925ITS CONTROLLER CABINET

925.01General Requirements

ITS controller cabinets shall be constructed such that it has a NEMA 3R rating. The cabinet shall be a rainproof cabinet with dimensions of 66 in. by 24 in. by 30 in. in depth. The cabinet top shall be crowned or slanted to the sides to prevent standing water.

The cabinet, sunshields, doors, and all panels shall be fabricated of 1/8 in. minimum thickness aluminum. The only exception to this aluminum thickness is the 10 detector rack, which shall be fabricated of 0.090 in. thickness aluminum. All exterior seams for the cabinets and doors shall be continuously welded. All exterior welds shall be ground smooth. All edges shall be filed to a radius of 5/16 in. minimum.

The cabinet, sunshields, doors, and all panels shall be fabricated from aluminum sheet in accordance with ASTM B209, 5052-H32 aluminum sheet.

Welding on aluminum shall be done by the gas metal arc welding process using bare aluminum welding electrodes. Electrodes shall be in accordance with AWS A5.10 for ER5356 aluminum alloy bare welding electrodes. 20

Procedures, welders, and welding operators for welding on aluminum shall be qualified in accordance with the requireme nts of AWS B2.1 “Specification for Welding Procedure and Performance Qualification” or AWS D9.1M/D9.1 Sheet Metal Welding Code.

Each aluminum surface shall be fi nished in accordance with Military Specification MIL-A-8625F(1), “Anodic Coatings for Aluminum and Aluminum Alloys”, Type II, class I coating, except that the anodic coating shall have a minimum thickness of 0.0008 in. and a minimum coating weight of 0.04 mg/sq mm. The anodic 30 coating shall be sealed in a 5% aqueous solution of nickel acetate (pH 5.0 to 6.5) for 15 minutes at 206°F. The anodized coating shall be silver in color. Prior to applying the anodic coating, the cabinets shall be cleaned and etched as follows:

Oakite 61A or Diversey 909, or equivalent, 45 to 60 g per liter, 160°F for 5 minutes.

925.01

45 g of sodium hydroxide per liter of distilled water at 140 to 150°F for 5 minutes.

temperature for 2 minutes.

The cabinet shall have single front and rear doors equipped with a lock. The doors shall use a Corbin lock No. 2, and each cabinet shall be equipped with two No. 2 keys. When each door is closed and latched, th e door shall be locked. Keys shall be removable in both the locked and unlocked positions. The door handles shall have provision for padlocking in the closed position. The handle shall have a minimum length of 7 in. and shall be provided with a 5/8 in., minimum, steel shank. The handle shall be fabricated of cast aluminum or stainless steel. The cabinet door frame shall be designed so that the latching mechanism shall hold tension on and form a firm seal between the door gasket and the door frame. 60

The cabinet shall not include a police door or have provisions for a police door.

The latching mechanism shall be a three-point cabinet latch with nylon rollers. The center catch and pushrods shall be zinc-plated or cadmium-platted steel. Pushrods shall be turned edgewise at the outer supports and shall be 1/4 by 3/4 in, minimum. The nylon rollers shall have a minimum diameter of 3/4 in. and shall be equipped with ball bearings.

All cadmium plating shall be in acco rdance with the Soci ety of Automotive 70 Engineers, SAE-AMSQQP416. All zinc pl ating shall be in accordance with ASTM B633.

The door hinges shall be three or four bolt butt hinges. Each hinge shall have a fixed pin. Doors larger than 22 in. in width or 6 sq ft in area shall be provided with catches to hold the door open at both 90° and 180°, ±10°. The catches shall be 1/3 in. diameter, minimum, plated steel rods. The catches shall be capable of holding the door open at 90° in a 56 mi/h wind at an angle perpendicular to the plane of the door. Door hinges, pins, and bolts shall be made of stainless steel. The hinges shall be bolted to the cabinet. The hinge pins and bolts shall not be accessible when the door is closed. 80

Door gaskets shall be provided on a ll door openings and shall be dust-tight. Gaskets shall be permanently bonded to the metal. The mating surface of the gasket shall be covered with a silicone lubricant to prevent sticking to the mating surface.

925.01

Both cabinet doors shall have louvered openings and shall provide ventilation. A filter shall be provided over the louvers and shall include an aluminum filter cover secured with a spring-loaded latch as shown on the plans. The filter shall be 12 by 16 by 1 in. Two spare filters shall be provided with each cabinet.

The cabinet shall be provided with two metal lifting eyes to be used when placing the cabinet on the foundation. Each eye shall have a minimum diameter of 3/4 in. and shall be capable of lifting 990 lb.

Machine screws and bolts shall not protrude beyond the outside wall of the cabinet.

925.02Model Approval

Each cabinet model will be subject to approval prior to use. A period of evaluation will commence when the Department receives a preliminary product evaluation form 100 accompanied by the product brochure, deta iled electrical schematics, and cabinet assembly drawings. The Operations Support Division will advise the manufacturer or vendor, in writing, of the date and location to deliver the cabinet for which model approval is requested. Electrical schema tics for the cabinet, cabinet assembly drawings, and parts lists shall be furnished with the controller when it is submitted to the Operations Support Division for evaluation and testing.

Only models from the QPL of Traffic Signal and ITS Devices in effect as of the date of letting, or as otherwise specified, shall be used on the contract. Continued failure and repeated malfunctions of a qualified controller or control equipment shall 110 be cause to remove that model from the QPL. A design change to a qualified model or cabinet will require re-submittal of the model for testing, evaluation, and approval. Permanent addition or removal of component parts or wires will be considered a design change.

925.03Warranty

The cabinet, sunshields, doors, and all ot her exterior surfaces shall carry a five year warranty against all material imperfections. All other electrical components and wiring shall carry a three year warranty against all imperfections in workmanship or materials. 120

925.04Cabinet Accessories

The following accessories shall be furnished and installed with each ITS cabinet.

The cabinet shall come equipped with standard Electronic Industries Alliance 19 in. rack frame assembly. The rack frame assembly shall have standard Electronic Industries Alliance vertically spaced threaded holes for attachment of equipment, mounting angles, and shelves. Frame mounting of equipment and shelves shall be available on both door sides of the cabinet. 130

925.04

The equipment rack shall be furnished with two adjustable equipment shelves. A 3 in. hole shall be provided in each shelf. The hole shall be fitted with a nylon snap bushing liner with an outside diameter of 3.16 in., inside diameter of 2.5 in. and a height of 0.72 in. The shelves shall be constructed of an aluminum screen tack welded between the shelf bottom and upper ribs. The shelves shall be capable of being moved in any location.

An aluminum panel sunshield shall be mounted on standoffs on the top and each side of each cabinet.

Two aluminum side panels shall be provided and mounted on the Electronic Industries Alliance rack parallel to the cabinet sides. One panel shall be designated as the “power distribution panel” and the ot her panel shall be designated the “heater panel”.

The data pocket is to be large enough to hold several drawings, a maintenance log notebook, and several pieces of reference material but not so large as to contact any of the installed equipment.

The labels shall have a non-reflective, exterior grade, low glare matte surface finish applied to flexible ABS plastic. The labels shall be black with white lettering and have an engraving depth of 0.002 to 0.003 in. Labels shall conform to the designations on the cabinet diagrams.

A power distribution terminal block shall be mounted on the power distribution panel. The power distribution block shall be a mechanical three-pole connector. The connectors for the incoming power shall be able to accept wire sizes between 12 AWG and 2/0 AWG. The load side connectors shall be able to accept wire sizes between 14 AWG and 4 AWG. The rating of the connector shall be 195 amps per pole. The connector elements shall be made from a tin plated, high conductivity aluminum alloy and insulated with high strength thermoplastic housing with a relative temperature index of 260°F. It shall be rated 600 volt, AL9CU. The dimensions shall be 4 by 5.2 by 3.23 in. high. The block shall come with one polycarbonate safety cover per pole. 170 Mounting screws shall be No. 10, 0.19 in. diameter. The block shall be UL Listed. The terminal block shall be a Burndy Model BDB-11-2/0-3.

The ground lug mounted on the power distribution panel shall be a heavy-duty one-hole ground lug, manufactured from electrolytic copper tubing and strip stock. UL Listed and CSA certified for stranded CU wire and for 600 volts. Wire range: 6 AWG 925.04

to 14 AWG. Bolt size: #10. Tang length shall be 1/2 in. Width shall be 5/16 in. The lug shall be an Ilsco Model SLUH-35.

The ground bus shall be rated to 600 volts. A maximum of 12 taps per ground bar suitable for wire ranging from 6 AWG to 14 AWG will be allowed. The main ground connection wire shall have a range from 4 AWG to 14 AWG. The ground bar shall be 5 15/16 in. by 3/4 in. by 11/32 in. and shall be UL Listed. The ground bus shall be an Ilsco Model D167-12.

The transient voltage surge suppression, TVSS, shall have individually fused suppression modes, thermal cutout, LED operational indicators to indicate loss of 190 protection or circuit fully operational, including neutral-to-ground, AC tracking filter with EMI/RFI filtering up to -50dB from 100 kHz to 100 MHz, and a short circuit current rating of 200,000 rms symmetrical amperes. Surge suppression shall be provided for each mode (L-N or L-L, L-G, N-G).

The TVSS shall be UL 1449 Second Edition Listed and UL 1283 Recognized. The TVSS shall have 120/240 volt split phase service voltage and dry contacts for each phase providing a summary alarm. The co ntacts shall be terminated in a DB-9 connector.

The surge capacity shall be 80 kA/phase. The response time shall be less than 1/2 nanosecond. The unit shall withstand 5000 category C3 impulses with less than 10% drift. It shall be suitable for use under non-condensing relative humidity range of 0 - 95%. The suppressed voltage rating shall be 330 volts L-N, L-G, N-G and 700 volts L-L. Operating frequency: 47 - 63 Hz. Operating temperature: -40°F to 140°F. External mount NEMA 1 standard enclosure. Standard size: 6 in. by 6 in. by 4 in. depth. Weight: 8 lb. The unit shall be an Advanced Protection Technologies Model TE/1XF.

The load center main breaker shall be an enclosed, two-pole, 240/240V AC, 60 amp breaker. It shall have a 10,000 rms symmetrical ampere short circuit current rating. The circuit breaker enclosure shall be a Square D, Model QO2TR.

The panelboard shall be a 120/240V AC, 600 volt, eight pole panelboard. The

panelboard shall have a neutral bus bar with three 10 amp breakers, four 15 amp

breakers and one spare. The load center shall be main lug only Square D, Model QO.

The circuit breakers shall be Square D, Model QO.

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The convenience receptacle shall be a duplex, three-prong, NEMA Type 5-15R

grounding type outlet and shall be in accordance with UL 943.

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A standard three-prong, NEMA Type 5-15R grounding type outlet shall be

mounted on the power distribution panel.

One 48 in. surge protected terminal strip with ten 15 amp outlets shall be furnished230

and installed.

The terminal strip shall have a low profile aluminum housing measuring 1 1/2 by

1 3/16 in. and have a 14/3 SJT cord and a NEMA 5-15P plug. The spacing between

the outlets shall be 4 in. and the grounding pin shall be positioned so that it is oriented

toward the bottom of the cabinet. The unit shall be in accordance with UL 1449 with

a 330 volt clamping level. The unit shall be a Wiremold Model 4810BCS with a 6 ft

cord.

Four dry-contact, one-pole-form-C (single-pole, double throw), switches shall be

provided and installed. Switch poles are to be electrically isolated. One set of switches

shall be rated for 5 amp at 120 volt AC to be used to automatically turn the lights off

when both cabinet doors are closed. The other set shall be rated for 1 amp at 5 volt DC

and are to be used to send a door open alarm. The switches shall be Omron part No. Z-

15GQ-B.

A toggle switch 20 amp, DPDT with 1/8 in. diameter hole in solder lugs shall be

provided and installed that will manually switch on the lights regardless of the door250

switch position. The switch shall be McGill Mfg. Co., part No. 0121-7013 or Eaton

part No. 7803K13.

Each cabinet shall be furnished with two lamp holders. The UL Listed device shall

have a medium phenolic base measuring 1.9 by 1.9 by 1.5 in. and rating 660 watt and

250 volt. The lamp holder shall be a Leviton Model 9063.

Each lamp holder shall be provided with a 100 watt rugged service incandescent260

bulb.

Three 110 cu ft/min, 4.7 by 4.7 by 1.5 in. cooling fans shall be installed within the

cabinet to circulate internal air. The fans shall have an allowable ambient temperature

range of 14°F to 158°F and a voltage rating of 115 volt. The fan casings shall be

aluminum alloy. The impeller shall be UL94V-O reinforced plastic. The fans shall

have ball bearings and an impedance protected, shaded pole induction motor. The fans

shall not be exposed or routed to the external environment.

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The environmental controller shall control fan operation. The fans shall activate

at 80°F. The fans shall be NMB Model 4715FS-12T-B50-D00.

Two 250 watt ceramic insulated strip heaters shall be furnished and installed in

the cabinet to protect against condensation damage and to keep the electronic

components above freezing in the winter. The strip heaters shall have a seamless

stainless steel sheath with ceramic element support and magnesium oxide packing.

The environmental controller shall control enclosure heater operation. Heating strips

shall not be installed on either door. The heaters shall be 8 in. long by 1 1/2 in. wide280

and shall have two wire terminals. The strip heaters shall be UL Recognized. The

heaters shall be Hotwatt Model CS-8.

Two solid state SPST-NO heater relays shall be installed on the power distribution

side panel. Load current range 0.04 to 25 amp, one-cycle surge 250 amp peak. Rated

for 120 volt AC and UL Recognized.

The cabinet shall be furnished with two thermostats installed. One thermostat290

shall activate the enclosure heaters and circulating fan with the internal cabinet

temperature goes below 35°F. The other thermostat shall activate the two circulating

fans at the top of the cabinet when the internal cabinet temperature goes above 80°F.

The thermostats shall be Thermodisc, TypeAL-1.

Double-deck compression clamp DIN rail terminal blocks shall be hard wired to

the Canoga Card Racks. A total of 64 terminal blocks shall be mounted to an aluminum

panel that is secured to the Electronic Industries Alliance rack. The terminal blocks

shall allow wires between 24 AWG and 10 AWG. Each measures 2.5 in. by 0.2 in.300

The terminal blocks shall be the Entretec part number 011527122 Type M 4/6 D2.

An isolated 8-Bit digital input module shall be provided and installed. It shall have

six fully isolated inputs and two share common ground inputs. High voltage inputs.

Logic levels: LOW +1.0 volt DC max, HIGH +3.5 to +30 volt DC. Input impedance:

3 kohm. Input isolation: 3000 vrms. Power consumption: 0.4 watt. Operating

temperature: 14°F to 158°F. The I/O module shall be a Measurement Computing,

Model CB-7052.

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The detector card rack shall be as shown on the plans.

Padlocks shall be classified as a high security padlock with hardened shackles,

laminated body, a minimum four-pin cylinder, and come complete with a weather

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cover to protect the lock body and cylinder from sand, dirt, water, and ice. A wafer

cylinder shall not be used. Keys shall not be provided with each padlock supplied. All

padlocks shall be keyed alike and shall be keyed identical to the keys currently in use

by the Department. The main body width of the padlock shall not exceed 3 in. and320

shall have a shackle length of 2 1/4 to 3 3/4 in. and a shackle diameter of 5/16 in. For

padlock information, contact the ITS Operations Engineer.

In addition to the equipment specified above, the cabinet shall be furnished with

all ancillary equipment, brackets, wiring ducts, and hardware as is necessary to provide

a neat and finished appearance. These items along with all associated cables,

connectors, wiring, and other incidental items shall be labeled on the required

submittal drawings.

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925.05Cabinet Wiring

All conductors used in ITS cabinet wiring shall be in accordance with the

following color-code requirements.

a continuous white or natural gray color.

a continuous green color or by a continuous green color

with one or more yellow stripes.340

not specified in (a) or (b) above.

All wire shall be Type THHN with color and gauge as shown on the plans, except

the microloop card rack wiring which will be two-pair twisted with a shield and

plenum rated.

Connectors used for interconnecting various portions of circuits together shall be

designed and constructed for the application involved. Connectors shall be designed350

to provide positive connection of all circuits, and easy insertion and removal of mating

contacts. Connections shall be permanently keyed to prevent improper connection of

circuits.

925.06Drawings

The Contractor shall provide three sets of cabinet wiring diagrams. The diagrams

shall be non-proprietary and shall identify all circuits, as installed, in such a manner

as to be readily interpreted.

In addition, three cabinet drawings shall be provided with each cabinet to show360

the component layout in elevation views from the front and rear. An elevation of both

aluminum side panels shall also be shown. Elevation views are to be detailed down to

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1215

the level showing mounting brackets and wiring ducts. All other mounting hardware

and cable ties need not be shown. All cables and connectors shall be clearly labeled.

Any data sheets for internal cabinet components that have been made available by the

manufacturer shall also be provided.

One set of the wiring diagram and cabinet drawing shall be placed in a heavy-duty

side-opening clear plastic pouch and inserted into the data pocket. The pouch shall be

of such design and material that it provides adequate storage and access to the370

drawings. The other two sets of drawings shall be delivered to the attention of the ITS

Field Engineer.