2004 Specifications SPECIAL SPECIFICATION 6027 Lane Control Signal Equipment 1. Description. Furnish and install Lane Control Signal (LCS) equipment. 2. Material. Provide new, corrosion resistant materials in accordance with the details shown on the plans. Provide LCS Control Panels, load switches, and all pertinent hardware, cabling, and wiring. Provide LCS heads, hardware, brackets, rigid and flexible conduit, electrical wire and cable. A. Lane Control Signal Head. Provide fiber optic LCS heads with dot matrix indications on a flat, black, non-reflective, rectangular face. Provide glass optic fibers, i.e. Corning, AT&T, or equivalent. 1. Signal Indications. Form the signal indications by forming a group of dots to which light is transmitted from a central light source through glass fiber bundles. Fit individual lenses over the end of each fiber optic bundle for increased intensity and improved view angle in the forward direction. Use color filters to obtain the color of any indication. Provide color filters that are changeable in the field without requiring removal of the signal from the case. Illuminate each indication with 2 Quartz Halogen lamps (40 watts nominal). Provide lamps that have at least an average life of 8,000 hr. at the operating voltage. 2. Dimming Provision. For each signal indication, provide a light source designed for operation with both lamps on during bright ambient light and with one lamp on during dim ambient light. Provide burnout protection for the dimming mode so as not to turn off the bulb when the other 1 is burned out. 3. Fiber Randomization. Arrange fiber optic bundles in each signal with alternate bundles leading to the same lamp so that in the event of failure of one of the lamps, the other will continue to display a discernible indication. 4. Extra Fiber Bundles. Provide a minimum of 6 extra bundles of fibers, properly protected within chaff resistant casing for insertion in lenses, for each LCS head. 5. Fiber Protection. Protect fiber optics bundles to avoid damage when installing, or during maintenance on other components in the signal head. 6. Visibility. Provide LCS heads with indications that are clearly visible and legible for 1/4 mi. distance within a 20 cone centered about the optical axis under 1-8 6027
normal atmospheric conditions and under any lighting conditions. Visors or hoods will not be permitted or required. B. LCS Controller. Provide LCS Control Panels capable of controlling up to 6 independent LCS heads in each cabinet. Provide LCS Control Panels that are each 1 integral unit, with power supplies located on the unit. Install LCS Control Panels as shown on the plans, or as directed. Provide LCS Control Panels that are capable of displaying all indications on the LCS in either of the 2 selectable modes of operation. Provide LCS Control Panels that provide both the manual selection of the LCS indications via the mechanical switches, and the remote selection of LCS indications by passing through a signal from the Local Control Unit. 1. Local Mode. When in local mode, the LCS responds to the signal select switches located on the LCS Control Panel. The signal indication selected on the signal select switches remains until another signal is selected, or the mode is changed. 2. Remote Mode. When in remote mode, the Local Control Unit controls the Lane Control Signal. 3. LCS Control Panel and Indicators. Provide LCS Control Panels with the following clearly labeled switches and indicators. On/Off Switch. This switch controls the power to the LCS and the LCS Control Panel. This switch may be located elsewhere in the cabinet. Control Panel Mode Switch. This switch controls the mode of operation of the LCS Control Panel. The positions of the switch are Local and Remote. Only 1 position can be selected at a time. LCS Head Switch/Indicators. Provide LCS Control Panels with fitted front panels with a 6 position interlocking pushbutton mechanical switch, with lock-out feature, for each LCS head (6 per control panel). The first 5 positions correspond to the required indications and the sixth position turns off power to the head. Furnish each sixth position switch with 6 corresponding light emitting diodes (LED) that are colored to match the indication selected by the associated switch. Clearly silkscreen label each switch position, and corresponding LED, with the indication that switch activates on the LCS head. Equip LCS Control Panels with a lamp test switch to check all panel indicators. 2-8 6027
4. Load Switches. Include the load switches required to operate the lane control signals. Provide solid state load switches with no moving parts. Provide load switches that comply with Section 5 of NEMA Standard TS2, latest revision. Provide load switches that are capable of controlling all 3 lamp sets in a LCS head. Use a pair of 3 circuit load switches to control the 5 lamp sets. Provide an indicator light for each circuit on each load switch. The indicator light turns on when a true input to the load switch is present. Provide load switches capable of operation at 10 amps of tungsten lamp load over the specified temperature range. Mount and connect the load switches and field wiring to the Cabinet Back Panel. C. Functional Requirements. Furnish and install LCS on bridge beams, existing sign bridges, or overhead structures as shown on the plans. Each LCS head will be independently controlled to indicate the status of each lane. Provide LCS heads that display the following indications: Red X, Yellow X, Yellow Down Arrow (slanted at 45 deg. right), Yellow Down Arrow (slanted at 45 deg. left), Green Down Arrow. The LCS Control Panel drives the LCS heads via the Cabinet Back Panel. Commands to the LCS Control Panel will be from the following sources: Manual Control switches mounted on the front of the LCS Control Panel, Remote Control Mode via the communications network from the Traffic Management Center. Provide identical and interchangeable LCS equipment at each field location. LCS equipment includes the following: Up to 6 lane control signal heads at each location as shown on the plans, One LCS Control Panel for up to 6 lane control signal heads, Load switches mounted on the Cabinet Back Panel, or on the remote field equipment load switch panel, Control switches, indicators, cabling, supporting hardware, and mounting hardware required to functionally complete, test, and operate LCS installation. 3-8 6027
D. Electrical Requirements. 1. LCS Control Panel Interface. Provide LCS Control Panels with inputs and outputs that comply with Section 13 of NEMA Standard TS2, latest revision. Provide LCS Control Panels with LCS Commands and Confirms as shown in Table 1 for each head: Table 1 LCS Commands and Confirms Commands Confirms Red-X Red-X Yellow Down Arrow Yellow Down Arrow Yellow Arrow (slanted 45 deg right) Yellow Arrow (slanted 45 deg right) Yellow Down Arrow (slanted 45 deg left) Yellow Down Arrow (slanted 45 deg left) Green Arrow Green Arrow One Online Command One Online Confirm One Local Control Confirm Blank Command Blank Confirm The confirm signals described above are true confirmed. These signals originate from the control lines, between the back panel and the LCS head, and place a 0 VDC (true ground) signal on the appropriate connector pin. A true command causes the corresponding indication to be displayed or action taken. A true confirm indicates illumination of the signal head or LCS Control Panel in a particular mode. 2. Signal Confirms. Provide wiring to generate a signal confirm for each green, red, and yellow signal display. These confirms are generated based on the current load of the 115 VAC signals between the load switch and the LCS head lamp transformer. The signal confirms are set true when the signal is illuminated and are fully compatible with the Local Control Unit (LCU) back panel signal interfaces. Provide plug-in current sensing devices, each with a visual indication when the device senses current flow. No toroid will be acceptable. 3. Power Requirements. Provide LCS equipment that meets all specified requirements when the input power is 115 VAC ± 10%, 60 Hz ± 3 Hz single phase. Do not exceed a maximum power requirement of 200 watts. Provide LCS equipment that operates unaffected by transient voltages, surges, and sags normally expected on commercial power lines. Check the local power service to determine if special design is needed for the equipment on the LCS cables. 4. Primary Input Power Interruption. Provide equipment that complies with Section 2.1.4 Power Interruption of the National Electrical Manufacturers Association (NEMA) Standard TS2, latest revision. 4-8 6027
5. Power Service Transients. Provide equipment that complies with Section 2.1.6 Transients, Power Service of the NEMA Standard TS2, latest revision. 6. Wiring. Provide wiring that complies with the NEC. Cut wires to proper length before assembly. Do not double back wire to take up slack. Neatly lace wires into cables with nylon lacing or plastic straps and secure with clamps where necessary. Do not use adhesive backed cable guides. Supply and install wiring to interconnect the LCS load switches in the Cabinet and the LCS heads. Use signal cables, as shown on the plans, for each of the LCS heads. If additional wires are required, install them at no cost to the Department. Provide wiring and interface equipment for interconnecting the multiplexers by means of NEMA-type inputs and outputs. 7. Grounding. Ground the LCS support bracket and field Cabinet as shown on the plans. 8. Transient Suppression. Provide diodes across the coils for transient suppression on all DC relays, solenoids, and holding coils. 9. Power Service Protection. Provide equipment that contains readily accessible manually resettable or replaceable circuit protection devices (such as circuit breakers or fuses) for equipment and power source protection. 10. Fail Safe. Design equipment such that the failure of the equipment does not cause the failure of any other unit of equipment. 11. Lane Control Signal Field Equipment. Install a 25 PR, 19 AWG, twisted pair cable to control the interface cabinet load switches, so the lane control signal field equipment for all remote interface cabinets require the LCU, through the interface backpanel, to drive all of the remotes. The Signal Confirms, Section 2.D.2., provide the LCU and the data system with the status of which LCS head is present, or true. The remote signal field equipment consists of the following: Load switch panel, 19 in. rack mounted, LCS head panel for Remote/Local controls, Voltage and current interface converters for the load switch confirms that interface to the LCU back panel, Standard cabinet power and signal electrical suppression equipment panels, Conduit as shown on the plans, Ground boxes as shown on the plans, 25 pair, 19 AWG, twisted pair communication cable, and 7 conductor, 12 AWG electrical cable. 5-8 6027
12. Surge Protection. Provide LCS cabinets that incorporate surge protection as detailed in Special Specification, ITS Field Equipment Cabinets. E. Mechanical Requirements. 1. LCS Head. Provide LCS heads with lane control signal faces 18 in. in width and height, in a minimum 0.100 in. thickness sheet aluminum case that is primed with epoxy type paint. Degrease and prime the interior and exterior of each LCS head with 1 coat of vinyl butyral primer, between 0.1 mil and 1 mil in thickness. Cover the primer coat with 2 coats of aliphatic urethane flat black, to a thickness of 3 mil. If the bracket anchor bolts and conduit runs are attached to the surface of a concrete bridge beam, paint the bracket anchor bolts and conduit the same color as the bridge beam. Paint in accordance with Item 446, Cleaning and Painting Steel. Provide galvanized brackets, anchor bolts, and conduit runs for corrosion resistance when attached to steel truss overhead sign bridges. To minimize legibility when the signal is not illuminated, provide LCS heads with black-colored front panels of the signal and lens mount. No color appears in the lens when not illuminated, regardless of sunlight intensity. Provide a barrier type terminal strip in each signal for the connection of field wires. Clearly mark the function of each terminal. Mount all fiber optics and lamps on a hinged door. All components are readily accessible when the door is opened. The only tool required for maintenance or replacement of components is a standard screwdriver. The signal housing case, together with door and mounting attachments, comprise a dust and moisture proof housing for the optical unit, connecting wiring, and terminal block. The signal housing and door, fittings, and accessories are made of non-corrosive, rust resistant materials capable of withstanding constant exposure to sunlight and corrosive atmospheres, and provide adequate strength for its intended purpose. Provide a lamp socket designed to prevent the formation of corrosion on either the lamp or socket contacts. Provide lamp sockets that do not allow the lamps to work loose from the socket when vibrated. Provide LCS heads capable of withstanding 100 mph wind loading. Provide LCS heads with MS type connectors so that each head can be electrically disconnected and replaced without having to remove wire from the terminal box. 2. LCS Control Panel. Fabricate LCS Control Panels from durably finished sheet metal with indicators, switches, capable of selecting and displaying the status of the signal indications. All connections for the LCS Control Panel are made by type MS connectors (metal casing) locating on the LCS Control Panel. Provide LCS Control Panels no larger than 11 in. wide X 12 in. high X 11 in. deep. All local selection switches are multiple push button switches with an interlocking lock-out feature. 6-8 6027
3. Construction. 3. Modular Design. Design the equipment to be modular for ease of replacement. Key modules of unlike function to prevent insertion into the wrong socket or connector. Identify modules and assemblies with name, model number, serial number, and any other pertinent information required to facilitate equipment maintenance. 4. Connectors and Harness. Make all external connections by means of keyed connectors to prevent improper hookups. Color code or appropriately mark wires between the connectors. 5. Environmental Design Requirements. Provide LCS equipment that meets the specified requirements during and after subjection to any combination of the following: Ambient temperature range of -40ºF to +140ºF, Temperature shock not exceeding 30ºF per hour, during which the relative humidity does not exceed 95%, Relative humidity range not exceeding 95% over the temperature range of 41ºF to 111ºF, and Moisture condensation on all surfaces caused by temperature changes. a. Primary Power Variation. Provide equipment that meets the specified performance requirements when the input voltage is ±10% from the nominal value of 115 V. b. Relative Humidity. Provide equipment that meets the specified performance requirements when subjected to a temperature and relative humidity of 60ºC and 22% respectively for 48 hr. c. Vibration. Provide equipment that shows no degradation of mechanical structure, solder components, plug in components, or satisfactory operation in conformance with the manufacturer s equipment specifications after being subjected to the vibration test as described in Section 2.2.5 Vibration Test of the NEMA standard TS2 latest revision. A. General. Utilize the latest available techniques to minimize the number of different parts, subassemblies, circuits, cards, and modules to maximize standardization and commonality. Provide components that are standard off-the-shelf models. Design equipment for ease of maintenance. Provide component parts that are readily accessible for inspection and maintenance. Provide equipment that requires only simple hand held tools, basic meters, and oscilloscopes for maintenance. Provide test points for checking voltages and wave forms. 7-8 6027
Silk screen all text, markings, diagrams, and labels on housings and panels. Chemically etch in place all text, markings, diagrams, and labels on circuit boards. B. Electronic Components. Provide electronic components that comply with the Special Specification Electronic Components. Provide LCS Control Panels of solid state construction. Mechanical relays will not be accepted. C. Mechanical Components. Furnish stainless steel external screws, nuts, and locking washers. Do not use self-tapping screws unless otherwise directed. Provide corrosion resistant materials and materials resistant to fungus growth and moisture deterioration. Separate dissimilar metals with an inert dielectric material. D. Testing. Perform testing in accordance with Article 2, Special Specification, Testing, Training, Documentation, Final Acceptance, and Warranty. E. Training. Provide training in accordance with Article 3, Special Specification, Testing, Training, Documentation, Final Acceptance, and Warranty. F. Documentation. Provide documentation in accordance with Article 4, Special Specification, Testing, Training, Documentation, Final Acceptance, and Warranty. G. Warranty. Provide a warranty in accordance with Article 6, Special Specification, Testing, Training, Documentation, Final Acceptance, and Warranty. 4. Measurement. This Item will be measured as each unit. 5. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for Lane Control Signal Equipment or Lane Control Signal Equipment (Remote). This price is full compensation for all equipment furnished, installed, and fully operational and testing including all cables and connectors, documentation, warranty, labor, hardware, materials, training, tools, and incidentals. New conduit will be paid under Item 618, Conduit. New ground boxes will be paid under Item 624, Ground Boxes. New traffic signal cables will be paid under Item 684, Traffic Signal Cables. New electrical conductors will be paid under Item 620, Electrical Conductors. 8-8 6027