954ELECTRICAL DISTRIBUTION

954.1DESCRIPTION—This work is the furnishing and installation of the electrical distribution for the control

and illumination of traffic signals.

954.2MATERIAL—

• Traffic Signals-General. Section 950.2

• Poles and Bases. Section 1101.02

• Certification. Section 106.03(b)3

rigid metallic conduit, galvanized inside and outside.

conduit, and UL-514 Listing for fittings.

conduit manufacturer.

• High-Density Polyethylene (HDPE). HDPE 3 -way factory bundled microduct with a polyethylene oversheath. Each microduct is to be smooth on the outside, micro -ribbed on the inside, and have a co-extruded permanent lubrication layer.

• Microduct oversheath is to be orange. Inner microduct colors are to be green, orange, and blue.

• Microduct sizes are referenced using an outer dimension or inner dimension. The 3 -way microduct must meet or exceed the 27 mm outer dimension or 20 mm inner dimension.

• HDPE SDR11 1 1/4-inch inner dimension. Reels can be separate or combined onto a single reel.

• Colors of the HDPE are to be green, orange, and blue.

20-1.

B8 for soft, annealed copper.

permanent tags such as tape will not be allowed unless used for temporary applications such as during construction.

acceptable type support, to secure cable to span wire.

jacket is to be UV resistant polyethylene and contain water blocking gel or dry gel tape for water resistance. Provide weathertight RJ45 connectors on all exposed ends.

• Provide junction box cover with “Traffic Signal” wording on the surface, as shown on the Standard Drawings.

• Precast Junction Box. Section 714.

• Steel or Cast-Iron Junction Box. Steel or cast-iron conforming to the requirements for cast-iron junction box, as specified in Section 1101.10.

• Reinforced Plastic Mortar Junction Box. Provide heavy duty junction box with nonskid surface and a watertight connection to the housing. Provide a minimum design load 15,000 pounds with a test load of 22,500 pounds.

4.a Enclosure. Galvanized steel, aluminum, or stainless steel, with a hinged door having provisions for a padlock and no external handles or switches; conforming to the NEMA Standard for Type 3R, Type 3S, or Type 4. Provide a brass padlock for outdoor use, with two keys. All padlocks must be keyed alike.

4.b Main Disconnect. Provide a means for disconnecting the service conforming to NEC and local utility requirements where applicable.

4.c Fuses. UL-Listed Type K-1, 30 A minimum.

4.d Fuse Block. UL-Listed for K-1 fuses.

4.e Power Line Surge Protector. UL-Listed, rated for a maximum permissible line to ground voltage of 175 V (rms). Clamping voltage not to exceed 250 volts. Provide model with LED to indicate proper

functioning of protection and device failure for each line.

a minimum of 600 V, and suitable for the applicable wire size. Connect each set of terminals by means of a removable link. Separate each set of terminals by a molded barrier. Provide a marker strip for terminal identification.

use of a locked police door using a No. 2 key or standard police key.

the emergency power source. Provide system capable of automatic switch over between AC line utility and generator power.

an external power source according to the latest NEC, that is compatible with the municipal generator, and has neoprene all weather flexible protective boots on each end.

no more than 250 V at 20,000 A.

on the street side of the cabinet and visible from the center of the intersection. The indicator lights will be field located and connected to the cabinet with watertight connections to prohibit water intrusion into the cabinet. The red LED indicator light is to be wired to the load side of the transfer switch and is to be illuminated whenever the signals are operating under generator power. The green LED indicator is to be wired to the AC Line In and is to be illuminated at all other times.

conversion power conditioner UPS or line -interactive true UPS (stand -by UPS will not be allowed), compatible with the controller assembly and the following:

• Provide a UL-listed BBS for use with traffic signal equipment.

• Provide UPS with ethernet port for laptop connection for information downloads.

• Provide BBS capable of having a transfer time of 8 milliseconds (1/2 the sine wave) or less.

• Provide BBS with full-time line conditioning.

• Provide BBS with surge protection compliant with IEEE/ANSI C.62.41 Category A and B.

• Provide BBS with automatic transfer switch and manual override, compatible with UPS, manufacturer rated at 120VAC/30A.

• Provide BBS capable of automatic switch over between AC line and UPS Power. Transfer switch should also be capable of bypassing the UPS for safe removal of the UPS unit for maintenance by way of manually operated UPS supply breaker.

• All connectors must be finger safe and all transfer relay contact wiring must be according to the national electric code.

• The BBS system is to be monitored and controlled using readily available terminal emulation software. Proprietary application software is not allowed. Web-based software is allowed.

• Provide BBS with intelligent staged charger with control system. The integral intelligent system must use temperature compensation. The charging system must compensate over a range of 2.0 to 6.0mV/°C per cell, user-adjustable when required. Batteries, when charged, must not exceed a battery temperature of 50 °C. Battery must not be recharged when battery temperature exceeds 122F. Temperature probe must be included with UPS.

• Provide batteries that are deep cycle or float cycle, scaled prismatic lead -calcium based Absorbed Glass Mat/Valve Regulated Lead Acid (AGM/VRLA) or Nickel Zinc based.

• Provide red and green LED indicator lights (1.0 inch diameter) mounted to the cabinet on the street side of the cabinet and visible from the center of the intersection. The indicator lights will be field located and connected to the cabinet with watertight connections to prohibit water intrusion into the cabinet. The red LED indicator light is to be wired to the load side of the transfer switch and is to be illuminated whenever the signals are operating under battery back-up power. The green LED indicator is to be wired to the AC Line In and is to be illuminated at all other times.

• Provide a system with minimum 8-hour backup operation at minimum 450-watt load.

• Provide all warranty information to the Representative at final acceptance.

• Provide auxiliary cabinet as necessary to accommodate the required number of batteries and Automatic Transfer Switch as specified in 952.2(c)1.1.f as necessary and as indicated.

only used by service technicians working on the signal controller system. No other internal equipment is to be connected to the service receptacle. Minimum rating 20A.

• Fine Aggregate, Type A or Type B. Section 703.1

• High Early Strength Cement Concrete. Section 704

• Asphalt Material. Asphalt Cement, Class PG 64S-22. Section 702

954.3CONSTRUCTION—Sections 910.3(a) and 950.3, as shown on the Standard Drawings, and as follows:

Excavate for conduit runs parallel to the roadway, or as indicated.

Install microducts under roadway pavement and paved shoulders. Use directional boring for the installation of microducts when crossing under roadway pavement, unless indicated otherwise on plans. Place a detectable underground warning tape within the last layer of backfill material for the entire length of the trench.

trench and backfill, require full slab sidewalk replacement as specified in Section 676.3. Restore existing pavement. For flexible pavement, use asphalt material of a type equal to the existing pavement, as determined by the Representative. For rigid pavement, use High Early Strength Cement Concrete as specified in Section 704.1 and installed as specified in Section 516.

depth of the pavement. Excavate microduct trench to a depth that provides 15 inches of cover over the microducts. Excavate trench width to maintain a one-half inch clearance between the trench walls and the bundled microducts. Provide a one-inch Type A or Type B Fine Aggregate bedding for the microducts. Cover microducts with 9 inches of Type A or Type B Fine Aggregate and backfill the remainder of the trench with suitable material. Use no rock or coarse aggregate for trench backfill. Compact backfill material for the full trench width, as specified in Section 206.3(b) for the specific material type placed. Restore shoulders or roadways to original grades, cross slope, shoulder type and pavement type according to Department specifications. For flexible pavement, use asphalt material of a type equal to the existing pavement, as determined by the Representative . Seal the asphalt surface course joints resulting from the microduct trench with hot PG 64S-22 asphalt binder. For rigid pavement, use High Early Strength Cement Concrete as specified in Section 704.1.

indicated on plans, before the start of directional boring. The depth of directional borings should be below the existing roadway subgrade , below the existing pavement base drain, and as shown on the Standard Drawings. Conduct utility test pits according to applicable PA One Call laws. Do not deform the pavement. Guide the boring. Pneumatic hammers are not allowed. Keep boring pits at least 2 feet from the edge of pavement unless otherwise authorized in writing. Do not use water or drilling fluids to the extent that the pavement might be undermined, or subgrade softened. Maintain drilling fluid in bore hole to increase stability of the surrounding soil. Angle the entry/exit holes so that the curvature of the entry/exit holes does not exceed the allowable bending radius of the traffic signal conduit. Cover the boring pits with adequate planking if the drilling operation must be left overnight. Refill and compact boring as specified in Section 206.3(b).

If allowed by the Representative, indicated conduit runs may be changed to avoid underground obstructions. Install conduit as indicated. Install high -impact, plastic spacers a maximum of 8 feet on center, if more than two rigid, nonmetallic conduits are to be installed in a common trench. Install conduit into a junction box using a knock-out hole or by cutting a circular hole 1/4 inch larger than the outside diameter of the conduit. Drill holes approximately 10 to 18 inches above the bottom of the junction box. Field drilled holes must not cut into structural reinforcement, reinforcing rib, corner of the box, or box lip to avoid damaging structural integrity. If the conduit installation into a junction box creates tension stress on the installation of the fiber optic cable, install the conduit through the open bottom of the junction box as an alternative to the preferred side entry method. All conduit entering the bottom of the junction box must extend a minimum of 12 inches above the gravel base. Seal knock-out holes after installation of conduit. Submit As-Built drawings to the Representative in the file format requested by the Department before the start of construction. Make all conduit couplings in a junction box meeting ANSI Tier 22 load ratings and minimum 17 inches by 24 inches by 36 inches dimensions. Install the conduit in such a way the manufacturer’s minimum bending radius and force limitations are not violated before, during, or after installation. Minimum conduit bend radius is calculated at 20 times the diameter of conduit.

Perform acceptance testing between pull points or at all transition points. Before fiber optic cable installation, verify duct integrity to discover any missing sections, improper couplings, kinks, or blockage in the ducts. Use sponge testing to clean out water and debris. Repair, replace, or clean duct to ensure cable installation meets or exceeds manufacturer’s guidelines. After installing all related cables, seal all conduits within junction boxes and foundations, including all spare or abandoned conduits, with electrical putty or an approved sealant as recommended by the cable or conduit manufacturer. Insert grade 3 or 4 stainless steel wool at a minimum of 2 inches in the conduit before the sealant. When installing conduit to an existing foundation, do not compromis e the integrity of the foundation. Restore any concrete loss to the foundation. Exposed conduit accessing an existing foundation must be rigid metal as specified in Section 954.2(b)1.

depth between 36 inches and 48 inches. Install under highways and commercial driveways at a minimum depth of 60 inches and under residential streets at a depth between 36 inches and 48 inches. Install conduit as indicated. Maintain at least a 12-inch separation between conduit and other perpendicular underground utilities. Maintain a minimum 18-inch separation in all directions for a parallel installation with existing utilities. Pull strength of the conduit is calculated at 80 % of tensile or breaking strength which for a HDPE SDR11 1 1/4-inch conduit is approximately 1,700 pounds.

Each microduct will have a 1/2-inch-wide pull line with a minimum pull strength of 1,250 pounds. Pull line made of polyester or similar material and have sequential footage markings. Perform separate pressure testing on each individual microduct. Each microduct must maintain 100 pounds per square inch for a period of 1 minute with a minimum of 5% pressure drop allowed. Record and deliver to the Representative each test result upon completion and before installing cable. Complete proof testing of each microduct from pull point to pull point and all transitions. Each microduct must be proofed with an appropriately sized proofing ball to ensure that a minimum of 80% of the published inner dimension is maintained.

Standard Drawings, as specified in Section 910.3(q), and as follows: Provide a continuous mechanical and electrical grounding system from the controller assembly through the electrical distribution system. Bridge grounding bushings on rigid metallic conduit. Thread bonding bushings on the free ends and lock in place with stainless steel set screws, lug mountings, and binding screws. Provide bushings on all conduit ends entering enclosures.

Install cables inside supports and brackets. Insert cable in conduit using lubricant. If new cable is to be installed in conduit with existing conductors, remove the existing cable, clean the conduit, as specified in Section 910.3(g), and then insert both old and new cable into the conduit as a unit. Replace existing cable damaged during removal process as directed. If existing cable is being abandoned and not reused, permanently remove the old cable. If the new cable is replacing the old cable, permanently remove the old cable. Use insulated, locking, spade terminals for conductor terminations. Neatly arrange conductors and tie with cable ties within fixtures. Attach cable tags at splices, indicating signal head number, within all junction boxes, pole bases, and cabinets. Terminate all spare signal conductors collectively with a pressure-type mechanical lug and cover with electrical tape. Ground spare conductors in controller cabinet only. Attach conductor terminations in controller cabinets to barrier -type terminal blocks with no more than one conductor per screw, otherwise use pressure -type mechanical lugs to accommodate the number of conductors being terminated. Identify and mark blocks.

Terminate on grounding bus and identify spare and reserved conductors. Provide enough slack cable in pole bases, controller cabinets, and junction boxes to allow for proper wiring connections. For pole mounted signals and pedestrian pushbuttons, install signal cable inside pole to the terminal block of the signal or pushbutton. For span wire installations, lash cable to the span wire, or secure using cable rings and saddles. Provide drip loops at wire entrances to poles and signal heads. Secure drip loops with outdoor -type, self-locking cable ties.

2.a Pedestrian Pushbutton.

Cable 1 Black —Spare* 2 White —Logic Ground 3 Red —Pedestrian Call Detector

2.b Pedestrian Signal.

5/C Cable 1 Black —Walking Person (Walk) 2 White —Neutral 3 Red —Upraised Hand (Don't Walk) 4 Green —Reserved 5 Orange —Spare*

7/C Cable 1 Black —Walking Person (Walk 1) 2 White —Neutral 1 and 2 3 Red —Upraised Hand (Don't Walk 1) 4 Green —Reserved 5 Orange —Walking Person (Walk 2) 6 Blue —Upraised Hand (Don't Walk 2) 7 White/Tracer —Spare*

2.c Vehicular Signal.

5/C Cable 1 Black —Green Ball/Arrow 2 White —Neutral 3 Red —Red Ball/Arrow 4 Green —Reserved 5 Orange —Yellow Ball/Arrow

7/C Cable 1 Black —Green Ball 2 White —Neutral 3 Red —Red Ball/Arrow 4 Green —Reserved 5 Orange —Yellow Ball/Arrow 6 Blue —Green Arrow 7 White/Tracer —Yellow Arrow/Flashing Yellow Arrow/Spare* * Or as indicated.

service type. Perform necessary circuit connections to complete service to the controller assembly as shown on the Standard Drawings. Install power service outlets in cabinet as specified in Section 954.2(k) and the NEC. Install service pole as specified in Section 910.3(k) and as shown on the Standard Drawings. Verify with the utility company the location of the service conduit on the service pole or to the service manhole.

Notify the utility company of service requirements. Ensure that service is inspected as required by the utility contractor responsible to ensure that electrical service is initially set up in the name of the municipal traffic signal owner. Reimburse the municipal traffic signal owner for all utility fees incurred during construction.

• Ground wires within junction boxes.

• Signal wires and cables in pole bases.

When splicing signal cables within pole bases, perform splices according to National Electric Code (NEC) wet environments.

of the electrical distribution system, before connecting to operating equipment, and in the presence of the Service Representative. Complete testing as follows:

• No electrical energy is to be applied to any equipment or components before system testing. The Contractor's service engineer must initiate operation of the equipment.

• All grounding electrodes are adequately installed and individual ground rod(s) at each signal support including the cabinet measure 25 ohms or less to earth and the entire grounding system as shown on the Standard Drawings measure 8 ohms or less to earth.

• The Contractor’s Representative must verify that instruments, have been properly installed, configured, and meet the manufacturer's qualifications for warranty.

• Submit a certificate from the manufacturer, or from the Service Representative, stating that the installed equipment has been inspected, adjusted, approved, and certified to be satisfactory before field testing.

• Correct and recheck any equipment not functioning correctly. Provide corrective measures to remove any ground loops found during start-up.

• Immediately correct any defects and malfunctions with approved methods and materials.

• Include in the testing, but not limited to, taking all variables to their limits (simulated or actual process) to verify all alarms, failure interlocks and/or transfers, and operational interlocks.

the following information on the documentation as a minimum:

• Product Data. For each component, include manufacturers descriptive literature; product specifications; published details; technical bulletins; performance and capacity rating curves, charts, and schedules; catalogue data sheets; and other submittal materials as required to verify that the proposed products conform to the quality and functionality as required for the installation.

• Identification. Clearly indicate by an arrow on submissions covering more than one product type or style exactly which product is being submitted for approval.

• Equipment Characteristics. Size, location, weight, and electrical requirements.

• Manufacturer. Include the catalogue name, company name, address, and telephone number for each product submitted.

• Arrangement Drawings. Provide Arrangement Drawing for all signal controller cabinets showing the external front panel, and internal side and rear mounting sub -panels. Provide Bill of Materials, on Arrangement Drawing, identifying equipment shown and all software.

• Reference equipment by a numerical item number. Include the following information:

ͦ Item ͦ Identity ͦ Quantity ͦ Description ͦ Manufacturer ͦ Catalog Number

• Provide wiring diagrams for each signal controller cabinet illustrating the power connections to each internal device and all field connections. Display all wiring in a ladder diagram format.

• Submit shop drawings/catalog cuts of the adaptor kit, as specified in Section 954.2(i), before installation. Provide and attach to the signal controller cabinet after approval.

• Test in the presence of the municipality and District Traffic Engineer or Representative. Demonstrate operation of traffic signal for a minimum of 5 minutes using a municipal generator and provided cord. Test the electrical automatic relay switch over.

• Provide true-online double conversion or line-interactive true UPS.

• Initiate a 30-day test only after the total system is running and functional.

• Install and test the UPS according to the manufacturer's specifications.

• Mount UPS display in the cabinet and label the indications for easy visibility by service personnel.

• Wire controller cabinet auxiliary receptacle to AC Line.

• Locate and mount batteries on risers such that batteries will not come in contact with water from rain or snow/ice melt events.

• UPS installed using auxiliary cabinet, where cabinet assembly already exists, must place the UPS inside existing cabinet assembly, if space allows, with batteries placed in auxiliary cabinet.

• UPS battery placement with use of an auxiliary cabinet shall be installed as follows:

ͦ Pole Mounted. Mount auxiliary cabinet to the pole. Do not mount auxiliary cabinet to side of existing pole mounted cabinet. ͦ Ground Mounted. Auxiliary cabinet may be attached to side of existing signal cabinet. Set auxiliary cabinet on the top of the existing cabinet foundation.

954.4MEASUREMENT AND PAYMENT—

For the type indicated. The unit price includes stainless steel wool and conduit sealant.

For the type indicated.

necessary according to applicable PA One Call laws.

The unit price includes cable, identification tags, cable lashing , and any removal of existing cable. Replacement of existing cable damaged during the process as specified in 954.3(e)1 is incidental to this item.

For the type indicated. The price includes service pole, ancillary wood poles, service head, meter socket, service disconnect, power line surge protector, exposed conduit, conduit fittings, service wire, generator adaptor kit, ground rod, ground wire, municipal coordination, and utility fees.

The price includes all necessary hardware, components, and logic or circuitry to make the system operational and functional with the controller assembly.

The price includes all necessary material and labor to add generator adaptor kit to existing controller assembly. A g enerator adaptor kit provided on a new controller assembly installation is incidental to controller assembly item as specified in Section 952.4.

The price includes all necessary material and labor to add conduit to an existing traffic signal support.