637Illuminated Sign System

637.1General Description

This Specification describes the complete sign illumination system. Complete a secure installation according to the recommendations of the American Association of State Highway and Transportation Officials (AASHTO), the Illuminating Engineering Society, the standards of the National Electrical Code, and the applicable local ordinances. For temporary overhead guide sign structures, except wire-supported signs, light the signs as soon as they are erected. Keep them lit during darkness until the temporary sign is no longer required. The cost of temporary signs and electrical energy are included in the price bid for Section 150 when shown in the Proposal as a Pay Item. Otherwise, payment is as shown in Section 150. Ensure that illumination complies with Subsection 637.3.05.H, Externally Illuminated Signs. 637.1.01 Definitions The terms “cable” and “wire” are used synonymously in this specification. 637.1.02 Related References

NEC Section 370-18(c) in conjunction with NEC Section 250-42 ANSI C 80.1 EEI/NEMA publications 637.1.03 Submittals Before purchasing materials or equipment, submit to the Engineer for approval a complete list of the products proposed for use. On the list, show the manufacturer’s name and catalog number of each item to ensure compliance with the requirements of these Specifications. Include in this submittal the calculations or computer printouts for sign illumination and uniformity values. Submit voltage drop calculations for each circuit to verify that proper voltage is furnished to the sign luminaires. Provide alternate equipment or a sample board to be activated for in-service evaluation, when the Engineer requires.

637.2Materials

Have electrical material approved by the Underwriter’s Laboratory or other acceptable testing agency. Provide the fittings, devices, materials, and Work to install the complete functional system. Use methods that comply with local ordinances, rules, and regulations. See Section 636 and Section 638. 1107 1107 1107 1107 1107

Use cable and wire of sufficient size to safely carry the capacity intended and to prevent the voltage from dropping more than 5 percent from the service point to the farthest light.

If the cable size is not specified on the plans, determine the safe size after studying the plans and specifications. Wire and cable sizes as indicated below are for copper. Do not use aluminum wire unless otherwise noted on the plans. Acceptable copper cable and wire sizes (commercial) are as follows: No. 2/0 AWG 19 strand No. 1/0 AWG 19 strand No. 2 AWG 7 strand No. 4 AWG 7 strand No. 6 AWG 7 strand Use smaller wire sizes (No. 10 AWG minimum) on the sign structure only if it is adequately protected with fuses inside the handhole of the structural support. Ensure that the fuse rating is the same as the ampere rating of the wire, such as 30 A for No. 10 AWG wire. Do not reduce the wire size to a size that carries more than 80 percent of its rated amperage. If the number of luminaires on the sign structure is too many for No. 10 AWG wire, run two separate circuits from the base of the structural support to the luminaires. Fuse each of these separate circuits at the handhole of the sign structure.

The neutral/ground wire shall have white insulation or mark it with strips of white tape at each access point. On the cable installed underground, use 600 V, type RHH/RHW/USE, 75 °C insulation. On the cable installed on the sign structure and connected to the luminaires, use 600 V, type RHH, XHHW, or THHN, 90 °C insulation. Install a waterproof boot, furnished by the fuse holder manufacturer, over each end of the fuse holder.

When noted on the Plans, furnish and install a lighting contactor and a photoelectric control, complete with receptacle and accessories. Mount the photoelectric control near the top of the service pole so that it is exposed to the north sky. The control shall provide ON operation as shown in Subsection 637.2.I, Photoelectric Controls.

Use ground rods 5/8 in. (16 mm) in diameter (± 1/16 in. [± 1.6 mm]) and 8 ft. (2.4 m) long unless otherwise specified on the plans. Use ground rods that are galvanized steel. Ensure that the galvanization coating is at least 2 ounces/ft.² (610 g/m²) according to the requirements of ASTM A 153/A 153 M. 1108 1108 1108 1108 1108

Use conduit approved by the Underwriters’ Laboratories, Inc.

Use rigid steel conduit, including elbows and couplings, that conforms to American National Standards Institute Specification C 80.1.

both surfaces).

thickness of the zinc coating by using a magnetic or electromagnetic thickness gage.

Unless otherwise noted, use Type II, schedule 40 (heavy wall) polyvinyl chloride (un-plasticized) nonmetallic conduit that conforms to Subsection 923.2.02.

Ensure that the flexible conduit consists of a galvanized steel core and a polyvinyl chloride cover. Ensure that it contains a continuous copper ground and is liquid tight.

Use quick-make and quick-break circuit breakers with a thermal magnetic molded case. Use circuit breakers with the following characteristics: • Over-the-center, toggle operating type with the handle positioned between ON and OFF to indicate automatic tripping • Single handle and common trip multi-pole breakers • Multi-pole breakers with a voltage rating 240 V or more from line to ground • Bolt-on type with industrial rating and a minimum interrupting capacity of 10,000 RMS symmetrical amperes • Lugs large enough to accommodate the cable used • Lockable, weatherproof enclosure

Use fuses with the appropriate ampere rating and voltage rating for the operating voltage. Use in-the-line and waterproof fuse holders.

Use metal oxide varistor lightning arresters rated 650 V with the number of required poles unless otherwise specified. Provide a pole for each ungrounded leg of the service voltage.

Ensure that the photoelectric controls have a factory setting for turn-on at 1.5 foot-candles (16.1 lx) ambient light level. Provide controls with a differential between turn-on and turn-off levels to prevent cycling at critical levels. Use controls that meet these requirements: • Operates on a supply voltage of 105 V to 130 V, 50/60 Hz, AC with an in-rush rating of 120 A at 120 V and a lamp load rating of 1,000 W for incandescent and 1,800 V amperes for mercury vapor and fluorescent • Contains built-in surge and lightning protection • Has a rated life at full load of at least 5,000 on-off operations • Withstands an ambient temperature range of –65 °F to 158 °F (-54 °C to 70 °C) and is moisture proof 1109 1109 1109 1109 1109

Provide single-pole, single-throw (SPST), normally closed (NC) relay contacts. Ensure that the dielectric strength is at least 5,000 V between a current carrying part and the metal mounting surface. The housing shall be approximately 2.25 in. (57 mm) high with a base diameter of no more than 3.25 in. (83 mm). The chassis shall be molded phenolic with three locking type blades and a neoprene gasket that conforms to EEI/NEMA publications. Mount the photoelectric control on an approved receptacle.

Use lighting contactors specifically designed for use on tungsten and ballast (fluorescent and high-intensity discharge) lamp loads without derating. Use a contactor with these characteristics: • The number of poles required to open each ungrounded conductor • Lugs large enough to accommodate the cable used • Lockable, weatherproof enclosure

Use 400 W mercury luminaries with H 33-GL-400/DX lamps and a box-type configuration, unless otherwise specified. Mount on horizontal luminaire support channels. Ensure that the luminaire contains: • Integral regulator ballast and a prewired terminal board to connect the supply voltage • Conduit openings on each side for through wiring • Rain-tight housing made of aluminum with baked-on enamel finish • Noncorrosive hardware • Seals or gaskets at critical points to form a weathertight, breathing seal. • Porcelain enclosed mogul socket, with spring loaded center contact and lamp grips, attached to ensure proper lamp positioning • Lamp support on the end opposite from the socket to prevent the lamp from breaking from vibration • Highly polished anodic-surfaced aluminum reflector and a removable, stippled, heat and shock tempered glass refractor • Integral hinge system for the door that must be in a specified position to remove the door • Detachable locking brace to hold the door open during maintenance • Heavy-duty spring-loaded latch on the front of the luminaire that produces a watertight seal between the door and housing when closed Ensure that the luminaire support framework is designed to withstand wind and 1 in. (25 mm) of ice accumulated on the entire framework as shown on the plans. Ensure that lamps are 400 W deluxe white mercury vapor and have 24,000 hours rated life at 10 hours per start.

Use regulator-type ballast that provides rated lamp watts to the lamp through a range in primary voltage of plus or minus 10 percent. Use high-power ballasts with a power factor of at least 0.90 and enough open circuit voltage to start lamps at a temperature as low as -20 °F (-29 °C). Enclose ballasts for external or cabinet mounting in an epoxy-encapsulated covering. 637.2.01 Delivery, Storage, and Handling General Provisions 101 through 150. 1110 1110 1110 1110 1110

637.3Construction Requirements

637.3.01 Personnel

The person performing this work must be on the Department list of approved electrical contractors or electrical subcontractors.

A qualified electrician has a Class II license issued by the Georgia State Construction Industry Licensing Board, has completed an approved four-year apprenticeship training program, and is classified as a Journeyman Electrician. The qualified electrician shall show evidence of this classification to the Department Engineer in charge of the Construction. For further definition, see Subsection 755.1.01. Always have a qualified electrician on the job site when pulling electrical wiring or making electrical connections. 637.3.02 Equipment General Provisions 101 through 150. 637.3.03 Preparation General Provisions 101 through 150. 637.3.04 Fabrication

Construct pull and junction boxes installed in the ground according to the design and dimensions, and at the locations shown on the plans. Use a type approved by the Engineer.

concrete boxes. Manufactured units are permitted when the Engineer determines that they are equal in design, quality, and

structural strength.

370-18(c) in conjunction with NEC Section 250-42.

steel, stainless steel, or cast aluminum and conform to NEC requirements.

plugs of plastic, bituminous fiber, or other approved material to prevent foreign matter from entering.

637.3.05 Construction

Pay the fees and permits required by power companies or governmental agencies.

Notify the power company at least 30 days before the power source connection is needed. 11111111111111111111

Use a power supply of 120/240 V, 3-wire, single phase, with a supply point where the Department and the serving

electric utility determine, unless otherwise noted. The supply point is usually near the right-of-way line near the

sign location.

The sign lighting pay Unit includes setting a wooden service pole that meets the requirements of Section 863 near

the edge of the right-of-way to receive the service from the utility company, unless otherwise indicated. Use at

least a 30 ft. (9 m) Class 5 pole or as shown on the plans.

containing circuit breakers of the appropriate voltage and ampere rating.

service pole and a lighting contactor in a weatherproof housing on the service pole.

ungrounded conductor.

Ensure that the circuit breakers and lighting contactors have proper lugs, sized for the cable to be used. Do

not cut the cable strands to attach to the circuit breakers or lighting contactors.

the plans.

arrester to the grounding system.

alike if more than one padlock is required on a project.

transition areas between rigid members. Do not splice cable or wire except in junction boxes.

recommendations. Splicing is subject to the Engineer’s approval.

tubular splices.

compression ring tongue terminals on each conductor. Bolt the terminals together with stainless steel or

high-strength silicone bonze hardware.

wall supplied by the manufacturer.

Select the shrink tube so that when it is applied over the connector it has an insulation thickness equal to or

greater than the insulation thickness of the conductor used.

Ensure that the heat shrinkable tubing is UL listed and meets ANSI C 119.1 (latest edition) requirements for

submersible and direct buried splices.

during shrinking.

on each side of the splice after the tube is fully recovered.

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illuminated signs.

illuminated signs.

The photoelectric control operates the lighting contactor that supplies power to the lighting circuit. If the supply

voltage is other than 120/240 V, furnish and install a transformer in a weatherproof enclosure to provide 120 V

control voltage.

cabinet(s) located on the service pole accessible from the ground.

Install the grounding rods adjacent to each structural support foundation where the supply voltage enters and

adjacent to the service pole.

the lighting system.

ground rod at each structural support, and the ground rod at the service pole.

finished ground.

ground wire to the ground rod. Connect it to the grounding point on the structural support.

If penetration cannot be obtained in the above manner:

horizontal pattern and at least 12 in. (300 mm) below the finished ground.

solid, soft drawn, or medium-hard drawn copper ground wire and ground rod clamps.

Furnish and install the conduit, boxes, fittings, circuit breakers, fuses, wiring supports, and accessories to

complete the work for each circuit as required by the National Electrical Code.

Construct and install the fuse holder to retain the fuse on the load side if disconnected or broken apart. Install a

waterproof boot, furnished by the fuse holder manufacturer, over each end of the fuse holder.

House the lightning arrester in a watertight housing. Encapsulate or seal the lead entrance into the housing.

For units that are not factory sealed, apply silicone caulk to the lead entrance and install heat shrinkable tubing

with precoated sealant on the interior surface over the lead entrance.

Ensure that the lighting system provides on the face of the signs at least 30 foot-candles (320 lx), average

maintained, at 60 °F (15 °C) ambient temperature with a uniformity ratio (average/minimum) of no more than 3.5:1.

Tilt the sign 3 degrees off perpendicular toward the pavement. 11131113111311131113

sign and at a horizontal distance to provide uniform illumination.

design will direct the longitudinal separation of luminaires.

channel solidly fastened to the structural support with galvanized steel or aluminum clamps. Do not drive

holes into the structure.

lamp replacement.

Ensure that the ballasts for high intensity discharge (HID) or fluorescent lamps are integral with the luminaire

housing or are in a separate weatherproof housing attached to the luminaire housing, unless otherwise

specified. Use ballasts when using multiple circuits, unless otherwise specified, and when operating at

voltages shown on the plans.

Provide a light shield plate made of 0.10 in (2.54 mm) thick, B-209 alloy 6061-T6 aluminum sheet 12 in. (300

mm) wide and the combined length of the signs.

Erect the shield below the signs at an elevation that will eliminate glare from the luminaires to motorists

traveling in the opposite direction from the face of the sign. Mount the shield to the catwalk supports with

U-clamps according to Section 911.

637.3.06 Quality Acceptance

The Department will accept luminous intensity using a color and cosine corrected lux meter. The Department will

measure at random points by placing the meter flat against the surface of the sign with the light cell parallel to the face

of the sign.

The maintained luxfoot-candle values will be calculated using depreciation factors of 0.75 for the luminaire and 0.70

for the lamp (combined value = 0.525) to provide a minimum of 30 foot-candles (320 lx) average maintained during the

service life of the system.

Complete and energize each lighting circuit as early as possible. Before beginning the testing period, have an

electrician with a megger, voltmeter, and ammeter perform the following tests in the presence of the Department

Inspectors for each lighting circuit.

wiring and lightning arresters, megger the circuit conductors to ensure that the phase conductors are free

of grounds.

reading is one megohm after the test voltage has been applied for 10 minutes. Test the system as follows:

conductors and between each phase conductor and the neutral or ground.

up and repeat the above voltage measurements.

the neutral at the service point. Ensure that the current in the phase conductors is balanced and no

current is in the neutral.

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Final acceptance of the lighting system will be withheld for a 30-day testing period of continuous nightly automatic

operation after the lighting work is complete or until other items in the Contract (except grassing) have been

accepted, whichever occurs later. If a portion of this testing period occurs after Final Acceptance, other Work will

not be charged against the Contract Time.

Correct defects in material or workmanship that occur during this 30-day period of continuous nightly automatic

operation and until the Project is accepted, whichever occurs later. If defects are found during the 30-day test,

continue testing it until achieving 30 days of continuous nightly automatic operation.

Assume the energy cost of each circuit or part of the circuit during this test period. Others will assume the energy

costs after the successful 30-day test period.

After the testing period and at the time of Final Acceptance, have an electrician with a voltmeter and ammeter

perform the following tests in the presence of the Department Inspector for each lighting circuit.

and between each phase conductor and the neutral or ground at the service point.

that the current in the phase conductors is balanced and there is no current in the neutral.

637.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

637.4Measurement

Each illuminated sign system completed and accepted at the location specified is measured for payment per

Lump Sum.

637.4.01 Limits

General Provisions 101 through 150.

637.5Payment

Each illuminated sign system measured for payment will be paid for at the Lump Sum price bid for each system. Price

and payment is full compensation for furnishing and installing each complete and functional system, including designs

when furnished by the Contractor, drawings, electrical apparatus and wiring specified, required excavation, backfill,

concrete for conduits, and other materials, labor, equipment, and incidentals to complete the Item.

Structural supports for overhead highway signs will be erected and paid for separately according to Section 638.

Signs will be paid for according to Section 636.

Payment will be made under:

Item No. 637 Illuminated sign system—sta.___ Per lump sum

637.5.01 Adjustments

General Provisions 101 through 150.. 1115 1115 1115 1115 1115