34 90 00 Access Range MCX.pdf

WO 6978542 REPAIR ROADS AND PAVEMENT ACCESS, RANGE AND MCX

SECTION 34 90 00

TRAFFIC SIGNALS

03/20

PART 1 GENERAL

1.1 SUMMARY OF WORK

The purpose of this project is to upgrade existing traffic signal equipment at signalized intersections within the project limits and to replace loop detection demolished by the project's pavement milling and resurfacing. This project includes replacement of existing NEMA controllers and cabinets with new Model 2070E controllers housed in Type 332 base-mounted cabinets as well as signal display upgrades at selected locations.

Perform the following tasks under this contract, as shown in the Plans (the list that follows is not meant to be all-inclusive):

1. Provide underground conduit and junction boxes (i.e., pull boxes);

2. Provide 2070E traffic signal controllers with Siemens SEPAC local controller software and 170 cabinets with ancillary equipment, extending existing field wiring as necessary;

3. Demolish existing control equipment and cabinets and existing junction boxes, where designated in the Plans;

4. Provide detector loops, loop lead-in cable, junction boxes, and lead-in cables to replace existing detector loops demolished by pavement milling and resurfacing;

5. Provide pedestrian signals pushbuttons;

6. Upgrade existing controller cabinet grounding systems;

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Wiring Diagrams; G

Provide detailed wiring diagrams that include interconnection (wired and wireless) of equipment with pin-out configurations, pin functions, and cable parts numbers. This includes configuration at each field equipment cabinet. Use naming convention approved by the Contracting Officer and conforming to Belcore standards. Provide two paper copies and one electronic copy of the wiring diagrams in both Microstation and AutoCAD format. See Figure 1 in Attachment A for sample.

SD-03 Product Data

Provide a Type 3 material certification in accordance with Article 106-3 of the NCDOT Standard Specifications. When requested by the Government, provide additional certifications from independent testing laboratories and sufficient data to verify item meets applicable specifications. Ensure additional certification states the testing laboratory is independent of the

SECTION 34 90 00 Page 1 June 22, 2020 material manufacturer and neither the laboratory nor the manufacturer has a vested interest in the other.

Identify all proprietary parts in Contractor-provided material. The Government reserves the right to reject material that uses proprietary components not commercially available through electronic or electrical supply houses.

For Contractor-provided material listed on the NCDOT ITS & Signals QPL, provide submittals in the format defined by the QPL.

For Contractor-provided material not on the QPL, provide three copies of the equipment list including three copies of catalog cuts. Clearly identify proposed material on catalog cuts by a reproducible means (highlighter pen does not transfer to copies). Ensure material lists contain material description, brand name, manufacturer's address and telephone number, stock number, size, identifying trademark or symbol, and other appropriate ratings.

Submit for approval catalog cuts and/or shop drawings for materials proposed for use on the project. Allow 30 days for review of each submittal. Do not fabricate or order material until receipt of Government's approval. All submittals will be returned as either "Approved (as submitted)", "Approved as Noted" or "Rejected." The Contractor may proceed with fabrication or ordering for items marked "Approved." If an item is marked "Approved as Noted" without any stipulation for resubmittal, then the Contractor may proceed with fabrication or ordering. For any other notations, the Contractor must revise the submittal, address comments and resubmit for approval.

Submit three copies of each catalog cut and/or drawing and show for each component the material description, brand name, stock-number, size, rating, manufacturing specification and the intended use (identified by labeling all components with the corresponding contract line item number). Present the submittals neatly arranged in the same order as the contract bid items.

Electronic submittals of catalog cuts and drawings may be accepted in lieu of hard copies.

Controllers and Cabinets including conflict monitors, base adapters;

G Conduit; G Junction Boxes; G Pushbuttons; G Stainless Steel Hardware; G

SD-06 Test Reports

Test Reports; G

Conduct an approved, standalone equipment installation test at the field site. Test all standalone functions of the field equipment using equipment provided as detailed in the Plans.

Complete approved test plan forms and turn them over to the Contracting Officer for review as a basis for rejection or acceptance. Provide a minimum notice of 30 calendar days prior to all tests to permit the Contracting Officer or his representative to observe each test.

If any unit fails to pass its standalone test, correct the unit or substitute another unit in its place, then repeat the test.

SECTION 34 90 00 Page 2

If a unit has been modified as a result of a standalone test failure, prepare a report describing the nature of the failure and the corrective action taken and deliver it to the Contracting Officer prior to re-testing the unit. If a failure pattern develops, the Contracting Officer may direct that design and construction modifications be made to all units without additional cost to the Government or an extension of the contract period.

Utilize vendor supplied device software to perform diagnostic tests of each device. The vendor supplied diagnostic software must be provided to the Government before final acceptance. Test the following features of each competent as described below.

The following items, not otherwise required to be tested elsewhere, must be tested for each controller and cabinet provided under this project: cable continuity, grounding, power-up self-test, proper controller sequencing, detector and pedestrian pushbutton calls.

SD-10 Operation and Maintenance Data

Provide at least two hard copies along with one electronic copy (on CD or DVD) of the following manuals:

Operator's Manuals; G

Maintenance Procedure Manuals; G

Training Manuals; G

Provide installation, operations, and training manuals for all Contractor-provided software.

The manuals provided above must be in addition to manuals provided with and stored inside each control equipment cabinet.

SD-11 Closeout Submittals

As-built Drawings; G

Provide all manuals and plan of record (i.e., "as-built") documentation.

All as-built plans and documentation must be reviewed and accepted by the Contracting Officer prior to final acceptance of the project. All documentation, except as otherwise specifically approved by the Contracting Officer, must meet the following requirements:

1. Provide final as-built plans on 11" x 17" paper along with a PDF of each as-built plan sheet. Provide draft as-built plans for Government review on 22" x 34" paper. No documentation for as-built plans smaller than 11" x 17" will be accepted.

2. Provide any documentation that exceeds the size of 11" x 17" paper in a reproducible format 22" x 34" in size.

3. For electrical schematics and cabinet wiring diagrams not bound into printed manuals, provide paper copies at least 22" x 34" in size.

4. No non-plan documentation smaller than 8.5" x 11" will be accepted.

5. Do not fold or crease reproducibles.

SECTION 34 90 00 Page 3

As a minimum, provide the documentation described in the paragraphs below.

Plan of Record Documentation:

Provide as-built drawings that depict any changes of components, measurement or layout of the Plans. Show all construction changes, with the final location and depth of conduits, wiring external to the cabinet, detector locations, etc., in detail in a reproducible format. Submit as-built construction changes within 10 consecutive calendar days after the Observation Period begins. Note and date each change on the drawings.

Failure to revise as-built documentation to reflect current work may result in withholding of payments until the as-built documentation is brought current. The submitted as-built documentation may be field-checked by the Contractor Officer at the Contracting Officer's discretion. If the as-built documentation is found to have an unacceptable number of inaccuracies, the Contracting Officer may withhold payment until the as-built plans are corrected.

Store documentation for signals in a manila envelope placed in a weatherproof holder inside the cabinet drawer. Store all documentation provided with the controllers and cabinets, including manuals, electrical schematic diagram, and cabinet wiring diagram inside the envelope in the weatherproof holder. Provide two marked-up "redline" copies of the signal plan and the electrical and programming detail, placing one copy in the weatherproof holder inside the cabinet drawer immediately upon installation of the cabinet and giving the second copy to the Contracting Officer.

The Government will provide the Contractor one electronic copy of the Plans for the Contractor's use in developing the as-built drawings. Modify the original electronic file such that all changes are marked with callout boxes or other method approved by the Contracting Officer. Any other base maps that may be necessary for the Contractor to prepare the as-built drawings in accordance with this Specification will be the Contractor's responsibility.

Use CAD conventions that are consistent with those used on the original plans.

Within 10 consecutive calendar days after the Observation Period begins, provide one reproducible copy of the draft as-built plans in hard copy format for review. Provide draft hard copy as-built drawings on 22"x 34" bond plan sheets.

Upon receipt of review comments from the Contracting Officer, correct any errors and make all necessary revisions to the draft as-built plans prior to final acceptance of the project. Submit final as-built plans in electronic and hard copy format. Provide final hard copy as-built drawings on 11"x 17" bond plan sheets. Provide electronic plans in MicroStation (latest release in use by the North Carolina Department of Transportation (NCDOT)) format along with copies of the same files saved/exported in AutoCAD (latest release in use by the Government) format.

GPS Coordinates; G

Provide real world GPS coordinates for all junction boxes and controller cabinets provided or utilized under this project as well as for any existing controller cabinets that are retained and reused. Provide the coordinates in feet units using the North Carolina State Plane coordinate system (1983 North American Datum also known as NAD '83). Provide coordinates that do not deviate more than 1.7 feet in the horizontal plane and 3.3 feet in the vertical plane. Global positioning system (GPS) equipment able to obtain

SECTION 34 90 00 Page 4 the coordinate data within these tolerances may be used. Submit cut sheets on the GPS unit proposed to collect the data for approval by the Contracting Officer.

Provide both digital copies and hard copies of all information regarding the location (including to but not limited to manufacturer, model number) in the Microsoft Excel spreadsheet using the format shown in example table below.

In addition to Excel format, provide a digital copy of the location information as an ESRI Shapefile (.SHP file format).

Name Location Latitude Longitude Manufacturer Model #

Equipment Cabinet

Junction Box 1 (Phase 2 Side)

Junction Box 2 (Phase 2 Side)

Junction Box 3 (Near Cabinet)

Junction Box 4 (Phase 6 Side)

Junction Box 5 (Phase 6 Side)

Junction Box 6 (Phase 4 Side)

1.3 OBSERVATION PERIOD

1.3.1 General

A 30-day Observation Period will begin upon the successful completion of the installed site tests, as well as the correction of all known deficiencies, including minor construction items and punch-list items developed by the Contracting Officer. During this period the Government will observe equipment and software operation to determine that all components operate properly according to the requirements of the Plans and these Specifications over an extended period of time.

During the Observation Period, respond to failures of the Contractor's equipment within two hours and make repairs within eight hours. For items that pose a traffic safety hazard such as a controller failure, make repairs within four hours. If any failures affect major system components

SECTION 34 90 00 Page 5 for more than 48 hours, the Government will suspend the Observation Period beginning when the failure occurred. Resume the Observation Period after successful repair or replacement.

A successful 30-day Observation Period must consist of continuous operation with no more than a total of five calendar days of non-operation due to mechanical, electrical, or other malfunctions.

The Observation Period must be completed by the project completion date and prior to final acceptance of the project. The Observation Period will not begin without the approval of the Contracting Officer.

1.3.2 Final Acceptance

Final acceptance is defined as the time when all work and materials described in the Plans and this Specification have been provide by the Contractor; all parts of the work have been approved and accepted by the Contracting Officer; and the traffic signals have been operated continuously and successfully for the 30-day Observation Period.

Final acceptance will not occur until operational tests have been satisfactorily completed, all punch-list discrepancies have been rectified, all documentation has been delivered and accepted.

1.4 WARRANTY

Unless otherwise required herein, provide manufacturer's warranties on Contractor-provided equipment for material and workmanship that are customarily issued by the equipment manufacturer or that are at least one year in length, whichever is greater, from the date of final acceptance of the project by the Contracting Officer. Include unconditional coverage for all parts and labor necessary or incidental to repair of defective equipment or workmanship and malfunctions that arise during warranty period.

Ensure all Contractor-provided equipment, including pieces and components of equipment, hardware, firmware, software, middleware, internal components, and subroutines which perform any date or time data recognition function, calculation, or sequencing will support a four digit year format for a period of at least 50 years and will support user-definable parameters for setting the start and end dates for daylight savings time.

Upon receipt of the Contracting Officer's written final acceptance of project, transfer manufacturer's warranties with proper validation by the manufacturer to the Government. Provide warranties in the name of the Government.

PART 2 PRODUCTS

2.1 GENERAL

Provide new equipment, materials, and hardware unless otherwise required.

Inscribe manufacturer's name, model number, serial number, and any additional information needed for proper identification on each piece of

SECTION 34 90 00 Page 6 equipment housed in a case or housing.

Except for the signal controller and cabinet , signal equipment, material, and hardware must be pre-approved on the NCDOT ITS and Signals Qualified Products List (QPL) by the date of installation. Equipment, material, and hardware not pre-approved when required will not be allowed for use on the project. Consult the QPL website to obtain pre-approval procedures.

The 2018 NCDOT ITS and Signals QPL is available on the NCDOT's website at the following address:

https://connect.ncdot.gov/resources/safety/ Pages/ITS-and-Signals-Qualified-Products.aspx

2.1.1 Operation and Maintenance Data

Provide the following for all products:

Operator's Manuals

Maintenance Procedure Manuals

Training Manuals

2.2 OBSERVATION PERIOD

Prior to final acceptance, all Contractor-provided equipment and software must successfully complete a 30-day Observation Period.

The 30-day Observation Period is considered to be part of the work included in the total contract time and must be completed prior to final acceptance of the project.

Final acceptance will occur following the successful completion of the 30-day Observation Period and after all documentation requirements have been fully satisfied.

Refer to the "Installed Site Tests" and "Observation Period" subsections of this Specification for additional requirements.

2.3 FIRMWARE AND LICENSING UPGRADES

Provide the Government with a license to duplicate all programmable devices in equipment for maintenance and software upgrades. Provide binary or hexadecimal format files for each device that may be programmed by the Government. Ensure files are provided on PC compatible compact disks or other approved media.

Ensure software/firmware performance upgrades that occur during the contract period up through final acceptance of the project are provided to the Government at no additional cost.

Make software/firmware upgrades that are developed to correct operating characteristics available to the Government at no additional cost until the warranty period expires.

Provide licensed copies of all software/firmware to the Government for any

SECTION 34 90 00 Page 7 programmable devices provided by the Contractor under this project. The Government will have the right to install any and all software/firmware for maintenance and support on all hardware provided under this contract.

This includes traffic signal controllers. Provide software/firmware for maintenance and support on workstations, laptop computers, system support software, utility software, traffic signal controllers and all other programmable devices.

2.4 WIRE AND CABLE

Provide wire and cable on reels. When requested by the Contracting Officer, provide samples of wire and cable to the Government at no additional cost.

2.5 PERFORMANCE OF WARRANTY REPAIR AND MAINTENANCE

Ensure the manufacturer agrees to provide prompt technical support to the Government electronics technicians for a period of one year after the end of the warranty period at no cost to the Government. Defective parts replaced under warranty by the Government will be returned to the vendor at the vendor's request. After project acceptance and at the request of the Government, the manufacturer must perform warranty repairs to equipment which fails during the warranty period at no cost to the Government including freight costs to ship repaired equipment back to the MCAS Cherry Point. Ensure all equipment is repaired and returned to the MCAS Cherry Point within 21 calendar days of receipt by the manufacturer.

2.6 PEDESTRIAN SIGNAL PUSHBUTTONS

Provide 2-inch diameter pedestrian pushbuttons with weather-tight housings fabricated from die-cast aluminum and threading in compliance with the NEC for rigid metal conduit. Provide a weep hole in the housing bottom and ensure that the unit is vandal resistant.

Provide pushbutton housings that are suitable for mounting on flat or curved surfaces and that will accept 1/2-inch conduit provided in the top.

Provide units that have a heavy duty push-button assembly with a sturdy, momentary, normally-open switch. Have contacts that are electrically insulated from the housing and push-button. Ensure that the push-buttons are rated for a minimum of 5 mA at 24 volts DC and 250 mA at 12 volts AC.

Provide standard R10-3 signs with mounting hardware that comply with the MUTCD in effect on the date of advertisement. Provide R10-3E signs for countdown pedestrian heads and R10-3B for non-countdown pedestrian heads.

2.7 UNDERGROUND CONDUIT - GENERAL

Provide material, equipment, and hardware under this section that is pre-approved on the ITS and Signals QPL.

Refer to the following articles of the Standard Specifications:

Backfill 1018-2

Graded Stone 545-2 and 545-3

SECTION 34 90 00 Page 8

2.7.1 Conduit Bodies, Boxes and Fittings

Use conduit bodies, boxes, and fittings that meet UL Standard 514A or 514B for electrical and communications installations.

2.7.2 Conduit Types

2.7.2.1 Rigid Metallic Conduit

Provide rigid hot dipped galvanized steel conduit that meets UL Standard 6 with rigid full weight sherardized or galvanized threaded fittings.

2.7.2.2 PVC Conduit

Provide non-metallic conduit and duct including associated couplings, approved for below ground use with or without concrete encasement in accordance with UL Standard 651A. Provide Schedule 40 conduit unless otherwise specified.

2.7.2.3 Solid-Wall HDPE Conduit

Use HDPE conduit that conforms to UL Standard 651B. Provide conduit meeting the requirements of the table below with minimum wall thickness ratios corresponding to EPEC-40 (Schedule 40), EPEC-80 (Schedule 80) or EPEC-B (SDR 13.5) as listed in UL Standard 651B, Table 5.1, 5.2 and 5.3.

Conduit Trade Size Provide

1" EPEC-40

1-1/4" EPEC-40

1-1/2" EPEC-B (SDR 13.5)

2" EPEC-B (SDR 13.5)

2-1/2" EPEC-B (SDR 13.5)

3" EPEC-B (SDR 13.5)

4" EPEC-B (SDR 13.5)

5" EPEC-80

6" EPEC-80

Ensure the PE resin compounds used in manufacturing the conduit meet or exceed the cell classification PE 334420C (black with 2% minimum carbon black) or PE 334420E (colored conduit with UV inhibitors) in ASTM D3350 and the table below.

SECTION 34 90 00 Page 9

Property Requirement Test Method

Density 0.940 - 0.947g/cm3 ASTM D1505

ASTM D792

ASTM D4883

Melt Index (condition 190/2.16 is acceptable)

< 0.4 grams/10 minutes ASTM D1238

Flexural Modulus 80,000 psi, min. ASTM D790

Tensile Strength 3,000 psi, min. ASTM D638

Elongation 400%, min. ASTM D638

Slow Crack Growth Resistance An ESCR as per condition B, 10% IGEPAL requirement of F50>24 hrs is allowable

ASTM D1693

Hydrostatic Design Basis "0" for Non-Pressure Rated Pipe

ASTM D2837

UV Resistance (Outdoor Conduit Only)

Stabilize with at least 2% by weight carbon black or colored with UV Inhibitor

ASTM D4218

Provide conduits in the colors for the applications shown in the table below. For conduits manufactured with stripes, ensure the stripes are uniformly located around the conduit with 120 degrees of separation. Do not use "Solid Yellow" or "Black with Yellow Stripes" conduit.

Conduit Contents Preferred Solid Color Alternate

Signal Cable Black None

Loop Lead-In Cable White Black w/ White Stripes

Electrical Power Cable Red Black w/ Red Stripes

Ensure the HDPE conduit is resistant to benzene, calcium 1 chloride, ethyl alcohol, fuel oil, gasoline, lubricating oil, potassium chloride, sodium chloride, sodium nitrate and transformer oil and is protected against degradation due to oxidation and general corrosion.

Provide factory lubricated, low friction, conduit with a coefficient of friction of 0.10 or less in accordance with Telcordia GR-356. Ensure the supplied conduit is identified and certified as meeting, UL Standard 651B.

Ensure the conduit is marked at least with the following information on 10 ft or less intervals:

1) Material: HDPE

2) Trade Size: i.e., 2"

3) Conduit Type: SDR 13.5 or EPEC-B

SECTION 34 90 00 Page 10

4) Manufacturer's name or trademark

5) Manufacturer's identity code to identify manufacturing date, facility, etc.

6) UL symbol or UL listing number

Provide coilable conduit that is supplied on reels in continuous lengths for transportation and storage outside. Ensure that the process of providing the coilable conduit on the reel does not alter the properties or performance of the conduit for its intended purpose.

2.7.3 Conduit Plugs and Pull Line

Provide conduit plugs that provide a watertight barrier when provided in conduit. Provide conduit plugs sized in accordance with conduit. Ensure conduit plug provides a means to secure a pull line to the end of the plug. Provide removable and re-usable duct plugs. Conduit plugs are not required to be listed electrical devices.

For all spared conduits, provide 3/4", pre-lubricated, woven polyester tape, pull line with minimum rated tensile strength of 2,500 lb. Pull lines are not required to be listed electrical devices.

2.7.4 Mechanical Couplings for HDPE Conduit

Provide mechanical couplings that are both watertight and airtight for joining two segments of HDPE conduit of like diameter. Provide couplings designed to accommodate pneumatic methods of cable installation. Provide couplings suitable for burial underground and which meet the following requirements:

a. The coupling must not fail by leakage when subjected to sustained internal pressure testing as noted in ASTM F 2176.

b. The coupling must not fail by leakage when subjected to sustained external pressure testing as noted in ASTM F 2176.

c. The coupling assemblies tested must be able to comply with the tensile loading requirements as specified in ASTM F 2176.

d. As specified in ASTM F 2176, the coupling must not fail when conditioned at low temperature conditions of 10° F and tested by an impact with a force of 20 ft-lb using Type "B" as described in Test Method ASTM D 2444.

2.7.5 Duct and Conduit Sealer

Use duct and conduit sealer or mastic which is a putty-like compound and:

a. Is permanently non-hardening, non-oxidizing, and non-corrosive to metals, rubber, plastic, lacquer and paints;

b. Is readily workable for thumbing into openings and forming into seals around wires inside conduits and openings around conduits;

c. Has a service temperature range of minus 30°F to 200°F;

SECTION 34 90 00 Page 11

d. Is clean, non-poisonous and non-injurious to human skin;

e. Seals against water, dust and air and must adhere to wood, glass, plastics, metal, rubber and painted surfaces; and

f. Is non-conductive.

2.8 JUNCTION BOXES - GENERAL

Provide electrical junction boxes with covers of the type and size indicated by the contract or the Plans for the termination of conduits, for splicing loop wires to loop lead-in cables and for storing spare cable.

Except for special-sized junction boxes, material, equipment, and hardware provided under this section must be pre-approved on the ITS and Signals

QPL.

Provide #57 or #67 washed stone aggregates in conformance with Sections 545 and 1005 of the Standard Specifications.

2.8.1 Polymer Concrete (PC) Junction Boxes

Provide polymer concrete (PC) boxes which are stackable, have bolted covers and have open bottoms. Ensure vertical extensions of 6 inches to 12 inches are available from the junction box manufacturer.

Use polymer concrete material made of an aggregate consisting of sand and gravel bound together with a polymer and reinforced with glass strands to fabricate box and cover components which are exposed to sunlight. Other thermosetting glass-reinforced materials may be used for components which are not normally exposed to sunlight.

Provide certification that the polymer concrete boxes and covers meet Tier 15 requirements of ANSI/SCTE 77. Provide certification that testing methods are compliant with ANSI/SCTE 77.

Provide junction box covers with the required logos on the cover as follows (see NCDOT Roadway Standard Drawing No. 1716.01 for additional details):

a. For standard size and oversized junction boxes that contain traffic signal cable and loop lead-in cable, provide covers with the standard TRAFFIC SIGNAL logo;

b. For standard size junction boxes that house electrical service conductors, provide covers with the standard ELECTRIC logo; and Provide at least two size 3/8" diameter hex head stainless steel cover bolts to match inserts in the box. Provide pull slot(s) with stainless steel pin(s). Polymer concrete junction boxes are not required to be listed electrical devices.

2.8.2 Junction Box sizes

Provide junction boxes and covers of the following sizes as called for in the Plans:

SECTION 34 90 00 Page 12

Junction Box Size Minimum Inside Dimensions

Standard Size 16"(L) x 10"(W) x 10"(D)

Oversized 30"(L) x 15"(W) x 24"(D)

2.8.3 Loop Sealant

Provide the Contracting Officer with a Type 3 material certifications and material safety data sheets (MSDS) for the sealant in accordance with Article 106-3 of the Standard Specifications.

Provide loop slot sealant that completely encapsulates loop wire when provided according to manufacturer's instructions. Provide loop sealant that does not generate temperatures greater than 220° F. Ensure sealant bonds with asphalt and concrete pavement saw slots so sealant and encapsulated loop wire do not come out of slot. Ensure sealant is self-leveling, but with sufficient viscosity to prevent exit from saw slot when provided along a 10% grade.

Provide sealant that protects loop wire by preventing the entrance of dirt, water, rocks, sticks, and other debris into saw slot, and is resistant to traffic, water, gasoline, chemical and chemical fumes, mild alkalis, oils, and mild acids. Ensure sealant will not be affected by water and sealant does not chemically interact with pavement and loop wire insulation.

Ensure loop sealant has sufficient flexibility to permit expected pavement expansion and contraction due to weather and to permit pavement movement due to traffic without cracking for a temperature range of -40 to 160° F.

Provide sealant with a usable life of at least ten minutes once mixed, when the ambient temperature is 75° F. Ensure sealant dries to tack-free state in less than 2 hours, and does not flow within or out of saw slot after exposed surface has become tack free. Tack free time will be determined by testing with a cotton ball until no sealant adheres to cotton ball and no cotton adheres to sealant.

Ensure two-part sealant cures within 48 hours to attain 95% of published properties for the cured material.

Ensure one part sealant cures within 30 days to attain 95% of published properties for the cured material.

2.8.4 Loop Wire

Provide loop wire composed of 19-strand conductor insulated by a cross-linked polyethylene compound. Ensure insulated conductors are completely encased in tubes of low density polyethylene compound. Print manufacturer's name, manufacture year, and any applicable part number on encasing tube at intervals of 2 feet or less.

Provide #14 AWG copper conductors fabricated from 19 strands that comply with ASTM B3 before insulating. Ensure stranded conductors use either concentric or bunch stranding, and comply with circular mil area and

SECTION 34 90 00 Page 13 physical requirements of ASTM B8 or ASTM B174 for bunch stranding.

Provide insulating compound that is cross-linked thermosetting black polyethylene in accordance with ASTM D 2655. Ensure insulation is applied concentrically about conductor. Provide insulation thickness not less than

0.026 inch at any point and minimum average thickness of 0.030 inch as measured by UL Standard 62.

Ensure insulation of finished conductor will withstand application of a 60 Hertz or 3,000 Hertz, 7,500 volt (RMS) essentially sinusoidal spark test potential as specified in UL Standard 83.

Provide insulated conductors that are factory-provided in protective encasing tube that complies with the following:

a. Encasing tube fabricated of polyethylene compound conforming to ASTM D1248 for Type I, Class C, Grade E5.

b. Minimum inside diameter of 0.150 inch

c. Wall thickness of 0.040 inch ± 0.010 inch

d. Outside diameter of 0.240 inch ± 0.010 inch

2.8.5 Lead-In Cable

Provide lead-in cable with two conductors of #14 AWG fabricated from stranded tinned copper that complies with IMSA Specification 50-2 except as follows:

a. Ensure conductor is twisted with a maximum lay of 2.0 inches, resulting in a minimum of 6 turns per foot.

b. Provide a ripcord to allow cable jacket to be opened without using a cutter.

Provide length markings in a contrasting color showing sequential feet and within 1% of actual cable length. Ensure character height of the markings is approximately 0.10 inch.

2.9 SIGNS PROVIDED FOR SIGNALS

Comply with Signing section of these Specifications.

Use ASTM D4956 Type IV or better retroreflective sheeting, except for black sheeting. Use non-reflective for black sheeting.

Conform to the message layout, size, and color as required in the MUTCD.

For messenger cable mounting, provide either messenger cable hangers with free-swinging, 360° adjustable sign brackets or 3-bolt clamps as directed.

Provide aluminum, galvanized steel, or stainless steel sign supporting hardware.

For ground mounting, provide perforated steel square tube sign posts with anchor sleeve and hardware for ground mounting.

SECTION 34 90 00 Page 14

For mast-arm mounting, provide rigid aluminum, galvanized steel or stainless steel sign mounting brackets.

2.10 TYPE 2070E CONTROLLERS

Provide Model 2070E controllers that conform to CALTRANS Transportation Electrical Equipment Specifications (TEES) (dated March 12, 2009), plus Errata 1 (dated January 21, 2010) except as required herein. For consi st ency and compat i bi l i t y wi t h exi st i ng Model 2070E cont r ol l er s cur r ent l y i n use at MCAS Cher r y Poi nt , pr ovi de onl y Si emens Model 2070E cont r ol l er s wi t h Si emens SEPAC l ocal cont r ol l er sof t war e ( ver si on t hat i s cur r ent l y i n use at MCAS Cher r y Poi nt or newer , f ul l y compat i bl e ver si on) .

Provide Model 2070E controllers with Linux kernel 2.6.18 and device drivers, composed of the unit chassis and at a minimum the following modules and assemblies:

a. MODEL 2070-1C, CPU Module, Single Board, with 8Mb Datakey (blue in color)

b. MODEL 2070-2E+, Field I/O Module (FI/O)

c. Note: Configure the Field I/O Module to disable both the External WDT Shunt/Toggle Switch and SP3 (SP3 active indicator is "off")

d. MODEL 2070-3B, Front Panel Module (FP), Display B (8x40)

e. MODEL 2070-4A, Power Supply Module, 10 AMP

Provide a Board Support Package (BSP) to the state and to any specified applications software manufacturer when requested by the state to facilitate the porting of application software.

2.11 CABINETS - GENERAL

Provide a moisture resistant coating on all circuit boards.

Provide one 20 mm diameter radial lead UL-recognized metal oxide varistor (MOV) between each load switch field terminal and equipment ground.

Electrical performance is outlined below.

PROPERTIES OF MOV SURGE PROTECTOR

Maximum Continuous Applied Voltage at 185F 150 VAC (RMS)

200 VDC

Maximum Peak 8x20s Current at 185F 6500 A

Maximum Energy Rating at 185F 80 J

Voltage Range 1 mA DC Test at 77F 212-268 V

Max. Clamping Voltage 8x20s, 100A at 77F 395 V

SECTION 34 90 00 Page 15

PROPERTIES OF MOV SURGE PROTECTOR

Typical Capacitance (1 MHz) at 77F 1600 pF

Provide a power line surge protector that is a two-stage device that will allow connection of the radio frequency interference filter between the stages of the device. Ensure that a maximum continuous current is at least 10A at 120V. Ensure that the device can withstand a minimum of 20 peak surge current occurrences at 20,000A for an 8x20 microsecond waveform.

Provide a maximum clamp voltage of 395V at 20,000A with a nominal series inductance of 200 h. Ensure that the voltage does not exceed 395V. Provide devices that comply with the following:

Frequency (Hz) Minimum Insertion Loss (dB)

60 0

10,000 30

50,000 55

100,000 50

500,000 50

2,000,000 60

5,000,000 40

10,000,000 20

20,000,000 25

2.11.1 Type 170E Cabinets

Conform to the city of Los Angeles' Specification No. 54-053-08, Traffic Signal Cabinet Assembly Specification (dated July 2008), except as required herein.

Provide model 332 base mounted cabinets configured for 8 vehicle phases, 4 pedestrian phases, and 6 overlaps. Provide auxiliary output files in all 332 base mounted cabinets provided for this project. Do not reassign load switches to accommodate overlaps unless shown on electrical details.

Provide model 200 load switches, model 222 loop detector sensors, model 252 AC isolators, and model 242 DC isolators according to the electrical details. As a minimum, provide one (1) model 2018 conflict monitor, one

(1) model 206L power supply unit, two (2) model 204 flashers, one (1) DC isolator (located in slot I14), and four (4) model 430 flash transfer relays (provide seven (7) model 430 flash transfer relays if auxiliary output file is installed) with each cabinet.

SECTION 34 90 00 Page 16

2.11.1.1 Electrical Requirements

Provide a cabinet assembly designed to ensure that upon leaving any cabinet switch or conflict monitor initiated flashing operation, the controller starts up in the programmed start up phases and start up interval.

Provide two sets of non-fading cabinet wiring diagrams and schematics in a paper envelope or container and placed in the cabinet drawer.

All AC+ power is subject to radio frequency signal suppression.

Provide surge suppression in the cabinet for each type of cabinet device.

Provide surge protection for the full capacity of the cabinet input file.

Provide surge suppression devices that operate properly over a temperature range of -40º F to +185º F. Ensure the surge suppression devices provide both common and differential modes of protection.

Provide a pluggable power line surge protector that is installed on the back of the PDA (power distribution assembly) chassis to filter and absorb power line noise and switching transients. Ensure the device incorporates LEDs for failure indication and provides a dry relay contact closure for the purpose of remote sensing. Ensure the device meets the following specifications:

Peak Surge Current (Single pulse, 8x20µs)...........................20,000A Occurrences (8x20µs waveform)..........................10 minimum @ 20,000A Maximum Clamp Voltage................................................395VAC Operating Current...................................................15 amps Response Time...............................................< 5 nanoseconds

Provide a loop surge suppressor for each set of loop terminals in the cabinet. Ensure the device meets the following specifications:

Peak Surge Current (6 times, 8x20µs) (Differential Mode)...............................................400A (Common Mode)...................................................1,000A Occurrences (8x20µs waveform)................................500 min @ 200A Maximum Clamp Voltage (Differential Mode @400A)..........................................35V (Common Mode @1,000A)..............................................35V Response Time...............................................< 5 nanoseconds Maximum Capacitance...................................................35 pF

Provide a data communications surge suppressor for each communications line entering or leaving the cabinet. Ensure the device meets the following specifications:

Peak Surge Current (Single pulse, 8x20µs)...........................10,000A Occurrences (8x20µs waveform)..............................100 min @ 2,000A Maximum Clamp Voltage.........................Rated for equipment protected Response Time................................................< 1 nanosecond Maximum Capacitance................................................1,500 pF Maximum Series Resistance

Provide a DC signal surge suppressor for each DC input channel in the

SECTION 34 90 00 Page 17 cabinet. Ensure the device meets the following specifications:

Peak Surge Current (Single pulse, 8x20µs)...........................10,000A Occurrences (8x20µs waveform)..................................100 @ 2,000A Maximum Clamp Voltage...................................................30V Response Time................................................< 1 nanosecond

Provide a 120 VAC signal surge suppressor for each AC+ interconnect signal input. Ensure the device meets the following specifications:

Peak Surge Current (Single pulse, 8x20µs)...........................20,000A Maximum Clamp Voltage................................................350VAC Response Time.............................................< 200 nanoseconds Discharge Voltage.......................................<200 Volts @ 1,000A Insulation Resistance........................................>=100 MegaOhms

Provide conductors for surge protection wiring that are of sufficient size (ampacity) to withstand maximum overcurrents which could occur before protective device thresholds are attained and current flow is interrupted.

If additional surge protected power outlets are needed to accommodate Ethernet switches, modems, etc., provide a UL listed, industrial, heavy-duty type power outlet strip with a minimum rating of 15 A / 125 VAC, 60 Hz. Provide a strip that has a minimum of 3 grounded outlets.

Ensure the power outlet strip plugs into one of the controller unit receptacles located on the rear of the PDA. Ensure power outlet strip is mounted securely; provide strain relief if necessary.

Provide a door switch in the front and a door switch in the rear of the cabinet that will provide the controller unit with a Door Ajar alarm when either the front or the rear door is open. Ensure the door switches apply DC ground to the Input File when either the front door or the rear door is open. See Figure 2 in Attachment A.

Provide a fluorescent or LED fixture in the rear across the top of the cabinet and another fluorescent fixture in the front across the top of the cabinet at a minimum. Ensure that the fixtures provide sufficient light to illuminate all terminals, labels, switches, and devices in the cabinet.

Conveniently locate the fixtures so as not to interfere with a technician's ability to perform work on any devices or terminals in the cabinet. Provide a protective diffuser to cover exposed bulbs. Provide 16 watt T-4 lamps in the fluorescent or equivalent LED fixture. Provide a door switch to provide power to each fixture when the respective door is open. Wire the fluorescent or LED fixtures to the 15 amp ECB (equipment circuit breaker). See Figure 3 in Attachment A.

Provide a police panel with a police panel door. Ensure that the police panel door permits access to the police panel when the main door is closed. Ensure that no rainwater can enter the cabinet even with the police panel door open. Provide a police panel door hinged on the right side as viewed from the front. Provide a police panel door lock that is keyed to a standard police/fire call box key. In addition to the requirements of LA Specification No. 54-053-08, provide the police panel with a toggle switch connected to switch the intersection operation between normal stop-and-go operation (AUTO) and manual operation (MANUAL).

Ensure that manual control can be implemented using inputs and software such that the controller provides full programmed clearance times for the yellow clearance and red clearance for each phase while under manual control.

SECTION 34 90 00 Page 18

Provide a 1/4-inch locking phone jack in the police panel for a hand control to manually control the intersection. Provide sufficient room in the police panel for storage of a hand control and cord.

For model 332 base mounted cabinets, ensure terminals J14-E and J14-K are wired together on the rear of the Input File. Connect TB9-12 (J14 Common) on the Input Panel to T1-2 (AC-) on the rear of the PDA.

Provide detector test switches mounted at the top of the cabinet rack or other convenient location which may be used to place a call on each of eight phases based on the chart below. Provide three positions for each switch: On (place call), Off (normal detector operation), and Momentary On (place momentary call and return to normal detector operation after switch is released). Ensure that the switches are located such that the technician can read the controller display and observe the intersection.

Connect detector test switches for cabinets as follows:

332 Cabinet

Detector Call Switches Terminals

Phase 1 I1-W

Phase 2 I4-W

Phase 3 I5-W

Phase 4 I8-W

Phase 5 J1-W

Phase 6 J4-W

Phase 7 J5-W

Phase 8 J8-W

Provide the PCB 28/56 connector for the conflict monitor unit (CMU) with 28 independent contacts per side, dual-sided with 0.156 inch contact centers. Provide the PCB 28/56 connector contacts with solder eyelet terminations. Ensure all connections to the PCB 28/56 connector are soldered to the solder eyelet terminations.

Ensure that all cabinets have the CMU connector wired according to the 332 cabinet connector pin assignments (include all wires for auxiliary output file connection). Wire pins 13, 16, R, and U of the CMU connector to a separate 4 pin plug, P1, as shown below. Provide a second plug, P2, which will mate with P1 and is wired to the auxiliary output file as shown below. Provide an additional plug, P3, which will mate with P1 and is wired to the pedestrian yellow circuits as shown below. When no auxiliary output file is provided in the cabinet, provide wires for the green and yellow inputs for channels 11, 12, 17, and 18, the red inputs for channels 17 and 18, and the wires for the P2 plug. Terminate the two-foot wires with ring type lugs, insulated, and bundled for optional use.

SECTION 34 90 00 Page 19

P1 P2 P3

PIN FUNCTION CONN TO FUNCTION CONN TO FUNCTION CONN TO

1 CH-9G CMU-13 OLA-GRN A123 2P-YEL 114

2 CH-9Y CMU-16 OLA-YEL A122 4P-YEL 105

3 CH-10G CMU-R OLB-GRN A126 6P-YEL 120

4 CH-10Y CMU-U OLB-YEL A125 8P-YEL 111

Do not provide the P20 terminal assembly (red monitor board) or red interface ribbon cable as specified in the LA Specification No. 54-053-08.

Provide a P20 connector that mates with and is compatible with the red interface connector mounted on the front of the conflict monitor. Ensure that the P20 connector and the red interface connector on the conflict monitor are center polarized to ensure proper connection. Ensure that removal of the P20 connector will cause the conflict monitor to recognize a latching fault condition and place the cabinet into flashing operation.

Wire the P20 connector to the output file and auxiliary output file using 22 AWG stranded wires. Ensure the length of these wires is a minimum of 42 inches. Provide a durable braided sleeve around the wires to organize and protect the wires.

Wire the P20 connector to the traffic signal red displays to provide inputs to the conflict monitor as shown below. Ensure the pedestrian Don't Walk circuits are wired to channels 13 through 16 of the P20 connector. When no auxiliary output file is provided in the cabinet, provide wires for channels 9 through 12 reds. Provide a wire for special function 1. Terminate the unused wires with ring type lugs, insulated, and bundled for optional use.

P20 Connector

PIN FUNCTION CONN TO PIN FUNCTION CONN TO

1 Channel 15 Red

119 11 Channel 16 Red

2 Channel 14 Red

104 12 Chassis GND 01-9

3 Channel 13 Red

113 13 N/C

4 Channel 12 Red

AUX 101 14 Spec Function 1

5 Channel 10 Red

AUX 124 15 Channel 11 Red

AUX 114

6 Channel 9 Red AUX 121 16 Channel 8 Red 107

7 Channel 7 Red 122 17 Channel 6 Red 134

SECTION 34 90 00 Page 20

8 Channel 5 Red 131 18 Channel 4 Red 101

9 Channel 3 Red 116 19 Channel 2 Red 128

10 Channel 1 Red 125 20 Red Enable 01-14

Do not wire pin 12 of the load switch sockets.

Ensure the controller unit outputs to the auxiliary output file are pre-wired to the C5 connector. When no auxiliary output file is provided in the cabinet, connect the C5 connector to a storage socket located on the Input Panel or on the rear of the PDA.

In addition to the requirements of LA Specification No. 54-053-08, ensure relay K1 on the Power Distribution Assembly (PDA) is a four pole relay and K2 on the PDA is a two pole relay.

Provide a two-pole, ganged circuit breaker for the flash bus circuit.

Ensure the flash bus circuit breaker is an inverse time circuit breaker rated for 10 amps at 120 VAC with a minimum of 10,000 RMS symmetrical amperes short circuit current rating. Do not provide the auxiliary switch feature on the flash bus circuit breaker. Ensure the ganged flash bus circuit breaker is certified by the circuit breaker manufacturer to provide gang tripping operation. See Figure 4 in Attachment A.

Ensure auxiliary output files are wired as follows:

AUXILIARY OUTPUT FILE

TERMINAL BLOCK TA ASSIGNMENTS

POSITION FUNCTION

1 Flasher Unit #1, Circuit 1/FTR1 (OLA, OLB)/FTR3 (OLE)

2 Flasher Unit #1, Circuit 2/FTR2 (OLC, OLD)/FTR3 (OLF)

3 Flash Transfer Relay Coils

4 AC

5 Power Circuit 5

6 Power Circuit 5

7 Equipment Ground Bus

8 NC

Provide four spare load resistors mounted in each cabinet. Ensure each load resistor is rated as shown in the table below. Wire one side of each load resistor to AC-. Connect the other side of each resistor to a separate terminal on a four (4) position terminal block. Mount the load resistors and terminal block either inside the back of Output File No. 1

SECTION 34 90 00 Page 21 or on the upper area of the Service Panel.

ACCEPTABLE LOAD RESISTOR VALUES

VALUE (ohms) WATTAGE

1.5K - 1.9K 25W (min)

2.0K - 3.0K 10W (min)

Provide Model 200 load switches, Model 204 flashers, Model 242 DC isolators, Model 252 AC isolators, and Model 206L power supply units that conform to CALTRANS' "Transportation Electrical Equipment Specifications" dated March 12, 2009 with Erratum 1.

2.11.1.2 Type 170 E Cabinet Physical Requirements

Do not mold, cast, or scribe the name "City of Los Angeles" on the outside of the cabinet door as specified in LA Specification No. 54-053-08. Do not provide a Communications Terminal Panel as specified in LA Specification No. 54-053-08. Do not provide terminal block TBB on the Service Panel. Do not provide Cabinet Verification Test Program software or associated test jigs as specified in LA Specification No. 54-053-08.

Provide unpainted, natural, aluminum cabinet shells. Ensure that all non-aluminum hardware on the cabinet is stainless steel.

Ensure the lifting eyes, gasket channels, police panel, and all supports welded to the enclosure and doors are fabricated from 0.125 inch minimum thickness aluminum sheet and meet the same standards as the cabinet and doors.

Provide front and rear doors with latching handles that allow padlocking in the closed position. Provide 0.75 inch minimum diameter stainless steel handles with a minimum 0.5 inch shank. Place the padlocking attachment at

4.0 inches from the handle shank center to clear the lock and key. Provide an additional 4.0 inches minimum gripping length.

Provide Corbin #2 locks on the front and rear doors. Provide one (1) Corbin #2 and one (1) police master key with each cabinet. Ensure main door locks allow removal of keys in the locked position only.

Provid…