| Crosswalk Controller Logic and General Specifications (AC and Solar Powered Models) |
| 1. System controller shall support multiple MUTCD compliant regular and enhanced flash patterns, and be capable of auto-sequencing through all enhanced flash patterns, one pattern per activation period. |
2. Output pattern operation, power limitations and output flash pattern selection:
|
 |
a. Output A (Primary DC Power Output)
The maximum DC power output of the primary (10 amp limit) shall be 120 watts (150 watts for high-power model) when powered from an internal AC power supply. On the solar powered model, the actual available power is limited by the design of the solar power supply, up to this maximum limit. The output flash pattern shall be selected by the pattern selector control located on the control card. |
|
b. Output B (Secondary DC Power Output)
The maximum DC power output of the secondary (10 amp limit) shall be 120 watts (150 watts for high-power model) when powered from an internal AC power supply. On the solar powered model, the actual available power is limited by the design of the solar power supply, up to this maximum limit. The output flash pattern shall be selected by a set of output mode selector switches ( 1-4 ) located on the control card: 1-Same as primary; 2-In sync with primary, but non-enhanced; 3-Non-enhanced complement of primary; 4-Continuously on while primary is flashing. Notes: (a) Enhanced flash patterns cannot be used when operating in wig-wag mode. (b) Only one output mode switch can be on (closed) at a time for proper operation of the system. |
|
c. The combined output power of the primary and secondary DC outputs shall be 120 watts (300 watts for the high-power model) when powered from an AC power supply. On the solar powered model, the actual available power shall be limited by the design of the solar power supply, up to this maximum limit. |
|
d. A dual AC output option shall be available on the AC Model. The AC outputs are in sync with the primary and secondary DC outputs. The output power capability on each output shall be limited to 360 watts (120 volts x 3 amps). Enhanced flash patterns cannot be used when operating in the wig-wag mode. |
3. System controller shall be based on an integrated, high speed 8-bit microcontroller with non-volatile firmware and memory. All settings must be retained in the event that input power is removed.
|
4. System controller shall include the following controls and indicators:
|
|
a. Power LED Indicator: A visual indicator LED shall be provided to indicate the "power on" condition.
|
|
b. Activation Duration Setting: Activation duration shall be field adjustable in one second increments, over a range of from 1 to 99 seconds. Duration setting shall be displayed on a digital numeric display.
|
|
c. Flash Pattern Setting: Flash pattern setting shall be field adjustable and be displayed on a digital numeric display.
|
|
d. Push-Button Test and LED Indicator: System shall include an internal push-button used to activate the system during field tests. System shall include a visual indicator LED to indicate internal push-button and external activation device calls. |
|
e. Override Switch: System shall include an override switch to allow switching from manual system activation to continuous system activation. |
|
f. Output LED Indicators: System shall include visual indicator LEDs which indicate: system activation, primary output (A), and secondary output (B) status. |
5. System shall support activation from standard contact-closure type push-buttons, push-buttons with audio message capability, and passive pedestrian sensors.
|
| 6. System shall provide a field selectable option to allow an activation call to be ignored, or be used to reset the cycle during an ongoing crossing cycle. |
7. System shall include an adequate number of clearly labeled or color coded terminal blocks to allow easy system installation. Terminal blocks shall be located to provide adequate access for the installer.
|
| 8. System Protection: All DC outputs shall be protected with a replaceable fuse. In the AC powered model, the input AC voltage shall be protected by a thermal-magnetic circuit breaker integral to the AC power supply. The AC power supply shall include transient surge protection. All DC electronics shall be electrically isolated from the AC input voltage. All AC outputs shall be protected with a replaceable fuse. |
9. System Controller Enclosure (AC Model):
|
|
a. The system shall include a single enclosure for ease of installation. The system shall be housed in a NEMA 4 compliant, aluminum enclosure with a thickness of 0.125" and with approximate dimensions of (20" H x 16" W x 7.32" D, mounting tabs add an additional 3" in height) to provide protection from adverse weather conditions. The enclosure shall have a mill finish and be supplied with NEMA 4 compliant lock for security from unauthorized access, and come with a minimum of one key. |
|
b. The enclosure shall have double flanged door seals, a closed cell neoprene gasket around the entire edge of the door, and a stainless steel hinge. A set of brackets welded to the enclosure is used for mounting. The enclosure, using these brackets, can be pole mounted by using lengths of strut, clamps, and appropriate hardware (supplied by installer). Enclosures may also be mounted on walls, and within other enclosures using appropriate hardware (supplied by installer).
|
10. Warranty: The crosswalk system controller shall be warranted against defects in workmanship and materials for one year from date of shipment and is eligible for TSC’s 5-Year Limited System Warranty. For the solar model, the warranty on the solar array and battery are governed by the terms and conditions of their respective manufacturer’s warranty.
|
|
Power Supply Specifications for Solar Powered Model
|
1. General Requirements:
Solar power supplies provided for use with inpavement crosswalk systems shall be designed to act as a stand-alone power source for the system. Any response to bid shall require a sizing report containing the following data:
|
|
a. Site information shall include average monthly solar insolation on a horizontal surface, insolation at tilt, average monthly temperature at the site, and the elevation, latitude and longitude of the nearest city/town.
|
|
b. In the event that no data point exists for the given city/town where the installation will be done, sizing shall be prepared for the three nearest data points available around the installation site featuring similar geographical and/or climatic conditions. |
|
c. Load tabulation shall be included to detail the number, type and duty cycle of all loads in the system. If the manufacturer provides a range of power consumption for standard items such as LED lamps, the worst-case value of the load shall be used for design purposes. |
|
d. The report shall include the type of solar module to be used by model and manufacturer. Key technical data on the module such as open circuit voltage (V OC), peak power voltage (V peak), short circuit current (I SC), and peak power current (I peak) shall be provided. The electrical configuration of series and parallel modules shall also be specified as well as the array tilt angle through the year. |
|
e. Type of battery shall be provided by model and brand name. Technical data on the battery such as voltage and the capacity at the 100 hour discharge (C/100) rate shall be provided. The electrical configuration of the batteries (number of series and parallel) shall be provided. Projected days of autonomy shall be provided with the battery information. The system shall support a minimum autonomy of 5 days. |
|
f. The array to load ratio and projected battery state-of-charge (S OC) shall also be provided. Minimum acceptable array to load ratio for the solar system shall be 1.05 in December when using the maximum power draw for the loads. A projected battery "S OC" shall be specified in the report and shall indicate an "S OC" of 80% to 100% throughout the year. |
|
g. A system derating factor shall be included in the sizing report simulations to cover any losses from solar panel output mismatch, dirt/dust accumulation on panels, and losses due to system wiring. Losses may appear as a combined derating factor, but a thorough description of the sources of all losses accounted for shall be provided. Failure to provide a sizing report shall be considered non-responsive and result in disqualification, in which case the bid will be rejected.
|
2. Solar Modules and Mounting Structures:
|
|
a. The modules shall consist of a minimum of 36 crystalline cells in series. Cells shall feature an antireflective coating and a low iron glass covering. Cells shall be encapsulated to protect them from the environment. Each module shall feature a weather tight junction box for connecting the array output cable to the module terminals. Power modules greater than 60 watts shall feature a minimum warranty of 15 years for power output. Modules, 20 to 50 watts, shall feature a minimum warranty of 5 years for power output. All modules shall feature an anodized aluminum frame for mechanical support.
|
|
b. Alternative solar materials such as thin film modules consisting of either silicon or copper indium selenide (CIS) may be offered, as long as they are from a reputable manufacturer and offer a minimum 12 year warranty for power output.
|
|
c. Solar modules shall be able to be securely mounted to the top of a 4.5" O.D. pole assembly, or attached to larger diameter poles with a side pole mount structure that has been specifically designed to hold solar modules. All of the necessary hardware to install the modules to the mounts, and the mounts to the pole, shall be included in the bid. Security hardware for securing the module to the mount shall be included along with any special tools required for the hardware. Mounts made of steel will be powder coated or hot dip galvanized. Aluminum module mounts can be either powder coated or feature a mill finish.
|
|
d. A data sheet for the module shall be provided with the system, and shall be part of the bid response. Failure to provide this data will be considered non-responsive and will result in disqualification, in which case the bid will be rejected. |
3. System Batteries:
|
|
a. The system shall come equipped with the number and type of batteries detailed in the sizing report. The battery type shall be a sealed, maintenance-free, valve-regulated design. The battery shall use an absorbed glass mat (AGM) to suspend the electrolyte making it immobile. |
|
b. Gel batteries using a thixotropic gel to suspend the electrolyte, shall also be considered an acceptable alternate.
|
|
c. Acceptable battery sizes that can be accommodated shall include groups: U1, 22, 24, 27 and 31. Minimum capacity of the batteries at 25°C shall be a 36, 56, 80, 98 and 108Ah at the C/100 rate respectively.
|
|
d. Batteries shall use a chemical and crack resistant copolymer polypropylene case and cover. Non-removable, pressure regulated, flame arresting safety valves shall be standard.
|
|
e. Rated operating temperature shall be from -40°C to 72°C. Batteries shall also feature a low self-discharge rate of approximately 1% per month at 25°C.
|
4. Charge Controller:
|
|
a. The system shall include a charge controller specifically designed for use in solar power systems. It shall be a commercially available unit readily available from a number of sources in the U.S. The minimum rating for the unit shall be 10 Amps of charge current. The unit shall use an ambient temperature sensor to adjust the charge termination point, thus prolonging battery life (temperature compensated charging). The charge circuit shall also employ a pulse-width-modulation algorithm for charging the batteries, designed as a series switch, and implemented using solid-state technology. A green status LED shall be included to show when the unit is charging. Load power control shall be accomplished using a low voltage disconnect (LVD) circuit to disconnect power to the button control circuit when battery voltage falls to a low state-of-charge (typically 20% of rated capacity). The output circuit shall be solid-state and include a red status LED to indicate when power has been removed from the load due to low voltage disconnect (LVD). An LVD condition shall disable the system until such time that it has recharged to over 12.5 VDC. The charge controller shall also include a seven position terminal block with corrosion resistant hardware for securing the wires. An integral heat sink shall also be part of the controller.
|
|
b. A data sheet for the charge control unit shall be provided with the system, and shall be part of the bid response. Failure to provide this data will be considered non-responsive and will result in disqualification, in this case the bid will be rejected. |
5. Wiring Harnesses:
|
|
a. All systems shall feature a color-coded wiring harness for both the field wiring, battery circuit and the solar array output system. The harness shall be color-coded for ease of connection to the buttons, battery and solar array. A seven pin keyed locking connector shall be included in the harness to act as the main system disconnect, allowing the buttons and battery to be disconnected from the control electronics. The connector shall be located approximately 13" from the end of the harness that connects to the electronics panel. All connections shall be terminated with a crimped spade terminal for easy installation. Wire for the primary harness shall be thermoplastic equipment wire (TEW) or machine tool wire (MTW). |
|
b. The solar array output harness shall consist of a jacketed pair of conductors. The size of the conductors shall be dependent on the solar array output current. The jacket shall be a ultraviolet (UV) resistant polyvinyl chloride (PVC) or cross-linked polyethylene (XLP) material. Spade terminals shall be included for ease of installation. Minimum length shall be 14.5'. |
|
c. The power supply system shall feature a secondary harness that will be color-coded with a keyed connector for proper orientation of the pins. The harness shall use MTW or better, and terminate on a terminal block located inside the controller enclosure behind the control panel. This terminal block shall be considered as part of the secondary harness and provide connection points from the field wiring to the fixtures and auxiliary loads. It shall also provide terminations for the optional microphone and speaker drive outputs for systems employing activation devices with audio messaging capability. All terminal block positions shall be clearly marked for ease of installation. |
6. System Controller Enclosure (Solar Powered Model):
|
|
a. The system shall include a single enclosure for ease of installation. The system shall be housed in a 2-bay, NEMA 3R compliant, aluminum enclosure with a thickness of 0.125" and approximate dimensions of (26.25" H x 15.5" W x 15.5" D) to provide protection from adverse weather conditions. The enclosure shall be capable of holding up to two group 31 batteries. The enclosure shall have a mill finish. |
|
b. The battery compartment shall have a minimum of 1/2" of Styrofoam sheeting around the battery to minimize heat transfer between the battery and the wall of the enclosure. The name of the system manufacturer shall be placed on both the outside and on the inside of the enclosure door along with a phone number for troubleshooting assistance.
|
|
c. The enclosure shall be supplied with a No. 2 Pelco lock for security from unauthorized access and come with a minimum of one key. The keyhole for the lock shall have a cover attached to the door with a rivet.
|
|
d. The door shall cover the entire front of the cabinet and be constructed of a single piece of aluminum. It shall have a neoprene gasket around the entire edge of the door and have a louvered vent with screening on each side of each bay (a total of four vents). The louver screening shall be aluminum for longevity. An integral rain lip shall also be provided at the top of the main enclosure body to minimize entry of water. The door shall be attached to the unit using a continuous stainless steel hinge that is riveted to both the door and the body of the enclosure. The hinges shall be installed such that the rivets are not exposed when the door is closed. An integral rigid door stop shall be included in the unit so that the door can be fixed in the open position. An adjustable latch striker shall be included in the side of the main enclosure body to allow the user to adjust the pressure between the door gasket and the body of the enclosure.
|
|
e. Pole mounts shall be included as part of the enclosure and shall be suitable for mounting to a 4.5" OD pole. U-bolts and mounting hardware suitable for mounting to a 4.5" OD pole shall be included with the enclosure. The enclosure shall also be capable of accepting band style mounts, allowing it to be mounted to larger diameter poles (hardware supplied by the installer). |
|
System Documentation
|
| 1. Each system shall come with a complete "Installation and Owner’s Manual." As a minimum, the manual shall include the following information: |
|
a. Description of the crosswalk layout.
|
|
b. Installation of the inpavement fixtures.
|
|
c. Description of all the system components and their basic functions, including basic solar system theory (Solar Model). |
|
d. Description of the installation of the system controller.
|
|
e. Troubleshooting and maintenance of the system.
|
|
f. Complete drawings or illustrations throughout the manual to support and clarify the text.
|
|
g. Phone/FAX numbers for technical support of the system. Note: When requesting technical assistance, the system shall be identified by its part number and serial number which are located inside the enclosure.
|
|
h. Minimum page size of 8.5" X 11" to ensure drawings are large enough to be legible.
|
