Attachment 1 - EEQA-945 Red Line No. 3 Car LED Lighting Upgrade.docx

Equipment Engineering and Quality Assurance Technical Specification Specification:

EE&QA-945

MBTA RED LINE NO. 3 CAR LED LIGHTING UPGRADE Page 46 of 48

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

TECHNICAL SPECIFICATION

EE&QA-945

MBTA RED LINE NO. 3 CAR

LED LIGHTING UPGRADE

ISSUED:

September 8, 2023

REVISION:

1.1

EQUIPMENT ENGINEERING AND QUALITY ASSURANCE

Attachment 1

TABLE OF CONTENTS

REVISION HISTORY

Revision Number Revision Date

GENERAL

This specification details the requirements for the Massachusetts Bay Transportation Authority’s (MBTA) procurement of a new lighting system for the existing Red Line No. 3 cars to replace the current interior and exterior, incandescent and fluorescent lighting to LED lighting. Specifications have been written to define the requirements of the MBTA vehicles. The intent is to preserve the life of the current cars for an additional ten (10) years.

The lighting system shall meet the requirements listed in Section 5 for car lighting, as well as the requirements of this specification.

The lighting system consists of all interior ceiling lighting and exterior lighting. The design shall provide normal levels of lighting with a minimal degradation of color or luminosity over time. The upgrade shall ensure safe levels of lighting shall be provided in the event of emergency conditions.

The supplier must perform a study of the current vehicles layout and develop a lighting upgrade which fits the current lighting arrangement and fixtures and submit it to the MBTA for review and approval.

The design shall include:

Layout of the interior lighting, including emergency lighting.

Layout of the exterior lighting.

Sample light fixtures and control switches shall be submitted to the MBTA for review and approval, prior to the Design Review.

All lighting control switches and circuit breakers shall be located in the Operator’s cab area.

There shall be minimum impact and modifications made to the carbody, i.e. drilling, cutting, etc., and effort shall be made to maximize the use of existing equipment and components.

Existing carbody wiring and circuitry is to be utilized as much as possible. Replacement fixtures shall meet the same form, fit, and function as the existing fixtures.

There shall be no butt splicing. The contractor must use existing terminal block for wiring unless otherwise approved.

The Contractor shall ship material in the form of kits which shall makeup all components necessary for one full car to be fully upgraded with new LED Lighting materials.

Kits shall include a full bill of materials and be clearly labelled for ease of installation.

Kits shall include replacements for the following fixtures on the Red Line No. 3 Car. The Contractor shall supply kits with all necessary materials for full upgrade of the LED lighting system per this specification.

(per car)

Table 1: Red Line No. 3 Car Lighting Fixtures

CONTRACTOR REQUIREMENTS:

Qualifications and Technical Bid Submittal The Contractor shall demonstrate, as part of their bid submittal, that they have a minimum of five (5) years but preferably ten (10) years of successful experience in the design, manufacturing, integration, and post-sale support of LED lighting on rail vehicles operating in similar environmental conditions found in Boston, Massachusetts.

The Contractor shall provide, as part of the bid submittal, a list of at least three (3) projects within the last ten (10) years on which similar equipment was supplied, including agency name, quantity supplied, fleet size, and contact information (Including name, title, phone number and email address) for each project.

The Contractor shall provide, as part of their bid submittal, their proposed lighting, technical specification sheets, physical dimensions, weight, and a narrative describing anticipated changes and improvements to the units or vehicle to meet this Specification. The Contractor shall also supply a list of all domestic material suppliers.

The Contractor shall provide, as part of their bid submittal, a list of exceptions to this technical specification and narrative why the exception is being listed.

The list of exceptions will be subject to Authority review and approval.

The Contractor shall provide, as part of their bid submittal, a preliminary schedule for meeting the requirements of this Specification.

If the Contractor cannot meet the specified schedule requirements, the Contractor shall indicate such in their bid submittal and propose an alternative schedule. The alternative schedule will be subject to Authority review and approval.

PROJECT SCHEDULE

Thirty (30) days after receiving Contract Execution the Contractor shall submit a comprehensive schedule, which at a minimum identifies the time frames for the following:

Design, Delivery, Inspection, and Testing of the pilot vehicle equipment. The Contractor shall provide a complete material kit for one (1) married pair (two carsets) and assist with performing all of the necessary qualification tests and in-service tests. After the design performance of the pilot units is successful and deemed approved, the MBTA will provide notice for the Contractor to move forward with the production of the rest of the remaining car-sets of material. Installation and testing procedures must be developed by the Contractor for review by the Authority.

Delivery schedule of all documentation, including design review dates and meetings, training materials, maintenance manuals, etc.

First Article Inspection (FAI).

Delivery schedule for eighty-three (83) car-sets of equipment which meets the timeline identified in this specification.

Delivery of eighty-three (83) car-sets of materials is dependent on successful completion of the design, inspection, and testing of the pilot vehicle equipment and completion of the FAI (See Section 3.3).

Schedule of all major milestones.

The Contractor shall coordinate and deliver the pilot equipment and any materials necessary for the installation of the pilot equipment to the Authority no later than six (6) months after Contract Execution.

The Contractor shall coordinate and begin delivery of up-to eighty-three (83) carsets base order lighting equipment and any required installation materials to the Authority no later than six (6) months after written approval of the acceptance of the pilot unit from the Authority.

The base order shall be delivered at a minimum rate of three (3) married pair of equipment per month thereafter.

The Contractor shall update the Project Schedule and submit it to the Authority’s Program Manager, if or when there is a change to the schedule.

Scope of work

INTERIOR LIGHTING PASSENGER AREA

The lighting fixtures shall use LED cluster modules, cool white in color and powered by a DC Low Voltage Distribution Network.

The lighting fixture’s diffuser lens shall be translucent and shall provide a continuous lighting pattern. New lens must fit in existing lens fixture/mounting. Sample options shall be provided for MBTA acceptance.

The passenger main lighting fixtures shall be mounted in two continuous rows, one on each side of the aisle.

Figure 1: Interior Lighting Arrangement The main lighting in the passenger area shall be divided into three separate circuits, two for main lighting and one for emergency lighting. The lights attached to each circuit breaker shall be distributed throughout the car, such that loss of power from a single circuit breaker shall not darken one section of the car more than others.

The existing configuration consist of a combination 3ft and 4 ft lighting fixtures. The proposed design should follow this same configuration and utilize the existing wiring connections and carbody wiring.

Preferably, the existing lighting housing shall be used. The contractor can propose to attach the LED strips to the fixtures or use a bolt-on solutions. If new design fixtures must be implemented, then they should be compatible and interchangeable with new Red Line and Orange Line Cars, otherwise, if the existing housing is used, the new LED driver boards should be compatible and interchangeable to allow MBTA to use these as spare parts at the end of the RL #3 Car’s life.

CONTROLS

All passenger lighting fixtures should be controlled by the already existing Operator’s cab console control switch. Whenever possible, the existing controls shall be reused on the new design. However, the contractor may propose a new switch design but must be compatible with the current cab console interface.

The trainline control for passenger interior lighting shall be designed so that the main interior lights may be turned on or off from any cab in a train, whether the Master Controller transfer switch is in the ON position or not.

Cutout switches for passenger area lighting shall be located in the cab. Cutout switches shall de-energize all interior lighting, including emergency lighting for the car being operated. Cut-out switches do not control other cars via trainline.

OPERATOR’S CAB LIGHTING

Cab interior lighting, instrument lighting, and cab equipment compartment lighting shall use LED modules. The overhead lighting shall consist of two, directionally adjustable reading lights, one located on each side of the cab. The overhead lights shall be directed to avoid glare in the windshields and utilize the existing carbody wiring. The cab lighting shall utilize the existing circuitry and be installed in the same locations as the currently installed cab lighting.

EXTERIOR LIGHTING

Figure 2: Exterior Lighting Arrangement Headlights Headlights shall be provided at the No. 1 end of each car at locations approved by the MBTA. The headlights shall be LED lamps and shall provide high beam and low beam functions.

The headlights shall by default be activated and remain ON in the lead car when a train keyed-up from any cab.

The low beam shall be angled down so as not to blind passengers on station platforms or Operators of approaching trains.

Headlamp electrical connections shall be protected from water ingress.

If possible, the LED driver board of the headlights shall be compatible and interchangeable with the ones currently used on the new Red Line #4 cars and the Orange Line #14 cars All exterior lighting gaskets and seals must be replaced, even in the event that the existing housing is reused.

Headlights must be adjustable. Adjustment procedures must be submitted in advance to the Authority for review.

Lighting Controls The existing circuit breaker shall be utilized for the headlights.

The headlights shall be interlocked with the direction trainline. The headlights shall come on automatically and remain on as a safety feature in the event of a failure of cab control circuits.

The existing two-position switch, located in the Operator’s Cab Console shall be used for the high beam / low beam.

Marker lights, taillights, and stepladder lights are controlled by a contact of the coupler control switch.

Emergency lights are controlled directly from existing circuit breaker EVLB.

The ATP BYPASS light is controlled by an ATP bypass switch.

Door summary status lights are controlled by relay logic on the door control relay panel.

Door leaf status lights are controlled by switches of the local door operators.

The propulsion fault lights are controlled automatically by the car control unit.

All other lighting is controlled automatically by the cab control box in response to interface inputs from command switches on the rocker switch panel or limit switches used for component supervision.

Taillights and Marker Lights All exterior lighting gaskets and seals must be replaced, even in the event that the existing housing is reused. Taillights and Marker lights shall be provided at the No. 1 end of each car, at the correspondent existing locations Tail and Marker light LED lamps shall be mounted in waterproof fixtures.

Taillights shall be red LED lamps.

Marker lights shall be red LED lamps.

Lighting Controls The taillights shall be automatically illuminated at each uncoupled end. Taillights shall utilize existing circuitry and function as the currently installed taillights.

The marker lights shall be automatically illuminated and go off at each uncoupled end during coupling and uncoupling. Marker lights shall utilize existing circuitry and function as the currently installed marker lights.

Stepladder / Loop Step Lights An LED light shall be provided at each loop step on the No. 1 end of each car and shall function as the current installed fixture.

The loop step lights shall turn on and go off automatically during coupling and uncoupling.

Body End Door Vestibule Lights Each body end door vestibule light shall have an LED replacement fixture installed to replace the current light fixture and function as-is.

Parking / Handbrake Light A green Parking Brake LED light, visible in the transverse and longitudinal directions, shall be provided on each side of the car. The location shall be on the sidewall, adjacent to the first door leaf of the second door (see figure 2). The fixture lens should match the “cone” shaped lens of the current installed light and utilize the current carbody wiring.

The Parking Brake Light shall be illuminated whenever the Parking Brake is applied and should be visible from the Operator’s cab of the lead car.

Propulsion Fault Indicator Light The Propulsion Fault Indicator shall be a high brightness blue LED indicator light visible in the transverse and longitudinal directions. The indicator shall be provided on both sides of the car. The location shall be on the sidewall, adjacent to front door leaf of the first door (see figure 2) and should be visible from the Operator’s cab of the lead car.

The fixture lens should be of similar design to the “cone” shaped lens of the current installed light and utilize the current carbody wiring.

ATP Bypass Indicator Light The ATP Bypass Indicator shall be a high brightness amber LED light mounted on the front of the car, over the door or driver’s windshield, as close as possible to the center line of the car (see figure 2). The ATP Bypass Indicator shall be lit at all times except when the ATP system is bypassed.

The fixture lens should be of similar design to the “cone” shaped lens of the current installed light and utilize the current carbody wiring.

Snow Break / Sleet Scraper Indicator Light The Snow Brake/Sleet Scraper Indicator shall be a high brightness amber LED light and provided on both sides of the car. The location shall be on the sidewall, adjacent to rear door leaf, of the first door (see figure 2) and should be visible from the Operator’s cab of the lead car.

The fixture lens should be of similar design to the “cone” shaped lens of the current installed light and utilize the current carbody wiring.

EMERGENCY LIGHTING

Interior Lighting A minimum of (4) interior lights shall remain ON during emergency state. See Figure 1. The emergency lights shall utilize the existing car emergency circuitry for operation and also utilize the existing fixtures of the current emergency lighting on the car.

The proposed emergency lighting levels and duration shall meet or exceed the current emergency lighting levels and duration.

LIGHTING PERFORMANCE AND INTENSITY REQUIREMENTS

To avoid discomfort from high light levels that reach the eyes directly or indirectly through reflections from shiny surfaces or from improperly shielded light sources, lighting equipment should be located as far from line of sight as possible. All lighting performance and intensity requirements shall be demonstrated and verified by field testing. Previous, comparable test results may be submitted for MBTAs consideration.

Performance LED drivers shall not draw power when the LEDs lamps are off.

Control of LED currents shall not cause any noticeable light flickering.

LEDs should be driven by a constant current circuit with a setting not in excess of 65% - 70% of the LED maximum current rating.

Failure of a single LED shall not turn off the LED board and shall not reduce the life expectancy of the LED board.

Passenger Area The average illumination intensity within the vehicle at elevations of 33 inches (838 mm) above the floor on a 45º plane centered on the front edge of any seat, and 55 inches (1400 mm) above the floor on a 45º plane shall be at least 35 foot-candles (377 lux). The average illumination intensity on the floor in the passenger aisles and passenger side door vestibule areas between the windscreens shall be not less than 20 foot-candles (215 lux). The average illumination intensity on the end door threshold with doors open and passengers standing in the door vestibule must exceed 2 foot candles (21.5 lux) without any platform lighting.

The average illumination intensity on the end door threshold with doors open and passengers standing in the door vestibule must exceed 2 foot candles (21.5 lux) without any platform lighting.

Emergency interior lighting intensity levels shall demonstrate enhanced performance from the existing configuration.

Headlights The intensity and orientation of the high beam lights shall permit the Operator to see a dark object the size of a 50th percentile man 800 feet (244 m) ahead.

Headlights should be FRA compliant (49 CFR 229.125).

The high beam lights shall allow sufficient light to view a 50th percentile man wearing a reflective vest 1200 feet (366 m) away.

The low beam shall be angled down so as not to blind passengers on station platforms or Operators of approaching trains.

The low beam light shall strike the tracks at approximately 150 feet (45.7 m) in front of the car. It shall be positioned so as not to blind on-coming traffic or passengers when entering a station. The angle setting of the low beam light shall be finalized during the testing of the Pilot Cars.

Contractor will submit a headlight adjustment procedure for review by The Authority Other Exterior Lights The intensity of the loop step lights, handbrake lights and body end door lights shall be submitted for review and approval by the Authority.

Exterior Indicators All exterior indicators, when illuminated, shall be clearly visible from six cars away for those viewed in the longitudinal direction and minimum of 50 feet (15 m) for those viewed in the transverse direction. Tests shall be conducted in bright sunlight.

Interface requirements The upgraded interior and exterior LED lighting assemblies shall be designed to fit within the existing lighting fixture envelop. Fixture mounting holes and locations shall be utilized where practical.

The Contactor shall provide all hardware and interface connections between the lighting assembly and vehicle.

Interior and exterior lighting upgrades shall utilize the existing carbody wiring and fixture terminal boards.

Existing lighting circuitry and control shall be utilized where practical. Any design not able to utilize the existing circuitry and control shall be submitted to the Authority for review.

Excessive modifications are strongly discouraged.

Current draw The LED upgrade is expected to draw less than the currently installed lighting assemblies and shall utilize existing breakers.

RELIABILITY

The expected service life of LED interior lighting lamps shall be a minimum of 50000 hours to 70% of original luminosity.

The expected service life for interior/exterior LED indicator, marker and taillights shall be a minimum of 100,000 hours.

The expected service life of conditioning power supplies, if external to the lamp, shall exceed 200,000 hours. Mean time between failures for external conditioning power supplies shall exceed 200,000 hours.

The expected service life of headlamps shall be at least 1500 hours for the low beam and 1000 hours for high beam.

The Contractor shall supply documentation and testing procedures which show the components supply meet the requirements of Section 8 during the FAI phase.

MAINTAINABILITY

Lighting fixtures shall be designed to facilitate cleaning of lenses, housing removal and LED lamp or module replacement. Additionally, all fixture covers shall be retained by hinges and held closed by a spring latch, tamper proof, self-locking design. Lighting fixtures shall be dust-proof to minimize the accumulation of airborne dirt and dust inside the fixture.

Headlight fixtures shall be designed for quick removal and replacement of headlamps. Headlight replacement shall require no more than 15 minutes and require no angular adjustment of the lamp.

The LED fixtures shall have wiring quick-disconnects and “snap-in” features to facilitate ease of removal without the use of special tools. LED fixtures shall be mounted securely in such a way that vibration cannot cause them to fall.

Wiring diagrams, installation drawings and operation and maintenance manuals shall be provided for MBTA review and approval.

SAFETY FEATURES

All lighting equipment shall:

Have an over-temperature protection with an automatic reset.

Withstand voltage fluctuations and shall not be damaged by the intermittent or continuous application of the reverse polarity DC power.

Be designed such that when disconnected, the powered side of the connection is covered.

Interior overhead lighting fixtures shall have a retaining strap to prevent them from falling on passengers or repair persons in case they come loose from their mounting.

Lighting fixtures located on the vehicle exterior and in the interior, below ceiling level, shall be watertight.

FLAMMAbILITY, SMOKE AND TOXICITY All non-metallic components selected for use in the design shall be tested in accordance with smoke, flame and toxicity requirements of 49 CFR 238.103, and Appendix B to Part 238 - Test Methods and Performance Criteria for the Flammability and Smoke Emission Characteristics of Materials Used in Passenger Cars and Locomotive Cabs.

The Contractor shall submit laboratory test results for each test, including a technical data sheet, for approval per the following tables.

Function of Material (numbers in parentheses indicate applicable notes below)

Elastomers – Lock strip gaskets (1, 2, 3, 4)

ASTM C542

ASTM E662

Pass criteria in table 1 Ds (1.5) ≤ 100, Ds (4.0) ≤ 200

Wire Insulation (1, 2, 5) IEEE Std 383 Flammability

ASTM E662

Pass Ds (4.0) ≤ 50

Lighting Diffusers / Plastic Glazing (2, 6)

ASTM E162

ASTM E662

Is ≤ 100 Ds (1.5) ≤ 100, Ds (4.0) ≤ 200

Table 2 - FST Test and Performance Criteria

Numbered notes are based upon NFPA 130, and 49 CFR Appendix B to Part 238.

These comments have been quoted, combined from both, or adapted/edited to passenger transit applications.

1) Materials tested for surface flammability shall not exhibit any flaming running or dripping unless an appropriate fire hazard analysis is conducted and approved by the Authority.

2) The ASTM E 662-97 maximum test limits for smoke emission (specific optical density) shall be measured in both the flaming or non-flaming mode, values shall be provided for both cases.

3) Materials used to fabricate miscellaneous, discontinuous small parts (such as knobs, rollers, fasteners, clips, grommets, and small electrical parts) that will not contribute materially to fire growth in end use configuration are exempt from flammability and smoke emission performance requirements, provided that the surface area of any individual small part is less than 16 square inches (100 cm2) in end use configuration and an appropriate fire hazard analysis is conducted which addresses the location and quantity of the materials used, and the vulnerability of the materials to ignition and contribution to flame spread.

4) If the surface area of any individual small part is less than 16 square inches (100 cm2) in end use configuration, materials used to fabricate such a part may be tested in accordance with ASTM E1354 as an alternative to both (a) the ASTM E162 flammability test procedure, or the appropriate flammability test procedure otherwise specified in the table, and (b) the ASTM E662 smoke generation test procedure. Testing shall be at 50 kW/m2 applied heat flux with a retainer frame. Materials tested in accordance with ASTM E1354 shall meet the following performance criteria: average heat release rate (qÿ´´ 180) less than or equal to 100 kW/m2, and average specific extinction area (sf) less than or equal to 500 m2/kg over the same 180-second period.

5) Testing shall be conducted in accordance with ANSI/IEEE Standard 383-1974, section 2.5, with the additional requirement that circuit integrity shall continue for 5 minutes after the start of the test.

6) For double window glazing, only the interior glazing is required to meet the requirements specified herein. (The exterior glazing is not required to meet these requirements.)

Table 3 - NFPA 130 and 49 CFR notes Physical and Environmental Requirements General The new LED lighting shall be able to properly operate in weather conditions common to Boston, Massachusetts, including cold, heat, rain, and snow.

The Contractor shall provide documentation showing the supplied components have service proved history in similar climates as stated in Section 12 during the FAI phase. The pilot equipment will be tested over multiple seasons (Section 14) to verify operation under the conditions listed in Section 12.

Temperature and Solar Load Ambient air temperature external to equipment Minimum: -20°F Maximum: 120°F Humidity Minimum: 5% Maximum: 100% Precipitation Maximum rainfall rate: 4” (inches) per hour Maximum snowfall rate: 5” (inches) per hour Maximum snow accumulation: 18” (inches) Wind Maximum sustained: 40 MPH (miles per hour) Maximum gusting: 70 MPH (miles per hour) Air, Tunnel, and Road Contamination The new LED lighting shall operate as specified under the air contamination levels which occur in the coastal environment that exists in the Authority’s service area.

The new LED Lighting shall operate under the dust, trash, and leaf accumulation and subway tunnel dust (up to 85% metallic) conditions, experienced on rights of way in the Authority’s service area.

Shipping and Receiving A packing list shall be provided indicating all components in the shipment.

The Contractor shall ship material in the form of kits of LED lighting materials which shall makeup all components necessary for one full car to be fully upgraded with new materials.

Kits shall include a full bill of materials and be clearly labelled for ease of installation.

The Authority’s facility has street level unloading access only. A loading dock does not exist at the facility. The Authority has access to forklifts for removal of equipment from the vehicle, however, these forklifts can only access freight from street level.

The Contractor shall provide shipment via flatbed truck or through another method of transportation approved by the Authority. Shipments via an unapproved method will be rejected at the Authority’s property.

The Authority has forklifts with capabilities of lifting up to 7,500 lbs. and two-wheel dollies for moving materials onto and off of the Contractor’s vehicle. The Contractor shall be responsible for moving material around within the Contractor’s delivery vehicle so that the Authority may perform on-/off-load operations.

The Contractor shall be responsible for all logistics and costs associated with transportation and shipment of units and components between the Authorities facility, the Contractor’s facility, and any Subcontractors’ facilities.

The Contractor shall include pricing for delivery of material within their proposal.

The Contractor shall be responsible for all expenses related to the pick-up and redelivery.

Delivery Location All material kits shall be delivered to Cabot Yard Car house at the following address:

Massachusetts Bay Transportation Authority Cabot RTL Car House 275 Dorchester Ave Building 12-72 Boston, MA 02127 No deliveries or pick-ups shall be made to any other Authority facility without formal written notification from the Authority’s Project Manager.

Deliveries made to any other Authority address, not formally acknowledged as an MBTA Facility shall be picked-up and redelivered to the Authority address within two (2) business days of the acknowledgement of the incorrect delivery. The Contractor shall be responsible for all expenses related to the pick-up and redelivery.

If the Authority needs to, it may change the shipping address by providing the updated address via formal written notification. If the updated address changes the Contractor’s pricing, the Contractor shall formally notify the Authority with the new pricing rates.

DESIGN, QUALIFICATION, AND ACCEPTANCE REQUIREMENTS

General The Contractor shall provide all necessary information to enable the Authority to review and understand the proposed LED Lighting upgrade design, capabilities, functionality, and similar.

This information shall be provided via the submittals and milestones outlined below.

The Authority and Contractor may request a design review meeting and / or working session be held to help in the development and / or review of the design, submittals, and milestones.

Such meetings should be identified in the project schedule and agreed between both parties.

The Contractor shall provide all information for Authority review and approval prior to scheduling any deliveries.

The LED upgrade shall undergo qualification testing both at the Contractor facility and installed on the pilot vehicle to ensure it meets all requirements of this specification.

The Contractor may present previous qualification test records for Authority review and consideration.

Design Review Within sixty (60) days of receiving the Contract Execution the Contractor shall submit an initial design package consisting of the following for the Authority’s review and approval.

Description of Theory and Operation Mechanical Drawings Electrical Schematics Maintenance Manuals Illustrated Parts Catalog Qualification and Routine Tests (Bench and On-Vehicle) Pilot Program Test Plan Manufacturer data sheets for components / assemblies Schedule of Activities and Milestones First Article Inspection (FAI) The purpose of the FAI is to physically review and evaluate the performance of the Pilot married pair LED lighting. Approval of the FAI units will establish the baseline design for the remaining order.

Within ninety (90) days of receiving the Authority’s approval of the Final Design package the Contractor shall submit an FAI package.

The FAI package shall consist of the following documentation:

Qualification test procedures Draft installation procedures All manuals and parts catalogs Schedule of FAI Activities and Pilot testing activities.

Any associated documentation required to demonstrate compliance to the specification.

Thirty (30) days after receiving the FAI package, an FAI shall be conducted at the Contractor’s facility and include the following activities to be witnessed by the Authority:

Maintenance Demonstration and Manual Review During the FAI, the LED lighting shall be evaluated for ease of maintenance and compliance to the Technical Specification.

The Contractor shall complete a maintenance demonstration utilizing the approved Maintenance Manuals.

Two weeks prior to FAI, the Authority will identify to the Contractor specific sections of the manual to perform during the maintenance demonstration.

Vehicle Installation and Pilot Program Following approval of the FAI, the Contractor shall provide the Authority with a complete married-pair of LED lighting materials to be installed on vehicles identified by the Authority.

The Contractor and the Authority shall jointly install the first married-pair of LED lighting materials using a draft copy of the installation procedures defined in this section.

The installation will serve to validate the procedure or identify necessary revisions and afford the opportunity for the Contractor to obtain the necessary photographs for inclusion in the final procedure.

If extensive revisions to the procedure are necessary, the Authority may require additional joint installations to validate the procedure.

The Pilot vehicle components will remain installed on the vehicles for up to six (6) months.

Performance and reliability targets shall be jointly developed between the Authority and the Contractor.

The MBTA reserves the right to shorten the duration of the pilot vehicle testing.

The Contractor shall provide a six (6) month test plan as described in this section. This test plan will include in-service testing as well as qualification testing.

The Contractor shall provide periodic monitoring during the entire duration of the Pilot Program and respond to any Authority requests in a timely manner.

The Contractor shall provide maintenance instructions for Authority personnel to perform during the pilot program.

The Contractor is responsible for troubleshooting repairs and providing work instructions for Authority personnel to perform.

The Contractor shall provide these repair instructions within three (3) days of the failure.

The Contractor shall provide a final test report as described in this section.

Pilot Reliability Requirements The new LED lighting is expected to operate failure free during the pilot program.

If a failure occurs during operation, the failure shall be reviewed by both the Authority and Contractor.

If the LED lighting has continuous failures and /or failures which impact the operation of the vehicle to meet service, the Authority reserves the right to remove the equipment from the vehicle.

The Contractor must assist the authority in restoring the vehicle to the original configuration with work instructions and engineering support..

It will be the responsibility of the Contractor to develop a solution to the failure / issue that will be reviewed and agreed upon by the Authority before the unit is re-installed on the vehicle to continue testing.

If it appears to the Authority that no solution is forthcoming, the Authority reserves the right to terminate the pilot test and the remainder of the contract.

Base Material Order Upon completion of the Pilot test period, the Authority will review the operation and reliability of the Contractor’s LED Lighting upgrade to determine the success of the pilot program. The Authority shall notify the Contract that the base order of materials can now begin production.

The base order shall be delivered following the schedule requirements of this specification.

The base order shall be identical to the pilot program LED lighting and including any field modifications made during the pilot program.

Upon delivery of each carset of materials to the Authority, the materials will be installed onto a service vehicle and acceptance testing will be performed by the Authority to verify complete functionality of the assembly.

The Contractor will be notified in writing of any discrepancies identified during acceptance testing.

The Contractor shall provide a corrective action plan within three (3) business days of receiving notification of any discrepancies.

Acceptance testing will be repeated following any corrective action performed by the Contractor.

Conditional Acceptance will be provided by the Authority following successful acceptance testing.

documentation AND MANAGEMENT requirements:

General Unless otherwise specified, the Contractor shall submit the final revision of the documentation described in this specification with the delivery of the first pilot unit.

All documentation is subject to review by the Authority and will not be considered final until approved by the Authority.

The terminology used for each component, function and operation shall be consistent across all documentation.

Project Correspondence All formal project correspondence shall be conducted via numbered contract letters and include:

All contract deliverable submittals, recorded memorandums of conference, questions for clarification, deviation for an approved equal, and any other item requiring Authority approval.

Any conflicts shall be referred in writing to the designated Authority Program Manager.

Oral statements by any person or persons shall not be permitted in any manner or degree to modify or otherwise affect the requirements of this Technical Specification.

Pilot Program Test Plan The Contractor shall provide a six (6) month test plan, including pass/fail criteria for the required performance and reliability targets for review and approval by the Authority during the design review phase.

The test plan shall also identify any test equipment, special tools, or gauges required during the pilot program.

Pilot Program Final Report The Contractor shall provide a final test report documenting the performance and condition of the pilot assemblies.

The final report shall include an evaluation of the assemblies in terms of the performance and reliability.

Mechanical Drawings The Contractor shall provide fully dimensioned drawings of all custom-made parts and assembly drawings with a bill of material for the LED lighting.

These drawings shall be supplied electronically in ADOBE PDF, Autodesk DXF, and Solidworks format. Alternate formats may be proposed to the Authority for review and approval.

All drawings for this equipment will become the property of the Authority for maintenance purposes only.

Electrical Schematics The Contractor shall provide newly drawn schematics showing the entire wiring and electrical components of the replacement LED Lighting.

The schematics shall be supplied electronically in Adobe PDF format and Autodesk DXF format. Alternate formats may be proposed to the Authority for review and approval.

Maintenance Manuals The Contractor shall provide an addendum to the Running and Heavy Maintenance Manuals.

Digital copies of the manuals in PDF format shall be delivered.

Illustrated Parts Catalog The Contractor shall provide an illustrated parts catalog completely and unambiguously identifying every part of the replacement LED Lighting.

Digital copies of the manuals in PDF format shall be delivered upon completion of the Pilot installation.

Ten (10) printed and bound copies of the manual shall be delivered.

Qualification Test Procedures The Contractor shall provide step-by-step test procedures for all qualification tests required by this specification to validate the required functionality and performance of the LED Lighting.

The test procedures shall include pass / fail criteria for each step of the test.

Routine Test Procedures The Contractor shall provide step-by-step test procedures for routine testing of the pilot LED Lighting, both prior to shipment from the manufacturing location and after installation on the vehicle.

The test procedures shall include a check list sheet of all pass / fail criteria and recorded measurements to be kept on file by the Authority.

Installation Procedure The Contractor shall provide step-by-step procedures for installation of the pilot system components prior to delivery of the Pilot LED Lighting.

Each step of the procedure shall be annotated by photographs, renderings, or sketches.

The procedures shall include a check list sheet of required steps and recorded measurements to be kept on file by the Authority.

QUALITY REQUIREMENTS

Quality Assurance To provide a quality product to the Authority, the Contractor shall have planned and established a documented quality assurance program in compliance with ANSI/ISO/ASQ Q9001-2008 or latest revision, and FTA Quality Management System Guidelines, FTA-PA-27-5194-12-1.

The Contractor shall apply the principles of the appropriate ISO 9000 series processes or equivalent and enforce the elements of the quality assurance program within all parts of its organization and with all manufacturers, subcontractors, and vendors performing work on this Contract.

Quality system documentation must be consistent with the skills needed, methods used, and training resident among personnel performing Contract work in accordance with the requirements of this specification.

Record Keeping Records must be kept of all inspection and testing results before, during, and after assembly and delivery of the LED Lighting material to provide objective evidence that specified requirements have been met.

Records must include actual results of measurements taken and tests conducted.

Inspection and test records must include the identification and calibration status of all measurement tools and test equipment used.

Inspection and Test records must be included in the LED Lighting documentation and provided with each shipment.

Workmanship and Materials All LED Lighting shall be manufactured in compliance with Appendix A: EE&QA 770 Materials and Workmanship.

Facility Audit All work under this Specification must be performed at the Contractor’s or Subcontractor’s facilities.

Facilities used by the Contractor or Subcontractors may be subject to audit and approval by the Authority prior to conducting work under this contract.

The Authority may elect at any time to perform an audit of those aspects of the Contractor’s or Subcontractor’s facilities or operations that are related to work performed under this Contract.

Reasonable notice will be provided by the Authority in advance of an audit.

special tools The Contractor shall define any special tools needed to service the LED Lighting, other than standard hand tools in a mechanic’s toolbox such as wrenches and sockets up to one (1) inch, and screw and nut drivers.

The Contractor shall supply two (2) set of such required special tools with the Pilot vehicle LED upgrade and provide a quotation to enable the Authority to purchase more tools if necessary.

Warranty Warranty Coverage The Contractor guarantees and warrants that all work, materials, and equipment furnished under this Contract shall conform to the Contract requirements and be free of any defects.

Except where longer periods of warranty are specified, the Contractor warrants all equipment, spare parts, materials, and all labor performed, shall be in full accordance with the Technical Specification, and shall be free of all defects for a period of two (2) years upon Conditional Acceptance.

The warranty shall apply regardless of whether the equipment, materials or labor were furnished or performed by the Contractor or by any of its Subcontractors or suppliers.

The Contractor warrants that all parts, components, systems, equipment, design and Work covered by this Contract shall:

Conform to the Specification and all other technical and performance requirements of this Contract.

Fulfill its design functions and reliably operates be for its intended purpose.

Be free of all patent and latent defects in design, materials, and workmanship.

The Contractor shall pass through to the Authority any warranties that exceed the one (1) year Warranty period and the Authority shall administer such warranties after the one (1) year Warranty period expires.

Any parts, components, equipment, design and work found to be defective prior to the expiration of the Warranty Period shall be repaired, remedied or replaced (hereafter “Corrective Work”), by the Contractor, free of all charges, including transportation.

It is understood and agreed that all Corrective Work to be undertaken by the Contractor pursuant to the Warranty shall promptly commence following receipt by the Contractor of a written notice from the Authority.

All Corrective Work shall proceed according to a schedule to which the parties agree.

The Authority agrees that this warranty and all other express warranties in this Agreement, shall be in lieu of all other warranties, express, implied, statutory or otherwise, arising in law or at equity, including without limitation, warranty of merchantability and fitness for a particular purpose.

The Contractor and the Authority may mutually agree to have the Authority and/or its contractors carry out warranty repair, field modifications, change orders, and other work that is the responsibility of the Contractor, and to do so on the Authority’s property at rates to be mutually agreed upon.

Any warranty work shall be accomplished with a minimum of disruption of the Authority operations.

If the Contractor fails to proceed promptly with any Corrective Work as directed by the Authority such corrective work, may be affected at the Contractor’s expense by such method as the Authority may determine.

The Authority may deduct the cost of such Corrective Work from any amount owed to the Contractor or require the Contractor to reimburse such costs to the Authority.

Nothing herein shall affect Contractor’s warranties to the Authority.

The warranty for any parts and components replaced or repaired under this warranty shall be extended for a period of one (1) year from the time the Authority accepts any replaced or repaired parts and components.

If corrective work is performed under this warranty, a one (1) year warranty shall apply to the corrected work covering any discrepancies and defects in the corrected work that are discovered after the corrected work is accepted.

Emergency repairs by the Authority shall in no way void the Contractor’s warranty.

Schedule of Payment The Contractor is required to submit a Bid Price based on the following payment schedule:

Table 2: Milestone Payment Schedule

30%

650% (0.783.% per carset) 95%

Table 3: OPTION – Spare Material Order

Appendicies Appendix A: EE&QA 770 Materials and Workmanship.

Appendix B: MBTA Red Line #3 Car Lighting Schematics Appendix C: MBTA Red Line #3 Car Vehicle Manuals and Illustrated Parts Catalog image2.png image3.png image1.png