ITEM 599.06300008 – BRIDGE ELECTRICAL AND CONTROL …ITEM 599.06300008 – BRIDGE ELECTRICAL AND CONTROL SYSTEM Page 4 of 24 02-12-2020 3. The Electrical Contractor shall have been

ITEM 599.06300008 – BRIDGE ELECTRICAL AND CONTROL SYSTEM

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DESCRIPTION 1.1 WORK DESCRIPTION

A. This work shall consist of: 1. On the City of Kingston side, the contractor is responsible for removing excess

vegetation around the new bridge utility pole, installing new conduit and conductors on the new bridge utility pole, and installing new service entrance disconnect switches, utility meter sockets, and network service equipment on the west face of the north abutment wall. Refer to Electrical Plans for pole locations. Coordinate with Central Hudson Gas and Electric Corporation and the local network provider as required to perform this work.

2. On the Town of Esopus side, the Contractor is responsible for installing the new bridge service pole, conduits and conductors on the new bridge service pole, and service meter sockets and service entrance disconnect switches on the east face of the south abutment wall. Refer to Electrical Plans for pole locations. Coordinate with Central Hudson Gas and Electric Corporation as required to perform this work.

3. Remove existing electrical conduit and wire, junction boxes, flexible cables, panelboard, and associated mounting hardware on bridge span and north and south approaches.

4. Furnish and install power distribution panels and mini power centers in northwest and southeast chambers.

5. Furnish and install roadway lighting control cabinets and components inside the northwest and southeast chambers.

6. Furnish and install safety disconnect switches for dehumidifier equipment inside all 4 chambers.

7. Furnish and install raceway systems, pull boxes, terminal boxes, power wiring, control wiring, and communication wiring inside all 4 chambers and on bridge span.

8. Furnish and install PLC (Programmable Logic Controller) based system with control devices for control and monitoring of dehumidification equipment and roadway lighting.

9. Furnish and install maintenance receptacles and utility lighting in all 4 chambers. 10. Furnish and install decorative lighting control system for local and remote

control and monitoring of the color changing necklace lighting fixtures and LED adjustable flood lighting fixtures.

B. This section covers the electrical requirements for supply, service, delivery, storage, installation, testing and commissioning of bridge power and control system.

C. Provide supervision, labor, and assistance to manufacturer’s field representative

and/or technical directors for equipment to be installed as a part of this Contract.

D. The Contractor shall provide the services of qualified control system vendor to


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design, configure, program, and furnish a fully functional control system as described on the Plans and by these Special Provisions. All software (developmental and runtime), passwords, and hardware required to configure, modify, and operate this system shall be included in this Contract and shall be turned over to NYSDOT at the completion of the work. All applicable drawings, PLC programming, HMI programming, decorative lighting controller programming, and device configurations shall not be considered proprietary and all final installations shall be solely owned by NYSDOT.

E. All provisions of Section 670 shall apply to this specification except as modified

below. 1.2 REFERENCES

A. Electrical systems shall be engineered, manufactured and installed in accordance with the National Electrical Code.

B. The design and engineering of the electrical installation shall satisfy all requirements of the federal, state, and local authorities. The electrical installation shall be suitable for the site conditions as specified. Where relevant, the specific publications are referenced herein.

C. The following documents form part of the specification to the extent stated. Where

differences exist between codes and standards, the one affording the greatest protection shall apply. Unless otherwise noted, the referenced standard edition is the current one at the time of commencement of the work:

1. Occupational Safety and Health Administration – OSHA

2. National Electrical Safety Code - NESC 3. The American Association of State Highway and Transportation Officials –

AASHTO

4. National Fire Protection Association – NFPA

ANSI/NFPA 70 - National Electrical Code ANSI/NFPA 70B - Recommended Practice for Electrical Equipment Maintenance ANSI/NFPA 70E - Standard for Electrical Safety in the Workplace

ANSI/NFPA 101 - Life Safety Code

5. Institute of Electrical and Electronic Engineers – IEEE ANSI/IEEE C2 - National Electrical Safety Code


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ANSI/IEEE 43 - IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery

IEEE 81 - IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System Part I: Normal Measurements

IEEE 100 - The Authoritative Dictionary of IEEE Standards Terms

IEEE 519 - IEEE Recommended Practice and Requirements for Harmonic Control in Electric Power Systems

IEEE 1584 - IEEE Guide for Performing Arc-Flash Hazard Calculations

IEEE 1584a - IEEE Guide for Performing Arc-Flash Hazard Calculations – Amendment 1

6. International Electrical Testing Association – NETA

ANSI/NETA ETT - Standard for Certification of Electrical Testing Technicians

ANSI/NETA ATS - Acceptance Testing Specifications for Electrical Power Equipment and Systems

7. National Electrical Manufacturers Association – NEMA

NEMA AB4 - Guidelines for Inspection and Preventive Maintenance of Molded-Case Circuit Breakers Used in Commercial and Industrial Applications

1.3 QUALIFICATIONS AND RELATED REQUIREMENTS All contractors and/or sub-contractors undertaking electrical work related to this project shall be properly qualified, skilled, and experienced in the type of work involved. All vendors and manufacturers selected by the Contractor to provide products for this project shall be properly qualified, skilled, and experienced in the fabrication and/or manufacturer of the products involved. The Contractor will not be relieved of the responsibility to satisfy the requirements of the contract due to lack of qualifications, skills, or experience, stated or implied, of any contractor, sub-contractor, vendor, and/or manufacturer. A. Electrical Contractor

1. The Electrical Contractor shall be qualified to perform the work in the State of New York and be primarily and regularly engaged in the installation and service of industrial electrical power distribution and control systems.

2. The Electrical Contractor shall employ on site supervisory personnel who are licensed electricians experienced in the installation and maintenance of industrial electrical power distribution and control systems.


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3. The Electrical Contractor shall have been in the business of installing and servicing industrial electrical power distribution and control systems for at least ten continuous years as of the bid date.

4. In lieu of sub-contracting the electrical work to a separate Electrical Contractor, Prime Contractor personnel satisfying all of the above requirements may perform the electrical work.

5. Documentation demonstrating that the Electrical Contractor satisfies the requirements of these Special Provisions shall be provided prior to commencing any electrical work. If no separate sub-contractor is to be used, the Prime Contractor shall be clearly identified as the Electrical Contractor and documentation demonstrating that the Prime Contractor satisfies the requirements of these Special Provisions shall be provided.

B. General Vendors and Manufacturers 1. Vendors and/or manufacturers for electrical systems, sub-systems, and/or

products, other than the control system, shall be primarily and regularly engaged in providing the items for which they are responsible.

2. Contractor’s personnel and subcontractors shall be properly licensed for the type of work being performed.

C. Control System Vendor

The Control System Vendor shall be primarily and regularly engaged in the integration, installation, startup, and maintenance of industrial control systems, with demonstrable experience with PLC and HMI programming.

D. Decorative Lighting System Vendor

The Decorative Lighting System Vendor shall be primarily and regularly engaged in the integration, installation, startup, and maintenance of the decorative lighting systems including controls, light fixtures, and associated equipment.

1.4 SUBMITTALS A. Submit shop drawings for the required work and product data to include, but to not be

limited to, the following requirements applicable to all electrical work for this project: 1. Full schematic wiring diagrams depicting all required power and control wiring. 2. Field hook-up drawings. 3. Layout drawings showing the installation of the new equipment, and related

existing equipment and devices and required NEC workspace. 4. Complete bill of materials for all components. Present bill of materials in tabular

format. Clearly identify all components by designation and/or description, along


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with manufacturer's name and complete model or catalog number. 5. Ensure the required component descriptive data and system shop drawings are

submitted all together as a single package. 6. Installation drawings clearly illustrate the physical relationship between new and

existing components and features, including mounting methods and critical dimensions. All pertinent information regarding existing features, dimensions, etc., must be field verified by the Contractor prior to preparation of the drawings. Ensure dimensions obtained by field measurement are clearly indicated as such on the drawings. Ensure all equipment and/or materials are approved by the Engineer and the NYSDOT prior to their use/installation on this project.

7. Proposed PLC ladder logic and color HMI screen layouts. 8. Test reports and calibration data. 9. Training materials. 10. Paint and coating systems product data, application methods, and proposed colors. 11. Proposed decorative lighting control system layouts, including equipment layouts,

north decorative lighting rack layouts, control wiring layouts, and programming software screen layouts.

B. Do not perform any work without approved shop drawings. C. Submit brochures, catalog cut, certified prints with certified ratings and dimensions,

specification sheets, and other product literature for all products. D. Submit certified drawings for products when requested by the Engineer or as

otherwise required by the contract. Certified drawings must clearly depict all critical dimensions, as well as all electrical and mechanical ratings. Manufacturer's standard catalog drawings are not acceptable in place of certified drawings.

E. Each set of product submittal information must cover only one distinct product. F. Submit assembly drawings for fabricated items and assemblies. Detail custom or

commercial mounting hardware and mounting brackets. G. Clearly show on drawings the proposed method of attachment, mounting details,

specific hardware, holes to be drilled or cut in structural steel or masonry, etc. H. On conduit and raceway layout diagrams, show each raceway utilized, with all wire

numbers installed therein, in tabular or spreadsheet format. Use different symbols to clearly distinguish between underground, concrete encased, in-wall, and exposed conduits, as well as flexible cables, junction boxes, terminal cabinets, equipment, and enclosures. Fully coordinate drawings with all wiring diagrams, tabulations, and shop drawings.

I. Provide conduit and conductor tabulations to clearly indicate all wire numbers passing through or terminating in each raceway, box, cabinet, and equipment enclosures. Tabulate all raceways, boxes, cabinets, and equipment enclosures, device served and function of each conductor, and spare conductors with assigned wire numbers.

J. On multi-line power wiring diagrams, show all circuit phase, neutral, and grounding


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conductors. Identify all conductors on the diagrams by wire numbers that match the same respective conductors or connections shown on other diagrams and shop drawings. Clearly indicate the size and type of all conductors on wiring diagrams. Wiring diagrams are not intended to be to scale, but must show all equipment, terminal cabinets, splices, etc. Show items in their approximate geographic orientation to each other to the extent practical.

K. Submit drawings and installation procedures to the Engineer for review and approval, showing how each item will be mounted. Describe all installation procedures including alignment, testing, calibration, waterproofing etc. as recommended by the manufacturer of the equipment being installed.

L. Submit as-built PLC ladder logic documentation for inclusion in O&M manuals with complete documented program listing with cross references, contact labels and rung comments. An electronic searchable “PDF” version of the program listing shall also be provided. A complete electronic backup of the ladder logic program including all labels, configuration, and all related files in a format that can be read and downloaded by the PLC programming software shall also be provided.

M. As-built electronic backups shall be provided for the HMI display and lighting controller system. All reference data files, communications driver configuration, and source code shall be provided.

1.5 QUALITY ASSURANCE

A. Regulatory requirements: Perform electrical construction in accordance with industry acceptable practice and complies with applicable country, region and local codes.

B. Equipment and components shall be listed and labeled by Underwriter’s Laboratories (UL) or other nationally recognized testing laboratory. Equipment shall comply with all applicable (IEEE) standards. Components for use in hazardous locations shall be UL- listed or Factory Mutual (FM)-approved for the hazardous classification, division, and group.

C. Manufacturer of equipment specified shall be recognized in industry for normally supplying this type of equipment. Manufacturer shall be ISO certified.

D. Contractor shall develop detailed, step by step, testing and commissioning plan for placement of electrical equipment, apparatus, and completed electrical system in service. Contractor shall execute the plan and document the performance and test results. Contractor shall take corrective actions necessary to bring the failed and/or noncompliance test results into conformance at no additional cost to the Owner.

1.6 DELIVERY, STORAGE, AND HANDLING A. Pack, ship, handle, and store all equipment in accordance with manufacturer’s

requirements. B. Ship equipment completely factory assembled unless physical size, arrangement,

configuration, or shipping and handling limitations make this impracticable. Shipping splits and required field assembly shall be identified with equipment


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submittals. Shipping splits shall be provided with clear instructions for field assembly and designated interconnection terminations for interconnection between the shipping splits.

C. Separately packaged parts and accessories shall be consolidated and shipped together with equipment. Mark each container clearly to identify contents and as belonging with main equipment.

D. Equipment shall be protected against damage during shipment, handling, and storage. Damage incurred during shipment shall be repaired at no cost to Owner.

MATERIALS

2.1 PROGRAMMABLE LOGIC CONTROLLER A. Modular PLC hardware platform shall support distributed control architecture with

remote I/O using Ethernet networking (copper and fiber media). B. PLC hardware shall have UL 508 and CE approvals. C. Operating range shall permit extended operating temperature of -40 to +70 deg C

and 5-95% relative humidity. D. PLC shall support remote programming capabilities, utilizing HTML, DHTML,

Javascript, JSP, etd. for web-based application monitoring of the system with diagnostic tools, logging, and alarms. NYSDOT personnel shall use a web browser to access the PLC system to view various indications and live and historical feed from the PLC. Web-based monitoring shall have the capability to display all functions and/or indications as the local HMI’s. The remote processing shall be performed on the client workstation with no limit to the number of workstations that may be connected to the server. Additional management software shall be provided for multilevel security and implemented by the System Integrator. Access to the web browser shall be password protected to prevent unauthorized use of the system.

E. PLC processors shall have Ethernet and serial/USB communications ports. Remote I/O communication modules shall have Ethernet communications port.

F. Compatible Ethernet I/O (Input/Output) modules from the PLC manufacturer including digital inputs, digital outputs, relay outputs, and analog inputs shall be provided as shown on the Plans. Voltage ratings for I/O modules shall be coordinated as required for equipment to be controlled and monitored.

G. Provide all related accessories including terminal blocks, mounting hardware, cover plates, and labels.

H. PLC shall support ladder logic programing and include program documentation capability (address labels, rung comments, cross referencing).

I. PLC and I/O hardware shall be housed in appropriately sized NEMA 4X stainless steel wall mount type control cabinets. The Control System Vendor shall be responsible for designing, building, and testing the control cabinets. Each control cabinet shall have all necessary power and control terminal blocks, surge protection,


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supplementary circuit protectors, plastic wire duct, DIN rail, Ethernet switch, DC power supply(s), interposing relays, and other components as required to provide a complete functional system.

J. Control cabinet conductor color coding shall follow UL 508A for Industrial Control Panels. All point-to-point wiring internal to the control cabinets shall be stranded copper type THWN-2, MTW, or approved equal. Control wiring shall be minimum 14 AWG, unless a smaller size is approved by the Engineer for wiring interconnections to I/O modules. Power wire shall be minimum 10 AWG.

2.2 HUMAN MACHINE INTERFACE (HMI)

A. HMI’s shall be compatible with the PLC system and shall include all necessary communications drivers and hardware.

B. HMI’s shall have UL approvals and shall be rated NEMA 4X. C. Operating range shall be 0 to +50 deg C and 20-85% relative humidity. D. HMI’s shall have Ethernet communications port. E. Full color touchscreen display shall be 7”. F. Minimum of 32MB flash memory and 64MB SDRAM storage. G. HMI software shall provide configurable animated tools including switches,

pushbuttons, numeric displays, numeric data entry, real time clock, color indicators, alarm indication, and graphing/trending.

H. Software and HMI shall include integrated web server for remote access capabilities to allow HMI screens to be remotely and securely monitored.

I. . Provide complete programming software and all necessary cables. J. Provide external mouse and keyboard.

2.3 DISTRIBUTION PANEL

A. Distribution panel shall be UL Listed and rated for use as Service Equipment. B. Phase, neutral, and ground buses shall be constructed of hard-drawn copper. C. Equipped with thermal-magnetic molded case circuit breakers, with ratings as shown

on the Plans. Circuit breaker connections to the copper bus shall be bolt-on with vibration-proof hardware.

D. Panelboard bus bar connections to the branch circuit breakers shall be the "distributed phase" or "phase sequence" type. Three-phase, four-wire bussing shall be such that only three adjacent single-pole breakers are individually connected to each of the three different phases in such a manner that two- or three-pole breakers can be installed at any locations.

E. Provide appropriately sized NEMA 4X stainless steel enclosures for distribution panels with three-point latch system and lockable handle with ten spare keys.

F. Provide a typewritten or computer printed circuit directory to indicate installed


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circuit loads. G. Include integral SPD, 100kA minimum interrupt rating.

2.4 ROADWAY LIGHTING CONTROL PANEL

A. Roadway lighting control panel shall house molded case circuit breakers, lighting contactors, power distribution blocks, ground bars, and terminal blocks.

B. Circuit breakers shall be bolt on, molded case style circuit breakers, rated for 600VAC with a minimum interrupt rating of 18kA at 480VAC. Current rating and pole quantity as shown on the plans.

C. NEMA 4X stainless steel enclosure, details and size as shown on the contact Plans.

D. Lighting contactors shall be UL Listed, 22kA minimum interrupting rating at 480V, 120VAC coil voltages @ 60Hz, current rating and pole quantity as shown on the plans.

2.5 MINI POWER CENTER

A. Transformer/panelboard combination unit power centers shall be supplied at locations shown on the Plans.

B. Power centers shall be UL listed, NEMA 4X rated for outdoor installation, copper bus, configured for plug-on style breakers. Minimum 18kA interrupt rating.

C. Power centers shall include primary breakers, secondary breakers, and branch circuit breakers as shown on the Plans.

D. Provide a typewritten or computer printed circuit directory to indicate installed circuit loads.

2.6 HUMIDITY AND TEMPERATURE SENSORS

A. Combination wall mount type transmitter with integral probe shall be capable of measuring relative humidity and temperature.

B. Sensors shall have rugged IP65 housing with backlit LCD display to display current relative humidity and temperature.

C. Operating voltage for sensors shall be 10-35VDC. A minimum of two (2) configurable analog outputs shall be provided to permit the PLC to monitor the scaled relative humidity and temperature values. Analog outputs shall be 4-20mA current type outputs or 0-10VDC voltage type outputs as required to be compatible with the PLC’s analog inputs.

D. Humidity Sensor Range: 0 to 100% relative humidity. Accuracy +/-1% RH (0..90%).

E. Temperature Sensor Range: -40 to +140 degrees F (-40 to +60 degrees Celsius). F. Provide all necessary programming software and cables.


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2.7 DEHUMIDIFIER DISCONNECT SWITCHES A. Disconnect switches shall be UL listed, heavy duty, non-fused, 600-volt, NEMA 4X

rated, stainless steel type. Disconnect switches shall meet NEC 430 requirements for separate disconnecting means within sight of motor loads. The handle shall have provisions for padlocking the switch in the off position.

2.8 CHAMBER LIGHTS AND RECEPTACLES

A. Anchorage chamber lights shall be rough service LED type, UL listed for wet locations, IP66, 120VAC, 60Hz, rated for -29 to 40 degrees Celsius operation, Enclosure shall be gasketed polycarbonate or powder coated aluminum, ceiling or suspended mount, with frosted polycarbonate lens and stainless steel hardware.

B. Receptacles shall be duplex GFCI type with LED power and tripped indicators, heavy duty industrial grade, UL listed, weather resistant, 120VAC, 20A. Receptacles shall include cast aluminum weatherproof device box with heavy duty metallic while-in-use cover plate rated for damp locations.

2.9 TERMINAL BLOCKS

A. Power type terminal blocks shall be UL recognized, 600V AC/DC rated, and rated for use with copper conductors. Blocks shall be enclosed finger safe type or shall be supplied with manufacturer’s protective covers. Number of poles, amp rating, and wire size configuration shall be as required for the associated conductors.

B. NEMA type terminal blocks shall be UL recognized, screw clamp type, corrosion resistant zinc plated brass and copper construction, 600V AC/DC rated, minimum 25A.

C. IEC type terminal blocks for control wiring shall be UL recognized, finger safe, DIN rail mount, screw type, and with corrosion resistant plated components. Rating shall be a minimum of 300V AC/DC and 10A.

D. Provide all required accessories for terminal blocks including DIN rail, separation/end plates, retainers, jumpers, ground blocks, labels, and hardware.

2.10 BRIDGE SERVICE POLE A. New bridge service pole shall be Class 2, Southern Yellow Pine or Douglass Fir

treated wood pole or approved equal. B. Minimum pole height shall be 45’ and pole setting depth shall be according to

Central Hudson Gas and Electric Corporation standards. 2.11 POLE HARDWARE

A. Pole hardware (cross arms, braces, pins, insulators, cutouts, bolts, arrestors, etc.) shall be of a type specifically developed for utility pole line installation in accordance with Central Hudson Gas and Electric Corporation.

2.12 GUY ASSEMBLIES A. Guy wire shall be aluminum coated steel with a minimum Rated Breaking Strength


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(RBS) of 11367 lbs or greater as required by the work. Anchor Rods or Helix shall be appropriate for the soil conditions on site. Other required hardware shall be in accordance with Central Hudson Gas and Electric Corporation standards.

2.13 SERVICE ENTRANCE DISCONNECT SWITCH A. The circuit breaker shall be 480/277 VAC rated, 100A frame, trip setting as shown

on the Plans, 3 poles, and shall have a minimum interrupting rating of 22KAiC at 480VAC.

B. The service entrance disconnect switch enclosure shall be NEMA type 4X, stainless steel, type 304, and shall be suitable for service entrance application. The operating handle shall be capable of being padlocked in the OFF position and shall be interlocked with the door to prevent the door from opening when the breaker is ON.

C. The enclosure shall be supplied with insulated and groundable neutral kits, and breather and drain. Refer to Electrical Plans for additional requirements.

2.14 METER SOCKETS A. Meter sockets shall be according to Central Hudson Gas and Electric Corporation

standards. The Contractor shall coordinate with the Utility for approval prior to purchase.

B. Meter socket shall be UL listed, ringless, single position, rated for 200A and 480/277VAC, 3phase, 4 wire, 7 terminal, suitable for overhead or underground service, and provided with a lever bypass.

2.15 FIREWALL ROUTER A. Firewall router shall be industrial type, security network interface. Router shall have

an integrated managed 4-port ethernet switch to receive incoming ethernet-based network connection and distribute outgoing, individually isolated ethernet-based connections to the decorative lighting controller and PLC.

B. Router shall have a replaceable SD memory slot for configuration of the software. A redundant SD memory card shall be provided with pre-programmed software.

C. Router shall include web-based management software for local and remote programming of the router. Router shall provide maximum security of network with IPsec protocol on Layer 3.

2.16 DECORATIVE LIGHTING CONTROLLER

A. The decorative lighting controller shall be a microprocessor-based system specifically designed for control of RGBW decorative lighting fixtures in an architectural application.

B. The controller shall include programmable software, accessible from the local rack-mounted PC, with features including but not limited to: 1. Timeline-based programming and playback.


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2. Discreet input triggering options for control of the fixtures. 3. Comprehensive architectural and automated fixture library. 4. Tools for remote management of content and show programming.

C. Controller shall have internal real-time clock that continues to operate when external power is absent. It shall be capable of adjusting for daylight saving time automatically.

D. Controller shall have a capacity of 512 channels of DMX512 with RDM and network ethernet-over-DMX protocols for communication with 4-port gateways.

E. Controller shall store data in a non-volatile solid-state removable memory. Show data can be downloaded to controller via ethernet or USB connection. The operating software shall be stored in a dedicated non-removable software.

F. The controller shall be DIN rail mountable. G. The controller shall have local digital inputs for contact closure operating mode. H. The controller shall have a RJ45 socket for 10/100Based-TX ethernet connection. I. The lighting controller shall be locally controlled and programmed via rack-mounted

PC. For remote control and monitoring operations, the rack-mounted PC shall be accessed by utilizing Remote Desktop Systems Protocol (RDP), provided by the Windows Operating system installed on the rack-mounted PC or other licensed and installed remote desktop software.

J. Provide all related accessories including terminal blocks, mounting hardware, cover plates, and labels.

2.17 4-PORT GATEWAYS

A. Lighting control gateways shall be a microprocessor-based unit specifically design to provide DMX-512 control of lighting systems and be compatible with the decorative lighting controller. The gateway shall permit DMX-512 data to be encoded, routed over an ethernet network, and decoded back to DMX-512. Connections shall be made between gateways, lighting controller, and rack-mounted PC over standard Ethernet distribution systems utilizing 10/100BaseT connection.

B. The gateway shall have 4 individual DMX ports and comply with the requirements of ANSI E1.11 USITT DMX512-A standards. Each port shall incorporate one DMX512-A connection and control up to 512 DMX addresses.

C. The gateway shall support RDM (ANSI E1.20) D. The gateway shall be DIN rail mountable. E. The gateway shall contain Ethernet RJ45 connections, utilizing CAT5e cabling.

2.18 NORTH DECORATIVE LIGHTING RACK

A. The North Decorative Lighting Rack (NDLR) shall house the decorative lighting


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controller, rack-mount PC, two (2) 4-port gateways, ethernet switch, and equipment as shown on the Contract Plans.

B. NEMA 4X stainless steel enclosure, suitable for standard 29-inch depth equipment, front and rear doors with lockable latches, details and size as shown on the Contact Plans.

C. All necessary mounting hardware, patch cords, and accessories shall be provided to install the equipment listed above and shown on the Contract Plans to allow for ease of access to rack-mount PC.

D. Provide 120VAC heater and air conditioning unit sized to keep equipment inside NDLR within manufacturer recommended temperature values.

2.19 MISC. ELECTRICAL COMPONENTS

A. Ethernet switches shall be industrial type, having communications protocol capability as required for PLC, HMI, and decorative lighting controller equipment. Operating range shall be -40 to +167 deg F and 5-95% relative humidity. Switches shall have RJ45 10/100 Mbps copper and fiber optic ports as shown on the Plans with at least one spare copper port per switch. Provide multimode fiber optic ports compatible with connected fiber optic cable type and network optical transmission characteristics.

B. DC power supplies shall be industrial type, UL recognized or UL listed, DIN rail mount with finger safe terminals, 100-240VAC input/24VDC output, and with current rating as required for application. Operating range shall be -13 to +158 deg F and 5-95% relative humidity. Power output shall be as required to service control system and devices as shown on the Contract Plans.

C. Supplementary circuit protectors and fuses shall be provided to protect individual control components and where required by the NEC and shown on the Plans. Circuit protectors shall be UL recognized, DIN rail mountable type with tripping characteristic curve to match device type to be protected, sized as required for connected devices and conductors.

D. Fuses shall be fast acting type, sized as required to prevent nuisance openings under normal operating conditions, and rated for use in control circuits. Holders for fuses shall be DIN rail mountable style, finger safe, and shall include LED or neon blown fuse indicators.

E. SPD’s shall be installed for the incoming 120VAC control power for each control cabinet. SPD’s shall be UL1449 4th Edition recognized, DIN rail mount, with replaceable plug in module, minimum 40kA, rated for 120VAC, with visual status or fault indication

F. Control relays shall be UL listed general purpose plug-in type relays with DPDT contacts rated 10 amperes at 300 volts AC, 60 hertz. Relays shall include a LED indicator light, neon indicator light, or mechanical flag for indicating when the relay is energized. Sockets suitable for DIN rail or panel mounting, with retainer clips,


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shall be provided for each relay. Control relays shall be used for interfacing with lighting contactors, indicator lights, interfacing with other systems, or for isolating PLC inputs and outputs. Control relays are used in the PLC cabinets and I/O cabinets shown on the Contract Plans.

G. Alarm indicator lights shall be UL listed, LED type, NEMA 4X, IP67 rated, flat mount, 88mm polycarbonate base and translucent polycarbonate dome, 18-40VDC operating voltage, color as shown on the Contract Plans.

H. Anchorage chamber door switches shall be as detailed on the plans. I. Ethernet cable shall be rated TIA/EIA Category 5e, NEC type CM, CMR, CMB or

equivalent, shielded, with bonded pairs, and suitable for installation in raceways or cable tray. Outer jacket shall be sunlight and oil resistant PVC, 600V rated. Solid conductors shall be permitted for Ethernet cable. Ethernet cable shall be compatible with RJ45 connectors. The Contractor shall have the necessary training and tools to terminate the cable and to perform testing.

J. Fiber optic cable shall contain twelve individual 62.5µm multimode optical fibers. Cable shall be of heavy duty, all dielectric (non-conductive) construction. Fibers shall be housed in one or more gel-filled buffer tubes. Tubes shall be bundled together with a dielectric strength member and water-blocking filler system, surrounded by a polyethylene outer jacket. Cable shall have an operating range of -40°F to 158°F and a minimum crush resistance of 125lbs/in - short and 63lbs/in - long. Outer jacket shall be moisture and UV resistant. Coordinate connector and additional cable requirements as required for full compatibility with connected equipment.

K. Instrumentation cable shall be UL listed, with PVC outer jacket, overall shield, and individually shielded conductor pairs, cable rated at 600 volts. Shall be listed as type TC or MC, overall sunlight and oil resistant jacket, suitable for use in wet locations, and rated for use in cable trays. Conductor configuration shall be as required for equipment served, minimum 18 AWG.

L. Decorative lighting control cable located inside conduit, labeled on the Contract Plans as “2TSP”, shall be UL listed, with PVC outer jacket, 2 individually shielded twisted pairs, 24 AWG stranded (7x32) tinned copper conductors, DMX compatible cable. Cable shall have a nominal impedance of 100 Ohms and suitable for indoor and hazardous locations.

M. Provide a laptop computer with all necessary software installed to program and configure the PLC, the HMI, firewall router, and any other programmable devices associated with the dehumidification control system. Laptop shall be semi-ruggedized type (moisture, dust, vibration, and drop-shock resistant, and designed using MIL-STD-810G test procedures). Laptop computer shall meet the following minimum requirements, unless specified otherwise by the PLC manufacturer: 2.7GHz (or higher) Intel Core processor, 8GB system RAM, minimum 128GB Class 35 solid state hard drive, built in touchpad, external CD-RW / DVD-R, 14" High Definition full HD LED display, and Windows 10 Professional operating system. Ports shall include USB 2.0, USB 3.0, serial, VGA, HDMI, and RJ-45 10/100/1000


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Ethernet ports. Laptop shall also provide integrated 802.11a/b/g/n/ac Wi-Fi/Wireless. Laptop computer shall include a 120-volt AC power adaptor, long life battery, multiple format memory card reader, protective carry bag, original manuals, software packages with license information and original packaging materials. Dell Latitude 5420 Series or approved equal.

N. Provide a rack-mounted PC, including processor and monitor, with all necessary software installed to program and configure the decorative lighting controller. The rack-mounted PC shall be installed inside the north decorative lighting rack and be accessible from the front rack cover. The processor shall be a 19” 1-unit rack mountable computer. Rack-mounted processor shall meet the following minimum requirements, unless specified otherwise by the decorative lighting controller manufacturer: 2.7GHz (or higher) Intel Core processor, 8GB system RAM, minimum 128GB Class 35 solid state hard drive, and Windows 10 Professional operating system. Ports shall include USB 2.0, USB 3.0, serial, VGA, HDMI, and RJ-45 10/100/1000 Ethernet ports. Processor shall include a 120-volt AC power adapter. The monitor shall be a 19” 1-unit rack mount console with 19” LCD display, full 88-key keyboard and touchpad, all contained in a 1-unit slide-out housing. The monitor shall be supplied with all necessary cables to connect with processor and a 120-volt AC power adapter. All required software shall be installed on the rack-mounted PC, including Remote Desktop Protocol (RDP), for remote access capability.

O. Control switches shall be 3 or 4 position switches as shown on the Contract Plans. Switches shall be UL listed and IP66 rated, non-illuminated, maintained, 22.5mm, rated for 10A at 600VAC, round metal operator.

2.20 SPARE PARTS

A. (1) Humidity and temperature sensor, pre-configured/programmed. B. (1) PLC I/O module of each type provided. C. (1) DC power supply of each type provided. D. (2) LED indicator lights of each color provided. E. (2) Control selector switches of each type provided. F. (1) SPD of each type provided. G. (1) Lighting contactor of each type provided. H. (2) plug in and bolt on breaker of each type and size provided. I. (5) fuse and fuse holder of each type and size provided. J. (1) 4-port gateway K. (1) Ethernet Switch

CONSTRUCTION DETAILS

3.1 PROTECTION AGAINST CORROSION


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A. For outdoor installation of electrical equipment, provide stainless steel hardware such as, but not limited to, anchors, bolts, braces, boxes, bodies, clamps, fittings, guards, nuts, pins, rods, shims, thimbles, washers, and miscellaneous hardware.

B. Where connected to dissimilar metal, provide suitable fittings and treatment.

3.2 HAZARDOUS AREA APPLICATIONS: A. Electrical equipment, wiring devices, enclosures, junction boxes, raceways, fittings,

and seals in areas classified as hazardous shall be constructed and installed in accordance with the requirements of the National Electrical Code.

3.3 INSTALLATION A. Conduit and Wiring

1. Use insulated wires and cables with stranded copper conductors for the installation. Do not use solid and/or aluminum conductors.

2. Provide equipment grounding conductors in all conduit and cable runs. Size equipment grounding conductors equal to the largest circuit conductor in the conduit or cable. Coordinate all wire and cable requirements with manufacturers of the equipment served.

3. Handle and install wires and cables with care to avoid damage to conductors, insulation, jackets, armor, etc. Replace at no additional cost any wire or cable which is found to be damaged.

4. Permanently label all conductors, cables, and terminal blocks at every terminal or connection, splice, and tap. Assign each conductor or cable with one identifying number (including spares) throughout the entire electrical or control system. Coordinate identification numbers for consistency and accuracy with conductor numbers on the Contractor's approved wiring diagrams and shop drawings, field wiring diagrams, and any other diagrams containing the same respective conductor or cable.

B. Conduit and Cable 1. To the extent practical, maintain at least a 4-inch separation between power

wiring and communication and/or instrumentation cables. 2. Provide insulated throat bonding bushings or bonding nuts where conduits or

metal armored cables enter metal boxes or enclosures. Properly bond/ground conduit to the bonding/grounding hub. Connect bonding bushings and bonding nuts to the equipment grounding conductor included in the conduit or cable.

3. Install metal conduit and tubing in accordance with the Steel Tube Institute of North America's Guidelines for Installing Steel Conduit/Tubing.

4. Make bends in rigid conduit with tools which are specifically designed for bending the type and size of conduit in question. When bending conduit maintain proper internal diameter and wall thickness.

5. Do not make more than three quarter bends, equivalent to 270 degrees, in one


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conduit run between pull points such as conduit bodies, junction/pull boxes, terminal cabinets, and enclosures.

C. Conduit Penetrations 1. Provide conduit penetrations through walls, floors, ceilings, and abutments as

necessary for the installation of conduits. Following the installation, to the practical extent, restore floors, walls and ceilings with materials equal to the original construction and finish to match surrounding surfaces. Materials used will be subject to the approval of the Engineer for appropriateness.

2. Conduits passing through block out openings and sleeves shall be sealed with an approved weatherproof and fire-resistant material. Contractor installed sleeves for conduits or wiring holes through concrete walls and floors shall be PVC through slab sleeves or PVC pipe, cast-in-place or epoxied-in-place after drilling. Sleeves shall be trimmed flush with the concrete surface. All unused openings shall be appropriately sealed or plugged with mechanical type seals by the Contractor, and locations shall be documented on as-built plans.

D. Low Voltage Splices and Terminal Blocks 1. Conductor splices shall be made only in junction boxes, terminal cabinets, outlet

or device boxes, and equipment enclosures. Splices shall be made only on terminal blocks, except for splices at luminaries and wiring devices shall utilize compression type or similar approved connectors. Twist-on (wirenut) type connectors shall not be used.

2. After installation, insulate all splices made with crimp or mechanical type connectors with rubber and vinyl tape, or an insulating cover specifically designed for use with the connector. The Engineer may require the use of special splices or splice kits to address specific application considerations.

3. All terminal blocks shall be clearly labeled according to Control System Vendor's and Contractor’s approved wiring diagrams. Labels shall be machine printed, clearly readable, and smudge-free.

E. PLC Programming 1. The PLC I/O identification, annotations, and comments indicating purpose of

each coil and program logic module shall be included to deliver a complete PLC program incorporating all the systems as required under this Contract.

2. The logic shown on the Contract Plans is conceptual only. Additional logic development and program writing by the Control System Vendor will be necessary to complete the program suitable for performing operations as seen on the Plans.

3. In addition to hardware I/O addressing identification, the PLC program’s “Tag name” for each I/O address shall be listed on the corresponding electrical drawings.

4. The PLC logic shall assure correct sequence of manually initiated operations, and likewise control fully automatic operations.


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5. Program shall be designed to indicate fault conditions on the HMI displays in each chamber. Faults present shall illuminate a “RED” indicator light located on the corresponding north and south side chamber exterior.

6. For the documented PLC program listing, all contacts shall include a cross reference of their coil locations, and all coils shall be cross referenced with a list of their contact locations.

7. The Systems Integrator shall set up and personalize the web-based monitoring software per NYSDOT requests and supply all necessary information for modification and customization of the remote monitoring viewing platform. The web-base software shall be programmed to allow monitoring capabilities only, unless requested otherwise by the NYSDOT.

F. HMI Programing 1. Each chamber HMI display shall be configured to access all chamber data, as

listed below, from a single chamber location. The following data shall be displayed and/or accessed on each HMI with the ability to access from any HMI in all 4 chambers:

a. Percent relative humidity (actual and on/off control setpoints – allow user adjustment of setpoints within safe limits)

b. Temperature (Fahrenheit and/or Celsius) c. Dehumidifier run times d. Historical recorded input/output data e. Faults f. Real Time Clock (allow user adjustment) g. Status of bridge lighting control

2. The Owner shall approve display layout and content of each HMI in all four chambers.

3. PLC I/O status screen shall also be provided that show the current on/off states of all PLC digital inputs and outputs. Each individual I/O point shall be identified with the corresponding PLC hardware address, tag name, and a short description of the connected device (ex. I:1.I.Data.7 Dehumidifier 1 – fault present)

G. Decorative Lighting System Programming 1. The decorative lighting system shall be programmed with a minimum of five

light shows, type and style at the request of the NYSDOT, by the Systems Integrator.

2. Initialization and setup of the decorative lighting controller shall be completed as such to allow ease of access and modification to the various pre-programmed light shows, from local and remote locations, through the local rack-mounted PC. This shall include creating new light shows.

3. Each necklace lighting fixture (Item #670.02323408) and LED adjustable flood


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lighting fixture (Item #670.31010008) shall be identified in the program to mirror the naming as shown on the Contract Plans or as requested by the NYSDOT.

4. The controller shall be programmed to automatically turn the decorative light fixtures on and off by photocell and/or internal time clock.

5. The systems integrator shall instruct NYSDOT on the process of creating new and modifying preset light shows through the local rack-mount PC. Any remote and local monitoring and/or control of the system desired by the NYSDOT shall be programmed into the decorative lighting controller.

H. Identification 1. Legend plates for pushbuttons, selector switches, and indicator lights shall be one

piece engraved plastic type, white background with black text. Text shall be as indicated on the Contract Plans.

2. All conductors shall be labeled using self-sealing, adhesive type wire labels with machine printed permanent lettering at every terminal or connection. Conductor identification numbers shall be coordinated for consistency and accuracy with conductor numbers on the Contractor’s approved wiring diagrams and shop drawings.

I. Grounding and Bonding 1. Provide grounding and bonding in compliance with the requirements of NEC

Article 250 for grounding and bonding. 2. Do not use raceways and metallic cable armor/sheaths as the sole grounding or

bonding conductor for any circuit. 3. Solidly connect all electrical equipment to the equipment grounding conductor

serving that equipment. 4. Where bolted connections are used for connection of equipment grounding

conductors to equipment, clean the area around the connection down to bear metal prior to making the connection. Touch-up the area with corrosion resistant industrial rated enamel primer and topcoat system to match existing finishes.

J. Utility Service 1. Documentation that details the construction shall be submitted to the Department

and Central Hudson Gas and Electric Corporation for approval at least 10 business days prior to commencing work. No work shall begin until written approval has been received.

2. Construction methods shall be in accordance with Central Hudson Gas and Electric Corporation standards or as approved by the Department and Central Hudson Gas and Electric Corporation.

3. All new poles shall be augured to an appropriate depth for the pole height being installed. Poles shall be backfilled and compacted with material confirming to Section 73-04, Subbase Course, Type 2 or approved equal. Disturbed surface shall be restored to the existing condition.


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4. New poles shall be prepared in advance to the extent practical, to minimize shutdown times. Deenergizing of existing lines and reenergizing of the new lines will be conducted by Central Hudson Gas and Electric Corporation. It will be the Contractor’s responsibility to coordinate shutdown times with Central Hudson Gas and Electric Corporation and notify the proper entities of planned interruptions to electrical services.

5. Existing utility poles that have been abandoned by Central Hudson Gas and Electric Corporation will become the property of the Contractor and shall be removed from the site.

6. Removal of abandoned primary and secondary conductors, if required, will be performed by Central Hudson Gas and Electric Corporation.

3.4 REMOVALS A. Contractor shall remove all equipment as indicated on Plans. Unless otherwise

specified, all removed materials and debris resulting from execution of this project shall become the responsibility of the Contractor and removed from the premises. Materials not scheduled for reuse shall be removed from the site and disposed of in accordance with all applicable Federal, State and Local requirements.

3.5 FIELD QUALITY CONTROL A. Progress Cleaning:

1. Conduct work progress cleaning and leave Work area clean at end of each shift. 2. Upon completion of work remove surplus materials, rubbish, tools and

equipment in accordance with requirements of construction/demolition waste management and disposal of the contract.

3.6 INSPECTION, TESTING, AND COMMISSIONING

A. Submittals 1. Submit proposed testing procedures, including test instruments, up-to-date

instrument calibration proof, and other equipment to be used for approval at least 15 working days prior to testing.

2. Accurately record the results of all tests in a neat and orderly manner along with time and date of test(s), environmental conditions (temperature, humidity, general weather conditions, etc.), testing equipment used, conditions of test(s), and the name(s) of person(s) performing the test(s).

3. Submit all test results with all text in typewritten format no later than 10 working days from date of test(s). The results of these tests must be deemed acceptable by the Engineer prior to acceptance of the work in question.

B. General Requirements. 1. The Contractor is responsible for performing all testing, inspections, and any

resulting corrective work to ensure that, after the installation of the electrical materials and equipment for the required work, the entire bridge power and control


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systems must properly function as intended and as recorded by the Contractor prior to removals and as modified and required by the contract.

2. In addition to the specific tests described herein, perform all additional testing, and make any necessary repairs or adjustments to provide a complete, functional, and reliable installation. All testing, inspections, and demonstrations, and any resulting remedial work, will be deemed solely the responsibility of the Contractor and will not be considered cause for delay or additional payment.

3. Use test procedures and equipment in accordance with manufacturer’s recommendations, NETA Acceptance Testing Standards, any other applicable industry standards, and be appropriate for the specific test being performed.

4. Use true root mean square (RMS) type voltmeters and ammeters. Maintain in proper calibrated condition and use all tools and instruments specifically designed for measuring the quantity in question.

C. Shop Testing 1. Shop testing of the control system logic is required on the complete assembled

control system prior to shipment from the Control System Vendor's shop. The Control System Vender shall create and submit a shop test procedure for review and approval by the Engineer prior to scheduling the test. All relevant submittals must be submitted and approved by the Engineer prior to scheduling the test. The testing must be witnessed by the Engineer and any of the Department's designated representatives. The Department shall be notified at least two weeks prior to the test date. Testing shall include a complete run-through of the operating dehumidification and lighting control sequence from all HMI’s. Temporary indicator lights and control switches shall be utilized to represent dehumidifier inputs and outputs.

2. All PLC’s, HMI’s, control relays, and other related control system components shall be wired/assembled in the proper cabinet(s) and ready for preparation for shipping, pending any corrections or adjustments necessitated by testing results, before performing these tests. Any errors found in the system shall be corrected and the respective portion of the test rerun.

D. Testing and Inspection after Installation 1. After all wires have been installed and prior to connections of any circuit, test to

verify that all installed conductors are free of shorts, opens, or unintentional grounds, and properly terminated.

2. Perform tests after energizing any circuit and prior to connections to equipment to verify the following conditions:

a. Correct no-load voltage for the equipment to be powered. b. Correct phase sequence. c. Correct polarities.

3. After all connections have been made to all equipment and devices, visually inspect all electrical connections, and verify that all lugs, connectors, and terminals


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are tightened and torqued to the levels recommended by the manufacturer. E. Testing of Machinery

1. Visually inspect newly installed electrical equipment, including checking for excess mechanical or electrical noise, for excessive heating, for vibration, verifying proper tightening of all mounting bolts and coupling connections, and observation of any other physical indications of improper installation and/or operation. Measure and record the terminal voltage and current in the normal running condition with dehumidifiers connected.

F. Operational Tests and Demonstrations 1. When the installation of all systems is complete and ready for testing, test-run the

dehumidification and decorative lighting control systems. The systems must demonstrate a trouble-free operation, meeting all specified requirements with all interlocks properly functioning.

2. Perform additional miscellaneous operational tests as requested by the Engineer, or the NYSDOT’s representative to demonstrate and establish that the work as installed meets all specified requirements and is operating in a reliable manner.

G. Field Acceptance Testing 1. The Contractor must prepare a detailed testing procedure for field acceptance

testing of the installed work. Submit the field acceptance test procedure 3 weeks in advance for approval before beginning field acceptance testing.

2. Coordinate with NYSDOT and schedule the test at a time agreeable to all parties involved. Determine the schedule at least 2 full weeks in advance of the proposed start date for the testing.

3. At a minimum, the following tests must be completed on the electrical system assuring successful and error free operations:

a. All dehumidifiers successfully run in Auto and Manual operation, decreasing the humidity level in the designated chambers. In each chamber, the dehumidifiers alternate run time.

b. Offsite, remote monitoring of the dehumidification system, displaying all functions and features as requested by the NYSDOT.

c. All alarm and live status indications on the HMI’s display correctly. d. Roadway lights illuminate from dusk to dawn and turn off during daytime. e. Local and remote control and monitoring of the decorative lighting system,

performing various programmed light shows through the decorative lighting controller. Verify the necklace lighting fixtures and LED adjustable flood lighting fixtures change color with respect to the lighting controller and illuminate from dusk to dawn and turn off during daytime.

4. Perform additional tests and demonstrations to demonstrate to the Engineer and the NYSDOT’s representative that the installed systems satisfy the requirements and intents of the plans and special provisions.


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5. Correct any deficiencies revealed during testing and repeat the test until such time as the Engineer is satisfied with all test results and the overall performance of the bridge control system.

6. For final acceptance by the NYSDOT, all operations shown in this Special Provision and on the Plans must be successful and error-free.

H. Corrective Actions 1. For any test failure, or for any test result which fails to meet the specified

requirements or the stated acceptable values or conditions, or the Engineer finds unacceptable, the Contractor must investigate the cause of the failure, take appropriate corrective actions, and repeat the test(s). Repeat this procedure until such time as all test results are deemed acceptable by the Engineer, at no additional cost to the State.

3.7 PERFORMANCE VERIFICATION A. "Performance Verification Test" plan shall provide the step-by-step procedure

required to establish formal verification of the performance of the electrical operating system. Compliance with the specification requirements shall be verified by inspections, review of critical data, demonstrations, and tests.

B. The Owner and/or Owner’s Engineer reserves the right to witness all tests, review

data, and request other such additional inspections and repeat tests as necessary to ensure that the system and provided services conform to the stated requirements. The contractor shall inform the Owner and/or Owner’s Engineer at least 14 calendar days prior to the date the test is to be conducted.

C. Provide one 8-hour training session at the site at a time and place mutually agreeable between the Contractor and the Owner.

D. Provide session to train up to 10 operation personnel in the functional operations of

the system and the procedures that personnel will follow in system operation. A minimum of (4) hardcopies of training manuals shall be provided. This training shall include: 1. System operation overview 2. PLC setup and programming 3. HMI setup and programming 4. Decorative lighting controller setup and programming, development of new light

shows, and modifying existing light shows. 5. Humidity and temperature sensor setup and maintenance. 6. Trouble and Fault Alarms 7. Failure recovery procedures 8. Troubleshooting


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9. Remote monitoring and control of the decorative lighting controller 10. Remote monitoring of the PLC

METHOD OF MEASUREMENT The work for this item will be measured on a lump sum basis. BASIS OF PAYMENT The lump sum price bid shall include the cost of all labor, materials, training, and equipment required to complete the work of this item. Progress Payments for each bridge will be authorized as a percentage of the lump sum price based upon the following schedule:

Ten percent (10%) of the lump sum price per bridge will be paid upon completion and approval of shop drawings.

Twenty-five percent (25%) of the lump sum price per bridge will be paid upon procurement of equipment.

Twenty-five percent (25%) of the lump sum price per bridge will be paid upon initial acceptance of field installation.

Twenty percent (20%) of the lump sum price per bridge will be paid upon completion of all field testing and commissioning.

The remainder (20%) of the lump sum price per bridge will be paid once the punch list item, documentation, and final approval has been completed.

Documents

ITEM 599.06300008 – BRIDGE ELECTRICAL AND CONTROL …ITEM 599.06300008 – BRIDGE ELECTRICAL AND CONTROL SYSTEM Page 4 of 24 02-12-2020 3. The Electrical Contractor shall have been