2004 Specifications CSJ 0025-02-194, 0017-10-261, 0017-10-268 & 0017-10-271 SPECIAL SPECIFICATION 8939 Retrofit Existing Fiber Optic Dynamic Message Sign System to LED 1. Description. Retrofit existing Fiber Optic Dynamic Message Sign System to LED (Light Emitting Diode) optical system at designated field locations as shown on plans and as detailed in this Special Specification. Retrofit consists of (but is not limited to) removing internal Fiber Optic character display components from existing sign housing and replacing with new LED components, and removing existing Dynamic Message Sign (DMS) Controller from cabinet and replacing with new LED controller. The retrofit will result in a DMS with an LED display containing the same number of characters, of the same size, and in the same configuration as the original sign. The retrofitted sign will be fully compatible with and controllable by the existing TransGuide Central Control software with no changes to existing software. 2. Materials. Provide all new solid state display elements and modules. No mechanical or electromechanical elements or shutters will be accepted. Ensure new LED components are suitable for operations in exposed outdoor locations. New components must be 100% compatible with existing DMS housing. Provide equipment that utilizes the latest available techniques for design and construction with a minimum number of parts, subassemblies, circuits, cards, and modules to maximize standardization and commonality. Provide external screws, nuts and locking washers made of stainless steel. Provide parts made of corrosion resistant material, such as plastic, stainless steel, anodized aluminum or brass. Protect materials from fungus growth and moisture deterioration. Separate dissimilar metal with an inert dielectric material. A. General Requirements. Materials provided for and operation of retrofitted sign and new controller will meet requirements of the following: 1. Special Specification National Transportation Communications for ITS Protocol for Dynamic Message Signs (NTCIP) 2. Special Specification Electronic Components 3. NEMA TS 4, latest edition 4. NEMA TS 2 Section 2 (environmental requirements), latest edition 5. Ability to operate within temperature range of -13 F to + 160 F with no performance degradation 6. Ability to operate with existing external power configuration and at a minimum of 115VAC +/- 10% @ 30 Amps. 1-9 8939
B. LED Character Display Board. New display boards must have the following characteristics and capabilities: 1. Character height and width as defined by NEMA TS 4. 2. Interchangeability of display boards. No special tools or software required to change or relocate a character display board. Address of board to be shown on a label and able to be set automatically or via DIP switches. 3. Surface mounted amber LED s 4. Hardware design of LED driver circuitry must be such that the LED current will be hardware restricted to not exceed 75% of maximum forward current as defined by LED Manufacturer, regardless of software commands. 5. Change of brightness must occur simultaneously on all characters in sign. 6. Cone of vision must be at least 30 degrees centered around the optical axis. 7. Minimum Luminance of 12,000 candelas per square meter. 8. Chromaticity limits in accordance with NEMA TS 4 for yellow, with a wavelength of 590nm +/-5 nm. Test certificate must be provided to Engineer to show this. 9. Display must be able to change from one page of text to another in less than 100 ms. All lines of text must energize and de-energize simultaneously. 10. Display driving circuitry must be mounted directly on the display board; no separate driver boards are allowed. 11. All connections between boards must be rugged, positive-locking, quick release, and use polarized connectors. 12. Full diagnostic capabilities must be available directly on display board to include: a. Visual indicators on rear of display board to indicate: faulty board transmit/receive status between board and controller proper power supply to board. b. Test button that can activate a test sequence that illuminates all LED s to identify faulty pixels and to identify board s address. After test, board will revert to prior display. c. Diagnostic Port available for real-time diagnostics and configuration of board, either while the board is in the sign and operating or when the board is out of the sign for maintenance/repair. Minimum functions include ability to: Determine firmware version Upload new version of firmware Determine exact faulty pixel strings 2-9 8939
Determine address of the board C. LED Power Supply System. New LED power supply system must have the following capabilities and characteristics: 1. Integral cooling fan in each power supply unit 2. Ability to illuminate every character on the sign at full power, at 165 F. 3. Power supply must be a switching power supply that is at least 80% efficient at nominal voltage. 4. Includes a self-resetting internal thermal protection device that switches off the output in case of overload. D. LED DMS Controller. New controller must have the following capabilities and characteristics: 1. Fully compatible with existing TransGuide Operations Center software 2. Able to automatically control dimming, with a minimum of 16 and a maximum of 256 brightness levels 3. Ability to adjust the relationship between the degree of dimming and external light conditions 4. Dimming system must not be affected by variations in the AC supply voltage and must maintain a constant light output at all brightness levels. 5. NTCIP 1203 compliant 6. Intel PCS PXA 255 processor or equivalent 7. 32 MB of SDRAM 8. 16 MB of flash memory 9. Internal real time clock 10. Two (2) Ethernet 10/100 full duplex ports 11. Two (2) RS 232 serial ports 12. Two (2) RS 485 serial ports 13. Two (2) USB ports 14. Four (4) 2-wire digital outputs 15. Four (4) 2-wire digital inputs 16. One (1) reset push button 17. Power switch 3-9 8939
18. Polarized power connector 19. Capable of accepting modifications to firmware 20. One full-color screen to display the following overall status information, as a minimum, on a single screen: a. Sign luminance, temperature and humidity status b. Power supply status c. Display overall status d. Brightness control status e. Communication status f. Local/Remote status g. WYSIWYG display viewer h. Firmware version 21. Capable of the following operations from the controller front panel: a. Display faulty pixel location. b. Display pre-programmed messages. c. Display current date and time. d. Display test message that uses all font characters. e. Display Sign in test message. f. Display 16 locally-stored predetermined messages. g. Navigate through menus to access diagnostics information described above and ability to: Indicate brightness mode (fixed or automatic). Indicate ambient brightness level. Indicate message currently displayed. Indicate message validity. 3. Construction. DMS is to be retrofitted in place unless support structure is being removed due to roadway construction. Ensure the retrofitted DMS and controller present a neat, workmanlike, and finished appearance. Poor workmanship is cause for rejection. Maintain safe construction practices during retrofit. Protect equipment until it is accepted. A. Dynamic Message Sign Retrofit. 1. Prior to retrofitting existing Fiber Optic DMS, disconnect and isolate any existing electrical power supply and communication cables. 4-9 8939
2. Use care to prevent damage to the existing sign housing and the sign support structure. Any portion of the existing sign (that is to be re-used) or sign support structure, including components, mounting brackets, and hardware that is damaged or lost by the contractor will be replaced by the Contractor at no cost to TxDOT. 3. The following work is required for retrofitting a sign (includes but is not limited to): a. Remove existing fiber optic character modules and associated components. b. Remove existing character support frames from existing DMS housing and replace with new aluminum character support frames for new LED Character Display boards. New frames must be matte black and match overall dimensions of existing frame. Only minor modifications to existing hardware will be accepted to mount the frames within the existing DMS housing. c. Remove existing power supply units, day/night switching relay, and/or any other components that will no longer be utilized. d. Install new power supply units (having integral cooling fans). e. Install new surge protectors and internal temperature and humidity sensors that are capable of turning sign off if temperature exceeds 165 F. f. Install new LED Character Display boards and perform all necessary wiring to make sign fully operational with controller and the TransGuide system. g. Remove existing photocells and replace with two (2) new photocells and photo-sensor board. Photocells must have a minimum range between 2 and 100,000 lux. 4. Deliver all components removed from DMS housing to TransGuide maintenance. 5. If existing cables are damaged or not suitable for use in wiring retrofitted DMS, install new cables meeting requirements of manufacturer of LED retrofit components, subsidiary to this item. B. DMS Controller Retrofit. 1. Prior to removing existing Fiber Optic DMS controller components, disconnect and isolate any existing electrical power supply and communication cables. 2. Remove existing Fiber Optic DMS controller and associated equipment from controller cabinet. 3. Install new LED controller and all associated components in cabinet and perform all necessary wiring to make controller fully operational with the TransGuide system. 5-9 8939
4. Provide electrical drawings and schematic printed on water and tear-resistant material in controller cabinet. C. Technical Assistance. The presence of a representative of the manufacturer of LED retrofit components is required to provide technical assistance to the contractor s technical personnel with the following: 1. Installation of LED retrofit components (in sign and controller) 2. Equipment updates 3. Sign to controller cabling The contractor must not execute initial powering up of the sign without the permission of the LED retrofit component manufacturer s representative. 4. Documentation Requirements. Provide sufficient documentation to reflect as-built conditions and to facilitate operation, maintenance, modification, and expansion of the system or any of its individual components. Manufacturer supplied documentation covering the intent of this requirement is acceptable, subject to the approval of the See General Notes for other as-built documentation requirements. Provide five complete sets of operation and maintenance manuals. Include the following: A. Complete and accurate schematic diagrams. B. Complete installation procedures. C. Complete performance specifications (functional, electrical, mechanical and environmental). D. Complete parts list including names of vendors for parts not identified by universal part number such as JEDEC, RETMA, or EIA. E. Pictorial of component layout on circuit board. F. Complete maintenance and trouble-shooting procedures. G. Complete stage-by-stage explanation of circuit theory and operation. 5. Requirements for Shop Drawings. Submit 5 copies of supplier shop drawings for DMS retrofit to the Engineer for approval before fabrication. See TMS Submittals in General Notes. 6. Testing Requirements. It is the policy of the Texas Department of Transportation to require performance testing of all materials and equipment not previously tested and approved. If technical data are not considered adequate for approval, samples may be requested for test by the The contract period will not be extended for time loss or delays caused by testing prior to final Texas Department of Transportation approval of any items. 6-9 8939
The equipment referenced to this specification is subject to Design Approval Tests and Factory Demonstration Tests at the equipment manufacturer's facility to determine conformance with all the specification requirements except that the Engineer may accept certification by an independent testing laboratory in lieu of the design Approval Tests, to verify that the Design Approval Tests have previously been satisfactorily completed. The Contractor must arrange for and conduct the tests in accordance with the specification requirements stated herein. Unless otherwise specified, the Contractor is responsible for satisfying all inspection requirements prior to submission for the Texas Department of Transportation's inspection and acceptance. The Engineer reserves the right to have his/her representative witness all Design Approval Tests and Factory Demonstration Tests. Compare the results of each test with the requirements specified herein. Failure to conform to the requirements of any test shall be counted as a defect, and equipment shall be subject to rejection by the Rejected equipment may be offered for retest provided all noncompliances have been corrected and retested by the Contractor and evidence thereof submitted to the A. Stand-Alone Tests. Provide 5 copies of all stand-alone test procedures and data forms to the Engineer for approval at least 60 days prior to the day the tests are to begin. Include in the test procedures the sequence in which the tests will be conducted. Obtain Engineer s approval of test procedures prior to submission of equipment for tests. Furnish data forms containing all of the data taken, as well as quantitative results for all tests. Have an authorized representative (company official) of the equipment manufacturer sign the data form. Provide at least 1 copy of the data forms to the Conduct an approved stand-alone test of the retrofitted DMS at the field site. At a minimum, exercise all stand-alone (non-network) functional operations of the field equipment with all of the equipment installed as per the plans, or as directed by the Complete approved data forms and turn over to the Engineer for review to determine acceptance or rejection of equipment. Provide at least 30 working days notice prior to all tests to permit the Engineer to observe each test. Correct any units that fail the stand-alone test or replace them with other units and repeat test until units successfully pass test. Prepare and deliver to the Engineer a report detailing any modifications made to a unit as a result of a stand-alone test failure. Describe the nature of the failure and the corrective action taken. If a failure pattern develops, the Engineer may direct that design and construction modifications be made to all units without additional cost to the Department or extension of the contract period. B. System Tests. Provide 5 copies of all system test procedures and data forms to the Engineer for approval at least 60 days prior to the day the tests are to begin. 7-9 8939
Include in the test procedures the sequence in which the tests will be conducted. Obtain Engineer s approval of test procedures prior to submission of equipment for tests. Furnish data forms containing all of the data taken, as well as quantitative results for all tests. Have an authorized representative (company official) of the equipment manufacturer sign the data form. Provide at least 1 copy of the data forms to the Conduct an approved test of the retrofitted DMS system field equipment with the central equipment. At a minimum, exercise all remote control functions and display the return status codes from the controller for a minimum of 72 hours. Complete approved data forms and turn over to the Engineer for review to determine acceptance or rejection of equipment. Correct any units or components in the subsystem that fail the system test or replace them with other units or components and repeat test until units successfully pass test. Prepare and deliver to the Engineer a report detailing any modifications made to a unit as a result of a system test failure. Describe the nature of the failure and the corrective action taken. C. Final System Acceptance. Final system acceptance is defined as follows: 1. All work and materials provided for in this item have been furnished, completely installed, and made operational. 2. The retrofitted Dynamic Message Sign System has been operated in a satisfactory manner continuously for a minimum of 60 calendar days or as directed by the 3. All parts of the work have been approved and accepted by the 7. Warranty. Guarantee that equipment furnished and installed for this project will perform according to the manufacturer's published specifications. Warrant equipment against defects and/or failure in design, materials and workmanship in accordance with the manufacturer's standard warranty. Assign to the Department all manufacturers normal warranties or guarantees on all electronic, electrical, and mechanical equipment, materials, technical data, and products furnished for and installed on the project. Repair or replace defective equipment, at the manufacturer's option, during the warranty period at no cost to the Department. Provide equipment with 95% of the manufacturer's standard warranty remaining on the date that equipment invoices are submitted by the Contractor for payment. Any equipment with less than 95% of its warranty remaining will not be accepted by the Department. 8. Experience Requirements. Personnel involved in the retrofitting of existing Fiber Optic Dynamic Message Sign (DMS) Systems to LED must meet the following requirements: Two years experience in retrofitting existing Fiber Optic DMS Systems to LED, and installing and testing same. 8-9 8939
Two installed systems where retrofitted Fiber Optic DMS Systems, as described within these specifications, are installed and the systems have been in continuously satisfactory operation for at least 2 years. Submit photographs or other supporting documents as proof, and the names, addresses and telephone numbers of the operating personnel who can be contacted regarding the systems. One system with retrofitted Fiber Optic DMS Systems (which may be one of the two in the preceding paragraph) which the Contractor can arrange for demonstration to the Engineer and/or his representatives. 9. Training. Conduct a training class (minimum of 16 hours) for up to 10 representatives designated by Texas Department of Transportation on procedures of installation, operations, testing, maintenance and repair of all equipment specified within these specifications. Submit to the Engineer for approval 10 copies of the training material at least 30 days before the training begins. Conduct training within the local area unless otherwise authorized by the 10. Measurement. This Item will be measured as each existing Fiber Optic DMS System of the type specified, retrofitted to LED, tested, and made fully operational with the TransGuide system. 11. 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 bid price for Retrofit Existing Fiber Optic Dynamic Message Sign (TY-2) System to LED and Retrofit Existing Fiber Optic Dynamic Message Sign (TY-3) System to LED. This price is for equipment, cables and connectors; documentation and testing; Lane Closures, and labor, materials, warranty, training and incidentals. 9-9 8939