Electrical Systems Design Manual Division of Traffic Operations, First Edition (July 2020) Acknowledgments The California Department of Transportation (Caltrans) Electrical Systems Design Manual was developed through the dedication and remarkable efforts of the following Caltrans staff: Brett Scoubes − District 2, Traffic Engineering Operations Brian Chow − Headquarters, Traffic Operations Dave Gamboa, PE − Headquarters, Traffic Operations Derran Reitz, PE − Central Region, Project Development Hamid Zolfaghari, PE − Headquarters, Traffic Operations Ignacio Sanchez del Real, PE − Headquarters, Design James Elgin − District 2, Traffic Engineering Operations James Gilliam, PE − Headquarters, Traffic Operations Jeff Woody, PE - Division of Engineering Services, Office of Design and Technical Services John Castro, PE − Headquarters, Traffic Operations Kenneth Xu, PE − District 4, Electrical Design Lai Saetern, PE − District 3, Electrical Design Mary Ann Hudspeth, PE − District 3, Electrical Design Rajpreet Singh, PE − District 11, Traffic Management Center Yesenia Chavez − Headquarters, Traffic Operations The drafting services for this manual were provided by Leonard Hudnall and staff of the Division of Engineering Services: Elenita Stickler − Structural Design Detailing Michael Slayton − Structural Design Detailing My Nguyen − Structural Design Detailing 2 © California Department of Transportation. All Rights Reserved. Table of Contents Electrical Systems Design Manual ............................................................................................. 1 Acknowledgments .................................................................................................................. 2 Table of Contents ................................................................................................................... 3 Introduction ............................................................................................................................ 6 Chapter 1 − General ............................................................................................................... 7 Section 1.1 − General ......................................................................................................... 7 Section 1.2 − Plan Sheets ................................................................................................... 8 Section 1.3 − Staging Plans ................................................................................................ 8 Section 1.4 − Conduit .......................................................................................................... 8 Section 1.5 − Pull Boxes ..................................................................................................... 8 Section 1.6 − Conductors and Cables ................................................................................. 9 Section 1.7 − Service Equipment Enclosure ......................................................................12 Section 1.8 − Cabinets .......................................................................................................13 Section 1.9 − Controller Assembly .....................................................................................14 Section 1.10 − Vehicle Detectors .......................................................................................14 Section 1.11 − Loop Detector Sealants ..............................................................................14 Section 1.12 − Batteries .....................................................................................................15 Section 1.13 − Utility Service .............................................................................................15 Section 1.14 − Communication ..........................................................................................18 Section 1.15 − Accessible Pedestrian Signals....................................................................18 Section 1.16 − Transformers ..............................................................................................18 Section 1.17 − Electrical Fault Protection ...........................................................................18 Section 1.18 − Equipment Near Gasoline Stations .............................................................22 Section 1.19 − American Disabilities Act (ADA) Requirements ..........................................22 Section 1.20 − Maintenance Vehicle Pullout ......................................................................22 Section 1.21 − Supplemental Work ....................................................................................23 Section 1.22 − Department-Furnished Materials and Expenses .........................................24 Chapter 2 − Lighting and Sign Illumination Systems ..............................................................25 Chapter 3 − Signal and Lighting Systems ..............................................................................26 Section 3.1 − General ........................................................................................................26 Section 3.2 − Signal and Lighting Standards ......................................................................26 Section 3.3 − Backplates ...................................................................................................29 © California Department of Transportation. All rights Reserved. 3 Section 3.4 − Programmed Visibility Signal Sections .........................................................29 Section 3.5 − Visors and Directional Louvers .....................................................................29 Section 3.6 − Inductive Loops ............................................................................................30 Section 3.7 − Video Imaging Vehicle Detection System (VIVDS) .......................................32 Section 3.8 − Overhead Clearance ....................................................................................33 Section 3.9 − Battery Backup Systems ..............................................................................33 Section 3.10 − Signal Heads ..............................................................................................34 Section 3.11 − Pedestrian Signal Heads ............................................................................60 Section 3.12 − Phase Diagram ..........................................................................................60 Section 3.13 − Conductor and Conduit Schedule ...............................................................60 Section 3.14 − Pole and Equipment Schedule ...................................................................60 Section 3.15 − Signal Interconnect Cable ..........................................................................60 Section 3.16 − Railroad Preemption ...................................................................................60 Section 3.17 − Pedestrian Barricades ................................................................................61 Section 3.18 − Flashing Beacons .......................................................................................61 Chapter 4 − Ramp Metering Systems ....................................................................................62 Chapter 5 − Traffic Monitoring Station Systems .....................................................................63 Chapter 6 − Traffic Census Station Systems .........................................................................64 Section 6.1 − General ........................................................................................................64 Section 6.2 − Count Station ...............................................................................................64 Section 6.3 − Automatic Vehicle Classification Station .......................................................64 Chapter 7 − Flashing Beacon Systems ..................................................................................66 Chapter 8 − Pedestrian Hybrid Beacon Systems ...................................................................67 Chapter 9 − Extinguishable Message Sign Systems ..............................................................68 Chapter 10 − Highway Advisory Radio Systems ....................................................................69 Chapter 11 − Changeable Message Sign Systems ................................................................70 Chapter 12 − Camera Systems..............................................................................................71 Chapter 13 − Radar Speed Feedback Sign Systems .............................................................72 Chapter 14 − Roadside Weather Information Systems ..........................................................73 Chapter 15 − Interconnection Conduit and Cable ..................................................................74 Chapter 16 − Fiber Optic Cable Systems ...............................................................................75 Chapter 16.1 − General .....................................................................................................75 Chapter 16.2 − Vaults ........................................................................................................75 4 © California Department of Transportation. All Rights Reserved. Chapter 16.3 − Fiber Optic Cable .......................................................................................75 Chapter 16.4 − Fiber Optic Splice