Caltrans’ Controller Cabinet Standards - Western States Forum

Caltrans’ Controller CabinetStandardsModels 33x, 33xL and 34xLXPresent and FutureGUEST SPEAKERHERASMO INIGUEZ, P.E.BRANCH CHIEF, TRAFFIC CONTROL SYSTEMS BRANCHCALTRANS OFFICE OF TECHNOLOGYWestern States Forum, June 21-23, 2016

Scope of Presentation Caltrans’ 1989 Standard Cabinets L Cabinets TEES 2009 LX Cabinets TEES 2009 Errata No. 22

Caltrans CabinetStandardsTHE MODEL SERIES332, 334 & 336

Traffic Signal Control EquipmentSpecifications (TSCES) 1989The Caltrans Controller Cabinet Standard is Safe cabinet with 5 conditionsfor flash Manual and external flashreset Parallel I/O cabinet design 8-phase, 4-pedestrianoperation (2 right-turnoverlaps available) 36 detector channel capability (3per left-turn, 6 per throughmovement) 2-channel or 4-channel industrystandard detection modules Service required, single phase,120 V4

Cabinet Key Components Housing 1B 19” rack Mercury contactor Input files I and J Power Distribution Assembly (PDA) Output file Model 206 Power Supply Model 210 Conflict Monitor Houses a Model 170 or Model 2070 Controller5

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PDA Front7

PDA Back8

Output File Back9

Issues with 1989 Design Spec 27-year-old specifications and design Designed for incandescent signal heads Assembly Bill AB 1415 Prohibits the use of Mercury Contactors after January 2006 California Department of Toxic Substances Control (DTSC)exempts Caltrans and McCain until July 1, 200910

Issues with 1989 Design SpecContinue One vendor on Caltrans’ QPL ITS Cabinet not ready NEC and other obsolesce issues Lacking BBS Standard Interface Not in TEES11

L CabinetsTEES 2009THE L SERIES CABINETS332L, 334L & 336L

L Cabinet Key Differentiators Drawer shelf for laptop support and storage PDA xL Model 206L Power Supply SPA SSR Standard BBS Interface HI relay K24 relay13

L Cabinet FunctionDifferentiators L’s green design reduces energy consumption through the use ofa power-saving, high-efficiency power supply and eliminates theuse of the harmful toxic mercury. Energy Saving-Switch-Mode Power Supply (SMPS), Model 206L Raw and Clean Power Circuits Service Panel Assembly (SPA) with replaceable surge suppressor Reduced circuit capacity for LED Signal Heads SSR Failure Indicator Circuit14

Model 206L Power EfficiencyLOADModel 206Model 206LEfficiency (ɳ)1 Amp43 %75 %2.5 Amp60 %84 %5 Amp69 %86 %15

Power Savings CalculationsPd Pout ( 1/ɳ - 1)@ ɳ 60% for Model 206Pd 60 ( 1/0.60 -1)Pd 40 Watts@ɳ 84% for Model 206LPd 60 ( 1/0.84 -1)Pd 11.43 WattsPsavings 40 – 11.43 28.57 WattsPsavings in kWh per Year 28.57 x 24 x 365 250kWh16

Caltrans Yearly EnergySavings At 50% load, the Model 206L will save 250kWh per year percabinet. With a typical energy cost at 0.10 /kWh, resulting a typicalsavings 25 per cabinet annually, when compared to the Model206. With half of the 10,000 locations using the L Cabinet, it wouldamount to a savings of 25x 5000 125,000 per year17

SPA Key Components Main Circuit Breaker Surge Suppressor and Filter BBS Standard Interface Provides the Clean and Raw Power Circuits18

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SPA20

What is thepurpose oftheHE1750 orSHA-1250filteringsurgeprotector? The device provides clean power tosensitive electronic equipment: 2070 Controller Cabinet Power Supply Input Assembly(s) It is rated for 15 amperes It is both a line filter and surgesuppressor21

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Green On: NormalGreen Off: ReplaceYellow Off: NormalYellow On: CheckWhen toreplace theHE1750 orSHA-1250filteringsurgeprotector?Green On: NormalGreen Off: ReplaceRed Off: NormalRed On: Check23

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Cabinet Key Functionality5 Conditions for Intersection FLASHCauses1 Manual Flash Mode by PDA SwitchMaintenance2 Removal of MU and Door CloseMaintenance3 Circuit Breaker Fails and Switch ONCB fails4 Manual Flash Mode via Police Panel (causes stop time)Police5 Flash Mode by MUModel 206L failsModel 2070 WDT stopsGreen conflictYellow conflict25

PDA 2L26

Meet the LXCALTRANS LATEST CABINET STANDARD27

LX Cabinet28

LX CabinetsTEES 2009 Errata #2December 2014THE LX SERIES342LX, 344LX & 346LX

LX Series AssembliesProduct DifferentiatorsModel 210Conflict MonitorModel 206LPower SupplyModel 764Pre-Emption UnitModel 242LDC Isolator

LX Cabinet Key Differentiators Housing #3 4 fans PDA LX; redesigned PDA to betouch safe LED lighting Two standard 19” racks Removal of 120 VAC from Input Uses model 242L DC Isolatorfile Service PDA Output file model LX;redesigned to be touch safe Integrated C11 harness forbicycle detection Powder coated overaluminum with federalstandard 595C, # 17178 color

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LX SeriesAssembliesSPDA33

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PDA 2LX, Front35

PDA 2LX, Back36

Why LX Cabinets Users need for more rack space for traffic signal equipment Users need for more space for ITS equipmentMost Important: Personal Safety National Fire Protection Association (NFPA) 70E and need for aTouch Safe Cabinet.37

Features & Benefits Solid state relay (SSR) (MercuryContactor replacement) SSR Fault Indicator Light Relay safety feature interrupts24 VDC control to the loadswitches if the SSR fails during aflash condition Programmable “Yellow/Red” or“All Red” flashes through theuse of flash plugs DC isolation inputs forpedestrian push buttons andspecial functions 210/2010 signal monitor slot Transient voltage & surgesuppression filter Drawer / shelf combination C11 harness Lights, LED38

Personal SafetyNFPA Rules & RegulationsNFPA 70 Requirements Guarding of the Live Parts (Article 110-27):Live parts of electrical equipment operating at 50 volts or moreshall be guarded against accidental contact . Arcing Parts (Article 110.18):Parts of electrical equipment that in ordinary operationproduce arcs, sparks, flames, or molten metal shall beenclosed .39

Personal SafetyOSHA Rules & Regulations Occupational Safety and Health Act (OSHA) has similarrequirements to NFPA. Until now, current traffic standards did not address guarding oflive and arcing parts: NEMA TSCES ITS Cabinet Standard TEES40

Why 50 Volts?The Technical Details 6 mA-16 mA is known as “let-go” current range for human body. OhmVoltageVVoltCurrentIAmpere Resistance of human body R (total) R (skin-in) R (internal) R (skin-out) R (point of contact) R (total) 1,000 300 1,000 3,000 5,300 Ohm** The 5300 Ohm may vary depending on a person size, humidity, etc.41

Why 50 Volts?More Technical DetailsOhm’s Law: I V/R For a 120 volt system: 120 V / (5300 Ohm) 0.022A or 22mA For a 50 volt system: 50 V / (5300 Ohm) 0.009A or 9mA 9 mA falls between 6 mA-16 mA “let-go” range.42

Types of Electrical HazardsThe relationship for a 60-cycle, hand-to-foot shock of one second duration:Current LevelProbable Effect on Human Body1 mAPerception level. Slight tingling sensation. Still dangerous under certainconditions.5 mASlight shock felt; not painful but disturbing. Average individual can let go. Stronginvoluntary reactions to shocks in this range may lead to injuries.6 – 16 mAPainful shock, begin to lose muscular control. Commonly referred to as thefreezing current or "let-go" range.17 – 19 mAExtreme pain, respiratory arrest, severe muscular contractions. Individual cannotlet go. Death is possible.100 mA to 2AmpsVentricular fibrillation (uneven, uncoordinated pumping of the heart.) Muscularcontraction and nerve damage begins to occur. Death is likely. 2 AmpsCardiac arrest, internal organ damage, and severe burns. Death is probable.43

Why 50 Volts?So Basically 9 mA Falls Between 6mA – 16 mA “Let-Go”Current Range44

Solutions for Personal Safety Design and build equipment less than 50 volts It would involve massive number of equipment manufacturers While this may occur in near-term, it is not an immediatesolution Provide Personal Protective Equipment (PPE) for all employeesworking with high voltage equipment PPE is not cheap and requires continual training on proper use Design your cabinet assembly to guard against accidental contactand arc flash The TEES 2009 Errata #2 LX Series Cabinet offers a solution45

LX SeriesAssembliesKEY PRODUCT DIFFERENTIATORS46

LX Series Assemblies Forward thinking – proactive approach Addresses NFPA 70E/ OSHA Continue to utilize the 170/2070 controller, firmware andstandard plug-ins47

Output File LX48

LX in the FieldDEPLOYMENTS & AVAILABILITY49

Current LX CabinetDeploymentCabinet ModelCaltrans DistrictQTYProjectDate342LX1250I405 Improvement Project2018342LX84SR-91 Project RCTCApril 2016344LX1011VariousEarly 201650

District 10 Fiber Deployment51

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Master Purchase AgreementCurrent MPA with McCain TrafficCabinetPriceLX vs L PriceModel 342LX 4214 348Model 332L 3867Model 344LX 3640Model 334L 2893 74353

QPL Processfor StateFurnishedMaterial54

DISTRICTSTRANSLABTESTING for QPLNeed for StateFurnished Equipment/ QATRANSPORTATIONINDUSTRYProcurementProcess-Traffic OperationsGenerate- TEES- QPLDOTsITEFHWADHSManufacturersCitiesCountiesfor ElectricalEquipmentWarehouse- Executes PO- Distributes StateFurnished ElectricalEquipmentDPACReviews :- MPA- QPL- TEESEND USERSDistricts- Maintenance- ConstructionVENDORS- EquipmentDGS-MPAAdvertisingBiddingAwards55

ManufacturersI really like the LX Cabinet! Who Makes it?56

Recap The traffic signal cabinet standards and specifications donot cover the personal safety of the personnel. It has alwaysbeen assumed that the people who have access to cabinetsare qualified, trained and experienced. Other groups – such as the ITS group and consultants –may have access and may not have proper training orknowledge of the risk of working around high voltageequipment. The TEES 2009 Errata #2 LX Series Cabinet offers asolution.57

Any Questions?THANK YOU!

AcronymsBBSBattery Backup SystemCBCircuit BreakerDCDirect CurrentDGSDepartment of General ServicesDHSDepartment of Homeland SecurityDOTsDepartments of Transportation other than CaltransDTSCCalifornia Department of Toxic Substances ControlDPACDivision of Procurement and ContractsFTRFlash Transfer Relay

FU 1Flasher Unit Number 1FWHAFederal Highway AdministrationGFCIGround Fault Circuit InterrupterHIHealth Indicator RelayICurrentI/OInput/ OutputIRIsolation RelayITEInstitute of Transportation EngineersITSIntelligent Transportation SystemkWhKilo Watt HourLFlash ON Indicator LampLRLogic Relay

MCMercury ContactorMPAMaster Purchase AgreementMUMonitor UnitmAMilliamperesNEMANational Electrical Manufacturers AssociationNFPANational Fire Protection AssociationOSHAOccupational Safety and Health ActPDPower DissipatedPDAPower Distribution AssemblyPOPurchase OrderPPEPersonal Protective Equipment

QAQuality AssuranceQPLQualified Products ListSFSSR Failure IndicatorSMPSSwitch-Mode Power SupplySP 1Switch Pack Number 1SPAService Panel AssemblySSRSolid State RelayTBSTerminal Block-ServiceTEESTransportation Electrical Equipment SpecificationsTSCESTraffic Signal Control Equipment SpecificationsVVoltageWDTWatchdog Timer

Links of Interest and ReferencesTransportation Electrical equipment Specifications (TEES) www.dot.ca.gov/trafficops/tech/tees.html91 Project Fast Forward www.sr91project.info/design-build-scheduleOrange County Transportation Authority ams/All-ProjectsSurge Protection 2015, Pete Ganci, BSET, Sales Engineer at Emerson cCain, Inc. www.mccain-inc.comSafetran www.safetran-traffic.comEberle Design Inc. (EDI) www.editraffic.com63

Jul 01, 2009 · Caltrans’ 1989 Standard Cabinets L Cabinets TEES 2009 LX Cabinets TEES 2009 Errata No. 2 2 . Caltrans Cabinet Standards T H E M O DEL S E R I ES 332, 334 & 336 . Traffic Signal Control Equipment Specifications (TSCES) 1989 Safe cabinet with 5 conditions for flash