ITEM 633 TRAFFIC SIGNAL CONTROLLERS
633.02 Contractor Personnel Requirements
633.03 Materials and Equipment
633.06 Testing and Prequalification
633.13 Controller, Master, Traffic Responsive
633.14 Remote Monitoring Station
633.18 Uninterruptible Power Supply
633.01 Description. This work consists of furnishing and installing traffic signal control equipment, including controllers, cabinets, auxiliary equipment, and specified accessories, completely wired, at the locations shown on the plans and ready for service.
633.02 Contractor Personnel Requirements. Conform to the requirements of Supplement 1063 for the installation or testing of traffic signal equipment.
633.03 Materials and Equipment. Furnish new materials and equipment of first quality, of current design, and free from defects.
Use electrical parts, wire, switches, and other elements of the installation capable of carrying the required current without excessive heating or drop of potential.
Ensure that each item of equipment bears a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer. Use equipment conforming to the types, models, and systems specified.
Furnish material and equipment conforming to:
Concrete
.... (cabinet foundations and work pads)............... 499, 511
Conduit...................................... 725.04, 725.051, 725.052
Controller unit.......................................................... 733.02
Cabinet and auxiliary equipment.............................. 733.03
Cabinet riser............................................................. 733.04
Flasher controller..................................................... 733.05
Controller, master, traffic responsive....................... 733.06
Remote monitoring station....................................... 733.07
Telephone service.................................................... 733.08
Uninterruptible Power Supply……………………. 733.09
633.04 Certified Drawings. Furnish certified drawings according to 625.06.
633.05 General. Ensure that major items of traffic signal control equipment used in combination are compatible, interchangeable, and, whenever feasible, provided by the same manufacturer or supplier.
Ensure that controller cabinets are shop prewired according to 632.05.
Before starting installation, furnish to the Engineer, two copies of each cabinet wiring diagram, service manuals, and installation and maintenance instructions for each installation, including all components and interconnections. Supply one additional copy of the cabinet wiring diagrams in a clear plastic pouch fastened to the inside of the controller door. Before beginning the 10-day performance test, replace or modify these documents as necessary to reflect current conditions. Upon completion of the work and before its acceptance, replace or modify the documents as necessary.
Transfer manufacturers’ guarantees or warranties on all installed traffic signal control equipment to the maintaining agency upon completion and acceptance of the project.
If required by the plans to install equipment furnished by others, store and care of the equipment upon receipt.
633.06 Testing and Prequalification. For all traffic control equipment, perform functional tests and a 10-day performance test according to 632.28. Do not clear conflict monitor logs during the 10-day test. Ensure that logs note power-up to start the test and all events until the test is complete. Restart the test upon correcting a noted event. Notify the Engineer at least 3 days before beginning the 10-day performance test. The Engineer will notify the maintaining agency of the beginning of the test. Ensure that the following testing and prequalification requirements are met:
A. For traffic control equipment required by this specification to meet NEMA Standards Publication TS-1 or TS-2, conform to the following:
1. Furnish a certified test report indicating compliance to all requirements of NEMA Standards Publication TS-1 or TS-2 as applicable.
2. Furnish the name and location of the laboratory testing facility as well as the identification of the principal personnel who conducted the equipment testing and a summary of their qualifications.
3. Ensure that the laboratory provides Department representatives access to those parts of the laboratory where the testing was done.
4. Upon request, furnish a copy of the actual test data results for review and analysis.
B. For traffic control equipment required by this specification to meet CalTrans specifications, use a product or manufacturer as stated in this specification that is listed on the CalTrans Qualified Products List.
C. For Type 170/2070 controllers, use conflict monitors listed on the Department’s prequalified list as specified in Supplement 1076.
633.07 Controllers. Install controller units, consisting of the timing unit, software, and signal timing, into the specified type of prewired cabinet.
Program controller units as shown on the plans unless otherwise directed by the Engineer. If the plan timing data or the supplemental timing data supplied by the Engineer does not exactly fulfill the timing requirements of the installed equipment, notify, in writing, the Engineer of the problem and identify the discrepancies. The Engineer will consult with the maintaining agency and notify the Contractor within 2 weeks. After programming, briefly operate controllers, with the signals turned off by means of the signal shutdown switch, to ensure that operation is reasonable and conforms to the plans.
If the plans show two or more intersection controllers operated in a progressive signal system, coordinate signals by relating the various controller cycle start times to a zero time base, or other cycle start time at an adjacent signalized intersection. Ensure that the controller unit software provides coordination capability to allow associated controllers to be operated within the progressive traffic system. Coordination equipment shall supervise the operation of its associated controller by causing the end of certain phases and the beginning of the following phases to occur at set points. Program coordination timing according to the coordination timing data shown on the plans or provided by the Engineer.
633.08 Cabinets. Mount cabinets by attaching to pedestal or pole or by installing on a concrete foundation. Arrange foundation mounted cabinets so that control equipment, terminal blocks, or shelves are no closer than 6 inches (150 mm) to the top of the foundation. Attach pole or pedestal mounted controller cabinets at a height that allows convenient access to all controller components by service personnel.
Make field connections for the conductors of signal cable, power cable, interconnect cable, and detector lead-in cable. Neatly arrange and route all field wiring to the appropriate terminal blocks. Identify field wiring according to 725.02 except mark with either indelible pen or embossed letters.
Except for power wiring, fit field wiring entering the cabinet with spade terminals to ensure a good connection. For incoming power wiring, either use spade terminals or connect the bare conductor wire to terminal points utilizing screw or spring applied clamping surfaces compatible with either copper or aluminum wire and providing a positive grip. After completing field wiring, seal the conduit entering the cabinet in an approved manner with a removable sealing compound (no foam sealants), or a molded plastic or rubber device that is compatible with the cable jacket, the insulation, and the conduit material.
For foundation mounted cabinets, seal the joint between the controller cabinet and the foundation with a quality, clear silicone caulk.
When future phasing configurations are shown on the plans, furnish the cabinet and hardware to accommodate the future operation through only the future addition of load switches and detector units.
633.09 Cabinet Riser. Cabinet risers provide an extension of the cabinet between the ground mounted cabinet and the foundation. Bolt the riser to the foundation, and bolt the cabinet to the riser.
Use a type (size and shape) of cabinet riser compatible with the type of controller cabinets specified for the project.
Seal the joints between the controller cabinet and cabinet riser, and between the cabinet riser and foundation with a quality, clear silicone caulk.
633.10 Foundations. Construct foundations for controller cabinets according to 632.14, except that excavation by earth auger is not required and the foundation does not require reinforcing steel. Hold anchor bolts, conduit ells, and similar appurtenances in the proper position until the concrete has set. Pour foundations separately from controller work pad.
633.11 Controller Work Pad. Construct controller work pad according to 608.03, except that transverse joints are not required. Provide the top of the pad nominally 1 inch (25 mm) above ground line. If the controller cabinet has both front and back doors, the work pad shall encompass three sides of the cabinet foundation to include the non-hinged cabinet door side of the foundation. Pour controller work pad separately from foundations.
633.12 Flasher Controller. Furnish and install a flasher controller with cabinet and mounting hardware when indicated. The flasher controller is for the operation of flashing beacons.
633.13 Controller, Master, Traffic Responsive. The traffic responsive master controller supervises and controls the operation of an interconnected system of local controllers. Ensure that the master controller is able to communicate with a remote monitoring station. Locate this master controller in a local intersection controller cabinet unless otherwise shown on plans. If the local controller cabinet size is not sufficient to accommodate the master controller and its associated wiring, furnish the proper size cabinet for the local intersection controller to house the local controller, master controller, modem, and all auxiliary devices.
633.14 Remote Monitoring Station. Install, test, and operate the remote monitoring station, consisting of computer equipment, communications equipment, and software, in one or more locations in the maintaining agency’s facilities as shown on the plans. The maintaining agency shall furnish telephone service at these stations.
633.15 Telephone Service. Make arrangements with the local telephone company to have telephone service furnished to intersection cabinet locations shown on the plans. Maintain the telephone account until the signal system has been tested and accepted by the Engineer. After acceptance of the signal system, transfer the telephone account to the maintaining agency.
Furnish and install a minimum size 1-inch (25 mm) conduit, twisted pair, shielded telephone cable, and conduit risers necessary to bring the telephone line from the telephone company service location into the controller cabinet. Furnish and install the modem and the lightning protection for the telephone lines in the controller cabinet.
633.16 Training. Furnish training for the traffic signal control equipment installed as part of the Contract. Furnish all handouts, manuals, and product information. For the training, use the same models of equipment furnished for the project. The maintaining agency shall furnish the facilities in which the training will take place. Furnish all media and test equipment needed to present the training. Unless otherwise shown on the plans, the minimum training requirements are as follows:
A. Sixteen hours on how to operate the system, analyze system performance, and revise critical operating parameters.
B. Eight hours of field trouble-shooting and maintenance procedures.
C. Eight hours of follow-up training after the maintaining agency has operated the system for a minimum period of 30 days.
D. Four hours for preemption device training if emergency vehicle preemption is shown on the plans.
A. General. Prepare signal timing and traffic progression programs, load the programs into the signal system, evaluate the performance of the system, and refine the programs as necessary to optimize traffic flow and operation. Collect and evaluate traffic data, analyze traffic signal progression and timing, develop traffic adjusted pattern selection parameters, perform the system evaluation and refine the system operation, and prepare and submit a summary report for review and approval by the Engineer.
If a project contains individual sub-systems that are connected to the remote monitoring station, perform all work as outlined in this subsection for each sub-system. If required, analyze signal “sub-systems” together and coordinate traffic progression programs to optimize the overall traffic flow between the various sub-systems.
Optimize only the cycle lengths, phase splits, permissives, and offsets without changing the actual controller phasing provided in the plan.
B. Systems Engineer or Technician. Employ a systems engineer or technician to perform the work required by this subsection and submit to the Engineer for approval three copies of a resume documenting the following qualifications:
1. A minimum of 5 years experience in traffic engineering or traffic engineering technology.
2. The systems engineer or technician’s education including training in traffic engineering technology and signal system design.
3. The systems engineer or technician’s familiarity with the closed loop system installed and experience in setting up and fine tuning a system of that type. Furnish a list of other closed loop systems that the systems engineer or technician has programmed into the traffic responsive mode for documentation purposes.
Also, submit to the Engineer for approval a brief description of proposed methodology of data collection and analysis of:
a. System parameter usage in system evaluation.
b. Frequency and measurement of travel time and delay.
c. Comparison of actual versus system measurements of delays (level of service).
The systems engineer or technician, under authority of the Contractor, is responsible for the operation of the system from the completion of the signal system acceptance until completion and acceptance of the final summary report by the Engineer. The systems engineer or technician shall provide a 24-hour emergency phone number and shall respond to system related problems as deemed necessary by the Engineer 24 hours a day, 7 days a week. If there is a guarantee period, the Engineer reserves the right to request a systems analysis throughout the entire duration of this period, if new or continuing problems occur with the operation of the traffic responsive system.
The Engineer reserves the right to request that the Contractor furnish a new systems engineer or technician if the current systems engineer or technician fails to perform the required duties in a timely and professional manner or fails to have a firm understanding of the operation and programming of the closed loop system constructed.
C. Traffic Programs. The systems engineer or technician shall develop signal progression and timing programs from count and occupancy data obtained from the local intersection and system loop detectors, supplemented by field counts and measurements as required. The systems engineer or technician shall develop the following signal progression programs and parameters:
1. Three inbound preferential (a.m. peak).
2. Three outbound preferential (p.m. peak).
3. Three average (off peak). The three average programs should utilize varying cycle lengths based on traffic volume, density, and occupancy to minimize overall intersection approach delay time.
4. Two special programs for either high congestion or queue backup.
5. A minimum of three timing plans for a back up time base coordinated system. The systems engineer or technician shall program the timing plans into the system, to supplement the timing plans shown on the plans.
6. Define system parameters that enable the system to automatically transfer into a “free operation” mode during light traffic volume periods and to automatically transfer to a computer selected coordinated mode during heavy traffic volume periods. The systems engineer or technician shall establish the following system parameters:
a. Volume, occupancy and directionality thresholds.
b. Transition smoothing factors.
c. System detector assignment.
d. System detector weighting.
The systems engineer or technician may use the software provided with the remote monitoring station to help assist in the analysis of the operation of the closed loop system.
D. System Travel Time Studies. The systems engineer or technician shall conduct a series of travel time studies for each system or sub-system artery constructed as part of the project, to measure the time it takes to travel from 0.25 mile (0.4 km) in advance of the beginning of each system or sub-system to 0.25 mile (0.4 km) after the end of that system or sub-system, in each direction. Ensure that the travel time study parameters are based on the posted speed limit; however, be aware that during peak periods it may not be possible to obtain the posted speed due to larger traffic volumes.
The systems engineer or technician shall conduct four separate sets of travel time studies for each of the following field conditions:
1. Before beginning construction, with the existing signal system in operation (no lane closures shall be in effect during this analysis).
2. Before implementing the traffic responsive mode, while the new traffic signal system is operating under the “time of day” mode (as is shown on the plans).
3. After placing the system(s) in the traffic responsive mode.
4. After the system operation meeting and making final system adjustments.
Each set of travel time studies shall include a minimum of five runs through the system per direction. The systems engineer or technician shall conduct travel time studies during good weather conditions (i.e., no snow, rain, or fog). The Engineer may omit the pre-construction travel time studies if the project includes substantial changes to the roadway geometrics (i.e., roadway widening, reconfiguring of pavement markings, etc.) that would affect the results of a comparison of the level of improvement over preexisting conditions.
The four separate sets of travel time studies shall include the following:
1. Conduct the first set of travel time studies between the hours of 7:00 a.m. and 9:00 a.m. on weekdays.
2. Conduct the second set of travel time studies between the hours of 11:30 a.m. and 1:00 p.m. weekdays.
3. Conduct the third set of travel time studies between the hours of 4:00 p.m. and 6:00 p.m. weekdays.
4. Conduct the fourth set of travel time studies during any of the following non-peak hour periods:
a. 9:00 a.m. to 11:00 a.m. Monday through Saturday.
b. 7:00 p.m. to 10:00 p.m. Monday through Saturday.
c. 7:00 a.m. to 10:00 p.m. Sunday.
The systems engineer or technician shall furnish a written report documenting, at a minimum, the date of travel time study, day of week, time of day, total time of travel, and total time the vehicle was stopped for each trip.
The systems engineer or technician shall use the reports furnished from each of the four field conditions for which system travel time studies are prepared as one means of measuring the efficiency of the new system.
E. Draft System Summary Report. The systems engineer or technician shall prepare a draft system summary report after travel time studies for the first three field conditions are performed. Submit two copies each to the Engineer and the maintaining agency(s) of the signal system for the evaluation and review of the system programming, operation, and efficiency.
The report shall summarize the signal progression and timing programs that were entered into the system. The report shall also include a copy of the systems log after operating in the traffic responsive mode to verify the number of programs used throughout the day as well as the frequency of program changes. The systems engineer or technician shall provide a minimum of at least 4 days of systems logs. The systems engineer or technician shall limit three of the four logs to the weekdays of Monday through Friday; the fourth log shall be on a Sunday. The systems engineer or technician shall include copies of all data and analysis calculations for the system timing in the report. The draft system summary report shall include an evaluation of the system operation, efficiency, and performance and copies of all travel time study data.
F. System Operation Meeting and Final System Summary Report. After the draft system summary report has been submitted, the Engineer will schedule a meeting that includes the systems engineer or technician, the Contractor, the Engineer, and representative(s) from the maintaining agency(s) to discuss the operation of the traffic responsive closed loop signal system. This meeting shall occur within 4 weeks after the draft system summary report has been submitted to the Engineer and maintaining agency(s).
The purpose of this meeting is to discuss the operation of the traffic responsive closed loop signal system and to receive comments and recommendations from the Engineer and/or the maintaining agency(s) regarding potential modifications to the operation of the system. The systems engineer or technician shall answer questions regarding the system summary report as well as the operation of the closed loop system.
The systems engineer or technician shall make final adjustments to the system as directed by the Engineer to address any concerns discussed at this meeting. The systems engineer or technician shall perform the final travel time study before submitting the final report. The systems engineer or technician shall submit one copy of a final system summary report to the Engineer and one additional copy for each maintaining agency for review and approval. The final report shall include any revisions to the draft report that are required as a result of the system operation meeting.
633.18 Uninterruptible Power Supply (UPS). Furnish and install a Battery Backup UPS system to provide uninterruptible, reliable, emergency power to a traffic signal intersection in the event of a power failure or interruption. The transfer from utility power to battery power shall not interfere with the normal operations of the traffic controller, conflict monitor or any other peripheral devices within the traffic control system. The system shall be self-contained including all UPS hardware, the required number of batteries and its own separate ventilated enclosure.
633.19 Method of Measurement. The Department will measure Controller Unit, Type ___, with Cabinet, Type ___ by the number of each complete unit, and will include controller unit with software, all required auxiliary equipment, loop detector units, and a prewired cabinet, with all items completely wired and tested. Ground mounted cabinets will include anchor bolts and conduit ells for installation in the foundation. Pole mounted cabinets will include pole mounting hardware.
The Department will measure Controller Unit, Type ___ by the number of each controller timing unit with software, and will include any signal timing programming or installation. The Department will measure Controller Unit, Type ___, Furnish Only by the number of each controller timing unit with software, and will exclude any signal timing programming or installation.
The Department will measure Cabinet, Type ___ by the number of each complete prewired cabinet installed, and will include all required auxiliary equipment and loop detector units (excluding controller unit), with all items completely wired and tested. Ground mounted cabinets will include anchor bolts and conduit ells for installation in the foundation. Pole mounted cabinets will include pole mounting hardware. The Department will measure Cabinet, Type ___, Furnish Only by the number of each complete prewired cabinet, and will include pole mounting hardware and anchor bolts, but will exclude installation, controller unit, and detector units.
The Department will measure Cabinet Riser by the number of each unit, and will include materials, mounting hardware, and installation.
The Department will measure Cabinet Foundation and Controller Work Pad by the number of each complete unit, in place, complete and accepted, and will include excavation, concrete, backfilling, and disposal of surplus excavation. Cabinet foundation will include preformed joint filler between the foundation and adjacent paved areas. One complete Controller Work Pad unit may encompass several sides of a controller cabinet installation.
The Department will measure Flasher Controller by the number of each complete flasher assembly with cabinet installed and tested.
The Department will measure Controller, Master, Traffic Responsive by the number of each unit, and will include installation, signal system software, programming, and any increase in cabinet size to house the master controller in the local intersection cabinet. The Department will measure Controller, Master, Traffic Responsive, Furnish Only by the number of each unit, and will include software, but exclude any programming or installation.
The Department will measure Remote Monitoring Station by the number of each location shown on the plans, and will include all equipment, testing, and software.
The Department will measure Telephone Service by the number of each location shown on the plans for furnishing telephone service to an intersection controller, and will include the modem, conduit, trenching, and wiring.
The Department will measure Training on a lump sum basis, and will include providing the instruction materials, instructor travel expenses, and test or media equipment for presenting the training material.
The Department will measure System Analysis on a lump sum basis, and will include providing all materials, labor, software, printing reports, and incidentals to analyze all traffic responsive sub-systems included in the project.
The Department will measure Uninterruptible Power Supply by the number of each and will include all equipment, testing and certifications.
633.20 Basis of Payment. If a project contains individual sub-systems that are connected to the remote monitoring station, the cost for performing work, as specified in 633.17 is incidental to the bid item price for System Analysis.
The costs to obtain and maintain telephone service by the supply agency are included under Telephone Service.
The Department will pay for accepted quantities at the contract unit prices as follows:
Item Unit Description
633 Each Controller Unit, Type ___,
with Cabinet, Type ___
633 Each Controller Unit, Type ___
633 Each Controller Unit, Type ___, Furnish Only
633 Each Cabinet, Type ___
633 Each Cabinet, Type ___, Furnish Only
633 Each Cabinet Riser
633 Each Cabinet Foundation
633 Each Controller Work Pad
633 Each Flasher Controller
633 Each Controller, Master, Traffic Responsive
633 Each Controller,
Master, Traffic
Responsive,
Furnish Only
633 Each Remote Monitoring Station
633 Each Telephone Service
633 Lump Training
633 Lump System Analysis
633 Each Uninterruptible Power Supply