reference specification: s-4648-1 fleet: b-iv …...2017/05/16 · reference specification:...

Reference Specification: S-4648-1 Fleet: B-IV System: HVAC Latest Revision Date: 12/22/2016

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SEPTA TECHNICAL SPECIFICATION

1.0 SPECIFICATION TITLE

B-IV HVAC System Upgrade

2.0 PRE-RELEASE REVIEW

NAME INITIAL & DATE

Benjamin J. Leonard BJL 5/29/2015

John MacEwen JWM 11/03/2015

Wayne Krahn WBK 11/03/2015

Helena Kan HHK 11/25/2016

William Brown WJB 11/28/2016

3.0 APPROVAL FOR RELEASE

John MacEwen John MacEwen (Signature)

4.0 ORIGINAL SPECIFICATION RELEASE DATE

11/03/2015


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AGENDA and REVISIONS

SEPTA TECHNICAL SPECIFICATION

Revision No Release Date Reason for Issue Release Approval -1 12/22/2016 General Revision JWM 12/22/2016


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TABLE OF CONTENTS

1.0 SPECIFICATION TITLE ...................................................................................................................................... i 2.0 PRE-RELEASE REVIEW ...................................................................................................................................... i 3.0 APPROVAL FOR RELEASE ................................................................................................................................ i 4.0 ORIGINAL SPECIFICATION RELEASE DATE .............................................................................................. i 5.0 SCOPE ..................................................................................................................................................................... 1 6.0 DEFINITIONS AND ABBREVIATIONS ............................................................................................................ 1 7.0 SYSTEM REQUIREMENTS ................................................................................................................................ 1

7.1 GENERAL REQUIREMENTS ....................................................................................................................... 2 7.2 EXISTING EQUIPMENT OVERVIEW ........................................................................................................ 2 7.3 HEATING SYSTEM ........................................................................................................................................ 3 7.3.1 General .............................................................................................................................................................. 3 7.3.2 Overhead Heat .................................................................................................................................................. 4 7.3.3 Floor Heat ......................................................................................................................................................... 5 7.3.4 Layover Heat ..................................................................................................................................................... 5 7.3.5 Cab Heat and Defroster ................................................................................................................................... 5 7.4 VENTILATION ................................................................................................................................................ 6 7.4.1 General .............................................................................................................................................................. 6 7.4.2 Fresh Air and Mixing Plenum ......................................................................................................................... 6 7.4.3 Airflow Verification .......................................................................................................................................... 6 7.4.4 Blower Unit ..................................................................................................................................................... 10 7.4.4.1 Blower Assembly ............................................................................................................................................ 10 7.4.4.2 Air Ducts ......................................................................................................................................................... 10 7.4.4.3 Air Diffusers .................................................................................................................................................... 10 7.5 COOLING SYSTEM ..................................................................................................................................... 10 7.5.1 General ............................................................................................................................................................ 10 7.5.2 Design Criteria ................................................................................................................................................ 11 7.5.3 Overhead Unit ................................................................................................................................................. 11 7.5.3.1 General ............................................................................................................................................................ 11 7.5.3.2 Evaporator Coil .............................................................................................................................................. 11 7.5.4 Compressor/Condenser Unit ......................................................................................................................... 12 7.5.4.1 General ............................................................................................................................................................ 12 7.5.4.2 Refrigerant Compressor ................................................................................................................................ 12 7.5.4.3 Condenser Coil Assembly .............................................................................................................................. 12 7.5.4.4 Condenser Fan and Compressor Motor Assembly ...................................................................................... 12 7.5.4.5 Vibration Eliminators and Mounts ............................................................................................................... 12 7.5.4.6 Support Frame ................................................................................................................................................ 12 7.5.5 Piping Design and Installation ....................................................................................................................... 12 7.5.6 Leak Test, Evacuation, Charging, and Refrigerant/Oil Sampling ............................................................. 14 7.5.6.1 Leak Test ......................................................................................................................................................... 14 7.5.6.2 Evacuation ....................................................................................................................................................... 14 7.5.6.3 Charging with Nitrogen ................................................................................................................................. 14 7.5.6.4 Charging with Refrigerant ............................................................................................................................ 14 7.6 CONTROLS .................................................................................................................................................... 14 7.6.1 General ............................................................................................................................................................ 14 7.6.2 Motor Starter and Temperature Control/Heat Contactor Panel ............................................................... 14 7.6.3 Controller ........................................................................................................................................................ 14 7.6.4 Temperature Sensors ..................................................................................................................................... 15 7.6.5 Firestats ........................................................................................................................................................... 16 7.6.6 Lock-out Provision ......................................................................................................................................... 16 7.6.7 Interior Car Temperatures ............................................................................................................................ 16 7.6.8 Diagnostics ...................................................................................................................................................... 16


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7.7 PORTABLE TEST UNITS ............................................................................................................................ 17 7.8 BENCH TEST UNITS .................................................................................................................................... 17 7.9 BRAKE AIR COMPRESSOR DC TO AC CONVERSION KIT .............................................................. 18 7.10 DC-AC INVERTER REQUIREMENTS ...................................................................................................... 19 7.10.1 Inverter Enclosure .......................................................................................................................................... 19 7.10.2 Inverter I/O ..................................................................................................................................................... 19 7.10.3 Low Voltage Supply........................................................................................................................................ 19 7.10.4 Inverter Power-Up Time ................................................................................................................................ 19 7.10.5 Power Interruption ......................................................................................................................................... 19 7.10.6 Inverter Protection and Self-Recovery ......................................................................................................... 19 7.10.7 Inverter Mounting .......................................................................................................................................... 20 7.10.8 EMI, EMC and THD ...................................................................................................................................... 20 7.11 SUSTAINABILITY ........................................................................................................................................ 20 7.12 APPROVAL .................................................................................................................................................... 20 7.13 MOUNTING ................................................................................................................................................... 21

8.0 ENVIRONMENTAL REQUIREMENTS .......................................................................................................... 21 8.1 OPERATING ENVIRONMENT .................................................................................................................. 21 8.2 VIBRATION AND SHOCK REQUIREMENTS ........................................................................................ 21

9.0 PILOT AND PRODUCTION DELIVERY ........................................................................................................ 21 9.1 PROJECT MANAGEMENT ........................................................................................................................ 22

10.0 FLEET DEFECTS ................................................................................................................................................ 22 10.1 RELIABILITY REQUIREMENTS .............................................................................................................. 22

11.0 DOCUMENTATION ........................................................................................................................................... 23 11.1 INSPECTION, REFURBISHING, INSTALLATION AND TESTING MANUAL ................................. 23 11.2 PREVENTIVE MAINTENANCE MANUAL .............................................................................................. 23 11.3 TROUBLESHOOTING MANUAL .............................................................................................................. 23 11.4 HEAVY REPAIR MANUAL......................................................................................................................... 23 11.5 SOFTWARE/FIRMWARE USER’S MANUAL ......................................................................................... 23 11.6 RENEWAL PARTS CATALOG .................................................................................................................. 23 11.7 PTU OPERATIONS MANUAL .................................................................................................................... 23 11.8 BTE OPERATIONS AND MAINTENANCE MANUAL ........................................................................... 24

12.0 TRAINING ............................................................................................................................................................ 24 13.0 CONTRACT DELIVERABLES REQUIREMENTS LIST ............................................................................. 24 14.0 ATTACHMENTS ................................................................................................................................................. 25


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5.0 SCOPE

This specification establishes the requirements for replacing the existing Split DC-driven air conditioning system with AC-driven HVAC system powered with an inverter on SEPTA B-IV vehicles. The qualified Contractor shall design, build, test and provide installation procedures and on-site support, per this specification. The Contractor must manufacture the major system components such as the system logic controller, inverter and final assembly. Components such as the electric motors, evaporators and compressors may be contracted. Each system to include all necessary hardware, wire harnesses, mounting brackets, and documentation for this specification. The supplied systems shall be suitable for rail transit application. Contractors deviating from the specifications, for design, manufacturing or installation must obtain SEPTA’s project manager’s written approval. Upon completion of delivery, the supplier will have provided equipment for 125 vehicles, one complete capital spare kit, five of each major subsystem unit for maintenance purposes and ten of each repairable and replaceable component for maintenance purposes. The HVAC System shall be designed for a 20 year minimum life expectancy.

6.0 DEFINITIONS AND ABBREVIATIONS

AC Alternating Current B-IV Broad Street Subway cars CDR Conceptual Design Review CDRL Contract Deliverables Requirements List D/E Double-Ended cars DC Direct Current DDR Detailed Design Review DTE Diagnostic Test Equipment EMC Electro Magnetic Compatibility EMI Electro Magnetic Interference NTP Notice To Proceed Proven Experience Corporation having performed similar task, can substantiate record. PTU Portable Test Unit Qualified Bidder A contractor who meets the minimum requirements set forth in specification, and

includes financial ability, reputation, work quality, previous project management experience in similar HVAC designs used the rail transit industry

S/E Single-Ended cars SEPTA Southeastern Pennsylvania Transportation Authority Split System Evaporator/blower above ceiling and compressor/condenser below car floor THD Total Harmonic Distortion

7.0 SYSTEM REQUIREMENTS

New equipment to include: Air conditioning compressor/condenser assembly with AC motor Digital control devices, software and enclosure DC-AC conversion kit for air compressor motor


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Auxiliary inverter (for HVAC compressor, two evaporator blower motors and air compressor motor)

Existing equipment to be integrated: AC evaporator blowers and motors including power, controls and data interfacing Piping and ducting Mounting locations for current compressor/condenser assembly Mounting locations for current control boxes

Support and documentation to be provided: On-site support during pilot installation (performed by SEPTA) and testing program Complete set of manuals that are compatible with current documentation (Section 12) Training related to orientation, troubleshooting and maintenance of the new system

7.1 GENERAL REQUIREMENTS The Contractor shall replace the existing DC-powered air conditioning units, with new AC-powered split HVAC system, DC-to-AC conversion kit for vehicle braking air compressor (Wabtec or SEPTA approved equal), and a new overhead evaporator and DC/AC inverter capable of powering the above equipment. The control system shall be replaced with new controls as described in Section 8.6. The HVAC system shall operate using refrigerant R-407-C. Particular attention shall be given to the application of all new or upgraded components to facilitate installation, maintenance, troubleshooting, and repair without interference with other systems. All covers and doors will be side facing in order to access the equipment from the side of the vehicle with easily detachable doors and/or outfitted with appropriate prop rods. The overall vehicle weight requirements shall not significantly deviate from the existing weight balance nor exceed the existing overall vehicle weight. All components of the system shall conform to standard noise and vibration requirements. The HVAC Contractor for this system shall be SEPTA-approved and shall have proven and reliable service history in the rail industry. The HVAC system equipment design, construction, and assembly shall meet, as a minimum, the rules of the National Electric Code, ANSI/NFPA No. 70, NFPA-130, ASHRAE, and the safety requirements of UL 1995. The equipment shall be identified and marked with new supplier name plates according to UL 1995 or as specified in this Section. All references to standards within this specification are to be the latest revision.

7.2 EXISTING EQUIPMENT OVERVIEW A heating, ventilating, and air conditioning (HVAC) system is installed in each car to automatically provide the specified interior temperatures with any exterior ambient temperature from 0°F to 95°F (105°F at the condenser inlet) at the specified wet and dry bulb conditions. Above an exterior ambient temperature of 95°F, the system is able to maintain a car interior temperature of 20°F below the outdoor ambient temperature. This system performs this function regardless of normal variable internal heat loads such as passengers, miscellaneous electrical apparatus and lights, or external factors such as solar heat gain, maximum operating speed, and maximum frequency of door openings. The current HVAC equipment is a split system consisting of one underfloor-mounted Compressor/Condenser unit, two Overhead Evaporator-Blower units located above the low ceiling at the ends of the car, and inter-connecting piping with R-22 as the refrigerant. The cars are fitted with convective floor heaters. The system operates from the 600VDC third rail power supply. The HVAC controller operates from the low voltage power system. The control function is provided through a solid state non-microprocessor based temperature control panel containing pilot relays, time delay relays, and


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contactors that are used to switch on/off the system components. Floor Heat, Blower Fan, and the Air Conditioning Compressor are separately protected by fuses.

7.3 HEATING SYSTEM 7.3.1 General

Currently, the cars are electrically heated by a system capable of maintaining the car interior temperature at 62°F with an outside temperature of 15°F. Total Heating System output is approximately 15 kW at 600 VDC. The passenger area of the car is heated by electric resistance heaters powered by the nominal 600 VDC input. The heater elements are located under the passenger seats and are mounted in stainless steel enclosures integrated with the underseat boxes. See Figure 10-5 and Figure 10-6 for the arrangement of the heater elements in the S/E Car and the D/E Car respectively. See Figure 10-7 (in the attachments) for the electrical schematic of the heater elements. Positioned in the front of the heater elements are grilles which facilitate hot air convection and prevent entry of foreign matter into the underseat boxes. The grille panels are secured with triwing-head, quarter-turn latches so that the panels may be removed for the inspection and the replacement of

Figure 10-5. Arrangement of Heater Elements (S/E Car)


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the heater elements. The heater elements are wired to furnish two stages of heating system output. The 1st stage of heat output provides 2/3 (approximately 10 kW) heating system output. The 2nd stage of heat output provides full (approximately 15 kW) heating system output.

Figure 10-6. Arrangement of Heater Element (D/E Car)

7.3.2 Overhead Heat There are no existing overhead heaters. The Supplier must design and provide all required modifications to integrate the new reheat system into the cars’ existing evaporator envelope. New heating elements shall be installed and have adequate capacity to temper the fresh air input from the design heating condition to a minimum of 55°F without the use of floor heat at the nominal supply voltage of 600 VDC. Heater elements of an approved design with stainless steel terminations and insulated heater supports shall be used. There shall be no exposed, un-insulated, or unprotected high voltage components, wiring, or terminal connections in the overhead area. The heaters shall be fitted with nameplates per UL 1995 that are visible with the unit access panels opened.


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Each stage of overhead heat shall be protected by a circuit breaker located on the upgraded Fuse and Switch Panel. In order to reduce cold car pull-up time, overhead heat shall operate at full power when the return air sensor reading is 15°F or more below the required interior car temperature. A duct air sensor shall be provided in the main passenger distribution duct near the connection of each Overhead Evaporator-Blower-Heater Unit to limit the supply air temperature from exceeding 100°F or in an approved manner to maintain an acceptable temperature delta between the re-circulated air temperatures in order to meet the design requirements. The activation of the overhead heaters shall be interlocked with an airflow verification device, or field proven equivalent, to ensure the operation of the blower fans before energizing the heaters. In case of a blower failure, this device will prevent the heating system from activating. New self-resetting bi-metallic Klixon® style thermostats, or approved equal, shall be used for the first stage of protection. Upon detection of excessive temperature, it shall open the overhead heat contactors providing power to that unit. It shall not open at any temperature that is possible with all car equipment operating normally at the maximum supply voltage. Fusible links shall be used as back-up protection against overheat thermostats that fail to open.

7.3.3 Floor Heat Existing electric floor heating elements shall be cleaned and refurbished by SEPTA to a standard provided by the Contractor. When the Heating System is energized (PASSENGER HEAT Switch on Motorman's Console has been placed momentarily in the ON position or the Train line Relay HTLR is energized), the Temperature Control System functions automatically and selects the appropriate stage of Floor Heat according to the Car interior air temperature, as follows:

a. If the Car interior air temperature is below 62°F but above 60°F, one stage of floor heat (⅔ of the Heating System output or approximately 10 kW of heat at 600 VDC) will be energized. b. If the Car interior air temperature is below 60°F, both stages of floor heat (full capacity) will be energized. c. If either Car Over-temperature Sensor rises above 200°F, all Car floor heaters (Stage One and Stage Two) will be de-energized in the individual Car. This condition indicates a failure mode (a possible stuck or welded contactor). The Over-temperature Sensors (OHTs) act by directly de-energizing the Floor Heat Contactors (FHCs).

All surfaces of the floor heater enclosures accessible to passengers shall limit the surface temperature to the lowest practical value and in no case higher than 125°F in a stabilized condition. The Contractor shall provide an analysis of the design showing that the temperature of the guards

7.3.4 Layover Heat The Layover feature shall be cleaned and refurbished by SEPTA as needed. Layover Heat is controlled by a thermostat and operates automatically at 45°F provided that the following conditions are established:

a. The HEAT A/C CONTROL Circuit Breaker, located on the Low Voltage Switch Panel, is energized. b. The PASSENGER HEAT Circuit Breaker, located on the 600V Switch Panel, is energized. c. The ACTLR must be de-energized. The corresponding Air Conditioning Train line (ACT) is de-energized.

The layover thermostat is located beside the No. 3 door pocket. 7.3.5 Cab Heat and Defroster

The existing cab heat and defroster system shall be cleaned and refurbished by SEPTA to a standard provided


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by the Contractor. Each motorman's cab has a forced-air cab heater and a defroster mounted in the motorman's console pedestal which operate independently of and are not thermostatically controlled with the passenger heat. The cab heater and the defroster operate on a nominal 600 VDC. Compressed air from the main air reservoir supplies the air flow for the cab heater and the defroster. The air flow is fed through a filter and a pressure regulating valve. The opposite motorman's side is heated by a heater element mounted under the flip-up seat which is part of the Passenger Area Heating System. The output of each Cab Heater is: HEATER OUTPUT Defroster 0.4 kW Cab Heater (Low) 0.5 kW Cab Heater (High) 1.0 kW The Cab Heat Power Supply is interlocked with the air flow by means of a pressure switch. The heating elements cannot be energized unless there is an air flow.

7.4 VENTILATION 7.4.1 General

Existing ventilation of the car is accomplished by the blower fans supplied as part of the Overhead Evaporator-Blower units. The systems are currently designed to provide a nominal fresh airflow of 900 cfm/car at 78°F DB & 65% RH and a nominal return airflow of 1900 cfm/car, at 95°F DB & 78°F WB conditions, at all times regardless of the position of the car in the train and at any train speed. Ventilation shall be interlocked on the Motor Starter Control Panel, thereby not allowing heating or air conditioning unless the ventilation blower fans are operating.

7.4.2 Fresh Air and Mixing Plenum The present louvered openings in the carbody shall be cleaned and refurbished by SEPTA to a standard provided by the Contractor. The Contractor shall utilize to the greatest extent possible the existing fresh air ductwork, baffles, and screens. A fabricated steel plenum is mounted to the exhaust side of the Evaporator Coil Assembly (see Figure 10-71). The Rigid Plenum is equipped with duct guide and duct clips with wingnut fasteners to accommodate the Flexible Duct (Plenum) Connection (see Figure 10-64) to the Car Centerline Air Distribution Duct (see Figure 10-1). One inch insulation is fitted to the exterior surface of the Rigid Plenum and is held in place with insulation tape. This insulation prevents condensation on the chilled surface of the Rigid Plenum during System operation.

7.4.3 Airflow Verification Positive airflow verification shall be provided and interlocked within the cars’ HVAC system. The heating and air conditioning systems shall not be able to start unless the blower fans are operating. A pressure switch, or field proven equivalent, shall be used for this purpose.


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7.4.4 Blower Unit 7.4.4.1 Blower Assembly

Each vehicle in the fleet has one (1) evaporator blower motor located at each end in the ceiling area. Presently the two (2) blower motors are powered by a small DC-AC inverter also located in the B-end of ceiling area. The provided new HVAC system inverter shall have sufficient capability to supply the 220 VAC 60 Hz power for the 2 blower motors, as well as the provision of cabling between the new HVAC inverter under the car and the blower motors in the ceiling areas; thus SEPTA may use the new inverter to power these motors at a later time, if desired (Section 8.9). The existing blower assemblies were recently replaced and shall be cleaned as needed. The technical data for the motors is as follows:

Power: 1 hp, 3-phase, 60 Hz Voltage: 208-230 VAC RPM: 1725 Type: squirrel cage, Double ended Temperature: continuous at 122 F Bearings: Sealed perm lube anti-friction Class: B Model: Leeson 117736.00

7.4.4.2 Air Ducts The existing air ducts shall be cleaned and refurbished by SEPTA to a standard provided by the Contractor. See Figure 10-1 for layout.

7.4.4.3 Air Diffusers The existing air diffusers shall be cleaned and refurbished by SEPTA to a standard provided by the Contractor. Total air flow through the air diffusers is 2800 cfm. The air enters the Passenger Area through two continuous slot-type air diffusers which extend longitudinally on both sides of the main air duct bottom panels. Disposable air filters are located within the return air grilles. It is discharged into the Passenger Area from diffuser openings in the passenger light assemblies.

7.5 COOLING SYSTEM 7.5.1 General

Each Car has a thermostatically controlled Air Conditioning System which consists of a Compressor/Condenser Unit and an Air Conditioning Control Box mounted undercar, two Overhead Evaporator Units, each enclosed in a plenum chamber located above both low ceiling areas and temperature control sensors (see Figure 10-1 and Figure 10-2). Principal features of this System are as follows:

Evaporator Cooling Load (Two Units) 120,000 BTU/Hr (10 Ton System) Air Volume (Total) 2800 CFM @ 0.60" WG TSP Recirculated Air (Two Units) 1900 CFM @ 78°F DB & 65% RH Outside Air (Two Units) 900 CFM @ 95°F DB & 78°F WB Air to Condenser 105°F DB Suction Pressure (at Compressor) 65-75 PSIG Discharge Pressure (at Compressor) Compressor Motor @ 600 VDC Nominal (450/800 VDC Range)

275-325 PSIG

Horsepower 17.5/12.5 HP


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Normal Speed, Rated 1650 RPM Reduced Speed 1300 RPM Current: FF (Full Field) 27.5 Amps WF (Weak Field) 19.5 Amps

All refrigerant devices and piping shall comply with ASHRAE Standard 15 and UL Standard 1995. 7.5.2 Design Criteria

The ambient design heating and cooling conditions, and fresh airflow rate, have been revised from the OEM using latest railcar HVAC loading standards for consideration of energy efficiency. The Contractor shall submit performance calculations with a load analysis of the car detailing the required heating and cooling system capacities and the required supply airflow using the revised design criteria [CDRL 14-04]. The Contractor shall use actual air density for all capacity calculations. The air cooling equipment shall have sufficient capacity to condition the air inside the car to the requirements of this Section under the following loads:

Ambient Temperature (Cooling)

93°Fdb

76°Fwb

105°Fdb Condenser Inlet Air

Ambient Temperature (Heating) 10°Fdb

Maximum Operating Temperature 122°Fdb

80°Fwb

Car Interior Temperature Follow Section 8.6.7 of this Section

Passenger Load 125 passengers

450 Btu/hr/passenger at 55% SHR (Cooling)

Fresh Airflow 6 cfm/passenger minimum (OEM was 900 cfm)

Lighting Load To be determined at testing

Solar Load Stored in yard, operated underground

Infiltration Load Follow ASHRAE Recommendations 7.5.3 Overhead Unit

Overhead Evaporator/Blower Units provide ventilation and air conditioning. Ventilation is continuous when the AIR CONDITIONING Switch, located on the Motorman's Console, is energized. Fresh and Return Air flow into the plenum chambers where the recirculated air mixes with fresh air. This mixed air from the plenum chambers flows through disposable air filter panels and the Evaporator Coils. The air next flows into the main air duct(s) where it is discharged into the Passenger Area from diffuser openings in the passenger light assemblies.

7.5.3.1 General The Overhead Evaporator-Blower units shall have the evaporator coil replaced and a heater/reheat added. The design is restricted to existing location and envelope. The blower/motor assembly shall remain as-is. Carbody piping (refrigerant and condensate) shall be modified in accordance with Section 8.5.5.

7.5.3.2 Evaporator Coil The evaporator coil shall be replaced with a new coil meeting the specified cooling capacity using the design criteria established under Section 8.5.2. The coil shall be housed in a rigid stainless steel frame. The tubes shall be supported at each end and in the center; however distances between supports shall not be greater than 24-


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inches. The coil face area shall be sufficiently large to prevent condensate carry-over onto the overhead heater assembly and/or into the blower fan plenum or main air duct. The unit’s design shall also prevent any air bypass around or through the drain pan or around the evaporator coil and heater elements. Each evaporator coil shall be proof-tested by the manufacturer at 1.5 times the maximum working pressure.

7.5.4 Compressor/Condenser Unit Each car is equipped with one Compressor/Condenser unit that is resiliently mounted to the car underframe in a manner that will safely retain the unit if one or more mounting bolts fail. The condenser section is arranged to provide free rejection of heated air and to prevent the recirculation of heated air into the condenser coil. Air is taken in from the side of the car and moved over the condenser coil surface towards the center of the car. The Carrier-manufactured Compressor is a 3-cylinder, cast-aluminum crankcase, air-cooled, open-type, lightweight (approximately 150 lbs.) compressor, which is designed for flange mounting to an external driving motor. Two cylinders are unloaded automatically, in response to the lowering of the suction pressure, reducing the pumping capacity. Rotation of the Compressor is counterclockwise, when viewed from the oil pump end. The air-cooled Condenser is arranged for parallel flow of refrigerant. The fin pack contains six rows of 3/8 inch OD copper tubes with extended surface of 0.008 inch "wavy" copper plate fins spaced eight fins per inch. Using series-parallel circuitry, the Coil is designed to achieve 10°F sub-cooling of the refrigerant. An expanded metal screen guard protects the coil fin surface from ballast or other objects (see Figure 10-41). A removable fan guard is provided on the fan side (see Figure 10-41).

7.5.4.1 General The complete Compressor/Condenser unit shall be replaced in order to meet system design criteria. Carbody refrigerant piping shall be modified in accordance with Section 8.5.5.

7.5.4.2 Refrigerant Compressor The compressor shall be replaced with a new compressor meeting the specified cooling capacity using the design criteria established under Section 8.5.2. A semi-hermetic scroll compressor is preferred.

7.5.4.3 Condenser Coil Assembly The condenser coil shall be replaced with a new coil meeting the specified cooling capacity using the design criteria established under Section 8.5.2. The coil shall be Cu/Cu and housed in a rigid frame with suitable fan shrouding and protective screening. Each condenser coil shall be proof-tested by the manufacturer at 1.5 times the maximum working pressure.

7.5.4.4 Condenser Fan and Compressor Motor Assembly Compressor/condenser fan DC motors shall be replaced with an AC system.

7.5.4.5 Vibration Eliminators and Mounts All resilient mounts and piping vibration eliminators shall be replaced.

7.5.4.6 Support Frame The Compressor/Condenser support frames will be replaced with a frame similar to the existing having the same mounting points.

7.5.5 Piping Design and Installation Installers shall reuse the refrigerant piping. Reused refrigerant piping shall be repaired as necessary and flushed to an approved Contractor produced procedure.


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7.5.6 Leak Test, Evacuation, Charging, and Refrigerant/Oil Sampling Contractor shall produce procedures for the completed HVAC units, once installed on the car, to be subjected to the following:

7.5.6.1 Leak Test Internal pressure shall be induced through both the low and high sides and gradually raised to 150 psig by adding refrigerant vapor backed with nitrogen, through the low pressure gage connection on the service control box. Following this test, the compressor service valves shall be closed and the test mixture pressure shall be raised up to 450 psig. This pressure shall be established throughout the system except for the compressor body. The system pressure shall be monitored for possible presence of leaks for a minimum of 4 hours. The system shall then be checked with a leak detector calibrated for a rate of 1.5 ounces per year. Absence of detector signal shall constitute leak test acceptance.

7.5.6.2 Evacuation Each HVAC completed unit, and the entire system once installed on the car shall be evacuated to 100 microns or better. After isolating the vacuum pump the rise shall not exceed 300 microns in 2 hours. Alternate evacuation methods, as recommended by the ASHRAE HVAC Systems and Equipment Volume, may be considered for approval by SEPTA.

7.5.6.3 Charging with Nitrogen The Overhead Evaporator-Blower and Compressor/Condenser units shall be shipped to SEPTA with a minimum of 15 psig of nitrogen and appropriately tagged indicating this system pressure.

7.5.6.4 Charging with Refrigerant The required refrigerant charge shall be determined during the qualification test. All units thereafter shall be charged with the pre-determined refrigerant charge, by weight.

7.6 CONTROLS 7.6.1 General

The entire HVAC control system shall be replaced with a new control system as described in this Section. Details of the new control system design shall be submitted to SEPTA for approval [CDRL 14-05].

7.6.2 Motor Starter and Temperature Control/Heat Contactor Panel The HVAC Motor Starter Control Panel and Temperature Control/Heat Contactor Panel under the car shall be upgraded as described in this Section. The existing control panel, current relays, time delay relays, protective relays, contactors, and other ancillary control components shall be replaced. New components of the latest technology shall be provided to function with the new microprocessor-based control system described within this Section. New insulated control panels shall be provided. The control enclosures shall contain new high and low-voltage circuitry and wiring harnesses with associated connectors for the new heating and air conditioning control components, all of which shall be separated, permanently identified, and properly secured. Wire and insulation shall be of an approved type selected to meet the required ampacities for the ambient temperature conditions within the respective control enclosures. Cover hold-open devices and latches shall be designed for maximum ergonomics and maintainability. The Contractor shall review the venting of all power distribution and control enclosures and ensure that the new enclosures will provide adequate ventilation.

7.6.3 Controller An approved solid state microprocessor-based temperature control system shall be used, with temperature detection by thermistor sensors or approved solid-state temperature sensors. All other devices shall be contained in a heating/air conditioning control box, mounted in the current undercar location utilizing the existing mounting arrangement. Design calculations including FEA shall be submitted to SEPTA Engineering


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prior to delivery. [CDRL 14-03] Connections to a laptop PTU shall be provided in the control box and inside the operator’s cab motor cut-out box or a location that is easily accessible to SEPTA personnel but not the riders. All devices and their installation shall meet the requirements of Section 8.12, and shall be approved by the Engineer. During periods of low exterior ambient temperatures the air conditioning system shall be shut down, and during periods of high exterior ambient temperatures the heating system shall be shut down, using settings recommended by the Contractor. The controls shall be arranged to prevent damage to the units due to incorrect operation, and to prevent liquid "slugging" through the refrigerant compressors. Both systems shall operate as necessary in moderate climate conditions to maintain the proper interior temperatures. A thermistor shall be used to measure interior air temperature, and a second thermistor used to measure exterior air temperature. These sensors shall be mounted downstream of any air filters, located to be not unduly influenced by local sources of heat or the sun, protected from damage, especially during air filter maintenance, be tamperproof and readily accessible. They shall have a sensitivity of plus or minus 0.3 degrees F, and an accuracy differential of plus 0 degree F and minus 0.5 degree F. The thermistors shall withstand mechanical vibration of at least 10 g's. The layover heat thermostat shall be mounted within a stainless steel guard, and be enclosed in an approved concealed location. The control system shall consist of only solid state devices and shall be microprocessor-based. The thermistors shall not use pilot relays. Reheat and the refrigerant compressor shall not operate unless the ventilation blower is operating, as determined by the presence of voltage downstream of the blower contactor. The control system shall be protected against electrical faults, and shall be of a rugged design, proven in electric self-propelled transit vehicle service with high reliability, and properly insulated to prevent grounding. All electrical circuits shall be floated with respect to the carbody, and proper isolation shall be used for control circuit design. The control logic shall recognize faults and abnormal operation due to hardware failures, especially failures of the ventilation blowers and the heaters. These faults shall be indicated and visible from the control box. Complete means shall be provided to SEPTA with the DTE laptop units, using suitable password-protected software, to allow it to revise all temperature set points for the control system at no additional cost, both on a temporary and a permanent nature. Approved methods shall be provided to identify such changes by means of a revision level or similar to permit ease of identification of revisions to the system software.

7.6.4 Temperature Sensors The HVAC system is presently controlled by mercury-filled thermostats. These thermostats shall be replaced and disposed of properly by SEPTA. All control thermostats shall be replaced with thermistor sensors as described in this Section. The HVAC system shall be controlled using the recirculated and fresh air dry bulb temperatures, as required, with thermistor sensors. A supply air thermostat or alternative means shall be utilized to maintain supply air outlet temperature above passenger compartment control temperature (not to exceed 8°F) under all exterior ambient conditions without adversely affecting car return air temperature sensing and/or control. Thermistors shall be encapsulated in a protective stainless steel tube. Temperature sensors shall be mounted to ensure that they are not unduly influenced by local sources of heat, such as motors or resistors; that they are easily accessible for maintenance and replacement; that they are protected from damage during routine maintenance and servicing, such as replacing filters; and that they are not unduly influenced by fresh air. Temperature sensors shall have an accuracy of ±0.5°F for their design life within the temperature range as specified under Section 2.0. Sensors shall be capable of withstanding shocks up to 10g in any plane and vibrations of 10g up to 250 Hz in any plane.


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7.6.5 Firestats Currently, Two Firestats control the Blower Fan Motor Circuits for the individual ends of the Car. If the Return Air Temperature at either end of the Car rises to 150°F or above, the respective Firestat will prevent the associated Blower Fan Motor from operating at that end of the Car. If the Return Air Temperature at both ends of the Car decreases or is less than 150°F, both of the Blower Fan Motors will operate. A comparable system shall be included in the new system.

7.6.6 Lock-out Provision The HVAC controls shall contain a lock-out provision for the high pressure switch, low pressure switch, blower fan interlocks and overheat thermostats. This provision shall physically lock-out the operation of the heating and/or air conditioning system if three consecutive trips of the subject protective devices occur in a 15-minute period. The system shall require manual reset after a lock-out has occurred.

7.6.7 Interior Car Temperatures The existing train control, start-up methodology, and overall temperature control methodology shall be retained, or a new control scheme provided to meet the requirements of this Section in order to conserve energy (i.e. minimize the use of reheat where possible). The average temperature inside (Ti) the car shall be within the ranges shown below when the associated ambient temperatures are present. The ranges shown for (Ti) do not add to the allowable variations shown below:

Ambient Temperature (Ta) Interior Temperature (Ti) Ta ≤ 45 °F 65°F 45°F < Ta ≤ 55°F (if air conditioning is required) 70°F 55°F < Ta ≤ 93°F (interior conditions requiring reheat) 69°F < Ti < 72°F 55°F < Ta ≤ 93°F (interior conditions not requiring reheat) 72°F < Ti < 75°F 93°F < Ta ≤ 110°F Ti < (Ta – 20) 110°F < Ta As the system will provide

Under no circumstances shall the difference between the temperature of the conditioned air at the diffuser outlets and the average temperature of the air in the space occupied by passengers be greater than 25°F. The following variations in interior car temperatures are the maximum preferred. If the variations are found to be outside these boundaries and the result of the evaporator blower and/or ducting, the Contractor shall propose modifications and a remediation plan to SEPTA. Vertical: On any vertical line, 4 inches above the floor to 43 inches above the floor, not closer than 6 inches from walls, and not closer than 20 inches from doors: 5°F maximum difference between end points of the vertical line. Horizontal: Horizontal planes measured 4 inches, 43 inches, and 67 inches from the floor, not closer than 6 inches from walls and not closer than 20 inches from doors: The temperature at any point within each plane should not exceed +/- 3°F from the average temperature in that plane. When cooling is required, the interior relative humidity shall not exceed 60% under stabilized conditions where cooling loads are equal to the design conditions. Interior relative humidity shall not exceed 60% under stabilized conditions where the cooling loads are less than the design conditions. The design shall ensure against the formation of condensation on any area of the car air distribution system, ceiling panels, diffusers, or any other component installed in the car.

7.6.8 Diagnostics The faults shall be stored in non-volatile RAM and shall be downloadable to a PTU for troubleshooting and storage into a database. Faults downloaded by the PTU shall not be automatically deleted from memory. It shall be possible to ascertain the current software version of the system. It shall be possible to upload new control software to the HVAC system via a USB or Ethernet port.


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The system shall provide the capability to monitor status, faults and data in real time by maintenance personnel. The system data to be monitored shall be selectable by use of the laptop PTU. The system shall also have the capability to record the data for retrieval and playback on the PTU in a chart recorder format. An LCD display shall be provided on the system to view the selected system data in real time and to playback recorded data.

7.7 PORTABLE TEST UNITS The Contractor shall provide ten portable test units (PTU). These PTUs will be laptops that are set up for connection to the system for diagnostic testing and software updating. Each PTU device shall include all required cables, connectors and associated equipment required to interface with the system. The laptops shall be of a SEPTA approved configuration with ruggedized construction such as Panasonic Toughbook model CF-52. The laptops shall come with the enterprise version of the latest SEPTA approved operating system including the associated full office suite. There shall be no high voltage connections (greater than 150 volts) required between the car and any portable test device. It shall not be necessary to remove, dislodge, dismount or disconnect any component, card, wire, chassis, terminal or cable in order to perform periodic calibration or trouble diagnosis while using the portable test devices. The function of the portable test devices shall be to produce all of the operating commands and other input signals necessary to fully exercise all functions and components of the particular system under test, and to measure or indicate all of the signals, responses and outputs produced by a system by means of indicators such as lamps, meters, oscilloscopes, gauges, etc. It will be acceptable to require a visual check for system response such as closure of a contactor or a relay, or lighting an indicator, provided that the responding item of equipment does not require the test device operator to move more than 15 feet to make the required observation. The PTU shall have multiple login levels. One level will be able to run basic diagnostic processes; the second will be able to do the same plus force conditions such as voltages, currents and temperatures; the third will do the same as the first two as well be able to adjust system fault parameters. The PTU will supplement the built-in diagnostic features specified herein for the control system and shall not duplicate the specified features, but complement them by providing deeper and more comprehensive diagnostic capability. When used according to the instructions supplied by the Contractor, each portable test device shall enable the maintenance technician to fully check out and calibrate the system under test and to locate and replace any removable component which has failed. The need for connection of external apparatus to the portable test devices shall be kept to a minimum. When required, terminals shall be provided to allow connection of the apparatus to the portable test device. However, such apparatus shall be considered part of the portable test device and shall be supplied with it on a one-to-one basis.

7.8 BENCH TEST UNITS The Contractor shall provide a complete bench-type shop tester to facilitate the proper testing, troubleshooting, repair and calibration of the controls and power systems in a specialized workshop environment. The tester shall be delivered as a completely wired and assembled unit, and use shop electrical power and/or compressed air. Each tester shall have a receptacle for connecting to the device under test. Ease of operation to provide various inputs and for measurements of all signals shall be provided. The connections to the device under test, if not contained in the receptacle, shall be from the front of the tester and shall have provisions to neatly store out of the way when not needed. The Contractor shall coordinate with SEPTA to ensure compatibility with SEPTA's maintenance facilities Design of the testers shall be such that all inputs can be varied over the full working range of the device. The BTE computers shall also be supplied with the enterprise version of the latest


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SEPTA approved operating system including the associated full office suite. BTE computers shall provide back-up memory storage utilizing a RAID architecture. The BTE shall be supplied with the full software development suite with all licenses and the BTE test executive and test program source code. The bench test equipment shall be designed to enable a technician to perform rapid testing, troubleshooting to the discrete component level, repair and calibration of all equipment. The bench test equipment shall be automated to the extent possible so that a technician need only plug in or hook up a component for testing, identify the board or component, and the automatic test shall begin. This automatic test shall indicate the health of the unit under test and if the unit is acceptable for service or not, this shall include an evaluation of the unit's calibration status. If the unit under test is declared defective or out of calibration, the bench test unit shall allow the technician to troubleshoot the defective unit to determine which component is defective. For example, if a printed circuit board is under test and it is identified as being defective, the bench test unit shall allow the technician to single step, pause and loop through the automatic test to maintain the required inputs to the board for troubleshooting by the technician, which may include probing the circuit board to make various measurements, to determine which component, such as a resistor, capacitor, transistor or IC chip, is defective. It shall also include a manual mode to allow application of inputs to the unit under test as selected by the technician for troubleshooting. The Contractor shall provide all hardware and software required for perform these functions, for approval by the Engineer. Each supplier of circuit boards under this contract shall provide SEPTA all necessary electrical and physical information needed for fault finding and repair testing of these boards on this shop equipment. The shop testers shall be preprogrammed by the Contractor with algorithms needed to test and diagnose all of the car's circuit boards, as determined by the Engineer. Suppliers of circuit boards shall provide the information required to program the shop testers in a format designed for ease of entry and implementation by the Supplier. One set of any peripheral test equipment required to make the necessary tests and adjustments, such as frequency generators, digital voltmeters, oscilloscopes, etc., shall also be provided. They shall be rack mounted adjacent to and rear connected to the specialized equipment such that the end result is neat and tidy. These items shall be premium quality heavy duty devices supplied by Keysight, Tektronix, Fluke or other similar-quality approved supplier. The bench test equipment shall include all support devices required to enable testing of the line replaceable unit without the need to remove additional equipment from the car to support use of the bench test equipment. Microprocessor, EPROM, EEPROM, PLDs and other electronic device reprogramming tools shall be provided in order to program/reprogram firmware, boot loaders, etc. into the PCB integrated circuits. The PTU software shall also be integrated into the BTE.

7.9 BRAKE AIR COMPRESSOR DC TO AC CONVERSION KIT The Contractor shall provide a complete kit for the conversion of the WABCO D-4 air compressor from DC to AC power. This kit shall be Wabtec part number 06711781001 or equivalent.

Component Description Quantity 581243 SPACER 2 671419 HANGER-MOTOR MOUNTING 2 581061 CHANNEL-MOTOR HANGER 1 136157 KEY-WOODRUFF 1 580975 COVER-FRONT BEARING 1 578919 GASKET-FRONT BEARING COVER 1 580974 CRANKSHAFT 1 581308 COUPLING-FLEXIBLE 1 580995 ADAPTER-COMPRESSOR MOTOR 1 694104 KEY 1 696783 COMPRESSOR MOTOR-220VAC 1


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577004 SHAFT-FAN 1 671583 GUARD-COUPLING 1

7.10 DC-AC INVERTER REQUIREMENTS 7.10.1 Inverter Enclosure

The HVAC and Supply Air system DC-AC inverter shall be designed to meet NEMA Type 6P enclosure requirements as well as requirements for undercar mounting in a rail transit environment (including regular car wash cycles). The inverter enclosure shall have safety warnings on its exterior surface visible when installed on vehicle. Due to the enclosure type for the inverter, sufficient ventilation shall be incorporated into the inverter design to dissipate heat generated by the inverter power electronics. The Contractor shall present the proposed ventilation / cooling mechanism with engineering calculations and / or previous transit industry application to SEPTA engineering manager for approval. All wires/cables to the inverter shall be via moisture sealed grommet entrances. High voltage and low voltage wires/cables shall be separated and galvanically isolated. There shall be a power ON/OFF, high voltage and fault indicators on the exterior of the inverter enclosure.

7.10.2 Inverter I/O The inverter shall receive input voltage, nominal rated 650 VDC from underneath the car body, where the minimum input voltage could be 450 VDC and the maximum input could reach 800 VDC. The 650 VDC return is the running rails via the wheels. The inverter output shall be three (3) phases, 230 VAC, 60 Hz with a minimum efficiency of 90% to supply the above specified HVAC system, existing evaporator blower, air compressor motor and the existing evaporator blower motors.

7.10.3 Low Voltage Supply The 37.5 VDC low voltage power on the B-IV car is generated by the static converter, and has a floating return grounding system. The Contractor shall include all necessary low voltage power supplies in its inverter design to provide required low voltage power of inverter control, measurements, indications, etc. However, it shall be Contractor’s responsibility to evaluate the static converter’s capability, and make a determination if they choose to use the existing 37.5 VDC power for the inverter of the new HVAC system, and to ensure the reliability of both the new inverter and the existing vehicle electrical system.

7.10.4 Inverter Power-Up Time The supplied DC-AC inverter shall self-start within 5 seconds when the vehicle line breaker is closed and the input voltage between 550 VDC and 750 VDC is applied to the vehicle to provide 230 VAC, 3-phase 60 Hz as specified above.

7.10.5 Power Interruption Because the input voltage comes from a third rail collector shoe, normal operation includes power interruption due to rail gaps, possible shoe bounces or an icy rail. Therefore, the inverter shall be designed to withstand such condition without experiencing any failures or complete lockout conditions. Should the power interruption exceed 10ms, the inverter may stop and restart automatically as soon as the input voltage comes back into the nominal range. Repeated short term rail gaps shall not cause the inverter to completely shut down and lock-out, however the inverter may stop temporarily. Transient overvoltage or overcurrent incurred internally to the inverter by an input voltage interruption shall not cause a failure or lockout either. The inverter shall comply with the IEC 61287 Curve 2 (4kV/10ms transient positive overvoltage).

7.10.6 Inverter Protection and Self-Recovery The supplied inverter shall be self-protected against under voltage input, over voltage input and transient input spikes which could be as high as 1850 V lasting up to 20 micro sec. The inverter shall also self-protect against reversed input polarity, output short circuit and overcurrent. The inverter self-protection mode shall not cause


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it to cease operation. Therefore the inverter shall be designed in such a way that once the conditions for self-protection are removed the inverter shall resume to normal operation immediately without manual reset or shutting down by maintenance personnel. The inverter shall be designed for a minimum of 20 year design life. There shall be a fast acting fuse at the inverter input to protect the inverter. All inverter fuses shall be enclosed and shall not require manual reset or replacement during normal operation.

7.10.7 Inverter Mounting Each inverter shall be mounted undercar on a mounting bracket. SEPTA will provide or make available any relevant drawings, but Contractor shall make its own survey and measurements before the inverter design. The proposed inverter mounting location shall be presented to SEPTA engineering manager for approval before the final design. The Contractor shall provide inverter installation instruction to SEPTA for approval prior to the delivery of prototypes. [CDRL 14-06] Upon SEPTA engineering manager’s approval for the instruction, Contractor shall deliver the prototype system. All mounting brackets, panels, shims, hardware and cables/wires shall be provided by the Contractor. Design calculations including FEA shall be submitted to SEPTA Engineering prior to delivery. [CDRL 14-03]

7.10.8 EMI, EMC and THD The supplied inverter shall conform to the EMI and EMC qualifications provided in EN 50121-3-2. Certain frequency ranges shall be avoided in the inverter design in order to prevent from interfering with vehicle other electronic equipment as listed below:

60 Hz, for the primary track signal relays (PV-250) 1000 Hz -10 kHz, for radio audio overlays 1250 Hz, for the Kiepe propulsion chopper 90 kHz - 100kHz, for vehicle V-Tag system

The Total Harmonic Distortion (THD) for the output of the provided inverter shall be 5% max. The certificate of the THD measurements shall be presented to SEPTA engineering manager for approval.

7.11 SUSTAINABILITY The Contractor shall design the HVAC system to be, at a minimum, 10% more efficient than the current system and demonstrate these improvements through field testing.[CDRL 14-12] Reheat will not be run during this comparison test. A report of finding is to be submitted to SEPTA. SEPTA recommends the use of high efficiency components in the design of the HVAC system, such as high efficiency motors, low switching loss power semiconductors and electronics components. The use of GTO shall be avoided, if possible, in the inverter design.

7.12 APPROVAL A DDR for the overhaul of the system shall be submitted to SEPTA for approval [CDRL 14-02]. The Contractor shall also provide detailed installation drawings and schematics for any component/assembly being modified and/or upgraded. Except for outline drawings and system installation drawings, drawings are not required where the OEM equipment is not being changed. The Contractor shall submit a list of all drawings provided to SEPTA for approval [Part of CDRL 14-02]:

Diagrams/schematics: Electrical schematics, wiring and piping diagrams showing pipe sizes, switch ratings, resistance values of each resistor, contactor and solenoid valve coils, trip settings, component wattage, and wire sizes shall be submitted.

Detail drawings showing the installation of all major components. The following drawings as a minimum are considered applicable to this requirement:


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o Outline drawing of the Overhead Evaporator-Blower-heater unit; o Outline drawing of the Compressor/Condenser unit; o Installation drawings for the entire system; and o Major component assembly drawings.

7.13 MOUNTING It is the Contractor’s responsibility to provide all mounting brackets, plates, hardware, wires/cables and electrical terminations and connections for a secure mounting without excessive vibration or interference with existing equipment. The new compressor/condenser/motor assembly shall be designed to utilize the existing undercar mounting brackets. The Contractor shall survey the vehicle before designing its mounting equipment and develop an installation instruction/procedure, for SEPTA to use, based on its survey and design. The design must include survey results and calculations, including FEA, to be approved by SEPTA before submitting first prototype units for tests.[CDRL 14-03] The final installation instruction/procedure shall be submitted to SEPTA for approval before the first prototype delivery of the specified system. [CDRL 14-06] The HVAC unit shall remain within the existing static and dynamic envelopes of the vehicle. Non-structural modifications may be proposed to the HVAC mounting arrangement in order to remain within the existing vehicle envelopes. Modifications shall be submitted to SEPTA for review and approval [CDRL 14-03].

8.0 ENVIRONMENTAL REQUIREMENTS

8.1 OPERATING ENVIRONMENT It shall be put into design consideration for the above specified HVAC system that B-IV vehicle interior temperature ranges between -20 °F to 122 °F (-28 °C to 50 °C) with 0-95% non-condensed humidity. All system components shall be designed and tested to operate at or beyond this temperature range. The Contractor shall submit the test results to SEPTA Vehicle Engineering prior to prototype delivery.

8.2 VIBRATION AND SHOCK REQUIREMENTS The designed HVAC system, including mounting brackets and its associated components shall meet the vibration and shock requirements of IEC 61373. A certified test report shall be submitted to SEPTA Vehicle Engineering prior to prototype delivery. The certified test report shall indicate the equipment under test which shall include not only the HVAC system and inverter but also the mounting brackets attached.

9.0 PILOT AND PRODUCTION DELIVERY

Among the purchase quantity of HVAC systems, the Contractor shall provide 2 sets of prototype samples for SEPTA personnel to install on a B-IV vehicle, using Contractor provided installation instruction / procedure under Contractor’s close supervision, for testing and evaluation per the specification requirements for the 3 months of June 1st through August 31st. These prototypes must be of the same materials and quality as final production units. The Contractor shall be responsible for correcting, modifying and troubleshooting any issues during the prototype testing period. Upon SEPTA approval of the prototype samples the Contractor may start to provide production HVAC systems and associated equipment. The Contractor shall provide supervision when SEPTA mechanics install the two (2) prototype sample HVAC system assemblies at SEPTA Fern Rock shop, and verify the design functionalities. Pilot installations may be performed at any time, but this final verification must be completed prior to the commencement of testing on June 1st.


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9.1 PROJECT MANAGEMENT This contract is unique given the design and testing requirements outlined in specification. Project coordination between Contractor and SEPTA is crucial. Weekly conference calls between Contractor and SEPTA will begin one week after notice to proceed. Contractor will establish a conference call center. SEPTA’s project engineer will provide an agenda each week and forward it at a minimum of one day prior to conference call.

10.0 FLEET DEFECTS

In the event that during the warranty period specific repairs, replacements or modifications necessitated by defects in design or material of the same kind or type are required, SEPTA may declare a fleet defect if any of the following occur: (a) failures of the same component in the same application exceeds a failure rate of five (5) percent during any period of four (4) consecutive months based on the average number of such components in service during such twelve month period or (b) the installed system of the Car have failed the Reliability requirements of the Specification or (c) a failure analysis of a component, system or subsystem defines a problem The Contractor shall develop a plan to rectify regardless of the failure rate percentage or Reliability Requirements of Specification. The Contractor shall promptly institute an approved modification program for all Cars, regardless if the warranty period has expired for an individual Car. In the event that such defects or failures require the removal of major components or assemblies for the purpose of repairs or modifications, and such removals render the Cars inoperable or unfit for safe and efficient operation in regular service, the Contractor shall promptly furnish an adequate number of spare components or assemblies for the temporary use by SEPTA so as to minimize downtime of the affected Cars while repairs or modifications are being done. Any accepted Car which during the warranty period (including any extensions) SEPTA has found to be unavailable for service due to the unavailability of these above mentioned spare components shall be treated as a delayed delivery and subject to the conditions of the contract. This requirement shall also apply to items of Material and/or Equipment other than the Cars which are delivered under this Contract. After 10 or more of the Cars have been accepted, in the event during the warranty period that 15 percent or more of the Cars are simultaneously inoperable, or unfit for safe and efficient operation in regular service even though operable, due to defects in design or material whether or not of the same type or kind, as determined by SEPTA, SEPTA may require the Contractor, within a reasonable time after receipt of written notice, to submit a Contractor's proposal for a "Remanufacturing Program" or "Campaign" to affect the necessary repairs, replacements or modifications, at no additional cost to SEPTA, in the shortest time possible and with the least disruption to or interference with regular service. This shall also apply to any individual Cars in which the warranty period has elapsed

10.1 RELIABILITY REQUIREMENTS The supplied HVAC system and inverter shall perform reliably according to the above requirements for at least two (2) years based on average 18 hours daily, six (6) days per week operating time. A system failure shall include any in service interruption of the HVAC system or inverter operation due to hardware malfunction or software lockouts that require manual reset or reboot.


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11.0 DOCUMENTATION

A system schematic diagram and characteristic description shall be provided to SEPTA for 30 day review upon the contract award. Prior to the completion of all production delivery and after the completion of all warranty and retrofit repairs (if any), the Contractor shall provide as-built documentation for SEPTA to maintain the final product and its associated test equipment (PTU and BTE) in vehicle operation, in these media: Four (4) hard copies (paper in binders) and four (4) electronic copies (MSOffice or PDF formatted) on discs or portable drives for each of the following:

11.1 INSPECTION, REFURBISHING, INSTALLATION AND TESTING MANUAL This manual [CDRL 14-06] shall include all procedures needed to inspect and refurbish the existing items to be reused (including piping, ducting and equipment mounting). It will also include all procedures required to install the new equipment, integrate it with the existing equipment and test the complete system for proper operation and securement following installation.

11.2 PREVENTIVE MAINTENANCE MANUAL This manual [CDRL 14-07] shall include all recommended tests and inspections (if any) needed to maintain proper operation of the HVAC system and associated test equipment on a 60, 120, 180, and 360 day as well as a 5 year basis. This timetable has been established for the upkeep of the remainder of the vehicle and any required tests and inspections must coincide with this schedule.

11.3 TROUBLESHOOTING MANUAL This manual [CDRL 14-08] shall address system-level, unit-level, and circuit board-level equipment and shall include descriptions of the mechanical and electrical features of the system, schematic diagrams, functional descriptions of operation, manufacturer and model information, inverter functionality, detailed electrical schematics and operating theory, component layouts, wiring diagrams, control, fuse rating and location, input/output configuration and connection, communication port (if applicable), user interface, indication, display, internal battery (if applicable) and troubleshooting guides.

11.4 HEAVY REPAIR MANUAL This manual [CDRL 14-09] shall include complete, detailed maintenance instructions for all major components and their subassemblies necessary for complete teardown and rebuild of all units and components. These instructions shall also include detailed and numbered exploded-view drawings of each of the assemblies to denote proper configuration.

11.5 SOFTWARE/FIRMWARE USER’S MANUAL This manual [CDRL 14-10] shall include pertinent information of all software and/or firmware used in the HVAC system and associated test equipment including model numbers, revisions, functions, controls, configurations, settings, uploading methods, user interfaces, etc. Software and firmware manufacturers’ information shall also be provided in this manual.

11.6 RENEWAL PARTS CATALOG This manual [CDRL 14-11] shall include all replaceable parts for the delivered HVAC system and associated test equipment containing itemized parts illustration figures with part names, supplier part number, part description, manufacturer name, manufacturer part number and an empty column labeled “SEPTA C/L #” for SEPTA to populate later. An appendix giving the original supplier's website url, complete address, and telephone numbers for their offices responsible for parts ordering shall be included.

11.7 PTU OPERATIONS MANUAL This manual [CDRL 14-15] shall provide detailed instructions for each level of operator utilizing actual screen shots of the human-machine interface. This shall also include a full copy of the PTU help file for off-line


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purposes. 11.8 BTE OPERATIONS AND MAINTENANCE MANUAL

This manual [CDRL 14-16] shall provide detailed instructions for the technician utilizing actual screen shots of the test windows. It shall include copies of passing test reports including the pass/fail criteria, a BTE system-level functional diagram, detailed electrical and mechanical drawings, test interconnection drawings with wiring lists to be able to trace through all power/signal source and associated measurement equipment.

12.0 TRAINING

The Contractor shall provide an in-service Maintenance educational school on SEPTA’s premises. Maintenance Training shall be scheduled for a period of not less than 25, eight-hour days. The curriculum for the school shall incorporate all methods of safely and properly installing, maintaining and operating the delivered HVAC systems. Training classes shall be structured and divided in accordance to the intended audience. There shall be a separate course and courseware package [CDRL 14-14] for each worker classification including vehicle operators, maintenance manager, vehicle mechanics/specialists, vehicle HVAC specialists, and the component-level electronic technicians. The Supplier shall provide a system functions training aid comprised of the actual vehicle HVAC and inverter controllers which shall be interfaced in the same logical fashion as applied on the vehicle but with simulated input and output devices for use in the classroom portion of all the training classes. This training aid shall be serialized and tracked and is to be kept at the same revision level as the relative vehicle HVAC components. This training aid may not make use of SEPTA's pool of spare parts. Any special wiring and configuration details shall be provided in order to understand and maintain the training aid.

13.0 CONTRACT DELIVERABLES REQUIREMENTS LIST

CDRL Title Section Reference

14-01 CDR of HVAC Overhaul

Contract

14-02 DDR of HVAC Overhaul

7.12

14-03 Mounting Design and Calculations

7.6.3, 7.13, 7.10.7

14-04 Cooling and Heating Load Calculations

7.5.2

14-05 14-06

New HVAC Controls Design Car Testing , Report of Findings

7.6.1 7.3,7.4, 7.5, 9

14-07 Installation and Testing Manual

7.10.7, 7.13, 11.1

14-08 Preventive Maintenance Manual

11.2

14-09 Troubleshooting Manual 11.3

14-10 Heavy Repair Manual 11.4


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14.0 ATTACHMENTS

Figure 10-7 Electrical Schematic Figure 10-119 Interconnection Diagram ATTACHMENT A

14-11 Software/Firmware User’s Manual

11.5

14-12 Renewal Parts Catalog 11.6

14-13 14-14 14-15 14-16

System Sustainability Test Report Training Courseware Packages PTU Operations Manual BTE Operations and Maintenance Manual

7.11 12.0 11.7 11.8

Reference Specification: S-4648 Fleet: B-IV System: HVAC Latest Revision Date:

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Figure 10-7. Air Comfort System Electrical Schematic


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Figure 10-119-Interconnection Diagram


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GENERAL PROPOSAL FORMAT REQUIREMENTS - ATTACHMENT A

The technical proposal shall consist of five (5) sections: 1) Introduction; 2) Proposed Methodology and Work Plan; 3) Demonstrated acceptability of equipment to be supplied; 4) Experience and Qualifications of the Vendors and Subcontractors; and 5) Quality Assurance Plan

1.0 INTRODUCTION This section is to provide information concerning the company and any principal subcontractors (or other business entity). Information to include, 1. Date of founding; place of incorporation (if applicable); 2. Parent firm (if a subsidiary) or other ownership (individual, partnership, other); 3. Location of home and field offices; 4.Location and a summary description of facilities which will fabricate parts, assemble parts and perform test ; 5.Types of work in which the firm is engaged, 6.Substantial experience in similar design/ build projects

2.0 PROPOSED METHODOLOGY AND WORK PLAN This portion of the technical proposal is to provide Conceptual Design Review (CDR). This CDR will be a complete description of the work tasks and methodology to be employed by the proposer and a project schedule that delineates the time periods to complete the work tasks proposed by the proposer for completing the project within the contract schedule. The technical proposal shall include a project work plan. This project work plan is to define the major phases, activities, tasks and subtasks with associated contract deliverables. This section shall address each and every requirement of SEPTA’S technical specification. It is not necessary to actually provide the design solution to every requirement, but it is necessary to describe the approach that will be taken to comply with every requirement of this specification.

3.0 DEMONSTRATED ACCEPTABILITY OF EQUIPMENT TO BE SUPPLIED This section of the technical proposal should demonstrate that the proposed equipment and components have demonstrated acceptable performance characteristics, including reliability. This demonstrated acceptability must be in the following: Previous experience with HVAC systems used in the Railroad, Transit Car or Locomotive Applications. Submittal data shall include, but not necessarily be limited to the following: 1. Description of equipment supplied 2. Where used, including customer name and phone number 3. Quantity in use 4. Number of years in use (initial to present) 5. Mean Time To Repair (MTTR) 6. Record of satisfactory performance (number of failures versus quantity and time in use) 7. Nature of critical failures

4.0 EXPERIENCE AND QUALIFICATIONS OF THE PROPOSER AND SUBCONTRACTORS This section of the technical proposal is to provide a description of the experience and qualifications, as they relate to the design, manufacture and maintenance of equipment similar to that required by this project. All suppliers and subcontractors shall be named. Any deviation from these subcontractors must be approved in advance of the change by the SEPTA Engineering Project Manager.


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5.0 QUALITY ASSURANCE PLAN All suppliers and subcontractors shall have a quality assurance ISO 9000-style program in force which applies to raw materials, in-house manufactured and outside supplied articles. This provision shall apply equally to suppliers who are manufacturers of the material they sell as well as to suppliers who function as distributors of material manufactured by others. The quality assurance program required by this section shall be based on the following elements:

1) Quality Assurance Manual 2) Inspection and test checklists 3) Design and production document control 4) Measuring and test equipment calibration control 5) Incoming inspection procedures 6) In-process inspection procedures 7) Final inspection procedures 8) Article ID and traceability processes 9) Quality records control 10) Non-conformance procedures 11) Statistical process control 12) Purchasing review procedure

reference specification: s-4648-1 fleet: b-iv …...2017/05/16 · reference specification:...

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