ESBD_454757_1758140993109_03.TxDOT Special Specification DMS 11160.pdf

DEPARTMENTAL MATERIALS SPECIFICATION FLASHER CONTROLLER ASSEMBLY

TEXAS DEPARTMENT OF TRANSPORTATION 1 – 8 EFFECTIVE DATE: AUGUST 2004

DMS - 11160

FLASHER CONTROLLER ASSEMBLY

EFFECTIVE DATE: AUGUST 2004

11160.1. Description. This Specification governs for the materials, composition, quality, sampling, and testing of a Flasher Controller Assembly that includes a cabinet, a solid-state two-circuit flasher, a solid-state time clock (when required), and other cabinet accessory equipment.

11160.2. Units of Measurements. The values given in parentheses (if provided) are not standard and may not be exact mathematical conversions. Use each system of units separately.

Combining values from the two systems may result in nonconformance with the standard.

11160.3. Material Producer List. The Traffic Management Section of the Traffic Operations Division (TRF-TM) maintains the material producer list (MPL) of all materials conforming to the requirements of this Specification. Materials appearing on the MPL, entitled “Traffic Signals,” require no further testing, unless deemed necessary by the Project Engineer or TRF.

11160.4. Bidders’ and Suppliers’ Requirements. To be accepted on bids, materials must have approved product codes or designations and be from pre-qualified producers.

Use of pre-qualified materials does not relieve the contractor of the responsibility to provide materials that meet the specifications. All material may be inspected or tested at any time. Any material that does not meet the specifications and requirements of the plans will be rejected.

11160.5. Pre-Qualification Procedure.

A. Pre-Qualification Request. Submit a request for evaluation to the Texas Department of Transportation, Traffic Operations Division, Traffic Management Section (TRF-TM), 9500 North Lake Creek Parkway, Austin, Texas 78717.

B. Pre-Qualification Sample. Submit one flasher controller assembly with the pre-qualification request.

All materials submitted for pre-qualification tests will be at no cost to the Department.

C. Documentation. Supply one cabinet wiring diagram with each cabinet. Place the diagram inside each cabinet. Separate shipment of the diagram is not acceptable.

Upon request, furnish a copy of certification to NEMA specifications. Supply the following documentation with each two-circuit solid-state flasher:

• Complete and accurate schematic diagram

• Complete parts list including names of vendors for parts not identified by universal part numbers such as JEDEC, RETMA, or EIA

• Pictorial of component layout on circuit board ftp://ftp.dot.state.tx.us/pub/txdot-info/cmd/mpl/qtrfsigeqp.pdf ftp://ftp.dot.state.tx.us/pub/txdot-info/cmd/mpl/qtrfsigeqp.pdf

TEXAS DEPARTMENT OF TRANSPORTATION 2 – 8 EFFECTIVE DATE: AUGUST 2004

Supply the following documentation with each solid-state time clock:

• Complete and accurate schematic diagram

• Set of operating instructions

• Pictorial of the electronic-circuit component layout

• Pictorial of the time-clock assembly

• Complete parts list including names of vendors for parts not identified by universal part numbers such as JEDEC, RETMA, or EIA

D. Sampling and Testing. Flasher controller assemblies must meet or exceed all applicable Texas MUTCD and I.T.E. Standards and these specifications. In addition to testing of pre-shipment samples, complete testing of school-zone flasher assemblies may be required at any time prior to acceptance.

Sample and test in accordance with Tex-1170-T.

Specific tests are normally indicated in conjunction with specific specification requirements. However, the Department reserves the right to conduct whatever tests are deemed necessary to identify component materials and verify results of specific tests indicated in conjunction with specification requirements.

E. Warranty. All equipment must have no less than 95% of the manufacturer's standard warranty remaining on the date that the contractor submits equipment invoices for payment. The Department will not accept any equipment with less than 95% of its warranty remaining.

F. Evaluation. TRF-TM will notify prospective bidders and suppliers after completion of material evaluation.

1. Qualification. If approved for use by the Department, the material will be added to the MPL. If material is listed on the MPL, no additional submittals are required for that product.

Report changes in the composition or in the manufacturing process of any material to TRF-TE. Significant changes reported by the manufacturer, as determined by the Director of TRF, may require a re-evaluation of performance. Unapproved changes may result in removal of the manufacturer from the MPL for 1 year.

2. Failure. Producers not qualified under this Specification may not furnish materials for Department projects and must show evidence of correction of all deficiencies before reconsideration for qualification.

If materials fail to meet any of the specification requirements, the producer may not resubmit for pre-qualification until 1 year from original evaluation date. TRF-TE may waive this time limit if provided with documentation from an independent testing facility stating the materials meet all requirements. TRF-TE will enforce the 1-year time limit if, after retesting, the material again fails any of the specification requirements.

TEXAS DEPARTMENT OF TRANSPORTATION 3 – 8 EFFECTIVE DATE: AUGUST 2004

Costs for sampling and testing performed by the Department are normally borne by the Department; however, the contractor or supplier will bear the costs for sampling and testing of failing materials. The Director of TRF will assess this cost at the time of testing.

Amounts due the Department will be deducted from monthly or final estimates on contracts or from partial or final payments on direct purchases by the Department.

Products will not be retested until costs for previously failed tests have been paid.

11160.6. Material Requirements.

A. Cabinet. Configure the cabinet to allow use either as a flasher only or as a flasher with time clock.

Provide a cast-aluminum alloy or aluminum cabinet with a minimum thickness of 1/8 in.

and outside dimensions of 14 in. wide × 16 in. high × 10 in. deep ± 3 in. with the door closed.

Provide a gasket between the door and cabinet. Supply a stainless steel, aluminum, or other non-rusting alloy door hinge with a stainless steel hinge pin. Spot-weld the hinge pin at the top of the hinge.

Provide a police lock as an integral part of each door. Provide one brass key with each cabinet. The keyhole must have a metal keyhole cover.

Provide three 3/4-in. Myers hubs or exact equivalent with each cabinet. Mount two hubs on top of the cabinet. Position the two top hubs such that the 3/4-in. hole centers are

1.25 in. from the back of the cabinet and about the centerline that bisects the width of the cabinet. Provide a minimum of 1.5 in. space between the two top hub holes. Mount the third hub on the bottom of the cabinet; however, do not cut the mounting hole. Install watertight gasket seals around all hubs.

Bolt a solderless connector for No. 6 AWG wire to the inside bottom of the cabinet for grounding purposes.

Provide two 3/4 in. stainless-steel brackets for strap-type mounting on a wood or metal pole. Ship cabinets with the brackets mounted to the back of the cabinet.

Provide vent openings in the cabinet to allow adequate convection cooling of the electronic components. Design and locate vents to prevent the entry of water. Screen the vents to minimize the infiltration of dust and insects. Screen material must have openings no larger than 0.0125 sq. in.

Weatherproof the cabinet to prevent the entry of water. Seal unwelded seams with a clear or aluminum-colored weather-seal compound.

Provide tamper-resistant exposed hardware including screws, bolts, rivets, hubs, etc.

Mount a back panel on inside of the cabinet. Mount wiring and accessory equipment, including a flasher, on the back panel. Size and position the panel inside the cabinet to allow clearance for the two top-mounted hubs and the field wiring that must pass through them. The back panel must also allow for clearance for the mounting of the third hub in the bottom center of the cabinet.

TEXAS DEPARTMENT OF TRANSPORTATION 4 – 8 EFFECTIVE DATE: AUGUST 2004

The back panel must provide for the mounting of a maximum-size, two-circuit solid-state NEMA flasher. The maximum dimensions for the flasher are stated in the National Electrical Manufactures Association Standards Publication TS-2—Traffic Controller Assemblies with NTCIP Requirements, Section 6.3 “Solid State Flashers.” The flasher must be easy to remove and replace. Provide a support bracket for horizontal mounting.

Provide a flasher mating connector in accordance with the NEMA Standards Publication TS-2, Section 6.3.

The back panel must provide for mounting of a solid-state time clock with maximum overall outside housing dimensions of 10.25 in. high by 6.25 in. wide by 7.5 in. deep.

Configure the mounting holes as an inverted "T." Place the top hole 3 in. ± 0.05 in. from the top of the cabinet and 5.75 in. ± 0.05 in. above a horizontal line connecting the centers of the two bottom holes. Place the bottom 2 holes 2.3125 in. ± 0.05 in. apart from center to center. Position the top hole so that a vertical line through its center bisects the horizontal line. Drill and tap each screw hole for an 8-32 screw.

B. Cabinet Wiring. Equip the cabinet with a ten-section barrier terminal block with double 8-32 × 5/16-in. binder-head screw terminals or larger. Wire and label the terminals as follows:

• Terminals 1 through 4 must be neutral and must have wireless connectors between them. Terminal 1 must be for line neutral, and must have a solderless connector for a size 6 AWG wire.

• Terminal 5 must be line in and must have a solderless connector for a size 6 AWG wire.

• Terminal 6 must be flasher hot.

• Terminals 7 and 8 must be flasher out 1.

• Terminals 9 and 10 must be flasher out 2.

Wire the six-pin mating connector for the flasher in accordance with Section 8 of the NEMA Standards Publication TS 1-1989.

Wire all components properly. Route and tie the wiring neatly and firmly with cable ties or other such wire fasteners.

Provide fused receptacles and 8-amp fuses for the two-load terminals of the flasher.

Install a single-pole 20-amps thermal circuit breaker on the "line" or service side of the cabinet. Use a circuit breaker from GE THQC 1150L, Square "D" QUO 150 Series, Westinghouse QC1050, or equivalent.

Protect the load side of the 20-amp circuit breaker by a solid-state lightning arrester approved by the by the TRF Signal Operations Engineer.

Protect exposed AC wiring and connections, except the terminal block, with a nonconductive cover to prevent accidental contact by service personnel.

C. Two-Circuit Solid-State Flasher. Meet the electrical and physical characteristics for a two-circuit solid-state flasher in accordance with the NEMA Standards Publication TS-1-1989, Section 8.

TEXAS DEPARTMENT OF TRANSPORTATION 5 – 8 EFFECTIVE DATE: AUGUST 2004

Use a solid-state design with no electro-mechanical devices for the two-circuit flasher.

The two-circuit flasher must operate over a voltage range of 95 to 135 V AC. The nominal voltage must be 120 V AC at an operating frequency of 60 Hz ± 3.0 Hz.

Design the two-circuit solid-state flasher to operate at any ambient temperature range from −30°F to +165°F.

Construct the flasher for easy replacement of each component.

Use a Type III (dual circuit rated at 15 amps per circuit) unit for the flasher.

D. Solid-State Time Clock. The time clock must have a day program for each day of the week. The day program must have at least six on and six off events per day. Each of these events must consist of a time in hours and minutes and an output state (on or off). An on-off event must control a clock output that activates a single-pole, double-throw relay circuit. "ON" and "OFF" must refer to the normally open contact of the relay.

The time clock must have ten special-event day programs. Designate each special-event day program in month/day/year format. Each special-event day program must consist of all the same elements as a day program.

The time clock must have at least ten holiday programs. Designate each holiday program in month/day format with the starting and ending dates. If the ending date is earlier than the starting date, then the skip period must be from the starting date to the ending date of next year (e.g., December 24 to January 1).

The time clock must have a digital time-of-day display in hours and minutes of 12- or 24-hr. periods. A 12-hr. clock must have an AM-PM indicator. The time clock must also have a display that clearly indicates the day of the week. The month and year must be programmable but do not need to be displayed except when programming.

Liquid crystal displays (LCD) are required. The LCDs must be visible over a temperature range from −10°C to +74°C. All displays must have a rated minimum lifetime of ten years.

Enter programmable on-off events using pushbuttons or keyboard on the face of the clock.

The clock must be capable of being set to the correct time of day to the nearest minute.

Provide a separate indicator to indicate whether the output is on or off. The output must have manual on-off control independent of the time clock programming.

The output must remain in the last state programmed until the next programmed event changes the output state or the output is changed by the manual on-off control or if the current day program is disabled.

Use a telephone-type keypad (numbers 0 through 9 displayed) to enter data.

The time clock must automatically switch to and from daylight savings time. Manually enable or disable this feature by keyboard entry.

The time clock must have a download feature to transfer all information to another time clock. Locate a connector on the front of the time clock to allow this transfer. Supply one transfer cable for every two time clocks with a minimum of one cable.

TEXAS DEPARTMENT OF TRANSPORTATION 6 – 8 EFFECTIVE DATE: AUGUST 2004

The time clock must be capable of operating using either a 120 V AC or 12 V DC power supply.

Using an AC power supply, the time clock must operate over a voltage range of 95 to 135 V AC. The nominal voltage must be 120 V AC at an operating frequency of 60 Hz ±

3.0 Hz. Derive the time-base from the 60-Hz line frequency during normal operation.

Design the time clock to operate at any ambient temperature range from −30°F to +165°F.

Using a DC power supply, the time clock must operate over a voltage range of 11 to

14.5 V DC and maintain accuracy of 0.02% over the entire ambient temperature range from −30°F to +165°F.

The time clock must have a power backup capacitor capable of powering the timer for at least 48 continuous hours during the loss of AC power. During loss of power, the time clock must generate its own internal time-base. Maintain accuracy within 0.02% over the entire ambient temperature range from −30°F to +165°F while operating on the internal time-base.

Disable all displays and outputs during back-up operation.

The time clock must operate correctly and accurately regardless of mounting orientation.

Wire and equip the time clock with an AMP 206036-1 (16-pin male) connector mounted on the clock housing and an adaptor cable with an AMP 206037-1 (16-pin female) connector. Use 18-AWG, stranded-copper, 24-in. long wire for the adaptor cable. Use the following pin and color assignments for the connectors.

Table 1

Pin and Color Assignments

Pin Function Adaptor Cable Wire Color

1 AC Positive Black

2 AC Neutral White

3 Chassis Ground Green

4 Relay 1 Normally Open Red

5 Relay 1 Normally Closed Yellow

10 Relay 1 Common White/Yellow

11 DC Positive White/Red

12 DC Negative White/Black

The output relay must have a normally-open, normally-closed, and common terminal.

Identify these terminals clearly. Use a relay rated at a minimum of 10 amps resistive load at 120 V AC.

Enclose the time clock in a dust-resistant housing. The maximum overall outside dimension of the clock's housing must be 10.25 in. high by 6.25 in. wide by 7.5 in. deep.

The housing door must expose all adjustments when it is open. Configure the mounting holes as an inverted "T." Place the top hole 1.25 ± 0.05 in. from the top of the cabinet and

5.75 ± 0.05 in. above a horizontal line connecting the centers of the two bottom holes.

TEXAS DEPARTMENT OF TRANSPORTATION 7 – 8 EFFECTIVE DATE: AUGUST 2004

Place the bottom two holes 2.3125 ± 0.05 in. apart from center to center. Position the top hole so that a vertical line through its center bisects the horizontal line.

Provide a solid-state time clock with the exception of the output relay.

Provide a power-loss indication. If an AC power interruption affects the timekeeping and memory, the clock must automatically activate this indication upon restoration of AC power. Reset the indication with a pushbutton switch or by keyboard activation.

When AC power restoration occurs, the clock must resume operation with the event that would be currently in effect had there been no power failure.

All components must be amply de-rated with regard to heat-dissipating capacity and rated voltage so that with maximum ambient temperature and maximum applied voltage material shortening of life or shift in value does not occur. Use components with a design life of not less than 10 years when under operating conditions 24 hours per day in their circuit application.

Mount components on printed circuit boards. Make printed circuit boards from NEMA grade-10 epoxy glass or equivalent, with 2 ounces or more copper track. Place wire jumpers included on circuit boards in plated through holes designed to contain them.

Jumpers that are tack soldered to circuit traces or are added to correct board layout errors are not acceptable.

Design the time clock so that the printed circuit boards can be taken apart without desoldering.

Mount components in such a way that signal technicians may replace any one defective component. Do not enclose circuits in epoxy or use other methods that prevent repair and servicing by the Department.

Protect the time clock from line voltage surges with a fuse and a transient protection device, such as a varistor, on the incoming power line, as described in the NEMA Standards Publication TS 1-1989, paragraph TS 1-2.1.8.

Provide one spare set of proprietary components including ICs and programmed PROMs for every ten time clocks purchased (minimum of one set per order).

Mount all ICs with 14 or more pins and all proprietary components in high-reliability, high-contact force sockets. Use thermoplastic bodies for sockets meeting UL Specification 94V-0. Meet these requirements for any other IC sockets supplied.

Ensure all components (including transistors, resistors, diodes, capacitors, and integrated circuits) are available to the Department through at least two suppliers of solid-state devices. Successful bidders may be required to supply a list of sources for those components for which the Department cannot verify the existence of multiple vendors.

11160.7. Payment.

A. Procurement by the State. Payment for materials under this specification will be in conformance with the conditions prescribed in the Contract awarded by the Department.

B. Contracts. Payment for materials governed by this specification used in contract projects will be in accordance with the Department’s Standard Specifications for Construction and

TEXAS DEPARTMENT OF TRANSPORTATION 8 – 8 EFFECTIVE DATE: AUGUST 2004

Maintenance of Highways, Streets, and Bridges, Item 680, “Installation of Highway Traffic Signals,” or Item 685, “Roadside Flashing Beacon Assemblies.”