Controller Art. 1068.01 device shall be compatible with the bridge steel to facilitate safe and smooth retrieval of the luminaire from its operating position atop the structure. The track, lowering cables, winch, mounting hardware, controls enclosure, and all exposed system components shall be stainless steel or similar corrosion resistant material. SECTION 1068. CONTROLLER
1068.01 Lighting Controller. Lighting controllers shall be as follows.
a.General. The completed controller shall be an Industrial Control Panel under UL 508A.
b.Enclosures.
1.Single Door Enclosure.
a.Cabinet. The cabinet shall be single door design, fabricated from 0.125 in. (3 mm) thick ASTM B 209, Alloy No. 5052-H32 aluminum or AISI 304 stainless steel. The cabinet door frame shall be double flanged on all four sides. All external hardware shall be stainless steel. The cabinet shall have a NEMA Type 3R rating. Where no dimensions are indicated, the cabinet shall be sized to adequately house all required components with ample room for arrangement and termination of wiring. The back panel shall be designed so as not to exceed 60 percent of its fill capacity. Side panels shall not be used.
b.Door. The door shall be constructed from the same material and thickness as the cabinet. The door, when larger than 4 sq ft (0.37 sq m) in area, shall be equipped with a three point latching mechanism with nylon rollers at the top and bottom. The door handle shall be stainless steel and shall have a minimum diameter of 1/2 in. (13 mm) and have a padlock provision. The door shall be sealed with a neoprene gasket. The door hinge shall be a heavy gauge continuous hinge with a 1/4 in. (6 mm) diameter stainless steel hinge pin. The hinge shall be secured with stainless steel carriage bolts and stainless steel nuts and locknuts. A linkage-arm system, of simple construction, shall be attached to the cabinet doors to secure them in a wide open position to ensure safety during field operations. The door shall be furnished with a rain and ice resistant standard traffic signal lock and two keys. A weatherproof pocket for prints shall be permanently attached to the inside of the door.
c.Vent. The cabinet shall be equipped with a vent on top, designed to exclude moisture, dirt, and insects.
d.Post Top Mounting. The cabinet shall be mounted atop a 4 in. (100 mm) rigid aluminum schedule 40 conduit stem anchored to a cast aluminum pedestal base constructed of ASTM B 26 or B 108 Art. 1068.01 Controller A444-T4, A356.0-T61, or 356-T6 cast aluminum with an access handhole cover. The stem and base shall be painted as specified for the cabinet. When post mounted, the cabinet shall have a stiffener plate bolted to the bottom of the enclosure.
e.Base Mounting. Where indicated, the cabinet shall be mounted atop an enclosure base constructed from the same materials as the cabinet and of the same cross section as the cabinet. When specified, a steel transformer base shall be used for the enclosure base. When transformer base mounted, the cabinet shall have a stiffener plate bolted to the bottom of the enclosure. The transformer base shall be a non-breakaway base of a height and dimension as approved by the Engineer. The base extension shall be painted as specified for the cabinet. Where indicated, the foundation shall extend 12 in. (300 mm) above the surrounding grade to provide additional base extension.
f.Work Pad. Except where the cabinet is facing a sidewalk, a poured, 4 in. (100 mm) thick concrete pad, not less than 48 in. (1.2 m) square shall be provided in front of the cabinet.
2.Double Door Enclosure.
a.Cabinet. The cabinet shall be of the dimensions shown on the plans and fabricated from 1/8 in. (3 mm) thick ASTM B 209, Alloy No. 5052-H32 aluminum. The cabinet shall comply with UL 65 and UL 50 and be reinforced with aluminum angles.
b.Doors. The doors shall have stainless steel hinges. The door handle shall be stainless steel, a minimum diameter of 1/2 in. (13 mm) and be furnished with a rain and ice resistant lock. The doors shall be gasketed to exclude the entry of moisture, dirt, and insects. A linkage-arm system, of simple construction, shall be attached to the cabinet doors to allow securing in a wide open position during field operations.
c.Insulation. When specified, the interior compartment shall be insulated on the inside of the sides, back, top, bottom, and inside of the doors with 1 in. (25 mm) thick polyisocyanurate rigid foam insulation board. The foam board shall have foil facers on each side. The side facing the interior of the cabinet shall have a white tinted foil facer with a satin finish. The insulation shall have a minimum aged thermal resistance (R-value) of 8 at a 40 °F (4 °C) mean temperature. The insulation shall comply with Federal Specification HH-I-1972/1, Class 2.
d.Mounting. The cabinet shall be mounted as indicated on the plans.
e.Work Pad. The working pad shall be according to
Article 1068 — 01(b)(1)f above.
Controller Art. 1068.01
3.Wall Mount Enclosure. A wall mounted cabinet shall be according to
Article 1068 — 01(b)(1), except when a stainless steel cabinet is specified,
the following requirements shall be met.
a.Cabinet. The cabinet shall be a wall mounted type, NEMA Type 4X, not less than 14 gauge stainless steel, Type 304 of the dimensions shown on the plans. The cabinet shall be sized to adequately house all required components with ample room for arrangement and termination of wiring. All seams shall be continuously welded with stainless steel weld wire.
b.Door. The front of the cabinet shall have a hinged stainless steel door equipped with a handle and latching device suitable for installing a padlock. The door shall be gasketed to exclude the entry of moisture, dirt, and insects. The cabinet door shall be made of not less than 14 gauge stainless steel, Type 304. A print pocket shall be attached to the inside of the door. The enclosure shall have a continuous stainless steel hinge welded to the door and to the enclosure. The door shall be held closed by means of captive clamps fabricated from 12 gauge stainless steel and held in place with stainless steel hex head bolts. The clamps are to incorporate a depth stop to ensure uniform sealing pressure at all clamp points.
c.Finish.
1.Unfinished Enclosures. Stainless steel enclosures shall not be painted.
2.Finished Enclosures. All aluminum enclosures shall be finished to a #3 polish. When a painted finish is specified, the cabinet shall be cleaned before painting inside and outside with oxalic acid for five to ten minutes, or as otherwise recommended by the paint manufacturer and approved by the Engineer, to etch the metal surfaces. The cabinet shall then receive two sprayed coats of white polyamide epoxy primer with a corrosion inhibitor applied inside and outside to all surfaces. The primer shall have a solids content, by volume of not less than 65 percent and each coat shall be applied to a thickness of 3 to 5 mils (0.076 to 0.125 mm). All surfaces, interior and exterior, shall receive one final coat of silicone alkyd enamel paint. The finish paint shall have a solids content, by volume, of not less than 53 percent, and shall be applied to a thickness of 1.5 to 2.5 mils (0.038 to 0.064 mm). The color of the finish paint shall be ANSI No. 70 Sky Gray or as specified by the Engineer. The finish shall be applied according to the paint manufacturer’s recommendations and the manufacturer shall certify, in writing, to the Department, that the finish has been applied properly. Art. 1068.01 Controller Submittal data submitted for approval shall address the requirement for the paint manufacturer’s certification and shall include a standard, single source paint warranty by the paint manufacturer of the controller manufacturer to the Department.
d.Identification. The cabinet door shall have a stainless steel name plate of the dimensions and engraving indicated on the plans.
e.Control Components.
1.Time Switch. When specified, each controller shall have an electric time switch for automatic control of highway lighting circuits operating on a daily schedule having a fixed relation to sunrise and sunset. Turn- on and Turn-off times shall be adjustable ± 45 minutes from sunrise and sunset. All settings shall be field adjustable without special tools. Complete installation instructions, details on wiring connections, and information on time setting, manual operation, and necessary adjustments shall be furnished with each time switch. The time switch shall be a microprocessor-based two channel controller with astronomic functions on both channels. The latitude shall be adjustable from ten to 60 degrees in the Northern hemisphere. Latitude changes shall be user settable without the use of special tools. The time switch shall be programmable in an AM/PM format, with a resolution of one minute or better. The time switch shall automatically adjust for daylight saving time and have automatic leap year correction and operate on 240 VAC without the use of an additional transformer. A battery backup shall be integral with the controller and shall use a nickel-cadmium battery. The battery backup shall provide power to the controller memory for a minimum of 72 hours in the event of power failures. The published operating temperature range of the time switch shall be from -40 to 149 °F (-40 to 65 °C). The time switch output relay contacts shall be rated sufficiently to handle the inrush current of two 200 A contactors. The time switch shall have a NEMA Type 1 enclosure as a minimum. The time switch programming instructions shall be moisture proof and permanently affixed to the time switch or as otherwise approved by the Engineer.
2.Photocell.
a.General. The photocell shall consist of a metal electrode, molecularly bonded to a ceramic wafer, and coated with cadmium- sulfide. The photo cell shall be highly corrosion resistant without “Plastic dipping” with a nominal 0.75 sq in. (484 sq mm) in surface area. Color response of the cell shall be such that a maximum sensitivity is in the blue-green portion of the color spectrum. Controller Art. 1068.01
b.Switching Relay. The “On-Off” switching operations shall be accomplished by a normally closed contact which will be operated by means of an electro-magnetic relay. The response time shall be less than one second time delay for turn-on and three to thirty seconds time delay to prevent the “Turn-off” due to the light flashes of less than 10 footcandles (108 lux). Photocell shall be capable of less than one second time delay for both turn-on and turn-off when tested in full daylight. In the event of a circuitry failure, the lights will be turned on, or remain on.
c.Surge Arrester. Overvoltage protection shall be provided for the control components by the means of an expulsion type surge arrester capable of passing the surge outlined in ANSI C 136.10, except follow current is 10,000 A.
d.Chassis and Enclosure. The base of the unit shall be manufactured on a 3 in. (75 mm) wide, solid thermoset phenolic base. The bottom of the base shall have an integral, locking type, brass three prong plug according to ANSI C 136.10 and UL 773. The gasket shall be of a cross-linked polyethylene to ensure moisture proof seal to the luminaire socket.
e.Electrical. The control must be able to operate over the range of 105-305 V, 60 Hz AC. Its direct load rating shall be 1000 W Incandescent load and 1800 VA Mercury Vapor, High Pressure Sodium or other H.I.D. load.
f.Environmental. The control shall be stable and reliable over an operating temperature range of -40 to 158 °F (-40 to 70 °C).
g.Highway Lighting Operating Levels. Each control furnished shall be calibrated for a "Turn-on" setting of 0.5 to 2.1 footcandles (5.4 to 22.5 lux) of natural illumination and the "Turn-off" setting shall not exceed four times the "Turn-on" setting.
h.Waterway and Aviation Operating Levels. Each photocell furnished for navigation or aviation obstruction lighting control shall be calibrated for a “turn on” setting of 35 footcandles (377 lux) and “turn off” shall occur at 52 footcandles (560 lux) of natural illumination or according to the latest FAA and U.S. Coast Guard requirements.
3.Circuit Breakers. All feeders, branch circuits, and auxiliary and control circuits shall have overcurrent protection. The overcurrent protection shall be by means of circuit breakers. Circuit breakers shall be standard listed molded case, thermal-magnetic bolt-on type circuit breakers with trip free indicating handles. 240 V circuit breakers shall have a listed interrupting rating of not less than 10,000 rms symmetrical amperes at rated circuit voltage for which Art. 1068.01 Controller the breaker is applied. 480 V applications shall have a listed interrupting rating of not less than 14,000 rms symmetrical amperes at rated circuit voltage. Multi-pole circuit breakers larger than 100 A size shall have adjustable magnetic trip settings. The number of branch circuit breakers shall be as indicated on the Control Cabinet detail drawing or as indicated in the lighting system wiring diagram whichever is greater plus two spare circuit breakers.
4.Contactors. Contactors shall be electrically operated, electrically or mechanically held, as specified, with the number of poles required for the service and with operating coil voltage as indicated. Ampere rating of contactors shall be not less than required for the duty shown and shall otherwise be rated as indicated. Contactors shall be complete with a non-conducting inorganic, non- asbestos subpanel for mounting and shall be shielded with a clear cover. Electrically held contactors shall be used unless mechanically held contactors are specified. Electrically held contactors shall be NEMA, size 3, 2 pole, 60 Hz, 600 V, open panel mount type, normally open and electrically held. Mechanically held contactors shall be complete with coil clearing contacts to interrupt current through the coil once the contactor is held in position. The main contactor contacts shall be the double break, silver to silver type. They shall be spring loaded and provide a wiping action when opening and closing. The contacts shall be renewable from the front panel, self-aligning, and protected by auxiliary arcing contacts. The line and load terminals shall be pressure type terminals of copper construction and of the proper size for the ampere rating of the contactor. A lever for manual operation shall be incorporated in the mechanically held contactor. Protection from accidental contact with current carrying parts when operating the contactor manually shall be provided. The contactor operating coil shall operate at phase to neutral voltage. Single phase contactors shall be two pole devices with continuous rating for the amperage selected per pole. Open and closed positions for mechanically held contactors shall be clearly indicated and labeled in permanent manner as approved by the Engineer. Controller Art. 1068.01
5.Auto/Manual Switches for Mechanically Held Contactors. The cabinet shall be equipped with automatic and manual operating controls via two, single pole double throw switches, one being a maintained-contact manual-automatic selector switch and one being a momentary-contact manual on-off switch with a center rest position. Both switches shall be premium specification grade, rated for the applied duty but not less than 20 A at 240 V and each shall be mounted in a 4 in. (100 mm) square box with cover. Selector Switch for Electrically Held Contactors. The selector switch shall have a glove-hand operating handle and industrial duty rotating mechanism. Contacts shall be rated 10 A make/break and continuous at 60 Hz, 600 V. The switch position shall be designated by a permanent name plate of metal or rigid laminated plastic. The switch shall be listed. The control circuit shall have overcurrent protection as indicated and as required by NEC requirements.
6.Ground & Neutral Bus Bars. Separate ground and neutral bus bars shall be provided. The ground bus bar shall be copper, mounted on the equipment panel, fitted with 22 connectors of the type shown on the plans, as a minimum. The neutral bar shall be similar. The heads of connector screws shall be painted white for neutral bar connectors and green for ground bar connectors.
7.Interior Lighting and Receptacle. When specified, the cabinet shall have an auxiliary device circuit at 120 V single phase to supply a convenience receptacle and cabinet light. Where 120 V is not available directly from the service voltage, an outdoor dry type step-down transformer not less than 1 KVA shall be provided. It shall be according to Article 1068.02. The auxiliary circuit, including transformer primary and secondary, shall have overcurrent protection according to NEC requirements. The interior, 100 W incandescent lighting fixture with die cast guard shall meet the requirements of UL 1598 and be of the vaporproof enclosed-and-gasketed type. The light fixture shall be switched from a single pole, single throw, 20 A switch. The switch shall be premium specification grade in a suitable 4 in. (100 mm) box with a cover. A 20 A duplex receptacle, ground fault interrupting, premium specification grade shall be furnished in a 4 in. (100 mm) square box with cover, for 120 V auxiliary use.
8.Surge Arrester. The control cabinet shall be protected by a surge arrester meeting the requirements of Article 1065.02. Leads shall not be spliced and shall be kept as short as possible. The surge arrester shall be mounted as far from other components as possible or shall be isolated by a barrier. Art. 1068.01 Controller
9.Insulated Back Panel. The cabinet shall have a non-conducting inorganic, non-asbestos subpanel to cover the back of the cabinet on which to mount control components. When specified no insulated back panel shall be used and all components shall be appropriately bonded and grounded to a metal mounting surface.
f.Wiring and Identification. Power wiring within the cabinet shall be of the size specified for the corresponding service conductors and branch circuits and shall be rated RHH/RHW, 600 V. Control and auxiliary circuit wiring shall be rated RHH/RHW or MTW with jacket, 600 V. All power and control wiring shall be stranded copper. All wiring devices, such as bussbar, terminal blocks, lugs, etc. shall be copper. All wiring shall be tagged with self-sticking cable markers. When the contract drawings do not specifically indicate assigned wire designations, the manufacturer shall assign wire designations and indicate them on the shop drawings. All switches, controls and the like shall be identified both as to function and position (as applicable) by means of engraved two color nameplates attached with screws, or where nameplate are not possible in the judgment of the Engineer, by the use of cloth-backed adhesive labels as approved by the Engineer. The cabinet with all of its electrical components and parts shall be assembled in a neat orderly fashion. All of the electrical cables shall be installed in a trim, neat, professional manner. The cables shall be trained in straight horizontal and vertical directions and be parallel, next to, and adjacent to other cables whenever possible.
1068.02 Transformer, General Purpose. The transformer shall be dry type,
encapsulated, and weatherproof so that it may be installed indoors or outdoors without additional housing. It shall have an enclosure for splices with provisions for weather tight conduit connections. The transformer shall have four taps on the primary side, one at 2 1/2 percent, one at five percent, one at 7 1/2 percent and one at ten percent below rated voltage. The windings shall be copper and the insulation shall be rated 180 °C or higher and temperature rise shall be rated 115 °C or lower. The transformer shall meet the applicable ASA and IEEE standards. Mounting and back plates shall be of Aluminum Alloy 2024, 3003 or 6061. Bolts, nuts and washers shall be of Series 300 stainless steel. Bolts shall have hexheads. Nuts shall be hexagon and self locking. Washers shall be of the flat type.
1068.03 Obstruction Warning Lighting Controller. The completed controller
shall be an Industrial Control Panel under UL 508A according to Article 1068.01, except that the control circuit shall have dual control components where highway lighting is operated out of the same controller as obstruction warning lighting. The control circuit shall be as detailed in the plans and approved by the Engineer. Pole and Tower Art. 1069.01 Each photocell furnished for waterway or aviation obstruction lighting control shall be calibrated according to Article 1068.01(e)(2)h. SECTION 1069. POLE AND TOWER
1069.01 Light Poles. All light poles shall be designed, fabricated, and
furnished to provide a complete support system as follows. The detailed design and fabrication of the pole shaft, arms, tenons, and attachments shall be according to AASHTO “Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals, Sixth Edition 2013”. Light poles shall be designed for 90 mph (145 km/hr) wind velocity and a minimum design life of 50 years.
a.Loading. The following loading requirements shall include all possible luminaire and arm combinations up to and including the limits given. All other light pole configurations shall require the Contractor to submit for approval, detailed design calculations of each light pole including arm(s), luminaire(s), and any other attachments.
1.Poles with Arms. Poles with arms shall be designed and manufactured to withstand loadings of up to and including a 40 lb (18 kg) luminaire having an effective projected area of 1.6 sq ft (0.15 sq m) on a single 4 to 15 ft (1.2 to 4.5 m) arm, and shall also withstand loadings of up to and including the same luminaire on each of two 4 to 12 ft (1.2 to 3.6 m) arms (twin) oriented 180 degrees apart, meeting the criteria of AASHTO as specified above.
2.Poles with Tenon Tops. Tenon top poles shall be designed and manufactured to withstand loadings of up to and including twin 100 lb (45 kg) luminaires having an effective projected area each of 3.85 sq ft (0.36 sq m) on a twin tenon bracket. The tenon at the top of the pole shall meet AASHTO loading requirements for twin luminaires as specified above. The pole shall be designed to withstand wind induced vibrations in the shaft and arm(s) so that no damage occurs to the shaft, arm(s), luminaire(s), and/or their component parts. The pole shall be coordinated with all luminaires to be free of susceptibility to harmful harmonics and vibrations. A dampening device, as an integral part of the shaft, shall be installed in the shaft to alleviate such vibrations in aluminum poles and all other poles as necessary. The proposed vibration dampening device shall be included with the Contractor’s submittal. Deflection of the pole top as caused by the combined effect of wind and deadload referenced above shall be as required by AASHTO “Structural Supports for Highway Signs, Luminaires, and Traffic Signals, Sixth Edition 2013”. Pole deflection and loading compliance, certified by the manufacturer, shall be noted on the pole submittal.
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 984–992 of 1,217. View official source ↗