DMS-11010, Roadway Illumination Light Fixtures

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1 Overview Effective Dates: August 2004 January 2008 (new Specification). This specification governs the materials, composition, quality, sampling, and testing of 150-, 250-, and 400-W, high pressure sodium (HPS), mast-arm-mounted, cobra-head style roadway illumination light fixtures. Bidders' and Suppliers' Requirements Only materials, with approved product codes or designations, from prequalified producers are accepted. The Traffic Operations Division (TRF) of the Texas Department of Transportation (TxDOT) maintains the material producers list of approved producer product codes or designations. Use the following link to view this list: ftp://ftp.dot.state.tx.us/pub/txdot-info/cmd/mpl/riaes.pdf. Use of prequalified materials does not relieve the contractor of the responsibility to provide materials that meet the specifications. All material may be inspected or tested at any time. Any material that does not meet the specifications and requirements of the plans will be rejected. Notify the Department in writing as to which fixtures from the prequalified list of fixtures will be supplied on each project. Sampling and Testing Costs for sampling and testing performed by the Department are normally borne by Department; however, the contractor or supplier will bear the costs for sampling and testing of failing materials. Charges are assessed at the rate established by the Director of the Traffic Operations Division (TRF) in effect at the time of testing. Amounts due the Department will be deducted from monthly or final estimates on contracts or from partial or final payments on direct purchases by the Department. Products will not be retested until costs for previously failed tests have been paid. will be sampled in accordance with "Tex-1110-T, Sampling Lighting Assemblies. Include the following in the test report: control-section-job (CSJ) number, maintenance contract number, or purchase order number assigned to the fixtures unique test number on each fixture tested date of manufacture Texas Department of Transportation 1 08/04 01/08

2 quantities supplied and lot number per fixture type. Write the unique lab report number on the top of the fixture housing with a permanent marker. Ensure test lab retains test results for 5 yr. and allows access to the documentation. Ensure manufacturer retains records of manufacturing lots, test reports, lot quantities, and other pertinent details. Submit this information to the Department when requested. Ensure manufacturer provides access to the following: manufacturing facilities involved in fixture production inventories of fixtures produced records of fixture testing and tracking. Issuance of Departmental Test Reports Departmental test reports will be issued as described below. For projects requiring 1 15 fixtures of a particular wattage, TRF, Traffic Engineering Section (TE) will authorize a passing test report when the following steps have been completed: review of the submittal letter from the contractor to the Department identifying the fixture supplied review of the test reports supplied by the manufacturer showing the fixtures meet the photometric requirements of the specification review of the history of testing from the manufacturer shows consistent passing of the electrical, photometric, and fixture-construction quality requirements. For projects requiring 16 or more fixtures of a particular wattage, TRF-TE will authorize a passing test report when the following steps have been completed: review of the submittal letter from the contractor to the Department identifying the fixture supplied review of the test reports supplied by the manufacturer showing the fixtures meet the photometric requirements of the specification review of the history of testing from the manufacturer shows consistent passing of the electrical, photometric, and fixture construction quality requirements fixtures are shipped to the project and 2 fixtures are sampled and tested by the Department in accordance with "Tex-1110-T, Sampling Light Assemblies review of the photometric test reports from the Department s test facility shows compliance with the specification and comparison to photometric reports supplied by the manufacturer are within the tolerances allowed by the specification. Texas Department of Transportation 2 08/04 01/08

3 Prequalification Submit 1 sample of each type of fixture; submit 2 copies of catalog sheets for each fixture; submit published photometric data and recently tested photometric data (IES format, averaged and both sides of un-averaged data) for evaluation to: Texas Department of Transportation, Traffic Operations Division, Traffic Engineering Section, 125 East 11 th Street, Austin, Texas Provide additional samples when directed by the Department. Approved samples will be retained by the Department for comparison testing. Do not change material or manufacturing methods of approved fixtures without prior approval by the Department. Unapproved changes may result in removal of the manufacturer from the prequalified list for 1 yr. Texas Department of Transportation, Traffic Operations Division, Traffic Engineering Section (TRF-TE) tests samples for specification compliance and updates the list to include materials that meet specification requirements. If materials fail to meet any of the specification requirements, the producer may not resubmit for prequalification until 1 yr. from original evaluation date. TRF-TE may waive this time limit if provided with documentation from an independent testing facility stating the materials meet all requirements. TRF-TE will enforce the 1-yr. time limit if, after retesting, the material again fails any of the specification requirements. All materials submitted for prequalification tests will be at no cost to the Department. that inconsistently pass testing or are inconsistent with published photometric information will be removed from the prequalified list at the discretion of the Department. Provide a warranty that provides for the replacement of any fixture that fails to operate properly at any time up to 5 yr. from the date of installation. The manufacturer must deliver the replacement fixture to the installation site at no cost to the Department. Replacement fixtures must be on the prequalified list and pass all required testing or, if directed by the Department, the original cost of the fixtures may be refunded to the Department. QA/QC Requirements Submit QA/QC program documentation. Provide a written statement of the company s QA/QC policy. Provide the name of the QA/QC person employed who has special QA/QC training and has QA/QC as their primary job responsibility. Provide a written procedure specifically for handling orders for fixtures built to Department specifications. Provide a written procedure for keeping track of fixtures built, certified, and tested for Department orders. Provide a checklist of features for Department fixtures with QA/QC person s signature. Provide documentation of manufacturer s production line test requirements. Texas Department of Transportation 3 08/04 01/08

4 Material Requirements General Provide UL listed fixtures suitable for use in wet locations. Adjacent to the ballast, provide a label indicating that the fixture meets or exceeds IES Standard 529-IP 65. Label fixtures with date of manufacture. Meet ANSI wattage label requirements. Construct fixture housing, lens frame, and door from 96% copper-free, die-cast aluminum. Provide for fixture mounting to a 2-in. pipe arm. Equip fixture with a 4-bolt clamp capable of adjustments ±5 from level. Attach a level bubble to the fixture housing. Ensure level bubble is sensitive to 1 changes in position at any point within 5 of the level position. Ensure level bubble is clearly visible from the ground up to a 50 ft. mounting height. Meet ANSI , 3.0 G vibration requirements. Do not exceed 1.6 sq. ft. effective projected area. Do not exceed 60 lb. maximum weight. Equip fixture with a 3-prong photocell and shorting cap. Paint fixtures light gray when installing on galvanized poles. For all other fixtures, paint to match the color of the pole as directed by the Department. Use a thermoset powder-coat paint system. Ensure paint exceeds 1000-hr. salt-spray test in accordance with ASTM B117. Ensure a nominal paint thickness of 2.5 mil and no pigment loss upon 50 double-rubs using Methyl Ethyl Ketone (MEK) solvent per ASTM D5402, "Standard Practice for Assessing the Solvent Resistance of Organic Coatings Using Solvent Rubs." Use Type 316 stainless-steel hardware, brackets, nuts, bolts, washers, ballast tray, and parts except that: Hardware, brackets, nuts, bolts, washers, ballast tray, and parts may be fabricated from aluminum of adequate thickness as approved by the Department. Galvanize the 4 bolts, 4 flat washers, 4 lock washers, and clamp that attach the luminaire to the arm in accordance with ASTM A123 or A153. Glass lens retainer spring clips may be fabricated from galvanized steel in accordance with ASTM A153. Provide nylon throat-locking means for all stainless steel nuts. Texas Department of Transportation 4 08/04 01/08

5 Provide porcelain-insulated lamp sockets with nickel plated copper alloy screw shells. Equip socket shell with a spring tensioned contact. Use nickel-plated copper alloy or stainless steel for the spring and contact. Use nickel-plated copper alloy or stainless-steel screws to hold shell into socket, if necessary. Provide UL listed mogul base lamp sockets rated for 600 V, 1500 W that can withstand a 5000 V pulse. Meet UL 496 requirements. Provide one-piece or segmented polished aluminum reflectors coated with Alzak or another approved coating. Provide a direct seal between the glass lens and one-piece reflector to form an airtight envelope. Use seamless or vulcanized seam, closed-cell silicone to seal the reflector to glass lens. Use a non-adjustable lamp socket. Mount the lamp socket to the reflector so the lamp center is consistent. Use a one-piece seamless silicon gasket between the lamp support bracket and the reflector and lens assembly. Ensure segments of segmented reflectors attach at both ends (or opposite sides if segments are square) of the segment to a rigid aluminum base plate and side-wall support assembly. Use 92% reflective white paint on segment support base. Use a one-piece seamless silicon gasket or sealant to seal the glass lens to the lens frame assembly. Provide additional lamp support in the optical assembly to further stabilize the lamp within the lamp socket. Ensure the lamp center is positioned correctly so that the photometric performance of the fixture is the same as the standard used to publish the photometry. Construct lenses a minimum 3/16 in. thick using either clear, heat-tempered or borosilicate glass. Lens style may be sag or flat. Do not fuse pole-mounted luminaires. Fuse wall- or underpass-mounted luminaires with internal 10-amp, time-delay fuses. Equip fixture with a 2-position porcelain or phenolic insulated terminal block for landing supply wires. Provide phenolic terminal blocks that are of adequate strength as approved by the Department. Construct terminals from nickel, tin-plated brass, or aluminum. Use IEEE recommended MOV surge protectors. Connect MOV from line to neutral or from line to line. Connect MOV to the terminal board. Texas Department of Transportation 5 08/04 01/08

6 Lamp Requirements Provide Osram Sylvania Lumalux Plus high pressure sodium (HPS) lamps of the wattages shown on the plans, with the fixtures. Do not provide any other type of lamps. Ensure lamp fully extinguishes at the end of usable lamp life and remains extinguished without cycling. Do not provide lamps that burn at reduced output at end of life. Meet the Federal Toxic Characteristic Leachate Procedure (TCLP). Provide 55-V, 150-W lamps for 150-W fixtures. Supply lamps with fixture. Ballast Requirements Mount ballast and starter in a removable stainless-steel or aluminum tray of adequate strength as approved by the Department. Place a fixture wiring diagram on or near the ballast. Provide magnetic-regulating type, copper-wound ballast with 3 isolated coils. Ensure ballast factor is between 0.95 and 1.0. Permanently and clearly mark ballasts with the following information: lamp type catalog number voltage rating connection diagram manufacturer UL listing. Do not exceed the following ballast input wattages when the rated circuit voltage is fluctuated ±10%: 220 W for 150 W nominal lamp rating 440 W for 250 W nominal lamp rating 552 W for 400 W nominal lamp rating. Do not exceed a total of 20% lamp wattage fluctuation when the test voltage is varied plus or minus 10%. Maintain lamp wattage within the following limits: 110 W min. and 180 W max. for 150 W nominal lamp rating 175 W min. and 370 W max. for 250 W nominal lamp rating 280 W min. and 475 W max. for 400 W nominal lamp rating. Ensure the ballast power factor, when tested at the circuit voltage indicated on the plans, is not less than 90%. Texas Department of Transportation 6 08/04 01/08

7 Pass "Tex-1130-T, Ballasts of Lighting Assemblies. Pass "Tex-1140-T, Electronic Starting Aids of High Pressure Sodium Vapor Lighting Assemblies. Provide a starting pulse with amplitude of 2500 V minimum, 4000 V maximum. Ensure pulse width is a minimum of 0.8 microseconds at 2250 V. Ensure pulse width occurs when the open-circuit voltage is equal to or greater than 90% of peak open-circuit voltage. Ensure pulse repetition rate is a minimum of 1 per cycle. Ensure pulse current is a minimum of 0.18 amperes. Ensure starting aid discontinues pulsing when the lamp starts, or after a minimum of 3 min. and a maximum of 10 min. if the lamps fails to start. Photometric Requirements will be evaluated using published photometric data and photometric data obtained by testing sampled fixtures. Meet IESNA cutoff requirements for 150-W luminaires. Provide a minimum intensity of 0.20 foot-candle in a rectangular area measuring ft. by 30.0 ft. when mounted in a level position as indicated on the properly mounted fixture level bubble 20.0 ft. above the midpoint of either long side of the surface area. Do not exceed 50:1 maximum-to-minimum horizontal illuminance uniformity ratio within this rectangle. Meet IESNA Cutoff requirements for 250-W luminaires. Provide a minimum intensity of 0.20 foot-candles in a rectangular area measuring ft. by 45.0 ft. when mounted in a level position as indicated on the properly mounted fixture level bubble 40.0 ft. above the midpoint of either long side of the surface area. Ensure light intensities along a line parallel to and 20.0 ft. in from the long side of this rectangular area do not decrease by more than 0.50 foot-candles in any 5.0 ft. interval along the line from 10.0 to 90.0 ft. on both sides of the luminaire and provide a minimum intensity of 0.30 foot-candles at any point along the line. Do not exceed 20:1 maximum-to-minimum horizontal illuminance uniformity ratio with this rectangle. Meet IESNA Cutoff requirements for 400-W luminaires. Provide a minimum intensity of 0.20 foot-candles in a rectangular area measuring ft. by 60.0 ft. when mounted in a level position as indicated on the properly mounted fixture level bubble 50.0 ft. above the midpoint of either long side of the surface area. Ensure light intensities along a line parallel to and 30.0 ft. in from the long side of this rectangular area do not decrease by more than 0.75 foot-candles in any 10.0 ft. interval along the line from 10.0 to 90.0 ft. on both sides of the luminaire and provide a minimum intensity of 0.30 foot-candles at any point along the line. Do not exceed 20:1 maximum-to-minimum horizontal illuminance uniformity ratio with this rectangle. Texas Department of Transportation 7 08/04 01/08

8 Ensure un-averaged photometric performance matches published data or approved photometric reports (submitted during the prequalification process as the typical photometric output in lieu of published data) as follows: Ensure the points of maximum candela on tested fixture are within 5, both horizontally and vertically, of maximum candela points on approved data. Ensure points of maximum candela are within 20% of approved maximum candela. Ensure fixture efficiency is within 10% of the approved efficiency as determined by the Department. Texas Department of Transportation 8 08/04 01/08