664RAILROAD SIGNALS

664

6-275SECTION 664 – RAILROAD SIGNALS

664.01DESCRIPTION . 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

664.02MATERIALS . 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

664.03SUBMITTALS

and approval by the Engineer . Submittals shall meet the requirements of Subsection 105.0 6.

herein.

layout, including detailed bills of material. Fabrication drawings shall include detailed drawings of signal masts, cantilever gates, shelters and cases, and their respective foundations.

cantilever gates, and their respective foundations.

the new wiring.

including rack, lighting, convenience outlet arrangement, and exhaust fan mounting and location.

664 6-276 e. Drawings showing the location, size, and mounting arrangement of the manual control box.

types of buttons, plugs, levers, terminals, and lights that have been proposed to be furnished.

furnish and install.

circuited location. Design drawings will be used to generate the as -built drawings. As-built drawings shall meet the requirements specified in Subsection

( b)(2)

description of the mounted equipment and their proposed method of inter - and intra-rack wiring.

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.

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.

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.

664 6-277 b. Qualifications . Qualifications shall be based on the following criteria:

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.

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.

demonstrates compliance with the requirements of this specification for each specified cable type the Contractor intends to supply.

warranty prior to selection:

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.

664 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.

shipment of the cable:

intends to supply.

for approval:

approved testing procedures.

these specifications.

664 6-279 4. Information to be supplied by certified cable test reports shall include the following:

ii. Date and location of test. iii. Description of test and test conditions. iv. Complete cable or wire description.

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.

prepared and submitted for review and approval by the Engineer . Submittals shall meet the requirements of Subsection 105.0 6.

installed system and equipment has successfully passed the test. All test records shall be submitted to the Engineer upon acceptance of the AHCWS.

general principles and concepts upon which the Contractor shall base the design and location of the proposed system and equipment.

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.

664 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:

reading for troubleshooting and maintenance .

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.

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.

actual wiring of the circuits.

and terminal numbering to easily enable the tracing and testing of such circuits.

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.

664 6-281 11. Relay nomenclature shall appear at the top of the contact and at the top of the coil.

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 geographical succession insofar as possible and practical.

the same relay insofar as practicable. Different relay contacts and coils shall not line up. Stick contacts shall line up under the coil of controlling relay.

shall be included.

included. .

field appurtenances shall be included.

This list shall include the part number of all materials used on the project.

664.04DELIVERY, STORAGE, AND HANDLING

damage during transit. Any equipment damaged during transit shall be replaced at no additional

cost to the Agency.

shall be equipped with transit plugs or rubber stoppers to prevent spillage of the electrolyte.

Batteries shall be shipped separately from the housings in which they are to be used.

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.

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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.

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 least 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.

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, will 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.

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 high and an arrow not

less than 6 inches in length and 1/2 inch in width.

664.05DESIGN CRITERIA

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.

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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.

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.

Operating Railroad shall be notified prior to testing.

after the entering or leaving circuits are double-broke.

of vital repeater relays will not be permitted.

failure of any repeater relay to energize.

from both sides of the crossing and shall also include separate island circuits with 5 seconds

minimum loss-of-shunt.

on the crossing track plan. Total warning time shall be calculated as follows:

𝑇 𝑇𝑊 = 𝑇 𝑀𝑊 + 𝑇 𝐵 + 𝑇 𝐸𝑅 + 𝑇 𝐶 + 𝑇 𝑃

where:

TTW = Total warning time (seconds)

TMW = Minimum warning time (seconds)

TB = Buffer time (seconds)

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TER = Equipment response time (seconds)

TC = Clearance time (seconds)

TP = Preemption time (seconds)

The value of each variable shall be determined as follows:

signals and 15 seconds for crossings equipped with automatic flashing lights and

gates.

recommendation.

skewed angle crossings, or wide travel surfaces. Clearance times for wide crossings

are shown on the Plans and shall be verified and submitted to the Engineer for

approval prior to completion of the design.

relay (ECSR), preemption relay (PER) and other vital circuits included in the Contractor’s

design.

to control the gates.

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.

cutout switch and control of a red LED, indicating that the crossing is out-of-

service.

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practices where such practices do not conflict with these specifications.

make regular operating stops or perform switching operations on approach circuits, the

following requirements shall be met:

train enters the crossing.

the train that has stopped or is performing switch operations shall take precedence

over any cut-out features.

devices to operate without trains within the approach circuits when the switch is

reversed.

operating in either direction.

components shall be organized in plug-in assemblies or modules whenever practical and

shall be shelf-mounted, unless noted otherwise.

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.

function shall be connected to the same terminal of PC cards. PC cards containing the same

circuitry shall be interchangeable between subsystems.

of different subsystems shall be of the same design and construction wherever practicable.

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use of appropriate circuitry, stable components, and high-tolerance circuits. Adjustable

components, where used, 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 and 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.

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.

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 provided when frequent observation or adjustments are necessary or

when portable test equipment will not provide the necessary information or accuracy.

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.

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.

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.

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requirements of 49 C.F.R. Part 236.

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.

components that form a complete system, shall be furnished completely factory wired and

tested.

in accordance with the approved factory test as specified in Subsection 664.07(b) and

inspection as specified in Subsection 664.07(a)(3).

and clearly and permanently labeled with value or type identification.

temperature levels exceeding by 20% those which the components will be subject to in

service, unless otherwise specified herein.

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.

C&S Manual, Part 3.3.1 and AREMA C&S Manual, Part 3.1.15, except where such

instructions and requisites conflict with this specification.

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664.06INSTALLATION OF AHCWS

throughout the prosecution of work and ensure the safety of workers, pedestrians, and vehicular

traffic.

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.

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.

in accordance with Section 204.

tape as specified in Subsection 781.03(j)(31). The tape shall be placed in the backfill 12

inches below finished grade.

drawings.

access to test points, indicators, and adjustments.

manufacturer’s standard and at locations shown on the approved working drawings.

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or municipal electrical inspector, as applicable.

National Electrical Safety Code.

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.

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

supported 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.

541.14

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.

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.

successive tiers and at no time shall the cribbing be laid up higher than 3 feet above

the backfilled portion.

the case or signal of 6 feet.

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manner such as the distance between the split halves of the base shall be equal. The

heads of the bolts in the base assembly shall be squared with each other and facing

oncoming highway traffic.

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 flashing light signal equipment.

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.

shown on the Plans. If a bell is not specified, then a pinnacle shall be provided.

shall be pot headed, tagged, and terminated. 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.

AWG.

from the corresponding terminals in the next lowest cross-arm junction box.

the bell.

compression type terminals as specified in Subsection 781.03(j)(13).

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voltage shall be adjusted to 9.5 volts for LED lights (measured at the lamp) by

varying the resistor for the flasher unit.

visibility for oncoming highway traffic. The back lights of the flashing light unit

shall be focused to provide close up visibility for oncoming highway traffic from

the opposite direction.

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.

fastened with the hardware provided for that purpose as per the manufacturer’s

recommendation.

above the roadway.

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.

shall flash in unison with the mast or cantilever mounted lights.

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standards for the length of gate arm specified.

in a manner such that the distance between the split halves of the base shall be equal

when tightened.

provided for that purpose.

Shims, spacers, or other fillers shall not be used to level and plumb highway

crossing warning gates.

fastened to the mast with the hardware provided for that purpose.

gate arms, when in the down position, to be not more than 4-1/2 feet, nor less than

3-1/2 feet, above the crown of the roadway.

shall be pot headed, tagged, and terminated.

Part 10.4.1, except as modified herein.

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 without damage to the cables.

terminating posts to enable three re-terminations of the conductor due to

broken eyelets without re-servicing or re-pot heading the cable.

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cable during installation, or as finally installed.

terminating locations.

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)

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.

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 accordance with AREMA C&S

Manual, Part 15.2.15.

be used when pulling cables into conduit or pipe.

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.

inches below finished 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.

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.

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existing conduit is not provided, the cable shall be installed in a 4-inch

galvanized steel conduit, as specified in Subsection 752.06, and the conduit

shall extend 20 feet beyond the edges of the pavement.

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 accordance with AREMA C&S Manual, Part

15.2.15.

approximately 12 inches below final grade while backfilling each cable

trench. This tape shall be as specified in Subsection 664.06(b)(5).

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 instructions.

territory shall be bonded with one bond installed on the field side of the joint bars.

wires and switch heel bonds. Track switch, frog fouling bonds, and track circuit

connections shall plug-type rail web bonds.

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 non-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.

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to the rail. The Engineer reserves the right to require a test of each weld.

requirements 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.

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.

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.

± 3/16 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. 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.

and when in-place shall be tight to provide the best possible contact

throughout the web of the rail.

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 sleeves 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.

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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 electrical tape.

be located beneath the rail base and sealed with sealing compound in

accordance with the AREMA C&S Manual, Part 15.2.15.

defective prior to acceptance shall be removed and a new track circuit

connection installed at no additional cost to the Agency.

vandalism. A connector sleeve shall be used on the base of the rail.

with AREMA C&S Manual, Part 8.1.20 and AREMA C&S Manual, Part

8.1.25 for Type 2 plugs.

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.

± 3/16 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 installed on the same day, the bond hole

shall be protected against the elements with a suitable plug.

and when in-place shall be tight to provide the best possible contact

throughout the web of the rail.

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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.

one wire to be placed on the outside of the far rail and the other end of the

inside of the opposite far rail. The second wire installation shall be the

reverse of the first wire.

tie, opposite each other in the same tie bay. The fouling wires shall be

installed to avoid touching the tie plates. Fouling wires shall be left exposed

to allow visual inspection.

be defective prior to acceptance shall be removed and a new bond installed

at no additional cost to the Agency.

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 Engineer. Final determination of bonding

requirements shall be approved by the Engineer and Railroad.

leveling system provided as part of the shelter.

in the floor of the house behind the terminal boards.

(g)(9) and Subsection 781.03(j)(22)

provided. Cables shall be dressed, pot headed, tagged, and terminated as specified

in Subsection 664.06(c)(6).

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nomenclature and securely fastened in place with the hardware provided.

approved grease and battery connectors shall be securely fastened to the battery

posts.

working drawings.

shown on the approved working drawings, shall be shelf mounted with rubber

matting under the units.

specified in Subsection 781.03(g)(12).

in accordance with the National Electrical Code and the power company’s requirements.

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 approved by the

Engineer. The signs shall conform to the applicable Standard Drawings.

or passive crossing warning devices shall be removed by the Contractor and transported to

a site designated by the Engineer.

and related crossing protection expense, during periods that the warning system fails to

operate as specified in this section, shall be borne by the Contractor at no additional cost

to the Agency until the system is accepted by the Agency.

664.07TESTING OF AHCWS

Engineer and shall comply with all FRA rules and regulations.

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Contractor to perform the required tests and inspections. This equipment shall be in good

working order and properly calibrated at the time the tests or inspections are conducted.

of manufacture, and evidence of this inspection and acceptability shall be indicated on the

item where practicable.

specifications and design requirements shall be completed prior to any operational testing

of systems or subsystems.

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.

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 Engineer.

systems and subsystems and to prove the adequacy and acceptability of the total installation

specified herein. The tests to be performed shall cause each system 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.

shall be corrected and retested to prove compliance, at no additional cost to the Agency.

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.

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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.

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.

with the AREMA C&S Manual, Part 6.4.1.

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 drawings. Functions external to the housing shall be simulated

where required.

to, the following:

drawings.

to verify agreement with the approved design drawings.

design drawings. All incorrect wire sizes shall be replaced with the proper

size wire.

crosses exist.

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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.

approved design drawings. Tests may be done with energy on or off and shall verify

the following:

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.

approved circuit drawings and are located in the proper positions.

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.

as necessary to obtain proper operation.

submitted to the Engineer for approval.

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and subsystems shall be as specified elsewhere in this section.

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.

resistance, resistance of ground connections, 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.

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.

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.

record discrepancies found and action taken. This document shall be furnished to the

Engineer.

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.

identified by name, type, serial number, and calibration due date.

do not agree with the approved design drawings, 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 Engineer.

664

shall be rerun when any specific field test does not meet the requirements specified for the

test.

with the applicable test procedure.

AREMA inspections and tests do not conflict with the requirements of these

specifications.

ground resistance direct-reading single test meter using the alternating

current fall-of-potential method and 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.

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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.

include tests to verify the following:

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 reading 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 less than that specified in 49 C.F.R. § 234.267.

conductor and all other conductors in each multi-conductor cable shall be

tested. Power sources, made grounds, and connections to the rails shall be

disconnected from the circuits during testing.

resistance record forms and turned over to the Engineer upon their

acceptance of this test requirement.

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values shall be in accordance with field requirement values stated in the

AREMA C&S Manual, Part 6.4.1, Table 641-1.

and turned over to the Engineer upon their acceptance of this test

requirement.

off, the following checks and tests shall be performed. These tests shall

include but not be limited to:

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 drawings. 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.

that no crosses exist.

checks and tests shall be performed. These tests shall include, but not be

limited to, the following:

proper size according to the approved circuit drawings.

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ii. Turning on energy feeds and testing operation of power transfer for

proper operation.

iii. Measuring and recording each AC voltage input.

iv. Measuring and recording each power supply or charger output

voltage.

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.

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.

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:

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 wires

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 called for

on the approved circuit drawings and are located in the proper

positions.

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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 to

verify that the circuit operates in accordance with these

specifications and approved submittals.

recorded.

ii. A check 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.

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 alternative to test train operation, the Contractor may propose

a field train simulation test procedure for the approval of the

Engineer. Any such alternate procedure proposed shall be

accompanied by verification documentation of such field tests

performed by the Contractor for similar AHCWS installation

projects.

664

664.08TRAINING FOR SYSTEMS. The Contractor shall provide a qualified field engineer to instruct

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 two 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.

664.09METHOD OF MEASUREMENT. The quantity of Railroad-Highway Crossing Active Warning

System to be measured for payment will be on a lump sum basis for each system installed in the complete

and accepted work.

664.10BASIS 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 placement

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 restoration work; and for furnishing all labor, tools, equipment, and incidentals

necessary to complete the work.

Payment will be made under:

Pay Item Pay Unit

00 Railroad-Highway Crossing Active Warning System ..............................Lump Sum

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6-309SECTION 665 – RAILROAD TURNOUT CONSTRUCTION

665.01DESCRIPTION . 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.

665.02MATERIALS . 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.

665.03SUBMITTALS . 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.

All details, dimensions, quantities, parts, specifications, and sections necessary to fabricate and assemble the turnout shall be included i n the submittal.

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.

cleaning of the plates.