733  Traffic Signal Controller Material

733.01  References and Definitions.

“NEMA TS-2,”  “Type TS-2/A2,” and “Type TS-2/A1” refers to equipment manufactured in conformance with the National Electrical Manufacturers Association (NEMA) Standards Publication No. TS-2.

“NEMA TS-1”  and “Type TS-1” refers to equipment manufactured in conformance with the National Electrical Manufacturers Association (NEMA) Standards Publication No. TS-1.

“Type 332” and “Type 336” refers to equipment manufactured in conformance with the California Department of Transportation (CalTrans) specifications titled “Traffic Signal Control Equipment Specifications” and “Transportation Electrical Equipment Specifications“, including all addenda.

“Type 2070” refers to equipment manufactured in conformance with the California Department of Transportation (CalTrans) specifications titled “Transportation Electrical Equipment Specifications”, including all addenda.

“CalTrans QPL” refers to the California Department of Transportation (CalTrans) “Qualified Product List” for traffic signal equipment.

“IP” refers to equipment conforming to the Internet Protocol Suite communication protocols defined by the Internet Engineering Taskforce RFC 1122. 

733.02  Controller Units.

A.      General Requirements.  Ensure that each controller unit contains internal time based coordination and, if used in a hardwired coordination system, provide an internal communication device or transceiver for connection to interconnect cables including multi-conductor 120 volt cables, twisted pair low voltage cables or fiber optic cables as shown on the plans.

If used in a closed loop system, ensure that the local intersection controller contains all of the software features necessary to operate with the system requirements given in 733.06 and 733.07.  Furnish the necessary communications capability for isolated local intersections when part of the monitoring and control system described in 733.08.

When the signal timing and phasing configuration shown on the plans requires a pre-timed operation, ensure that the controller unit meets all requirements of this section and can also be configured in a pre-timed, sequential phase, fixed interval mode.

Furnish controller memories that are nonvolatile and do not require batteries or other sources of energy to retain data while power is removed from the controller.

B.      Software.  Furnish a communication port for connection to a laptop computer for database upload/download.  Furnish software for the personal computer to completely program all features of the controller unit.  Unless otherwise shown on the plans, provide the controller unit with software that provides the following features even if not used by the signal phasing operation shown on the plans:

1.      NEMA 8 phase, dual ring capability with four pedestrian movements, 4 overlaps, and the ability to program an exclusive pedestrian movement.  Ensure that the controller is capable of being programmed for sequential phasing operation.  All controllers shall be capable of implementing Flashing Yellow Arrow operation by remapping pedestrian channel yellow drivers to operate the yellow arrows. 

2.      Volume density functions

3.      Secondary coordination plans

4.      Time of day/day of week scheduler

5.      Time based coordination, minimum 3 dials, 3 offsets, 3 splits

6.      Internal preemption for railroad and emergency vehicles.  Railroad preemption shall conform to ODOT specifications. 

7.      Operator selectable single or dual entry in dual ring use

8.      Security access codes

9.      Detector features including delay timing, carryover (extension) timing and detector switching

10.    Simultaneous gap out feature

11.    If operated in a system, communication capabilities to interface with hardwired masters, dial up modems, and/or IP communication devices. 

12.    Data upload and download capability to a personal computer.  At least one IP port and one serial port shall be included. 

13.    Storage of detector counts utilizing phase detectors for a minimum 24 hour period in 15 minute increments

14.    Detector failure monitoring and logging features for constant calls and absence of calls

Furnish 60-month warranties or for the manufacturers’ standard warranty, whichever is greater for the following equipment: 

1.      NEMA Controller Equipment

          a.      TS-2 Controller Units

          b.      Bus Interface Units

          c.      Malfunction Management Units        

          d.      TS 1 Conflict Monitors

2.      CalTrans Controller Equipment

          a.      Model 2010 Conflict Monitor Units

          b.      2070L and 2070E Controller Units including the following subassembly units:

                   (1)     2070-1E, 2070-1B CPU Board

                   (2)     2070-2A Field I/O Module

                   (3)     2070-3B Front Panel.

                   (4)     2070-6A,B.

Ensure that the warranty period begins on the date of shipment to the project.  Ensure that each unit has a permanent label or stamp indicating the date of shipment.  Label shall indicate the equipment vendor name and or logo. 

C.      Type TS 2/A1.  Furnish a controller unit that meets NEMA TS-2 specifications and is shelf or rack mounted.  Ensure that controller settings are programmable through a keyboard on the front panel.  Ensure that the front panel contains an 8-line by 40-character display. Ensure the controller is equipped with a datakey to support controller database upload/download. Securely attach the datakey to the top of the controller with fiber-reinforced tape at the time of delivery to the project.

Furnish materials according to the Department’s Qualified Products List (QPL).

D.      Type TS-2/A2.  Furnish a controller unit that meets NEMA TS-2 specifications and is suitable for shelf mounting.  Furnish a controller unit that includes all ports and input/output connectors for complete interchangeability between NEMA TS-1 and TS-2 cabinets.  Ensure that  controller settings  are programmable through a keyboard on the front panel.  Ensure that the front panel contains an eight-line by 40-character display.  Ensure the controller is equipped with a datakey to support controller database upload/download. Securely attach the datakey to the top of the controller with fiber-reinforced tape at the time of delivery to the project.

 Furnish materials according to the Department’s Qualified Products List (QPL).

 E. Type 2070L. Furnish controller units that meet the specifications for “Transportation Electrical Equipment Specifications”, California Department of Transportation, including all addenda.  Furnish a controller unit that is listed on the ODOT Approved List.

The Type 2070E version controller unit consists of the following assembled modules:

Unit Chassis

Model 2070-1B:           CPU module, single board

Model 2070-2A:           Field I/O module

Model 2070-3B:           Front panel, Display B (8 lines of 40 char.)

Model 2070-4B:           Power supply module, 3.5 amp. [Power supply Model 2070-4A (10 amp) may be supplied in lieu of Model 2070-4B]

Model 2070-7A:           Async. Serial Communication Module

 F.      Type 2070E.  Furnish controller units that meet the specifications for “Transportation Electrical Equipment Specifications”, California Department of Transportation, including all addenda.  Furnish a controller unit that is listed on the ODOT Approved List.

The Type 2070E version controller unit consists of the following assembled modules:

Unit Chassis

Model 2070-1E                                                CPU Module, Single Board

Model 2070-2A                                                Field I/O for 170 Cabinet

Model 2070-3B                                                Front Panel, Display B (8 lines of 40 characters)

Model 2070-4A or Model 2070-4B                 Power Supply

Model 2070-7A                                                Async Serial Communication

  

Also, equip all versions of the Type 2070 controller unit with the following:

1.      The appropriate communication port, cables, and connectors for communicating with a laptop computer.

2.      Modems, ports, and cables for system communication, if the controller is to operate as part of an interconnected signal system or has a telephone drop shown on the plans.

3.  Furnish a serial communication cable to be used to establish periodic automatic time sync between the 2070 controller software and the conflict monitor.  The cable shall consist of six feet (2 m) of unshielded 4- conductor cable, minimum 24 gauge stranded conductors with protective jacket.  End connectors shall be 9-pin D-subminiature with backshell, male and female, with pin assignments shown in the table below.

 

9-pin Male

9-pin Female

3

3

5

5

2

2

1

4

8

4

 

4. 8Mb data key (SFK 8Mb).

Furnish materials according to the Department’s Qualified Products List (QPL)

733.03  Cabinet.  Ensure that all cabinets comply with the requirements of this Section. Equip all NEMA specified cabinets as follows:

          Supply two through four phase controller operation with a minimum twelve position backpanel, configured for four pedestrian movements and four overlaps, with a twelve channel NEMA TS-1 conflict monitor or NEMA TS-2 malfunction management unit.

          Supply five through eight phase controller operation with a minimum 12 position backpanel, configured for four pedestrian movements and no overlaps, with a NEMA TS-2 malfunction management unit.

          For signal phasing configurations that require a larger capacity backpanel or conflict monitor, supply a 16 position backpanel with a 16 channel NEMA TS-1 conflict monitor or NEMA TS-2 malfunction management unit.

          Furnish each cabinet main door with a sturdy, permanently lubricated lock that is covered with a weatherproof tab.  Key the project locks to the master key used by the agency that will maintain the equipment.  Supply two keys with each lock.  Also, equip the small door-in-door with a lock that is keyed to the maintaining agency’s master key, covered with a weatherproof tab. The door handle shall swing out away from the door edge, not toward the center of the door.

Furnish cabinet with drawings that show the following:

1.      Intersection map.  The map shall include street names, all lanes, crosswalks and stop bars, all vehicle and pedestrian phases, all loops and detection zones, vehicular and pedestrian signal heads, and pedestrian pushbuttons.  All of these features shall be labeled.  Include a legend that shows the type of vehicular and pedestrian heads and north.

2.      Field wiring hook-up chart for all signal heads.  The chart shall include signal head name, signal head display indication, and field terminal on back panel.   See example below.

 

Signal Head

G

Y

R

G

Y

G

Y

W

DW

1a

2G

2Y

2R

1G

1Y

 

 

 

 

2a

2G

2Y

2R

 

 

 

 

 

 

2b

2G

2Y

2R

 

 

 

 

 

 

4a

4G

4Y

4R

 

 

 

 

 

 

4b

4G

4Y

4R

 

 

 

 

 

 

4c

4G

4Y

4R

 

 

1G

1Y

 

 

6a

6G

6Y

6R

 

 

 

 

 

 

6b

6G

6Y

6R

 

 

 

 

 

 

8a

8G

8Y

8R

 

 

 

 

 

 

8b

8G

8Y

8R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

9G

9Y

B

 

 

 

 

 

 

 

10G

10Y

C

 

 

 

 

 

 

 

11G

11Y

D

 

 

 

 

 

 

 

12G

12Y

 

3.      Conflict Monitor/MMU channel assignments and functions, switch positions, and settings.  Also show program card jumper locations diagrammatically (if applicable).  If the Conflict Monitor/MMU is programmed via methods other than a program card detail this diagrammatically.

4.      Legend with all wire gauges and insulator colors used in the cabinet.  Apply this legend to all wiring shown in the drawings.  Also include components such as MOVs and diodes.

5.      Detector panel wiring.  Detail all detector landings.

6.      All cable and wiring harness pin assignments.

7.      Detector rack layout.  Label detector number and associated phase.

8.      SDLC cable assignments.

9.      Pedestrian pushbutton wiring.

10.    Load switch assignments.

11.    Flash programming buss and field terminals wiring.

12.    I/O board, load switch, and flash transfer relay wiring.

13.    Any video, radar, preemption, or other device wiring, interface, and cabling details.

14.    UPS as-built schematic (if applicable).  Detail all connections to cabinet and controller.

15.    Netlist detailing all connectivity of the cabinet.  It shall include all instances in the cabinet.  Provide a description of all instances.

A. Type TS-1.

1.      Cabinets.  Furnish a cabinet size that provides ample space for housing the controller unit and all associated electrical devices furnished with it, together with any other auxiliary devices that are specified.  Furnish a cabinet with sufficient shelf space to accommodate all existing, proposed, and designated future equipment.   Ensure that the space provided accommodates the appropriate controller unit frame as designated in NEMA TS-1, Section 14.

Construct the cabinets of cast aluminum or sheet aluminum, drawn or formed, with aluminum support and stiffening of members provided as necessary.  Ensure that the exterior is smooth with no sharp edges.  Weld all joints.  Ensure that the cabinet is rigid and is designed to support all components.  Ensure that the application of the following loads do not result in breakage, deformation, or loss of weatherproof qualities:  a 100-pound (445 N) load applied to any 1-inch (25 mm) square surface of the cabinet or door (open or closed), in any direction; or a 300-pound (1.3 kN) load applied vertically downward to any 4-inch (100 mm) square of the top surface or to the top edge of the closed and latched door.

Provide cabinet exterior surfaces of bare aluminum.  When the plans specify a cabinet color, prime and finish all cabinet exteriors with two coats of high-grade enamel paint of the specified color.  Ensure that the cabinet interior surfaces are the same as the exterior, or may be painted flat white.

Ensure that the cabinet contains at least one rain-tight louvered vent equipped with a replaceable filter.  Install vents to allow for the release of excessive heat and any explosive gases that might enter the cabinet.

Ensure that the cabinets are functional in design and have a door in the front providing access to substantially the full interior area.  Attach a gasket of elastomeric material to the cabinet or door to form a weatherproof seal.  Furnish door hinge pins of stainless steel or equivalent corrosion resistant material.  Furnish a door stop to retain the door in at least a 90 degree open position.

Include a small, hinged, and gasketed door-in-door (police door) on the outside of the main controller door.  Ensure that the door-in-door does not allow entrance to the controller mechanism nor to exposed electrical terminals, but provides access to a small switch panel and compartment (police panel).

Fit the cabinet with the necessary provisions for mounting, with a bottom conduit connection provided for pole-mounted cabinets.  Furnish suitable hardware and equipment for each cabinet mounting method, including bolts for drilled and tapped holes on metal supports, pole attachment clamps, pedestal slipfitter, and anchor bolts and conduit ells for installation in concrete foundations.  Furnish steel anchor bolts that are galvanized at least 1 inch (25 mm) beyond the threads.  Certified cabinet anchor bolts are not required.

Directly place all equipment designed for shelf mounting on a shelf except for loop detector units (amplifiers) and similar devices designed for stacking on each other.  Arrange components on shelves and devices on the door so that a 1-inch (25 mm) minimum space separates them when the door is shut.  Ensure that plugs, wires, controls, or similar items do not compromise this space.

Reserve a minimum 4-inch (100 mm) clear area on the bottom of the cabinet for the routing of cables.  Do not locate panel mounted equipment in the bottom 6 inches (150 mm) of the cabinet.  Do not locate shelves or components within 6 inches (150 mm) of the bottom of foundation mounted cabinets.

Arrange all equipment for easy withdrawal and replacement, without the necessity of disturbing adjacent equipment.  Permanently locate devices within the cabinet to allow free circulation of air and that do not restrict air flow from fan ducts or vents. 

Ensure that the auxiliary equipment operates within a weatherproof cabinet at ambient temperatures between ‑30 and 165 °F (-34 and 74 °C).

When  terminals and panel mounted devices with exposed electrical contact points are located next to shelf mounted equipment, provide spacers, shelf lips, or other means to assure that component units cannot be accidentally moved into contact with any exposed electrical terminal points.

Ensure that load switches, relays, flashers, fuses, switches, terminal blocks, and other equipment mounted or plugged into the back or side panels are readily accessible.  Ensure that switches, controls, and indicator lights are visible and easily operable without moving the components from their normal shelf positions.

Furnish materials according to the Department’s Qualified Products List (QPL).

2. Accessory Equipment 

a.      Ventilating Fan.  Equip all cabinets with a forced air ventilating fan.  Furnish a fan that provides a capacity of at least 100 cubic feet (2.8 m3) per minute.  Furnish a fan that is thermostatically controlled and adjusted to start at cabinet temperatures above 120 °F (49 °C) and to stop when the temperature has dropped below 100 °F (38 °C).

b.      Load Switches.  Furnish all cabinets with solid state, triple-signal load switches complying with NEMA TS-1, Section 5.  Additionally, ensure that all load switches have both input and output indicators.

c.      Conflict Monitor.  Furnish all cabinets with a separate solid-state conflict monitor device.  Ensure that the cabinet wiring, in the event of monitor disconnection, transfers the signals to a flashing condition.  Furnish conflict monitors that comply with NEMA TS-1, Section 6.  Additionally, ensure that all conflict monitors are capable of causing the signals to flash as a result of the following events:

(1)     All red lamps associated with a load switch are burned out;

(2)     Within one second when red and green, or yellow and green color pairings are displayed on the same phase;

(3)     The absence of a minimum yellow interval.

Ensure that the monitor indicates the exact load switch output channel upon which the failure event occurred.  Furnish conflict monitors that are capable of storing a minimum of nine  fault events (event logging feature).  Furnish a monitor that utilizes a LCD display and has a RS-232 port for connection to a laptop computer.  Furnish software and connector cables to diagnose the conflict monitor.

d.      Flashers.  Furnish solid-state flashers that comply with NEMA TS-1, Section 8.  When signals have a normal stop-and-go sequence that includes flashing, either ensure that the controller unit generates that flashing display or provide flashers.  For this purpose, provide separate flashers from those provided for emergency back-up.  Furnish flashers that are designed with two circuits of at least 10 amperes each.

Equip each controller cabinet with terminals that are wired so that, by an interchange of jumpers, the flashing operation is arranged to display either flashing yellow or flashing red on the vehicular signals.

e.      Relays.  Ensure that the relays required for proper operation of the specified equipment are furnished and completely wired.  Furnish relays that are enclosed, readily replaceable, and designed for one-million operations without failure or need for adjustment.

f.       Surge Protection Devices.  Furnish surge protection on incoming power lines, interconnect lines, and detector leads.

The primary surge protection device (SPD) shall be an EDCO SHA-1250 or approved equal.  A plug-in base shall be used to hold the device.  All wiring connections shall be made to the base, and appropriate cabinet clearances maintained, to allow the SPD module to be relaced by hand without the use of tools.

Furnish loop detector lead-in cable protection that consists of devices installed in each detector circuit where the lead-in connects to the terminal block.  House each device in a case that consists of two stages; a 3-electrode gas tube arrestor and a semiconductor circuit.  Ensure that the arrestor shunts to ground a common mode transient with a 1,000 ampere peak and an 8/20 microsecond wave-shape, ionizing at 400 volts within 100 nanoseconds when subjected to a 1,000 volt per microsecond transient.  Furnish a semiconductor circuit that clamps a differential transient to 30 volts within 40 nanoseconds of the appearance of the transient, and a common mode transient to 30 volts within 500 nanoseconds of the ionization of the gas tube arrestor.  Ensure that the second stage is able to withstand a peak current of 13 amperes.  Furnish a device that has impedance characteristics compatible with the detector unit so as not to cause false calls or increase the loop impedance above the sensitivity of the detector unit.

Furnish pedestrian pushbutton inputs with the same protection as specified for the loop detector lead-in cables.

Protect interconnect cable against transients by devices across each conductor of the cable and ground.  The devices may be either 2 or 3-terminal devices.  If 3-terminal devices are used, connect two conductors and ground to the same device.  Furnish a protection device that consists of a gas tube arrestor with a maximum ionization voltage of 1000 volts on a 10,000 volt per microsecond transient or a maximum ionization voltage of 950 volts on a 3000 volt per microsecond transient.  Ensure that the maximum time from beginning of the transient to ionization is 1.1 microseconds on a 10,000 volt per microsecond transient.  Ensure that the device is not ionized by normal voltage variations on a 120-volt AC line.  Furnish a device that is able to withstand a 10,000 ampere peak with an 8/20 microsecond waveshape.

g.      Main Power Breaker.  Furnish an incoming AC+ power line that is controlled by a main circuit breaker rated at 240 volts and an auxiliary breaker, with capacity and wiring as specified in NEMA TS-1, Section 10.3.2.2 and Figure 10-4.

If a power service disconnect switch is located before the controller cabinet, the neutral (AC-) and the grounding bar in the controller cabinet shall not be connected together as shown in NEMA TS-1, Figure 10-4.

h.      Radio Interference Filter.  Furnish an incoming AC+ power line that contains a radio frequency interference (RFI) filter installed between the main circuit breaker and the solid state equipment.  Also, provide RFI filtering for the load switches and flasher, unless the equipment furnished provides signal and flasher circuits switching at the zero voltage point of the power line sinusoid wave form.

i.       Convenience Outlet and Light.   Wire a convenience outlet into the cabinet for use by electrical maintenance equipment.  Ensure that the outlet contains at least one standard duplex three-wire NEMA 5-15 receptacle of the ground-fault circuit-interrupting (GFCI) type.  Wire a second GFCI convenience outlet, not fed thru the UPS system (if used). Furnish and mount a white LED lamp in the upper portion of the cabinet.  Furnish a door switch to control the convenience light.

j.       Manual Control and Pushbutton.  When required by the plans, provide intersection controller units with means for substituting manual operation of interval timing for automatic interval timing.  Ensure that manual operation provides the same interval sequence as when the controller unit is operating automatically.

Obtain manual interval timing by a momentary pushbutton contact switch mounted on a 5-foot (1.5 m) minimum flexible weatherproof extension cord.  Store that switch and cord behind the small door-in-door.

k.      Switches.  Furnish completely wired switches that are required for proper operation of specified equipment.  Clearly and permanently label switches as to function and setting position, and ensure that they are accessible without the necessity of moving components.

(1)     Signal Shutdown Switch.  Furnish a cabinet with a signal shutdown switch for turning off the power to the signals at the intersection.  Ensure that this switch only affects the power to the signals, and allows the controller to continue in operation.  Locate the switch in the panel behind the small door-in-door (police door).

(2)     Auto/Flash Switch.  Furnish a cabinet with a flash control switch for activating the flashing of vehicular signals in a preselected emergency flash display.  Ensure that the operation of the flash control switch causes a flashing display even under conditions of controller unit malfunction or of its removal from the cabinet.  Ensure that the operation of the switch overrides any operation commands from a local or remote time switch.  Locate the switch in the panel behind the small door-in-door (police door).

Program the transfer to and from flashing operation, when called remotely or by a local time switch, to occur only at points in the cycle allowed by the OMUTCD.

(3)     Automatic/Manual Transfer Switch.  Furnish a cabinet with an automatic/manual transfer switch.  In the automatic position, ensure that the controller unit automatically sequences the signal head displays.  In the manual position, ensure that the signal phase or interval sequencing occurs only upon manual activation of the manual control pushbutton.  Locate the switch in the door-in-door (police door).  Ensure that it is unnecessary, when switching from manual to automatic operation, or vice versa, to do so at any certain time or to make any time adjustments.

(4)     Run/Stop-Time Switch.  Furnish a cabinet with a run/stop-time switch that activates the controller stop-time feature when in the “stop-time” position.  Locate the run/stop-time switch on a switch panel in the cabinet.

(5)     Controller Shutdown Switch.  Furnish a cabinet with a controller shutdown switch that cuts off power to the controller unit, conflict monitor, and detector units.  Ensure that power is not cut off to those components required to maintain flashing operation.  Locate the controller shutdown switch on a switch panel in the cabinet.

(6)     Coordinated/Free Switch.  Furnish controllers operated in a coordinated system with a coordinated/free switch.  Ensure that this switch allows the choice of operating the controller under the supervision of a coordination device or operating the controller independently of coordination control.  Locate the coordinated/free switch on a switch panel in the cabinet.

(7)     Detector Test Switches.  Furnish momentary contact switches that will enter a vehicular or pedestrian call for any actuated phase.  Furnish a switch for each actuated phase vehicular and pedestrian detection input.  Conveniently group and label the switches.

l.       Terminal Blocks.  Furnish cabinets that include terminal blocks mounted on panels on the walls of the cabinet.  Ensure that the blocks are not obstructed by shelf-mounted devices.  Furnish sufficient terminal sets for each individual harness wire as well as for contacts of signal load switches, flasher transfer relays, flasher, and other components.  Also, provide separate terminal sets for field wiring connections, including power, signal, interconnection, and detector lead-in cables.  Group terminal sets to separate higher voltage (120 VAC) from lower voltage, and arrange them into logical groups.  Protect terminal blocks from accidental contact during the installation and removal of shelf-mounted equipment.  Locate the blocks no closer than 4 inches (100 mm) from the bottom of pole and pedestal mounted cabinets, and no closer than 6 inches (150 mm) from the bottom of foundation mounted cabinets.

Ensure that the terminal points are UL listed as suitable to carry the rated loading.  Ensure that the capacity and size of the terminals are as specified in NEMA TS-1, Section 10.2.5.  Ensure that the terminal points for signal field wiring for each circuit accommodates at least four 12 AWG conductors with spade type terminals.

Furnish terminal points for incoming power wiring that accepts either spade terminals or bare stranded wire and are suitable for either aluminum or copper conductors.

Space terminal sets for easy wiring.  Furnish at least six reserve terminal sets for controllers.  Harnesses may terminate on the back of terminal blocks using through-panel terminals.  Clearly mark terminal sets for ready identification including through-panel terminals that are identified on both sides.  Ensure that the contact between adjacent terminal points are made by bus bar, or by wire jumpers having spade type terminals securely attached to each end.

m.     Terminal Buses.  Furnish a cabinet with supply terminal buses fed from the line side of the incoming 120 VAC power line, after the phase wire has passed through the main power switch.  Ensure that the requirements for use of radio interference filters are according to Item 8 of this Section, with the buses supplying load switches and with flashers being filtered when required.  Ensure that a signal bus relay controls power to the bus supplying power for the signal load switches. .  The following overrides NEMA requirements for signal bus relays.  A solid-state relay shall be used for the signal bus relay.  The signal bus relay shall maintain output equal to or above the rating of the cabinet main overcurrent protection device over the NEMA TS-2 Environmental Operating Range of -50 to +185 degrees F (-45 to +85 degrees C).

Furnish a common terminal bus for the connection of the neutral wire of the incoming 120 VAC power line.  Ensure that the common bus has sufficient terminal points to accommodate all potential cabinet wiring as well as field wiring.  Use a separate common terminal, insulated from the panel, for the interconnect common.

Furnish bus terminal points that comply with Item 12 of this Section for conductor accommodation, attachment and identification.

n.      Grounding System/Bus Bars.  Furnish a cabinet that includes a grounding system as specified in NEMA TS-1, Section 10.3.2.1 with an adequate number (minimum of three) of ground terminal points. 

o.      Wiring.  Neatly organize and route the harnesses and wiring bundles to individual terminals.  Ensure that the harness provides a wire for each pin or contact of the device.  Connect each wire to a marked terminal position.  Use labeled spade type terminals or plug connections on all harness wiring.  Group and lash or restrain wire bundles in such a manner that they will not interfere with the access to components, terminal blocks or buses, or the legibility of terminal identification.  Ensure that the harnesses are of sufficient length to reach any point within the cabinet.  Ensure that the cables and harness bundles are easily traced through the cabinet to their terminations. Route all wiring terminated on printed circuit boards (as commonly done for BIU backpanel connectors) at right angles to the pin array; no wires shall pass over the connector pins.

Wire the cabinet so that controller pin connections associated with a given phase number matches the phase number assigned to the specified traffic movement as shown on the plans.

Furnish all wiring with stranded conductors.  Ensure that the wiring is adequate for the voltage and load that represents the ultimate load of the devices connected.  Ensure that the ampacity rating of the wires are as specified in NEMA TS-1, Section 10.3.3.1.  Ensure that the wiring is color coded as follows:

(1)     Solid white, AC common.

(2)     Solid green or green with yellow stripes, equipment ground.

(3)     Solid black, AC line side power (AC+).

p.      Loop Detector Units.  Furnish loop detector units that comply with the requirements of NEMA TS-1, Section 15, with the following modifications:

(1)     Furnish loop detector units that are shelf mounted and powered from 120 volts.

(2)     Ensure that the unit uses solid-state isolated output devices.

(3)     Furnish conductors in the cable harness for loop input pins that are twisted three to five times per foot (300 mm).

(4)     Furnish detector unit electrical connection plugs or wiring harness that are designed such that any multi-channel shelf mounted detector unit is readily replaced with single channel detector units.  Furnish only units with the connector type required for single channel shelf mounted detector units, or by wiring the controller back panel to single channel wiring harnesses which are, in turn, plug connected to an adapter harness that is mated to the multi-channel connector of the detector unit.

(5)     When shown on the plans, supply delay and extension timing capability on the detector unit; otherwise, the controller unit software requirements of 733.02 will provide these features.

(6)     Ensure that the harness provides a wire for each pin or contact of the device.

(7)     Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

If vehicle detector types other than “loop” detectors are required by the plans, provide these detectors by separate bid item.

Furnish  TS-1 cabinets according to the Department’s Qualified Products List (QPL).

B.      Type TS-2.

1.      Furnish TS-2 cabinets that utilize a high speed data channel to connect the controller unit, malfunction management unit, rear panel (terminals and facilities), detectors and bus interface units and also comply with the general requirements of 733.03.  Furnish a prewired cabinet with malfunction management unit, loop detector units, and all accessory equipment as specified in NEMA TS-2, except as follows:

a.      Section 5.3.4, use detector racks for both Type 1 (A1) and Type 2 (A2) controller units.

b.      Section 5.4.2.1, if a power service disconnect switch is located before the controller cabinet, the neutral (AC-) and the grounding bar in the controller cabinet shall be connected together.

c.      Section 5.4.2.7, provide an LED type light.

d.      Section 5.4.2.7.2, provide the LED lamp.

e.      Section 5.4.2.7.3, provide the door actuated light switch.

f.       Section 6.5.2.2.1, provide 2-channel detector units, without delay/extension features (Type A). Furnish momentary pushbuttons on the cabinet door or a detector rack panel for actuation of Detector BIU #9, channels 1-16, and the four opto-isolated pedestrian detector inputs on BIU #1 and BIU #2. Permanently label these pushbuttons as “VEH DET 1” through “VEH DET 16” and “PED DET 1” through “PED DET 8.”

g.      Section 7.2, construct cabinets of sheet aluminum.

h.     

Section 7.3, unless otherwise specified in the plans, provide a Size 5 cabinet for four phase or less pole mounted cabinets, Size 5 for four phase or less ground mounted cabinets, and Size 6 for 5 phase or more ground mounted cabinets.  Supply larger cabinets if required to house the equipment to meet the plan requirements; such as master controllers, preemption devices, 16 position backpanels or special detection units. 

         Furnish all wire passages through and over metal edges with edge protection polymer trim.

 

i.       Section 7.5.7, ensure that the police panel contains switches for AUTO/FLASH, SIGNALS ON/OFF and AUTO/MANUAL in the police panel.  Furnish a pushbutton with a 5-foot (1.5 m) cord, and panel connector, not hard wired.

j.       Section 7.7.3, supply unpainted cabinets.

k.      The following overrides the NEMA requirements for signal bus relays. A solid-state relay shall be used for the signal bus relay. This relay shall maintain output equal to or exceeding the requirements of the cabinet main overcurrent protective device over the NEMA TS-2 Environmental Operating Range of -50 to +185 degrees Farenheit.

2.      Furnish loop detector and pedestrian inputs that have lightning/surge protection as specified in 733.03.A.2.f.

3.      Include loop detector racks with the necessary number of two-channel loop detector units with the cabinet.  When shown on the plans, supply delay and extension timing capability on the detector unit; otherwise, provide the controller unit software with these features.  If vehicle detector types other than “loop” detectors are required by the plans, provide these detector units by separate bid item.  If the special bid detector units use standard TS-2 detector racks, furnish the racks as part of the pre-wired cabinet.

          Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

4.      Furnish switches to control the controller unit and cabinet functions as specified in the plans. 

5.      Furnish load switches that have both input and output indicators.

         6.       The primary surge protection device (SPD) shall be an EDCO SHA-1250 or approved equal.  A plug-in base shall be used to hold the device.  All wiring connections shall be made to the base, and appropriate cabinet clearances maintained, to allow the SPD module to be replaced by hand without the use of tools. Cabinet power distribution shall conform to Figure 5-4, NEMA TS-2 2003 v02.06. In addition, locates a non GFCI NEMA 5-15 utility outlet on the right side power panel. This outlet shall be powered independently of the UPS by direct connection to incoming utility power through a 15-amp circuit breaker labeled “UTILITY OUTLET.”

 

     7.      Include serial and/or Ethernet cables, 4-feet minimum length, to interface with laptop computer.  Include all interface software. 

     8.      Include datakey module.  Provide a datakey with each controller, taped securely to the top of the controller chassis.. 

          9.      Include an SDLC expansion board with three available ports, mounted on a cabinet side wall.

          10.    Include an SDLC in-line surge suppressor, EDCO SRS-BIU-15 or equivalent, located at the controller SDLC port.

          11.   Furnish an aluminum shelf with integral storage compartment in the space immediately below the controller. Ensure the storage compartment has telescoping drawer guides for full extension. Ensure the compartment top has a non-slip plastic laminate attached.

. 

Furnish  TS-2 cabinet according to the Department’s Qualified Products List (QPL).

 

C.      Type 332. 

1.      General.  Furnish Model 332L cabinets that meet the specifications “Traffic Signal Control Equipment Specifications” and “Transportation Electrical Equipment Specifications”, California Department of Transportation.  Ensure that the manufacturer of the cabinets is listed on the CalTrans and/or ODOT QPL at the time of delivery to the project.

2.      Cabinets.

a.      Ensure that the cabinets are constructed of aluminum and are supplied unpainted.  An anodic coating is not required.  Supply galvanized anchor bolts with nuts and washers with each cabinet.  Furnish 3/4-inch (19 mm) diameter by 16 inches (0.4 m) minimum length anchor bolts with an “L” bend on the unthreaded end.

b.      Fit the cabinets with a PDA-2 power distribution assembly.

c.      When shown on the plans, provide the cabinet with door hinges that are “right” or “left” mounted when facing the front of the cabinet.

3.      Terminals and Wiring.

a.      “Hardwire” output files.  Do not use printed circuit wiring in the output file except for the red monitor board.

b.      Ensure that the vehicle and pedestrian detector field wiring inputs connect to side mounted terminal blocks.  Install terminal blocks and associated wiring to the input file.  Label the field wiring terminals of the side mounted terminal block by a permanent screening process to identify the input panel (I or J), the input file slot number (1 through 14) and the channel terminal (D, E, J, or K).  An example is “I4-E”.  Ensure that all terminals on these detector blocks are accessible without removing equipment from the EIA mounting rack.

c.      Install red monitor cabling in the cabinets.  Install a program board to enable/disable red monitoring.  Ship the cabinets with the red monitor jumpers set in the “enable” position.

d.      Do not connect the pedestrian yellow load switch outputs to the conflict monitor card-edge connector.

e.      Supply each cabinet with a cable at least 5 feet (1.5 m) long to connect a laptop computer with the controller.  Ensure that the cable has a DB-9 connector on one end, and a connector on the other end to mate with the C2 on the back of the controller.  The cable will allow a laptop computer to upload/download data to the controller.

f.       Supply each cabinet with a Category 5e cable with 8P8C (RJ45) plug on each end, minimum 5 feet in length.  The cable will allow a laptop computer to upload/download data to the controller. 

g.      On the output file, wire pin No. 11 of each switchpack connector to AC- so that the output indicators on dual indicator switchpacks will display properly.

4.      Accessories.

a.      Fully equip the cabinets with two channel loop detector sensors, flashers, flash transfer relays, power supply, AC and DC isolators, conflict monitor, switchpacks (with both input and output indicators), and a DC isolator in slot 14 for flash sense/stop time.  Do not switch the input file channels from the standard layout in order to minimize the number of two-channel detector units utilized.  If vehicle detector types other than “loop” detectors are required by the plans, provide these detectors under a separate bid item.

In addition to the requirements of Caltrans TEES, furnish detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent). This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

Furnish loop detector sensors according to the Department’s Qualified Products List (QPL).

b.      Furnish a rack mounted detector test panel with test switches for all allthe 16 Channel Call inputs of BIU 9, labeled 1-16, and the 8 Pedestrian Detector inputs of BIU 1 and 2, labeled P1-P8vehicle and pedestrian phases.  Furnish switches with three position “on/off/momentary on” switches.

c.      Furnish a police panel in each cabinet that includes a removable pushbutton with 5 feet (1.5 m) cord and three switches labeled AUTO/FLASH, SIGNALS ON/OFF and AUTO/MANUAL.  Wire the pushbutton cord to the controller harness wiring by a molex plug connection and not through an AC isolator.  When placed in the manual position, apply “manual control enable” to the controller and apply “recall” to all phases.  Ensure that activation of the push button “advances” the controller, except prohibit the manual advancement during the minimum green, yellow, and red timing intervals.

d.      Furnish an aluminum shelf with integral storage compartment in the rack below the controller.  Ensure that the storage compartment has telescoping drawer guides for full extension.  Ensure that the compartment top has a non-slip plastic laminate attached.  Top of shelf shall be at least 30 inches and no more than 48 inches above the workpad surface.  For cabinets with risers, this may require relocating the drawer to a position below Input File #2. 

e.      Ensure that each cabinet has two white LED lights installed at the top of the cabinet, one near each door.  Wire the lights to the door switches such that opening either door will turn on both lights.

5.      Surge Protection.

a.      Furnish surge protection on pedestrian and detector inputs.  Furnish three terminal surrestors equivalent to EDCO models SRA-6LCA, SRA-6LCB, or SRA-6LC.

b.      Protect the cabinet’s incoming power lines with an EDCO SHA1250 or approved equal surge protector in lieu of the CalTrans specified surge protection.  A plug-in base shall be used to hold the device.  All wiring connections shall be made to the base, and appropriate cabinet clearances maintained, to allow the SPD module to be relaced by hand without the use of tools. 

6.      Conflict Monitor.  Ensure that the conflict monitor unit was tested and accepted according to Supplement 1076.

a.      Materials and Warranties.    Furnish electrical parts, switches, and other elements of the installation that are of ample capacity to carry the required current without excessive heating or drop of potential.

Use standard industrial quality components (integrated circuit chips, transistors, diodes, resistors, capacitors, etc.) wherever possible.  Clearly identify these components with the original identification.  Designate the other vital information such as voltage polarity, emitter or collector terminals, pin locations, etc., by an approved industrial procedure.  Ensure that the major items or assemblies of equipment bear a nameplate, indelible marking, or brand that identifies it as to type, model, catalog number, and manufacturer.

Transfer that manufacturers’ guarantees or warranties to the Department upon delivery and acceptance of the equipment.  Ensure that all conflict monitors are warranted for a period of 60 months or for the manufacturer’s standard warranty period, whichever is greater, for parts and labor from date of shipment to the project or the ODOT Signal Shop.  Ensure that each unit has a permanent label or stamp indicating the date of shipment and name of vendor supplying the unit and/or logo..

b.      General Requirements.

(1)     Minimum Standards.  This specification establishes minimum standards for Conflict Monitoring Devices designed for use in Model 332 and 336 Traffic Signal Controller Cabinets supplied to the Department. 

(2)     Indicator Lights.  Furnish indicator lights that are water-clear (not colored or diffused lenses), ultra- bright light emitting diodes (LED), whose states are clearly readable in direct sunlight.  Ensure that each conflict monitor channel provides separate red, yellow, and green LEDs.

(a)     Furnish a GREEN AC POWER indicator light.

(b)     Arrange indicator lights in a vertical pattern with FAULT status lights as the upper indications and the output channel lights as the lower indications [See 733.03.C.6.c.(1) and 733.03.C.6.c.(9)].  An acceptable alternative is to provide a single fault indication and a supplemental display that clearly indicates the fault type.

(c)     Ensure that a failure causes its respective indicator light to display.

(3)     Monitor Power.  Ensure that the Monitor does not use the 24VDC power supply being sensed to run any of its internal circuitry.  Ensure that the watchdog, stop time, external reset, and 24VDC monitor input circuits are optically isolated from the Monitor internal power supply and are conditioned to provide proper sense circuit operation throughout the operating range.

(4)     Power Fail.  Consider a line voltage less than 85 V ac ± 2 V ac as a power failure.  Ensure that a power failure does not result in resetting the Monitor.  Ensure that once the Monitor is triggered by detection of a fault that it remains in that state until a Reset Command is issued.  Reset is issued only by the Front Panel Control Switch or by the External Test Reset input.

(5)     Power Up.  Furnish a Monitor that is compatible with the Model 170E controller as well as the Model 2070 controller unit that requires several seconds to power-up.  When power is established, > 103 ± 2 Vac, the 2010 will power up in the FAULT RELAY RECOVERY mode:

When power is established, initiate FAULT RELAY RECOVERY.  For an interval of 6.0 ± 0.5 seconds, the following will take place:

(a)     The Output Relay contacts remain closed, and the Stop Time output remains active.

(b)     All fault monitoring functions remain suspended.

(c)     The AC POWER indicator light flashes at a 2 hertz rate.

At the end of this time interval, the Monitor begins counting Watchdog transitions from the controller and prepares to resume normal fault monitoring.

Ensure that the resumption of normal Fault monitoring occurs when either:

(a)     The Monitor has counted 5 transitions between the True and False state from the controller Watchdog; or

(b)     10 ± 0.5 seconds has elapsed from the time of LINE RECOVERY.

If the controller Watchdog output does not become active, ensure that the Monitor goes into a Latched Fault condition.

(6)     Cabinet Signals Monitored.  Furnish a Monitor designed to monitor Green, Yellow, and Red AC circuits at the field output terminals of traffic signal cabinets.  Monitor shall be capable of monitoring Flashing Yellow Arrow channels.  In addition, monitor the cabinet 24VDC supply, and the Model 170E/2070 controller Watchdog Timer output.  These signals are processed by the Monitor circuitry, and if a failure is determined to have occurred, ensure that a relay output contact closure (FAILED state) places the cabinet and intersection into flashing operation.

(7)     Failed State Output Circuits.

(a)     Use an electro-mechanical relay to provide the FAILED STATE output circuit.  Ensure that the relay contacts are normally closed (FAILED STATE).  In a NON-FAILED state (relay coil energized), ensure that the contacts are open.  The function of this output circuit is to initiate flash operation within the cabinet and transfer field circuits from the switch pack outputs to the flash bus during a FAILED STATE.

(b)     Furnish relay contacts that are rated for a minimum of 3 amperes at 120 V ac and 100,000 operations.  Ensure that the contact opening/closing time is 30 ms or less.  Furnish contacts that present a minimum impedance of 50,000 ohms in the open state.

(c)     Ensure that the Stop Time output is active whenever the output relay contacts are in the FAILED STATE (closed).  Ensure that it is inactive whenever the output relay contacts are in the NON-FAILED (open) STATE.

(8)     Monitor Unit Reset.  Furnish a front panel momentary SPST pushbutton switch labeled “RESET” to reset the Monitor to a Non-FAILED state and restores normal monitoring operation.  Position the switch on the front panel so that the switch can be operated while gripping the front panel handle.

Ensure that the External Test Reset input line resets the Monitor circuitry to a Non-FAILED state and restores normal monitoring operation.  Optically isolate it from the internal circuitry.  Ensure that a reset issuance by either source (Unit Reset) is triggered by only the leading edge of the input signal (this will prevent a constant reset due to either a switch failure or a constant external input).  Ensure that a constant reset input is ignored within 5 seconds of issuance.

(9)     Input Impedance.  Ensure that the input impedance for all monitored AC inputs are 200 kilohms ± 100 kilohms.

(10)  Connectors.  Furnish PCB 28/56P Type Monitor and Conflict Program Card Connectors.  Ensure that all edge connectors use the “bifurcated bellow” type contact or equivalent.

(11)  Door Ajar Circuit.  Connect pin 24 to pin 25 on the Monitor PCB at the edge connector and ensure that it is capable of carrying one ampere according to CalTrans specifications.

(12)  Handle.  Ensure that the handle placement and design is such that no interference between the handle and a closed cabinet door exists.

(13)  Fuse Holder.  Furnish low profile fuse holders on the front panel.

c.      Functional Requirements.

(1)     General.  The Monitor monitors the cabinet for conflicts and unsafe operation.  If an unsafe condition exists, the Monitor will enter into a FAILED state.  This places the cabinet into flash operation and applies STOP TIME to the controller unit.  Ensure that the Monitor is designed to monitor red circuits, yellow timing, multiple outputs, and lack of outputs on a switch selectable, per channel basis.  Specific conditions for failure follow:

(a)     24VDC FAIL.  The cabinet +24 volts DC does not meet the specified thresholds.

(b)     CONFLICT.  When the green or yellow input to one or more channels is ON and they are not programmed as permissive on the Conflict Program Card.

(c)     WATCHDOG TIMER (WDT) ERROR.  When the 170E/2070 controller unit watchdog output has ceased.

(d)     CONFLICT PROGRAM CARD AJAR.  Illuminates, if the Conflict Program Card is removed or if it is not properly seated in the connector.  When it is not inserted into the monitor, ensure that the warning indicator light is displayed.

(e)     MONITOR FAILURE.  A fault is detected within the operation of the 2010 Monitor itself.

(f)     MULTIPLE OUTPUTS.  Simultaneous indications of Green, Yellow, or Red field outputs on a single channel.

(g)     RED FAIL.  No active field outputs on a single channel (green/yellow/red).

(h)     YELLOW ERROR.  The absence of a minimum yellow field output during a green to red sequence.  Minimum yellow shall be 2.7 seconds ± 100 ms.

(2)     Operating Range.  Furnish a Monitor Unit that is fully operational using an 85 to 135 V ac power source.  Ensure that the Monitor suspends Fault monitoring below 85 V ac ± 2 V ac, closes the output relay, and de-energizes the AC POWER indicator light.

(3)     Watchdog Timing.  Furnish WATCHDOG Timing Circuitry to monitor the controller unit WATCHDOG output.  Ensure that the WDT Circuitry senses state changes and the time between the last change.  Ensure that an absence of change for 1.5±0.1 seconds places the Monitor in a FAILED state.

(4)     Channels Monitored.  Furnish a Monitor that senses and responds to conflicts and 24 VDC failures whenever the AC line voltage is within the 85 to 135 V ac operating range of the Monitor, except during FAULT RELAY OPERATION.

(5)     Yellow Inhibit.  Furnish means to selectively inhibit the monitoring of a Yellow channel input.

(6)     Power Fail after Fault.  In the event that the Monitor senses a fault, followed by a loss of operating voltage, ensure that the initial Failure Status is retained in memory and is redisplayed after restoration of power.

(a)     Once the Monitor is LATCHED in a fault condition for any reason, including the removal of the Conflict Program Card, ensure that it REMAINS LATCHED, even through a power fail/recovery, until a RESET is issued by the front panel reset switch, or by the external test reset line.

(b)     Display the status of the Green, Yellow, and Red inputs of all channels, at the time the fault was latched.  Ensure that a power loss does not affect the retention of this data.  An acceptable alternative is to save status of all channels in memory and only display the latched fault.

(7)     Insertion/Removal of Unit.  Ensure that it is possible to insert and remove the Monitor while the cabinet is energized without placing the cabinet into Flash operation provided that:  The cabinet door remains open and the reset switch is held depressed while the unit is being inserted or removed.  Any momentary disruption of field signal indications is less than 500 ms.

(8)     Microprocessor Use.  If a microprocessor is used in the Monitor design, ensure that its program is written so that:

(a)     Integrity tests are performed periodically on each memory cell of each memory device, relevant to each device type.

(b)     Hardware external to the microprocessor circuits is employed to constantly sense proper microprocessor operation.

(c)     The Monitor reverts to a FAILED state if a fault is detected with the microprocessor or during integrity tests.

(9)     Front Panel Indicators.  Ensure that the Monitor has red/yellow/green indicators for channel inputs and indicators to provide status and failure detection information.  Furnish a GREEN AC POWER indicator.  Ensure that all indicators are clearly readable in direct sunlight.  Arrange and label the indicators as shown below:

(a)     AC POWER.  Illuminates when the incoming AC Line Voltage exceeds 103 ± 2V ac, and FLASHES during FAULT RELAY OPERATION.

(b)     VDC FAIL.  Illuminates when the Monitor has detected a 24VDC failure.

(c)     CONFLICT.  Illuminates when a conflicting signal condition is detected.

(d)     WDT ERROR.  Illuminates when a Watchdog error is detected.  Do not provide a switch or similar device to disable WDT monitoring.

(e)     PC AJAR.  Illuminates when the Conflict Program Card is removed or is not properly seated in its connector.

(f)     MON FAIL.  Illuminates to indicate an internal Monitor failure.

(g)     RED FAIL.  Illuminates when the Monitor detects that there is no active output on any of the field outputs that comprise a monitored channel.  Ensure that the failed channels are displayed on the corresponding channel indicators.  If for any reason red fail is not enabled, ensure that the red fail indicator light flashes at approximately 2hertz.

(h)     MULT IND.  Illuminates when the Monitor detects simultaneous outputs on more than one of the field outputs that comprise a monitored channel (green/yellow/red).  Ensure that the failed channels are displayed on the corresponding channel indicators.

(i)      YELLOW.  Illuminates when the Monitor detects the absence of a minimum period of active yellow field output during a green to red sequence.  Ensure that the failed channel is displayed on the corresponding channel indicator.

(j)      1, 2, 3, 48.  Furnish channel indicators that illuminate a FAILED state in conformance with 733.03.C.6.c.(6).

(10)  Monitor Board Edge Connector.  Furnish monitor board edge connectors that conform to CalTrans specifications.

(11)  Monitoring of Conflicting Voltages.  Ensure that inputs to any channel that exceed the specified conflict threshold (see Section 6) are sensed as “ON” and illuminate their respective channel indicators.  Ensure that the number of active channels in no way affects the conflict threshold.

Ensure that the following voltage levels and times apply:  A conflict has occurred and will cause a FAILED state only when voltages appear at the field output terminals.

> 20 ± 5.0 V rms for a duration > 350 ± 150 ms.

 

(12)  Conflict Program Card.  Furnish conflict program cards that comply with CalTrans specifications.

d.      Fault Relay Operation.

(1)     Line Drop Out.  Furnish a Monitor that determines that a LINE DROP OUT has occurred when:

The AC Line Voltage is:

< 98 ± 2 VAC for > 400 ± 100 ms.

Within this time frame, ensure that the Monitor suspends all fault monitoring functions, closes the output relay contacts, enables Stop Time output, and the AC POWER indicator on the front panel flashes at a rate of 2 hertz ±20 percent to indicate LINE DROP OUT status.  Ensure that the Monitor remains in the FAULT RELAY mode until a LINE RECOVERY has occurred.

(2)     Line Recovery.  Ensure that the Monitor that determines that a LINE RECOVERY has occurred when:

The AC Line Voltage is:

> 103 ± 2 VAC for > 400 ± 100 ms.

(3)     Fault Relay Recovery.  When LINE RECOVERY is established, initiate the FAULT RELAY RECOVERY.  For an interval of 6.0 ± 0.5 seconds, the following will take place:

(a)     The Output Relay contacts remain closed, and the Stop Time output remains active.

(b)     All fault monitoring functions remain suspended.

(c)     The AC POWER indicator light flashes at a rate of 2 hertz ± 20 percent.

At the end of this time interval the Monitor begins counting Watchdog transitions from the controller and prepares to resume normal fault monitoring.

(4)     Resumption of Normal Monitoring.  Ensure that the resumption of normal Fault Monitoring occurs when either:

(a)     the Monitor has counted five transitions between the True and False state from the controller Watchdog; or

(b)     10 ± 0.5 seconds has elapsed from the time of LINE RECOVERY.

If the controller Watchdog output does not become active, the Monitor shall go into a Latched Fault condition.

e.      Red Monitoring Connector.

(1)     Connector.  Mount a connector, 3M-3428-5302, with two 3518 polarizing keys, or equivalent, on the Monitor front panel.  The pin assignments of the P20 connector and terminal assembly are defined in this specification.

Ensure that it is possible to plug and unplug the Red Monitoring Connector P20 without placing the cabinet into Flash operation.

P20 Connector Pin Assignments

Pin

Function

Pin

Function

1

CHANNEL 15 RED

2

CHANNEL 16 RED

3

CHANNEL 14 RED

4

UNDEFINED

5

CHANNEL 13 RED

6

SPECIAL FUNCTION 2

7

CHANNEL 12 RED

8

SPECIAL FUNCTION 1

9

CHANNEL 10 RED

10

CHANNEL 11 RED

11

CHANNEL 9 RED

12

CHANNEL 8 RED

13

CHANNEL 7 RED

14

CHANNEL 6 RED

15

CHANNEL 5 RED

16

CHANNEL 4 RED

17

CHANNEL 3 RED

18

CHANNEL 2 RED

19

CHANNEL 1 RED

20

RED ENABLE

 

Ensure that keying is between pins 3/5, and 17/19.  The odd numbered pins are on one side, and the even pins are on the other.  Key the P20 connector and the CMU connector physically alike (to prevent the Red Monitoring cable from being inserted into the P20 180 degrees out of alignment).

(2)     Red Enable Input.  Ensure that pin 20 of the Red Monitoring Connector provides the Red Enable input to the Monitor.  When the Red Monitoring Connector is disconnected, or Red Enable is not present, ensure that the Monitor checks for conflicting combinations of Greens and Yellows, Watchdog Timer, 24VDC, Conflict Program Card Ajar, and Monitor Fail.  When enabled, ensure that the extended Monitor functions become active including:  Red Fail, Multiple Output, and Yellow Fail.

(3)     Special Function 1 and 2 Inputs.

(a)     PIN 8, Special Function 1:  Furnish an AC input to the Monitor, which will DISABLE only the RED FAIL monitoring functions while it is active (e.g. during Railroad Preempt).

(b)     PIN 6, Special Function 2:  Reserved for future use.

Furnish a means to select either a PRESENCE of, or LACK of AC+ to enable these inputs.

f.       Electrical Requirements.

(1)     Operation Range.  Furnish a Monitor that is fully operational from an 85 to 135 V ac power source.

(2)     Isolation.  Isolate the Chassis Ground and AC - from one another.

(3)     Monitored AC Inputs.  The following voltage and time thresholds apply to all monitored AC inputs.

(a)     Green and Yellow Inputs.

Any inputs < 15.0 V rms are considered OFF.

Any inputs > 25.0 V rms are considered ON.

 

Both sinusoidal and half-wave inputs of the specified RMS values  are to meet these thresholds.

(b)     Red, Red Enable, and Special Function Inputs.

Any inputs < 50.0 V rms are considered OFF.

Any inputs > 70.0 V rms are considered ON.

 

Red inputs, both sinusoidal, and half-wave, of the specified RMS values, are to meet these thresholds.

Red enable and special function inputs are to meet these thresholds for sinusoidal waveforms only.

(c)     Timing of Conflicting Inputs or Multiple Inputs.

Inputs ON < 200 ms are NOT considered a FAULT.

Inputs ON > 500 ms are considered a FAULT.

 

(d)     Timing of Red Fail.

Lack of output < 1200 ms is NOT considered a FAULT.

Lack of output > 1500 ms is considered a FAULT.

 

(4)     Monitored DC Inputs.

(a)     24VDC Input.

Input < 18.0 VDC is considered Low VDC input.

Input > 22.0 VDC is NOT considered Low VDC input.

 

(b)     24VDC Timing.

Low VDC input < 200 ms is NOT considered a FAULT.

Low VDC input > 500 ms is considered a FAULT.

 

(c)     Watchdog Monitor Input.

Input < 4.0 VDC is considered a LOW STATE.

Input > 12.0 VDC (or OPEN) is considered a HIGH STATE.

 

(d)     Watchdog Error Timing.

Lack of valid input state changes for < 1400 ms is NOT a FAULT.

Lack of valid input state changes for > 1600 ms is a FAULT.

 

g.      Communications and Software.

(1)     Install an RS232 port for laptop communications on the front panel of the Monitor.  If specified in the plans, an IP port shall be used in place of RS232. 

(2)     Furnish a Monitor with compatible communications software for installation on a laptop computer, capable of interfacing with the communication port on the front panel.  Furnish the software on a 3 1/2-inch (85 mm) floppy disk with each Monitor.  Label each disk with revision number and date.

(3)     Unless specified otherwise in the plans, furnish a Monitor that is capable of being programmed and set-up for intersection operation without the use of a laptop computer and communication software.

(4)     Furnish a Monitor communications software that is capable of showing and/or programming the status of all programmable set-up parameters of the unit.  Furnish a communications software that is capable of displaying the following data:

(a)     Fault type

(b)     Field status (must update status continuously)

(c)     AC line voltage (must update status continuously)

(d)     Status of Red Enable

(e)     Previous fault data

(f)     Program card matrix

(g)     Yellow disable jumpers (if applicable)

(h)     Switch settings per channel (as applicable)

(i)      Option switches

(j)      Current time

(k)     Temperature (must update status continuously)

(l)      Event logs

(5)     Furnish a Monitor that is capable of storing events into memory.  Typical events are fault events, AC line events, reset events, etc.  When a fault event is stored into memory, the Monitor will store the fault condition (type), channel status, date, time, temperature, and line voltage.  Ensure that the log history stores a minimum of 100 total events.

h.      Diode Matrix, Programming Key, and Software.  Furnish a Monitor that loads the diode matrix or Programming Key programming into a non-volatile memory device.  When the diode matrix or Programming Key is loaded into memory, the memory will regularly compare with diode card or Programming Key and fault condition will occur if memory does not match the diode card matrix.

Furnish  332 cabinet according to the Department’s Qualified Products List (QPL).

E.      Type 336.

1.      General.  Furnish Model 336 cabinets that meet the basic cabinet specifications “Traffic Signal Control Equipment Specifications”, California Department of Transportation, latest edition.  Ensure that the manufacturer of these Model 336 cabinets is listed on the ODOT or CalTrans QPL for the Model 332 cabinets unless specified otherwise in the plans, a 336L cabinet shall be furnished.

2.      Cabinets.

a.      Furnish cabinets that are constructed of aluminum and are supplied unpainted.  An anodic coating is not required.

b.      The CalTrans Model 336 cabinet specification is only modified so that the cabinet supplied is the “stretch” type that provides approximately 10 inches of (250 mm) additional cabinet height.

c.      Supply galvanized anchor bolts with nuts and washers with each base mounted cabinet.  Furnish 3/4-inch (19 mm) diameter by 16 inches (0.4 m) minimum length anchor bolts with an “L” bend on the unthreaded end.

d.      Furnish pole mounted cabinets with two pole mounting brackets attached and bottom plates installed.  Ensure that both of the cabinet sidewalls are reinforced for pole brackets; however, also ensure that the cabinet is shipped with the brackets installed on the door hinge side of the cabinet.  When a pole mounted cabinet is ordered, ensure that the door hinges are specified as “right” or “left” mounted as looking into the front of the cabinet.  Ensure that the brackets are designed for banding to a pole.

e.      Fit cabinets with a PDA-2 power distribution assembly.

3.      Terminals and Wiring.  Comply with the requirements of 733.03.C.3.

4.      Accessories.  Comply with the requirements of 733.03.C.4.

5.      Lightning/Surge Protection.  Comply with the requirements of 733.03.C.5.

6.      Conflict Monitor.  Comply with the requirements of 733.03.C.6.

Furnish  336 cabinet materials according to the Department’s Qualified Products List (QPL).

733.04  Cabinet Risers.  Furnish the type (size and shape) of cabinet riser that is compatible with the type of controller cabinets specified for the project.

A. Cabinet Riser for NEMA Cabinet.  Furnish an aluminum riser that will raise the NEMA cabinet approximately 12 inches (0.3 m) above the concrete foundation.  Ensure that the bottom of the riser bolts to the standard cabinet foundation anchor bolts (not included with the riser) and the top of the riser bolts to the bottom of the cabinet.  Furnish attachment hardware for connecting the riser to the cabinet.

Construct the riser in a minimum of two pieces such that an existing cabinet can be raised off the foundation without disconnecting the field wiring and the riser can be inserted below the cabinet.  Furnish hardware for rigidly connecting the riser sections together.

Fabricate the riser from 0.125-inch (3 mm) sheet aluminum with flanges on the top and bottom to provide rigidity.  Furnish mounting flanges as necessary to connect with the controller cabinet and foundation anchor bolts.  Ensure that the outside surface of the riser has a smooth, uniform, natural finish unless controller cabinet painting is shown on the plans.  If painting is required, prepare and paint the riser to match the cabinet.

B. Cabinet Riser for Type 332, 334 or Type 336 Cabinet.  Furnish an aluminum riser that will raise the Model 332, 334 or 336 cabinet approximately 8 inches (0.2 m) above the concrete foundation.  Ensure that the bottom of the riser bolts to the standard cabinet foundation anchor bolts (not included with the riser) and the top of the riser bolts to the bottom of the cabinet.  Furnish attachment hardware for connecting the riser to the cabinet.  Manufacture the unit to CalTrans specifications.  Ensure that the outside surface of the riser has a smooth, uniform, natural finish unless controller cabinet painting is shown on the plans.  If painting is required, prepare and paint the riser to match the cabinet.

Furnish materials according to the Department’s Qualified Products List (QPL).

733.05  Flasher Controller.  Furnish solid-state flasher that complies with NEMA TS-1, Section 8, and have two circuits, each rated at 10 amperes.  Furnish a cabinet that conforms to applicable requirements of 733.03.A, except that the following items are not required:  a small door-in-door (police door), shelves, and a fan.  Ensure that the cabinet size is not less than 12 inches (300 mm) high by 10 inches (250 mm) wide by 6 inches (150 mm) deep.  Furnish cabinets that are designed for pole mounting with a 1-1/2 inch (38 mm) or larger conduit opening in the bottom.  Ensure that the auxiliary equipment includes:  on-off power switch with integral 20-ampere circuit breaker, lightning protection devices on incoming power lines, interference filters, terminal blocks, and a ground bus bar.

Furnish materials according to the Department’s Qualified Products List (QPL).

733.06  Controller, Master, Traffic Responsive.

A.      Description.  The traffic responsive master controller is one component of a distributive processing, traffic responsive, control, and monitoring “closed loop” system.  The master controller’s principal operational task is to select and implement traffic signal timing plans in response to both actual traffic conditions or time based events.  The master controller monitors, in real time, local intersection activity, and overall system performance, reporting failures and status conditions to the Remote Monitoring Station.

The master controller is typically located in a local intersection cabinet; however, in special circumstances it may be located at a Remote Monitoring Station site.  The master controller is capable of uploading/downloading information to local intersection controllers and the Remote Monitoring Station.

B.      Functional Requirements.

1.      Design.  Furnish a solid state, digital microprocessor master controller design.  Furnish a controller that uses menu driven prompts, unless of Type 170 design.  If the master controller is used with Type 170E or Type 2070 controllers, provide software unless otherwise shown on the plans.

Furnish a master controller that has a RS-232 port for connection to a laptop computer or printer.  Furnish software and connector cables for communication with a laptop.

2.      Local Controllers.  Ensure that each master controller is able to supervise and communicate with at least 24 local intersection controllers.

3.      System Detectors.  Ensure that each master controller is able to analyze traffic sensor data from at least 32 system detectors.  Distribute system detectors up to eight per intersection, but do not exceed the total system sensor capacity.

Ensure that the detectors are assignable to each of the computational channels in each group, with the channels representing cycle selection, directionality (offset), non-arterial flow (split), and special congestion indicators of queue or occupancy.

Furnish a master controller that is capable of monitoring and detecting system detector failure and removing failed detectors from volume and occupancy calculations.  Upon resumption of satisfactory sensor operation, sensors shall automatically resume input to volume and occupancy calculations.

4.      Timing Patterns.  Ensure that each master controller provides a minimum of 16 selectable patterns.  Ensure that each pattern shall consist of a combination of cycle, offset, and split numbers for each intersection in the system.

Furnish a master controller that is capable of implementing a “free” mode whereby all intersection controllers will operate without system coordination and a “flash” mode whereby all intersection controllers will operate in a flashing operation.

5.      Operational Modes.  Ensure that each master controller is able to operate in the following modes of operational control:

a.      Traffic responsive mode whereby pattern selection is based on dynamic traffic conditions as measured by system sensors located in the control area.  As a minimum, base the pattern selection on the quantitative traffic flow parameters of volume, occupancy, and directionality of the arterial traffic.

Base transfer of patterns on programmable threshold values.  Furnish system sensors that are capable of selective weighting.

b.      Time of day/day of week (time base) mode whereby pattern selection is based on a preprogrammed event scheduler with automatic adjustments for seasonal daylight savings time changes.  Ensure that this mode of operation is able to call or override traffic responsive mode.

c.      Manual override mode whereby pattern selection is made by operator control at the Remote Monitoring Station or master controller site.

Ensure that the system coordination control for each master controller is selected on a priority basis.  The priority from highest to lowest is as follows:

a.      Manual control entry or remote command

b.      Time base control

c.      Traffic responsive control

6.      Reports.  Ensure that each master controller monitors and formats intersection and system information for immediate output to the Remote Monitoring Station or for storage for a minimum period of 48 hours.  As a minimum, ensure that the following types of reports are generated:

a.      A local intersection activity log showing the time, date and activity of all monitored local intersection failure conditions.

b.      A system sensor failure log that includes time, sensor location, and type of failure.

c.      A system log with pattern changes.

d.      A system sensor data log that includes volume and occupancy for all system sensors.

7.      Alarms.  Ensure that each master controller continuously monitors intersection and system information for various systems and user defined critical conditions.  Upon detection of an alarm condition, ensure that the master controller attempts to transmit alarm information to the Remote Monitoring Station or a preprogrammed telephone number.  In case of failure to connect to the central software, the master will continue to periodically retry reporting to the Remote Monitoring Station.

8.      Communications.  Furnish a master controller that supports two-way dial-up communications to a Remote Monitoring Station computer for control, monitoring, data collection, and for timing pattern updating purposes.  Through continuous, 7 days/week, 24 hours/day system monitoring, ensure that the master controller is able to automatically dial-up the Remote Monitoring Station computer upon detection of user defined critical alarm conditions.

Furnish a master controller that includes any communication devices or modems necessary to interface with the local intersection controllers within its control area.

9.      Security.  Furnish a master controller that provides for a user specified security code before any data is altered.  In order to view any parameter, ensure that a security code entry is not required.  Furnish a master controller that has the ability to disable security code requirements, allowing for perpetual access without requiring hardware changes.

733.07  Remote Monitoring Station.

A.      Description.  The Remote Monitoring Station describes a distributive processing, traffic responsive, control and monitoring “closed loop” system.  The system monitors, in real time, local intersection activities, and overall system performance, reporting failures and status conditions both automatically and by operator request.  In order to meet current and future traffic control needs, the system also provides extensive control monitoring, data collection, reporting, and analysis functions.

For complete user flexibility, the system provides full access of each local system intersection controller from the Remote Monitoring Station site.  Full access includes the capability to upload all time settings, operation parameters, and status information, as well as the capability to download all time settings and operation parameters.

B.      System Architecture.  The system consists of four principal elements:

1.      Local intersection controller (see 733.02)

2.      Communication links

3.      Traffic responsive master controller (see 733.06)

4.      A Remote Monitoring Station consisting of computer equipment and software

C.      Local Intersection Controllers.  Furnish controller units conforming to 733.02 for the type of controller shown on the plans.  Furnish a controller that has internal communication capability compatible with the type of interconnect cable shown on the plans.  Furnish a local system controller that is capable of processing controller and detector data and provide all necessary intersection control functions.

D.      Communications.  Ensure that communication between the Remote Monitoring Station and the master controller is through an auto-answer/auto-dial external modem on standard dial-up telephone service.  Furnish telephone service at the Remote Monitoring Station site by the maintaining agency, unless otherwise shown on the plans.  Furnish telephone service at the master controller or the isolated local intersection location by separate bid item as specified for “Telephone Service”.

Include error checking in the software to assure transmission and reception of valid data between the local controller, master controller, and the Remote Monitoring Station.

E.      Equipment.  Ensure that the Equipment provided at each Remote Monitoring Station location is as shown on the plans and, as a minimum, consists of the following items:

1.      Microcomputer with monitor

2.      Software

3.      Modem

4.      Printer

5.      Accessory Items

F.      System Functional Requirements.  The system software provides a simplified user friendly, color menu format at the Remote Monitoring Station.  Ensure that no special computer programming skills are required for the user to fully access and operate this control and monitoring system.

1.      Graphical Representation.  Furnish system software that enables the operator to display in color, the vehicular signals, pedestrian signals, and detector actuations in a real time mode.  Ensure that the user is able to construct an intersection layout graphically by using predetermined intersection shapes.

2.      System Capacity.  Furnish a Remote Monitoring Station software that has the capacity to monitor and control at least 24 traffic responsive masters.  Ensure that the central software is also capable of monitoring and controlling isolated system controllers.

Furnish a system software that has the capability to manually select any timing plan, free mode or flash mode.

Ensure that the system software has the capability of accepting, formatting, and processing data from at least 32 system detectors from each master controller.

3.      Data Transfer.  Ensure that it is possible to upload/download the signal timing database, including coordination, and preemption settings, between the Remote Monitoring Station and the master controller or local intersection.

Furnish a Remote Monitoring Station that provides a means to compare a currently uploaded timing database with a previously developed database stored in the Remote Monitoring Station memory.  Ensure that it reports differences in the databases.

During either uploading or downloading operations, ensure that the normal traffic control operations are not suspended.

4.      Security.  Furnish a Remote Monitoring Station that provides for a user specified security code before any data is altered.  Maintain controller access procedures from the Remote Monitoring Station allowing the user full security control of all system components from a remote location.

5.      Isolated Intersection Management.  Furnish a Remote Monitoring Station software that includes the capability of accessing system controllers at remote intersection locations.  Ensure that this capability includes total access to controller timing parameters, alarm conditions, detector data, and intersection status conditions in real time without the use of a master controller.  Ensure that this feature utilizes the local intersection controller with a dial-up modem and telephone service.

733.08  Telephone Service.  Ensure that the telephone service is a standard dial-up service capable of supporting 2400 baud data transmission.  Ensure that the external modem provided is a Hayes compatible, auto-answer/auto-dial unit with all connections, cables, and lightning protection on the incoming wires provided.

733.09  Uninterruptible Power Supply(UPS). 

A.      Operation.  In addition to the material requirements below, furnish a UPS system with a minimum two and one half (2.5) hours of full run-time operation for an “LED-only” intersection with 1000 watts of active output power.

          Furnish a UPS compatible with all of the following traffic signal equipment; NEMA TS-1 and TS-2 controllers and cabinets, Model 332 & 336 cabinets, Type 170 & 2070 controllers and electrical service pedestals.

          The maximum transfer time allowed, from disruption of normal utility line voltage to stabilized inverter line voltage from batteries, shall be 65 milliseconds or less.  The same maximum allowable transfer time shall also apply when switching from inverter line voltage to utility line voltage.

          Include a means to switch the intersection from full-operation to flashing operation after 2-hours of run-time. This is to conserve battery operation during an extended utility power outage.

          Include standard form C relay contacts to trigger an alarm within the controller assembly, informing a technician the system is operating on battery backup.

          Operating temperature for both the inverter/charger, power transfer relay and manual bypass switch shall be -35 °F to +165 °F         (-37 °C to +74 °C).

          Both the power transfer relay and manual bypass switch shall be rated at 240VAC/30 amps, minimum.

          The UPS shall bypass the utility line power whenever the utility line voltage is outside the following voltage range: 100VAC to 130 VAC, + 2 VAC.

          When utilizing battery power, the UPS output voltage shall be between 110 VAC and 125 VAC, pure sine wave output, 60Hz ± 3Hz.

          When the utility line power has been restored between 100 VAC and 130 VAC for more than 30 seconds, the UPS shall dropout of battery backup mode and return to utility line mode.

          In the event of inverter/charger failure, battery failure or complete battery discharge, the power transfer relay shall revert to the NC (and energized) state, where utility line power is connected to the cabinet.

          Recharge time for the battery, from “protective low-cutoff” to 80% or more of full battery charge capacity, shall not exceed 10 hours.

          Include all necessary wiring and hardware for mounting (shelf angles, rack, etc).

Furnish a UPS with available buck/boost mode operation,  with a minimum input voltage range of 85 to 150 vrms. The unit display shall indicate when buck/boost mode is engaged. Default buck/boost setpoints shall be 108 vrms and 132 vrms unless specified otherwise in the Plans.

 

Furnish a UPS with an Ethernet port for remote monitoring and control. Provide interface software unless the Ethernet port has built-in web browser compatibility. Remote communication shall have the ability to make setting changes, review status, retrieve alarm and event logging that is time and date stamped for up to 50 events.  The logs shall be printable.

Ensure the UPS cabinet has a mastic tape seal between the cabinet bottom flange and the concrete foundation. Minimum tape thickness shall be 1/8-inch (3 mm) and the tape shall be continuous with no gaps between tape pieces or between cabinet and foundation.

The UPS output notifications for on battery, battery 2 hour timer and low battery shall be wired into the traffic signal back panel to provide special status alarms for each output into the signal controller.

This item shall include a red LED status indicator lamp to allow maintenance personnel and law enforcement to quickly assess whether a traffic signal cabinet is being powered by a UPS.  The LED housing shall be NEMA 4X, IP65 or IR66, rated for outdoor use and be tamper/shatter resistant.  It shall be a domed enclosure contained a red lens with LED that is visible from 100 foot minimum.  The enclosure and LED lamp unit should be placed and centered on the top surface of the UPS cabinet and sealed from water intrusion.  It should be wired using minimum 20 GA stranded, insulated hookup wire to the status relay outputs of the UPS.

The wires shall be terminated by lugs at the display end and permanently labeled "Backup Power Status Display," with wire polarity indicated.  The red LED shall only illuminate to indicate the cabinet is operating under UPS backup power (the "backup" operating condition).  This item also includes programming the UPS status relay outputs to produce the lamp status displays.  These status displays will be solid 100% duty cycle (not flashing) displays.  The operating voltage of the LED lamp shall be 120V AC unless otherwise indicated.

B. Maintenance, Displays, Controls and Diagnostics.  Furnish a UPS with a backlit LCD display that includes an event counter, hour meter, line and battery voltages/percentages and fault status.  The LCD display shall have touch keys for changing display statuses and to reset counters, hour meter date and time.

          Furnish a UPS with lightning surge protection compliant with IEEE/ANSI C.62.41.

          Furnish two (2) sets of equipment lists, operation and maintenance manuals, and board-level schematic and wiring diagrams of the UPS, and the battery data sheets. Manual shall conform to TEES 1999, Chapter 1 Section 1.2.4.2.

C. Battery System.  Supply a minimum of four (4) batteries with the UPS system. Each battery shall be 12VDC and be rated at a minimum of 95 Ahrs, 20-hour discharge rate to 1.8 volts/cell at 77 degrees Fahrenheit (25 degrees Celsius), to achieve the 2.5 hour run time requirement. Furnish batteries easily replaced and commercially available off the shelf.

          Furnish deep cycle, sealed prismatic lead-calcium based AGM/VRLA (Absorbed Glass Mat/ Valve Regulated Lead Acid) batteries.

          Furnish batteries certified in writing by the manufacturer to operate over a temperature range of -13 °F to +165 °F (– 25 °C to +74 °C).

          Place all batteries on battery heater mats in the enclosure. The battery heater mats are designed to extend the life of the batteries.

          An integral system shall prevent the battery from destructive discharge and overcharge. Batteries shall not be recharged when battery temperature exceeds 122°F±5°F(50°C±3°C).

D.  Enclosure.  Furnish an enclosure mountable to a standard Model 332, NEMA TS-1 or TS-2 traffic signal cabinet and be constructed of natural unpainted aluminum.  Furnish cabinet size adequate to house “all” the UPS equipment including the controller unit, manual bypass switch and the (4) batteries.  Key the enclosure to the State master #2 lock and include 2 keys.

Furnish a base seal for use between the enclosure to the concrete foundation or riser of continuous tape gasket material, minimum 1/8-inch (3 mm) thickness.  Completely seal the interface to the adjacent controller cabinet with silicone caulk.

Furnish an enclosure with a vent, fan and thermostat as per TEES Chapter 7, Section 2-Housings.

E. Warranty.  Provide a two (2) year factory-repair warranty for parts and labor on the UPS from date of acceptance by the State. Warrant batteries for full replacement for two (2) years from date of purchase.

 

Furnish materials according to the Department's Qualified Products List (QPL).