1-18 6287
1993 Specifications CSJ 0072-12-153, etc.
SPECIAL SPECIFICATION ITEM 6287
Lane Control System
1.0 Description
This Item shall govern for the furnishing and installation of FTM
(Freeway Traffic Management) Lane Control Signal (LCS) Field Equipment, and all necessary associated electronic devices and hardware in
designated field locations and equipment cabinets as shown on the plans, as detailed in accordance with these specifications, and as directed by the Engineer.
2.0 Material
2.1 GENERAL REQUIREMENTS
The Contractor shall provide software as specified in Special Specification "Software System Interface", to interface with existing equipment and software located in the Transguide Control Center.
All materials furnished, assembled, fabricated or installed under this Item shall be new, corrosion resistant, and in strict
accordance with the details shown on the plans and in the Specifications.
Equipment to be furnished at each lane control signal (LCS) field site shown on the plans shall include, but not be limited to, the following:
. Lane Control Signals (number shall be as shown within the plans)
. LCS Controller
. Cabling, rigid metal conduit and connectors from LCS to controller
Equipment to be furnished at the LCS master site shown on the plans shall include, but not be limited to, the following: . LCS master controller with monitor and printer
. Portable notebook computer 3.0 Functional Requirements
Lane Control Signals (LCS) shall be furnished and installed on the overhead sign structure as shown on the plans. Each LCS head shall be independently controlled to indicate the condition of each lane.
All symbols shall be double stroked with two (2) rows of fiber optic bundles
Pixels shall be spaced 12 to 18 millimeters.
Light output per pixel shall be 20 candles at a distance of one foot.
2-18 6287 The signal head shall display the following indications:
. Steady Red X
. Steady Green Arrow . Steady Yellow X . Steady Yellow Arrow
. Steady Yellow Arrow - Slanted down at 45 degrees right . Steady Yellow Arrow - Slanted down at 45 degrees left
The lane control signals shall be driven by an LCS Controller located in an equipment Cabinet in the field.
Lane control signal controller shall control eight lane control signals per direction of travel.
4.0 Lane Control Signal Head 4.1 Signal Indications
The lane control signal (LCS) head shall be capable of displaying all six (6) messages described above. It shall be a fiber optics type unit with dot matrix indications on a flat, black, non-reflective, rectangular face.
Signal indications shall be formed by a group of dots to which light is transmitted from a central light source through glass fiber
bundles. Individual convergence cone or lens, minimum 4 millimeters in diameter, shall be fitted over the end of each fiber optic bundle for increased intensity in the forward direction. The color of any indication shall be obtained by use of color filters. Color filters shall be changeable in the field without requiring removal of the signal from the case. Each indication shall be illuminated by two Quartz Halogen lamps (50 watts nominal). Lamps shall have an average life of not less than 8,000 hours at the operating voltage of 10 V maximum.
4.2 Dimming Provision
Light source for each signal indication shall be designed for operation with both lamps operating at 10V in "Day Mode" and the voltage reduced to approximately 6V for "Night Mode" operation. Ambient light shall be monitored by a photo-cell mounted in close proximity to the LCS signal head and oriented north or method approved by the Engineer.
Burnout protection shall be provided during the dimming mode so as not to turn off the bulb when the other one is burnt-out.
The average service life of the lamp shall be 8000 hours as rated by the manufacturer.
Out of service lamps shall automatically be reported to the LCS Master and printer or to the notebook maintenance computer provided with the system. It shall be possible to determine the status of any lamp, in any LCS, from the LCS Master.
4.3 Fiber Optic System
3-18 6287 4.4 Fiber Randomization
Fiber optic bundles in each signal shall be arranged with alternate bundles leading to different lamps, so that every other bundle will remain lit at full intensity in the event of a lamp failure.
4.5 Extra Fiber Bundles
A minimum of ten (10) extra bundles of fibers properly protected for insertion in lenses shall be provided for each LCS head.
4.6 Fiber Protection
Fiber optics bundles shall be protected by a jacketed sheathing to avoid the possibility of damage when installing or relamping. 4.7 VISIBILITY
The LCS shall be clearly visible and legible for 1/4 mile distance within a 12 degree cone centered about the optical axis under normal atmospheric conditions and under any lighting conditions. Visors or hoods shall not be necessary for legibility.
4.8 Border
The LCS shall be surrounded by a flat black border to enhance the readability of the message in backlighted condition. The size of the border shall be approved by the Engineer. Border shall not be
painted. 4.9 Finish
The LCS exterior finish shall be black anodized aluminum or equal approved by the Engineer. Painting of any element shall not be allowed.
5.0 LCS Controller Cabinet 5.1 General Composition
The controller cabinet shall contain the following subassemblies: . Outer key lockable protective enclosures.
. Inner key lockable nonvented enclosure. . Microprocessor based controller.
. Communication interface with DSU. . Over-voltage protection device. . Power supply and power distribution. . Lamp driver system.
. Photoelectric controller devices. . Internal cabinet lighting.
. Phone Jack with headset.
The controller cabinet and its sub-assemblies shall be designed for continuous operation over an outside temperature range of -13º F to +149º F without requiring fans.
4-18 6287 5.1.1 Protective Enclosures
The controller cabinets shall be of the double enclosure type specified below:
The cabinets shall be constructed using unpainted anodized aluminum with a minimum thickness of 0.125 inch. No wood, wood fiber products, or other flammable material shall be used in the cabinet. All welds shall be neat and of uniform consistency.
The cabinets shall be completely weatherproofed to prevent the entry of water. All unwelded seams shall be sealed with a clear or aluminum colored weather-seal compound.
The external enclosure shall be fitted with ventilation louvers ensuring natural cooling.
The inside enclosure shall comply with the NEMA type 3S standard (IEC 55).
Both internal and external enclosures shall be fitted with key lockable access doors.
The transformer supplying power to the lamps shall be housed on the inside of the external cabinet enclosure.
The internal and external cabinets shall be base mounted on a concrete foundation, as detailed on the plans.
5.1.2 LCS Controller
The LCS controller shall be software-oriented microprocessor type and shall be provided with resident software stored in
non-volatile memory.
The LCS controller shall consist of the following: . A 19 inch rack with front panel
. Status indicators containing printed circuit boards . Power supply module
. Central processor module . Lamp control module(s)
The rack shall include an inter-PCB connection bus, carrying signals and power, onto which all PCB's are connected. It may also be designed as a single board.
Connections from the controller to the interfaces may be accomplished via standard type "D" connectors mounted on the front panel. Alternatively, ribbon cable and compatible connectors may be used.
5.1.3 LCS Controller Communication Interface
The LCS controller shall include RS-232C/V24 serial interfaces for communication with both the LCS Master Controller and the notebook computer.
One EIA RS-232D serial interface shall drive asynchronous modems for full duplex communication with the VMS Master Controller over dial up lines or on a multi drop network. Switching between dial up and multi drop operation shall not require software
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A cable for communications between the notebook computer and the second EIA RS-232D serial interface shall be permanently
installed inside the sign controller cabinet. The communications cable shall be easily accessible when the cabinet door is open. For dial-up operation, the Contractor shall acquire and bear the charges of installing and connecting the dial-up telephone line. The Contractor shall provide all needed modems or data service units. The Contractor will pay all phone bills incurred until system acceptance.
To facilitate system testing, start-up and on-site maintenance, it shall be possible to connect a notebook microcomputer to the LCS controller serial interface.
The serial interface port shall be easily accessible to the notebook microcomputer when the cabinet door is open.
6.0 Photoelectric Sensor Devices
The cabinet shall be fitted with two (2) adjustable threshold electronic devices connected to one (1) of the photo-electric sensors located on the LCS. These devices shall permit automatic light intensity adjustment, dependent on conditions at each LCS location.
7.0 Lighting
The internal controller cabinet shall be illuminated when the outer cabinet door is opened and extinguished when closed.
8.0 Phone Jack
A jack for voice communication equipment shall be provided at a convenient location on the inside wall of the cabinet.
9.0 LCS Controller Functions
The LCS shall be controlled from the LCS Master Controller, which shall send to the LCS controller a signal to be displayed, together with the associated parameters.
The LCS controller and its software shall perform the following functions:
A. Signal display: 1. Steady Red X
2. Steady Green Arrow 3. Steady Yellow X 4. Steady Yellow Arrow
5. Steady Yellow Arrow - Slanted down at 45 degrees right 6. Steady Yellow Arrow - Slanted down at 45 degrees left
B. Error and failure messages, including: 1. Data transmission error
2. Receipt of invalid data 3. Loss of communications 4. LCS sign controller failure
6-18 6287 C. Message and status monitoring:
The LCS controller shall transmit a return message to the LCS Master Controller whenever it receives a valid transmission. The return message shall contain the following:
1. Address of the LCS controller 2. Indication being displayed 3. Origin of transmission
4. Central/Local switch position
D. The LCS will blank any signal displayed in the event of power or LCS controller failure.
E. The LCS controller shall be capable of directing a test sequence which will exercise each element in the LCS from the notebook computer.
F. The system shall be capable of operating without a battery backup system.
G. The LCS controller shall be designed for fail-safe prevention of improper display in the case of the system malfunction.
H. Failure of any LCS not directly associated with another LCS or communication line shall not affect operation of any other non-associated LCS in the system.
The notebook computer shall provide on-site simulation of all commands.
The Contractor shall be permitted to incorporate both the LCS and VMS controller into the same cabinet if constructed by the manufacturers and approved by the Engineer.
A battery shall be used to record system time when no power is available.
9.1 Modes Of Operation
The mode of operation determines which level of control governs the LCS selection. The two modes of operation are:
Central - The central control computer or the LCS master controller determines the appropriate display.
Local - The notebook computer software via the LCS controller determines the appropriate display.
Normally, the LCS controller's mode of operation will be central, allowing the central control computer or the LCS master to select the LCS head indications. When the notebook computer is being used to select the LCS head indications, the mode of operation shall be local and the notebook computer's commands honored. 9.2 Description Of The Various Commands
As a minimum, the following commands shall be available: Display command from the LCS Master Controller.
Display command from the notebook computer (Local mode). LCS Status request:
7-18 6287 This command shall provide a report concerning the LCS: . LCS indication.
. Operating mode.
. Mode of the displayed message if any (local/central). . Status of the photoelectric sensors.
. Light output level (day/night). . LCS number, location, or ID. Lamp status request:
This command shall provide an instantaneous indication of the status of all the primary and backup lamps (operational/nonoperational). Day/Night switching command.
"Abort" command.
Sign off command (set to blank-out). Echo command:
This command shall be used to receive from the controller(s) or the master controller the indications currently displayed.
Simulation Mode:
All LCS lamps off and controller continues to run in simulation mode.
10.0 LCS Master Controller 10.1 Hardware Requirements
The LCS Master Controller hardware shall meet the following specifications:
- Intel 80386 running at 20 MHZ minimum - 1 MB of dynamic RAM, minimum
- One floppy disk drive of 1.2 MB capacity in 5 1/4 inch format, and one floppy disk drive of 1.44 mb capacity in 3 1/2 inch format. - One 150 MB hard disk drive with an average track to track access
time less than 30 ms.
- Six (6) EIA RS-232C asynchronous communication ports to allow for external communication with the satellite computer, LCS and
portable computer.
- One parallel port for communication to a printer. - One VGA compatible display interface.
- One 14 inch color VGA compatible display monitor capable of displaying 25 lines of 80 characters minimum.
- Disk operating system shall be MS DOS Version 3.3 or later. 10.1.1 Printer
A printer with the following features shall be provided: - Table mounted unit; 18 inches square, maximum;
- Character set: 64 standard ASCII; - Interface: Parallel;
- Characters per line: 80 minimum;
- Horizontal spacing: Ten (10) characters per inch; - Vertical spacing: Six (6) lines per inch;
- Printing type: Dot matrix;
- Printing speed: 150 characters per second minimum;
- Controller: Built in independent controller with full buffer memory;
8-18 6287 - Paper: Untreated fanfold paper.
Two (2) cartons of paper and twelve (12) black ribbons shall be supplied at the time of final system acceptance.
The printer shall be housed in a sound deadening cabinet. The design of the cabinet shall conform in quality of construction and appearance with the existing computer equipment cabinets. 10.1.2 PORTABLE NOTEBOOK COMPUTER
A battery powered portable computer in conformance with Special Specification, "Portable Notebook Microcomputer", shall be
provided for local control in the event of LCS Master Controller communication link failure and for remote operation. The
portable computer shall provide the following capabilities as a minimum:
A. LCS startup
B. Display any combination of lane control signal head indications.
C. Create an activity log, for later transfer to the LCS Master Controller, in order to maintain a complete historical record if the Master Controller is unable to do so.
D. Dial-in to LCS Master Controller and provide remote access to all Master functions.
E. All maintenance diagnostics and provisioning. 10.2 Software Requirements
The LCS Master Controller software shall be written in the following high-level structured language: C.
Assembly language, if required for speed, shall be limited to drivers and/or I/O management.
The LCS Master Controller software shall be designed to be user friendly using windows and colors.
The software shall control all locations as shown on the plans. Communication with the LCS shall be asynchronous through the RS-232C ports.
Parameters for communication shall be fully programmable.
The LCS Master Controller software shall poll each connected LCS for status retrieval once every 60 seconds on dedicated lines or user specified on dial-up lines.
The LCS Master Controller software shall include a function to view the status and current display of all connected LCS as retrieved at the last polling.
Any malfunction of a connected LCS shall be recorded in the log file and printout made.
The LCS Master Controller software system shall be easily programmable to support any type of dot matrix printer.
9-18 6287 The LCS Master Controller shall permit access by a minimum of 16 users. Each user shall be identified by a name, password and access rights.
Access rights shall be fully programmable by levels for each user and shall entitle the user to access or deny each individual function. To gain access to the system, each user shall enter his/her name and his/her password which shall be recorded in the log file.
Each event shall be recorded in a log file. In addition, if a printer is connected, the event shall be printed. The record shall include: The event number, the date/time, sign name/user name, and event description. Status logs and display libraries shall be stored to a MS-DOS formatted disk in ASCII format.
The LCS Master Controller shall automatically start a new log file at the beginning of each month.
The LCS Master Controller software shall have the capability of displaying or printing any log file on the system sorted by users logging, LCS event, or period of time.
Software shall perform a lamp test as follows:
. Primary mode: All "Primary" lamps are operational.
. Backup mode: If a primary lamp is found not to be operational, the controller shall automatically turn on the associated backup lamp.
. Abort: In the event that a lamp does not turn off on command, the controller shall automatically cut off the lamp power supply. This "Abort" function shall also be capable of being controlled at the Central Control Center in case of emergency.
11.0 Communications
The LCS controller shall be addressable by the LCS Master Controller via the communications subsystem.
The LCS Master Controller RS-232C or RS-232D communication ports shall be linked with other computers as shown on the plans.
Each LCS controller shall be provided with error detection and reporting features, which shall be utilized to guard against incomplete or
inaccurate information transmission. These shall include:
A. Redundancy checking of all data received from the LCS Master Controller, with positive acknowledgement for all transmissions. B. Status monitoring for communication line malfunction or break. C. Content validation of all received transmissions for logic or date
errors.
The communication line circuits may be point-to-point or multi-point and shall be half-duplex asynchronous data transmission at a minimum of 2400 bps.
Each LCS controller shall be assigned an address unique within the
10-18 6287 LCS Master Controller and the LCS controller shall be encoded in the ASCII representation using one start bit, seven data bits, one parity bit, and one stop bit. Parity shall be even.
All data transmissions shall be of the form: : SOH : ADR : Type : Content : ETX : LRC : Where
SOH = ASCII start of header character
ADR = selected controller address character Type = identifier for type of transmission
Content = information as appropriate to type of transmission (possibly null)
ETX = ASCII end-of-text character
LRC = Longitudinal redundancy check character, consisting of the modulo- 2 sum of the seven data bits in all preceding characters in the
transmission (including SOH), with proper even parity.
The LCS controller shall acknowledge all transmissions from the LCS
master controller. A negative acknowledgement shall be sent if a parity, LRC, or data content error is detected; a positive acknowledgement shall be sent if no error is detected.
Any variations to the above requirements shall be submitted in writing for written approval by the Engineer.
Telephone voice communications type line circuit with two (2) telephone jacks and two (2) telephones shall be provided for voice communication between the LCS controller and LCS. One jack/telephone with headset shall be installed in the LCS controller cabinet and one jack/telephone with headset shall be installed at the LCS. Jack at LCS shall be located as directed by the Engineer.
Each telephone with headset shall be provided with a 50 foot cord. 12.0 Power Requirements
The LCS Equipment shall meet all of its specified requirements when the input power is 115 (+ or -) 20 volts AC, 60 (+ or -) 3 Hz single phase. The maximum power including the LCS heads required shall not exceed 200 watts per signal head.
The equipment operation shall not be affected by transient voltages, surges and sags normally experienced on commercial power lines. It shall be the Contractor's responsibility to check the local power service to determine if special design is needed for the equipment. The extra costs, if required, shall be included in the bid price of this Item. 12.1 Primary Input Power Interruption
The equipment shall meet all the requirements in Section 2.1.4 "Power Interruption" of the National Electrical Manufacturers Association (NEMA) Standard TS1-1989 or latest revision.
11-18 6287 12.2 POWER SERVICE TRANSIENTS
The equipment shall meet the requirements of Section 2.1.6
"Transients, Power Service" of the NEMA Standard TS1-1989 or latest revision.
12.3 Wiring
All wiring shall meet the requirements of the National Electric code. All wires shall be cut to proper length before assembly. No wire shall be doubled back to take up slack. Wires shall be neatly laced into cables with nylon lacing or plastic straps. Cables shall be secured with clamps. Cable slacks shall be provided to facilitate removal and replacement of assemblies, panels, and modules.
The Contractor shall supply and install under this Item wiring to interconnect the LCS load switches in the field cabinet and the LCS heads. Signal cables shown on the plans shall be used for each of the inbound and outbound signal heads. If additional wires are required, the Contractor shall install them at no additional cost. The Contractor shall also provide wiring and interface equipment for interconnecting the controller and the multiplexors by means of NEMA -type inputs and outputs.
12.4 Grounding
The Contractor shall insure that the LCS support bracket and equipment Cabinet are grounded as indicated on the plans. 12.5 Transient Suppression
All DC relays, solenoids and holding coils shall have diodes across the coils for transient suppression. All AC contractors shall have snubbers.
12.6 Power Service Protection
The equipment shall contain readily accessible, manually resettable or replaceable circuit protection devices (such as circuit breakers or fuses) for equipment and power source protection.
Circuit breakers or fuses shall be provided and sized such that no wire, component, connector, pc board or assembly shall be subjected to sustained current in excess of their respective design limits upon the failure of any single circuit element or wiring.
Micro-failures of less than one cycle shall have no effect on the sign display.
Power failure of more than one cycle shall result in the following: . Extinguishing of the sign lamps.
. Saving of all the parameters including the current display in CMOS protected RAM.
. Shutdown of the controller.
. Updating of the current date, time, and remaining display time using an internal battery.
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At power recovery, the controller shall resume the original display, duration time permitting, and report the power failure and power recovery date and time to the LCS Master.
12.7 Fail Safe
The equipment shall be designed such that the failure of the
equipment shall not cause the failure of any other unit of equipment. 13.0 Mechanical Requirements
13.1 LCS Head
The lane control signal face shall have a width and height of 18 inches. The case shall be sheet aluminum with a minimum thickness of 0.100 inch, primed with an epoxy type of paint. The interior shall be painted with a dull black enamel to eliminate internal reflection. The exterior of each LCS shall be given two coats of high gloss black enamel. All brackets, anchor bolts, and conduit runs attached to the surface of the bridge or sign structure shall be painted the same color as the bridge beam or truss. (All painting shall be subsidiary to related items.)
The front panel of the signal and lens mounts shall be colored black to minimize legibility when the signal is not illuminated. No color at all shall appear in the lens when not illuminated, regardless of sunlight intensity.
A barrier type terminal strip shall be provided in the signal for the connection of field wires. The function of each terminal shall be clearly marked.
All fiber optics and lamps shall be mounted on a hinged door. All components shall be readily accessible when the door is opened. The only tool required for maintenance or replacement of components shall be a standard screwdriver.
The signal housing case, together with door, and mounting
attachments, shall comprise a dust and moisture proof housing for the optical unit, connecting wiring, and terminal block. The signal housing and door, fittings, and accessories shall be of
non-corrosive, rust resistant materials capable of withstanding constant exposure to sunlight and corrosive atmospheres, and shall provide adequate strength for the purpose for which it is utilized. The lamp socket shall be designed so as to preclude the formation of corrosion on either the lamp or socket contacts. The lamps shall not work loose from the socket when vibrated. The LCS head shall be able to withstand 100 mph wind loading.
13.2 Modular Design
The equipment shall be modular in design such that major portions may be readily replaced in the field. Modules of unlike function shall be mechanically keyed to prevent insertion into the wrong socket or connector.
All modules and assemblies shall be clearly identified with name, model number, serial number and any other pertinent information required to facilitate equipment maintenance.
13-18 6287 13.3 Connectors and Harness
All external connections shall be made by means of connectors. The connectors shall be keyed to preclude improper hookups. All wires to and from the connectors shall be color coded and/or appropriately marked. All connectors shall be coated with a minimum of 50 microns of gold.
13.4 Environmental Design Requirements
The LCS equipment shall meet all of the specified requirements during and after subjection to any combination of the following
requirements.
. Ambient temperature range of 0 F (-17 C) to +158 F (70 C) . Temperature shock not to exceed 30 F (17 C) per hour,
during which the relative humidity shall not exceed 95 percent.
. Relative humidity range not to exceed 95 percent over the temperature range of 40 F (4 C) to 110 F (43 C).
. Moisture condensation on all surfaces caused by temperature changes.
13.4.1 Primary Power Variation
The equipment shall meet the specified performance requirements when the input voltage is plus or minus 20 volts from the nominal value of 115 volts. The equipment shall be operated at the extreme limits for at least 15 minutes during which the Operational Test of the FDT shall be successfully performed.
13.4.2 Relative Humidity
The equipment shall meet the specified performance requirements when subjected to a temperature and relative humidity of 158 F (70 C) and 22 percent respectively. The equipment shall be maintained at the above condition for 48 hours. At the conclusion of the 48-hour soak, the equipment shall meet the requirements of the Operational Test of the FDT within 30 minutes of beginning the test.
13.4.3 High-Frequency
The equipment shall meet the requirements of the Operational Test of the FDT when subjected to the high-frequency and voltage transient interference specified in Article 12.0 of this Specification. 13.4.4 Vibration
The equipment shall show no degradation of mechanical structure, soldered components, plug in components or satisfactory operation in accordance with the manufacturer's equipment specifications after being subjected to the following vibration test. The device shall be secured to the shaker head of suitable electro mechanical shaker in the vertical, lateral and longitudinal planes. The object of the test is to vibrate the device in each of the three mutually
perpendicular axes, in accordance with the following levels and/or parameters:
Amplitude - 0.06 inch Double Amplitude (peak to peak) Linear Acceleration (g's) - 0.5 maximum
14-18 6287 Linear Velocity - approximately 7.4 inches per second Frequency - 40 Hz
Duration - 5 minute dwell in each axis 14.0 Construction Methods
14.1 General
The equipment design and construction shall utilize the latest available techniques with a minimum number of different parts, subassemblies, circuits, cards and modules to maximize
standardization and commonality.
The equipment shall be designed for ease of maintenance. All component parts shall be readily accessible for inspection and maintenance. The only tools and test instruments required for
maintenance by maintenance personnel shall be simple hand held tools, basic meters and oscilloscopes. Test points shall be provided for checking essential voltages and wave forms.
14.2 Electronic Components
All electronic components shall comply with the Special Specification for "Electronic Components" included in the project.
14.3 Mechanical Components
All external screws, nuts and locking washers shall be stainless steel. No self-tapping screws shall be used unless specifically approved by the Engineer. All parts shall be made of corrosion resistant material, such as plastic, stainless steel, aluminum or brass. All materials used in construction shall be protected from fungus growth and moisture deterioration.
Dissimilar metals shall be separated by an inert dielectric material. 14.4 Documentation Requirements
Five (5) complete sets of operation and maintenance manuals shall be provided. The manuals shall, as a minimum, include the following:
. Complete and accurate schematic diagrams. . Complete installation procedures.
. Complete performance specifications (functional,
electrical, mechanical and environmental) on the unit. . Complete parts list including names of vendors for parts
not identified by universal part numbers such as JEDEC, RETMA or EIA.
. Pictorial of components layout on circuit board. . Complete maintenance and trouble-shooting procedures. . Complete stage-by-stage explanation of circuit theory and
15-18 6287 15.0 Testing Requirements
15.1 General
It is the practice of the Texas Department of Transportation to require performance testing of all materials and equipment not
previously tested and approved. If technical data is not considered adequate for approval, samples may be requested for test by the Engineer. Contract period will not be extended for time lost or delays caused by testing prior to final Texas Department of Transportation approval of any materials and/or equipment. Unless otherwise specified, the Contractor is responsible for satisfying all inspection requirements prior to submission for the Engineer's inspection and acceptance. The Engineer reserves the right to witness all demonstration and stand alone tests.
The results of each test shall be compared with the requirements specified herein. Failure to conform to the requirements of any test shall be counted as a defect, and the equipment shall be subject to rejection by the Engineer. Rejected equipment may be offered again for retest provided all noncompliances have been corrected and retested by the Contractor and evidence thereof submitted to the Engineer.
The tests on all of one type of equipment must be completed within five (5) days and any delays in performing all these tests will
result in the Contractor paying the additional costs of providing the Engineer's representatives for the additional testing.
Final inspection and acceptance of equipment shall be made after installation at the destination specified, unless otherwise specified herein.
15.2 Design Approval Tests
Design Approval Tests shall be conducted by the Contractor on one or more sample equipments of each type, as approved by the Engineer, to determine if the design of the equipment meets the requirements of this specification. All tests shall be conducted in accordance with the approved test procedure as described in these specifications. The Engineer shall be notified a minimum of 25 working days in advance of the time when these tests are to be conducted. 15.2.1 Temperature and Condensation
The equipment operational test for the Factory Demonstration Tests (FDT) shall be successfully performed under the following conditions in the order specified below:
A. The equipment shall be stabilized at 0 F. After
stabilization at this temperature, the equipment shall be operated without degradation for two (2) hours.
B. Moisture shall be caused to condense on the equipment by allowing it to warm up to room temperature in an atmosphere having relative humidity of at least 40 percent and the equipment shall be satisfactorily operated for two (2) hours while wet.
16-18 6287 C. The equipment shall be stabilized at 140 F (60 C). After
stabilization, the equipment shall be satisfactorily operated for two (2) hours without degradation or failure.
15.2.2 Primary Power Variation
The equipment shall meet the specified performance requirements when the input voltage is plus or minus 20 volts from the nominal value of 115 volts. The equipment shall be operated at the
extreme limits for at least 15 minutes during which the operational test of the FDT shall be successfully performed. 15.2.3 Relative Humidity
The equipment shall meet its performance requirements when
subjected to a temperature and relative humidity of 140º F (60º C) and 40 percent respectively. The equipment shall be maintained at the above condition for 48 hours. At the conclusion of the 48-hour soak, the equipment shall meet the requirements of the operational test of the FDT within 30 minutes.
15.2.4 High-Frequency
The equipment shall meet the requirements of the operational test of the FDT when subjected to the high-frequency and voltage
transient interference specified in section 2.1.6 "Transient, Power Service" of the NEMA standard TS1-1989 or latest revision. 15.2.5 Vibration
The equipment shall show no degradation of mechanical structure, soldered components, plug-in components, or satisfactory
operation in accordance with the manufacturer's equipment specifications after being subjected to the vibration tests as described in section 2.2.5 "Vibration Test" of the NEMA standard TS1-1989 or latest revision.
15.2.6 Consequences Of Design Approval Test Failure
Design Approval Tests shall be performed on units randomly
selected from the prototype design manufacturing run, or if only one design prototype is manufactured, they shall be performed on that unit. If the unit fails the Design Approval Test, the design fault shall be corrected and the entire Design Approval Test shall be repeated. All deliverable units shall be modified, without additional costs to the State to include design changes required to pass the Design Approval Tests.
15.3 Factory Demonstration Tests
The Contractor shall be responsible for conducting Factory
Demonstration Tests on all units at the manufacturer's facility. These tests shall be performed on each unit supplied. The State shall be notified a minimum of 25 working days before the start of the tests. All tests shall be conducted in accordance with the approved test procedure of Article 15.0.
15.4 Stand-Alone Tests
The Contractor shall conduct an approved Stand-Alone Test of the equipment installation at the field site. The test shall, as a minimum, exercise all stand-alone functional operations of the field equipment with all of the equipment installed per the plans for as directed by the Engineer. Approved data forms shall be completed and turned over to the Engineer as the basis for review and rejection or acceptance. At least five (5) working days' notice shall be given
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prior to all tests to permit the Engineer or his representative to observe each test.
If a unit fails to pass its Stand-Alone Test, the unit shall be corrected or another unit substituted in its place and the test successfully repeated.
If a unit has been modified as a result of a Stand-Alone Test failure, a report shall be prepared and delivered to the Engineer prior to retesting of the unit. The report shall describe the nature of the failure and the corrective action taken. If a failure pattern, as defined by the Engineer, develops, the
Engineer may direct that design and construction modifications be made to all units without additional cost or extension of the contract period.
15.5 Test Procedures
The Contractor shall provide all design approval, factory
demonstration and Stand-Alone Test procedures and data forms for the Engineer's approval. The test procedures shall include the sequence of conducting the tests. The test procedures shall have the
Engineer's approval prior to submission of equipment for tests. The Contractor shall furnish data forms containing all of the data taken, as well as quantitative results for all tests. The data forms shall be signed by an authorized representative (company official) of the equipment manufacturer. At least one (1) copy of the data forms shall be sent to the Engineer.
16.0 Experience Requirements
Personnel involved in the installation and testing of the Lane Control Signal System shall meet the following requirements:
Three (3) years experience in the manufacturing, installation and testing of lane control systems.
Two (2) installed systems where lane control signal systems are installed and the system has been in continuously satisfactory
operation for at least two (2) years. The Contractor shall submit as proof, photographs or other supporting documents, and the names, addresses and telephone numbers of the operating personnel who can be contacted regarding the system.
One (1) lane control signal system (which may be one of the two in the preceding paragraph) which the Contractor can arrange for demonstration to the Engineer.
17.0 Measurement
This Item will be measured as each lane control system unit furnished, installed, made fully operational, and tested in accordance with these Special Specifications or as directed by the Engineer.
18-18 6287 18.0 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 each "Lane Control System". This price shall include all equipment with all cables and connectors, all documentation and testing, and shall also include the cost of furnishing all labor, materials, software training, and equipment necessary to complete the work.
