be of the size s shown on the approved design drawings.
3.All energy distribution shall be checked using a resistance test instrument to verify agreement with the approved design drawings.
4.All wire gauge s shall be verified as matching that called for on the approved design drawings. All incorrect wire sizes shall be replaced with the proper size wire.
5.Each energy bus shall be tested to all other energy buses to ensure that no crosses exist. 6-301 6. During energy distribution breakdown, a wire count on each terminal, relay contact, etc. shall be taken to ensure that only the number of wires called for on the approved design drawings are present at each terminal, relay contact, etc. Any discrepancies found shall be corrected and excess wires, if found, shall be removed.
7.Tags shall be verified for proper nomenclature and terminal location.
8.All power supplies shall be checked for correct setting and quantities.
c.Wiring Verification Test . All circuitry shall be checked for accuracy against the approved design drawings. Tests may be done with energy on or off and shall verify the following:
1.Point to point wiring.
2.During wire verification test, a wire count on each terminal, relay contact, etc. shall be taken to ensure that only the number of wires called for on the approved design drawings is present at each terminal, relay contact, etc. Any discrepancies found shall be corrected.
3.Tags and nomenclature where applicable.
4.That all components, relays, resistors, etc. are the same as called for on the approved circuit drawings and are located in the proper positions.
d.Vital Circuit Tests .
1.Tests shall be conducted with energy on during simulation testing.
2.All vital circuits shall be tested to ens ure that the opening of each contact in a control circuit cuts off the control current under the conditions shown on the approved design drawings following through all multiple circuits and cut arounds. When a circuit is broken by a relay contact twice or when it is broken by some other relay contact, whose coil circuit is opened by opening the relay, the wires in the circuit shall be disconnected in addition to opening the relay.
3.Adjustments and corrections of defects in the housing wiring shall be made as necessary to obtain proper operation.
4.All design changes found necessary to obtain proper operation shall be submitted to the Engineer for approval. 6-302 e. Other Factory Tests . Factory tests and inspections of other components, products, and subsystems shall be as specified elsewhere in this section. (d) Field Test Procedures . (1) The field tests performed shall cause each installed system and subsystem to be sequenced through its required operations, including the imposition of simulated conditions, to demonstrate that the installation complies with all specified fail -safe design requirements and operational functions. (2) The quality of the installation shall be demonstrated by field tests for continuity, insulation resistance, resistance of ground con nections, circuit breakdown, visual inspection, and any other tests required by this section. These tests shall be performed prior to any operational testing of systems or subsystems. (3) The Contractor’s test procedures shall consist of pre -printed data s heets or inspection sheets for each test. When completed by the field test personnel and checked for accuracy and completeness, the sheet shall be submitted as the test report. (4) When tests require specific meter or test instrument readings, the pre -printed data sheet shall show the allowable range of values for each part of the test. The test report shall also contain a check -off system for each action and a blank space adjacent to the expected value in which to record the test readings. (5) The test rep ort shall also contain a final description sheet on which the Contractor shall record discrepancies found and action taken. This document shall be furnished to the Engineer. (6) All test reports shall be dated and signed by the responsible employee of the Contractor or subcontractor on the day the test is performed. Space shall also be provided for the signature of those witnessing the test, including the Engineer and Operating Railroad inspector. (7) The report shall show the specific test instruments used on each test, with the instruments identified by name, type, serial number, and calibration due date. (8) Should an error be discovered during field testing due to field wiring and connections that do not agree with the approved design dra wings, the Contractor may correct such errors without prior approval of the Engineer. The Contractor shall not, however, make any changes which affect the safety of operation of the approved circuits as designed without prior written approval of the Engine er. 6-303 (9) The Engineer will make all final determinations as to whether only a part, or the whole test, shall be rerun when any specific field test does not meet the requirements specified for the test. (10) Any changes made after completion of the test pro cedure shall be retested in accordance with the applicable test procedure. (e) Field Tests and Inspection . (1) General Field Tests . General field tests shall include, but not be limited to, the following:
a.Ground verification test.
b.Power racks – energ y distribution system and failure alarm checks.
c.Breakdown test of all vital circuitry.
d.Wiring verification of all non -vital circuitry.
e.Vital function tests.
f.Operating tests.
g.All applicable tests prescribed by AREMA C&S Manual, Part 2.4.1 , where the AREMA inspections and tests do not conflict with the requirements of these specifications. (2) Specific Field Tests .
a.Ground Resistance Testing .
1.Testing . The Contractor shall perform testing of all signal locations using a ground resistance di rect-reading single test meter using the alternating current fall -of-potential method and two reference electrodes.
2.Test Procedure .
i.The ground electrode to be tested and the two reference electrodes shall be oriented in a straight line spaced a minimum of 50 feet apart. ii. The two reference electrodes shall be driven 5 feet deep. 6-304 iii. The maximum resistance value goal of the main ground for wayside outdoor locations shall be within a range of 1 ohm to 5 ohms. If it is found that the resistance value of the main ground exceeds this range, the Contractor shall install additional ground rods, up to a maximum of 4. Additional ground rods shall be spaced no less than 10 feet apart. If, after additional ground rods are installed, excessive resistance readings persist, the Contractor shall notify the Engineer. iv. The Contractor may propose an alternate method to the fall -of- potential method for approval by the Engineer in consultation with the Operating Railroad. Any such alternate method shall be supported by documentation that validates that the resultant measurement readings are analogous.
b.Insulation Resistance Tests . The procedure for testing insulation resistance shall include tests to verify the following:
1.All wire and cable installed for v ital circuits along the right -of-way and wire and cable entering or leaving wayside instrument housings shall be tested after installation to ensure that insulation of wires and cable and connected equipment meet the specified resistance value. A direct re ading instrument, having a 0 -megohm to 200 -megohm -scale range and a self -contained DC power supply rated 500 volts minimum to 1,000 volts maximum, shall be used to measure the insulation resistance. Resistance between conductors and ground shall not be les s than that specified in 49 C .F.R. § 234.267 .
2.The insulation resistance of each conductor to ground and between each conductor and all other conductors in each multi -conductor cable shall be tested. Power sources, made grounds, and connections to the ra ils shall be disconnected from the circuits during testing.
3.The point used as ground shall be the most convenient ground available.
4.Insulation resistance test values shall be recorded on approved insulation resistance record forms and turned over to the Engineer upon their acceptance of this test requirement. 6-305 c. Vital Relays .
1.All DC vital relays shall be tested for pick -up and drop -away values. These values shall be in accordance with field requirement values stated in the AREMA C&S Manual, Pa rt 6.4.1, Table 641 -1.
2.These measured values shall be recorded on the approved relay record forms and turned over to the Engineer upon their acceptance of this test requirement.
3.These tests shall be performed after the housing has been set.
d.Energy Distribution .
1.Energy -Off Tests . With all power to AHCWS instrument shelters or case off, the following checks and tests shall be performed. These tests shall include but not be limited to:
i.Verifying that circuit breaker size compares to that of the approved design drawings. ii. All energy distributions shall be checked using a resistance test instrument to verify agreement with the approved fabrication drawings. iii. Wire gauges shall be compared with those called for on the approved circuit draw ings. All discrepancies in wire sizes shall be replaced with the proper size wire. iv. Terminal board tags shall be verified for proper nomenclature and terminal location.
v.Each energy bus shall be tested to all other energy buses to ensure that no cross es exist.
2.Energy -On Tests . Upon completion of the energy -off tests, the following checks and tests shall be performed. These tests shall include, but not be limited to, the following:
i.Inserting circuit breakers for power supply feeds and verifying proper size according to the approved circuit drawings. 6-306 ii. Turning on energy feeds and test ing operation of power transfer for proper operation. iii. Measuring and recording each AC voltage input. iv. Measuring and recording each power supply or charger o utput voltage.
v.Verifying that the proper voltage is present at all distribution points. vi. Checking circuit power failure alarms, and all other alarms that indicate to Central Control. vii. Checking battery water level and specific gravity of all cells .
3.Circuit Continuity Tests . All wire and cable installed by the Contractor shall be tested to verify the continuity of each conductor and that each conductor is connected to the proper terminal as shown on the approved drawings. Where parallel circuits exist, each parallel path shall be tested independently to verify the continuity of each path.
4.Circuit Wiring Verification . All vital and non -vital circuit wiring shall be checked for accuracy against the approved design drawings. Tests may be performed with energy on or off and shall verify, but not be limited to, the following:
i.Point to point wiring. ii. A wiring count of all field installed wires shall be conducted for each terminal, relay contact, etc. to ensure that only the number of wi res called for on the approved designed drawings is present at each terminal, relay contact, etc. Any discrepancies found shall be corrected. iii. Tags and nomenclature where applicable. iv. That all components, relays, resistors, etc. are the same as call ed for on the approved circuit drawings and are located in the proper positions. 6-307 5. Breakdown of Control Circuits .
i.All vital relay circuits shall be tested in their entirety for the correct operation of and response to each contact on each circuit element, such as relays and contactors. Where parallel paths exist, the tests shall validate each path, and circuits shall be opened when required to ensure the proper tests. ii. Each circuit shall be tested by simulating all operating conditions t o verify that the circuit operates in accordance with these specifications and approved submittals.
6.Power Tests . The following power tests shall be performed and recorded:
i.The voltage of the main power feeders shall be measured and recorded. ii. A ch eck of all circuit breakers shall be performed for correct size and type. iii. All power supplies, battery chargers, and batteries shall be checked for correct setting and quantities. iv. Bus-to-bus checks shall be made to determine that no shorts, crosses , or grounds exist.
7.AHCWS Operational Tests .
i.A test train shall be used to verify that any AHCWS motion sensor or predictor equipment installed under this Contract has the specified warning time at each highway grade crossing. ii. Tests of the AHCWS shall be performed in both directions at various speeds to the satisfaction of the Engineer. iii. As an alternat ive to test train operation, the Contractor may propose a field train simulation test procedure for the approval of the Engineer. Any such alter nate procedure proposed shall be accompanied by verification documentation of such field tests performed by the Contractor for similar AHCWS installation projects . 6-308 664.08 TRAINING FOR SYSTEMS . The Contractor shall provide a qualified field engineer to i nstruct maintenance personnel on recommended initial setup, troubleshooting, and maintenance procedures for predictor, motion sensor, or Style C systems . This training course shall be conducted on the Operating Railroad’s property and will be limited to tw o 8-hour days of instruction. The Contractor shall submit a request for the Agency to arrange the training 14 calendar days in advance of the proposed date.
664.09 METHOD OF MEASUREMENT . The quantity of Railroad -Highway Crossing Active Warning
System to b e measured for payment will be on a lump sum basis for each system installed in the complete and accepted work.
664.10 BASIS OF PAYMENT . The accepted quantity of Railroad -Highway Crossing Active Warning
System at the location specified will be paid at the Contract lump sum price. Payment will be full compensation for designing, furnishing, transporting, handling, placing, and testing and placing in service the materials and equipment specified, including all new equipment, as -built signal circuits for p lacement in the shelter, insulated joints, and traffic pre -emption interconnection; concrete, backfill, permanent number signs, excavation, trench excavation, trench pavement replacement, and removal of existing signal lights; resurfacing or other restorat ion work; and for furnishing all labor, tools, equipment, and incidentals necessary to complete the work. Payment will be made under: Pay Item Pay Unit
664.1000 Railroad -Highway Crossing Active Warning System .............................. Lump Sum
6-309 SECTION 665 – RAILROAD TURNOUT CONSTRUCTION
665.01 DESCRIPTION . This work shall consist of providing new welded railroad turnouts, including a
complete timber switch tie set; connecting the turnout to the existing track, including realignment of existing track, installation of new rail, welds, and compromise welds, as required; raising, aligning, and surfacing turnouts and crossovers; and the removal of turnouts and crossovers.
665.02 MATERIALS . Materials shall meet the r equirements of the following subsections:
Aggregate for Railroad Ballast ................................ ................................ .................. 704.03 Switch Ties ................................ ................................ ................................ ................. 709.04(d) Tie Plugging Material ................................ ................................ ................................ 709.04(e) New Rail ................................ ................................ ................................ .................... 715.0 6(a) Railroad Turnouts ................................ ................................ ................................ ......715.07 Other Track Material (OTM) ................................ ................................ ..................... 715.0 8 New turnouts shall be of the rail section and weights shown on the Plans. Ballast shall be of the type shown on the Plans.
665.03 SUBMITTALS . The following information shall be prepared and submitted for review and
approval by the Engineer . Submittals shall meet the requirements of Subse ction 105.0 6. (a) Fabrication drawings shall be submitted in accordance with the requirements of Subsection 105.06 . All details, dimensions, quantities, parts, specifications, and sections necessary to fabricate and assemble the turnout shall be included i n the submittal. (b) A complete schedule of the materials proposed for installation and the source of the material. Information to be provided on the rail shall include rail weight, rail section, drilling pattern, typical rail length, date rolled, and the name of the mill where the rail was rolled. (c) Sub-assembly component and bolt certificates of origination. (d) Source for ballast and gradation analysis of a sample from the ballast source. (e) Manufacturer’s certificate of compliance for all materials that are incorporated into the work. (f) Manufacturer’s cut sheet of lubricant or graphite for application to switch plates following the cleaning of the plates.
Source: Vermont Standard Specifications for Construction, 2024 Edition. Pages 1049–1082 of 1,380.