ROADWAY LIGHTING SYSTEMS (2545)

Transcription

1 GENERAL LIGHTING MATERIAL REQUIREMENTS General material requirements must be in accordance with MnDOT SERVICE CABINETS 3850 Lighting service cabinets Type L1, Type L2, Type A, Type B, and Type RLF are on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting. The lighting service cabinets described below can accommodate branch circuits for roadway lighting as indicated. Lighting service cabinets are rated for either 120/240 or 240/480 VAC single phase service. Service Cabinet Type L1 SYSTEMS (2545) This is an equipment pad mounted service cabinet with power distribution blocks, a two pole 100 ampere main circuit breaker and four (4) two pole 20 ampere branch circuit breakers. A 3- wire locking type mounting receptacle is located inside the cabinet at the PEC windows for the photoelectric control device. 14-1

2 Service Cabinet Type L2 This is an equipment pad mounted service cabinet with power distribution blocks, 2 two pole 100 ampere circuit breakers and eight (8) two pole 20 ampere branch circuit breakers. A 3-wire locking type mounting receptacle is located inside the cabinet at the PEC windows for the photoelectric control device. 240/480 service cabinets (Type L1 and L2) may include a cold sequence disconnect (ahead of the meter) that meets the requirements of the electric utility company. Xcel Energy does not allow the use of the cold sequence disconnect. Information on equipment pads for service cabinets can be found in Chapter 10 Foundations & Equipment Pads. 14-2

3 Service Cabinet Type A This pole mounted service cabinet is similar to an equipment pad mounted Type L1, with a two pole 100 ampere main circuit breaker and four (4) two pole 20 ampere branch circuit breakers. This allows for four runs from the cabinet. A 3-wire locking type mounting receptacle is located inside the cabinet at the PEC windows for the photoelectric control device. Service Cabinet Type B This pole mounted service cabinet has a 60 ampere 2 pole main circuit breaker and two (2) two pole 20 ampere branch circuit breakers. This allows for two runs from the cabinet. A 3-wire locking type mounting receptacle is located inside the cabinet at the PEC windows for the photoelectric control device. 14-3

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5 Rural Lighting and Flasher (RLF) Cabinet This equipment pad mounted Rural Lighting and Flasher (RLF) 120/240 VAC service cabinet is used for smaller lighting and flasher systems. A 3-wire locking type mounting receptacle is located inside the cabinet at the PEC windows for the photoelectric control device. SERVICE EQUIPMENT INSTALLATION L All wiring within the lighting service cabinets must meet the requirements of the National Electrical Code (NEC). All L1 and L2 lighting service cabinets must have utility termination lugs installed on the line side wire way, unless the cabinets are being installed in the Xcel Energy service area. Lighting service cabinets must include all required wiring, internal and external, for a complete lighting service cabinet installation. All components are to be listed by a National Recognized Testing laboratory (NRTL). Install lighting service cabinets in accordance with MnDOT L. Position the cabinet door from 90 degrees to 180 degrees to the roadway, away from traffic. 14-5

6 The electric utility company must be contacted for information on size of meter socket, exact location of meter, etc. Meters are furnished and installed by others. Lighting service cabinets are large enough for additional equipment to be installed internally if requested by the electric utility company. Lighting service cabinets are rated for either 120/240 or 240/480 VAC single phase service. Circuit breakers must be labeled in accordance with Specification P.2.a. The Contractor is required to fill out an Electric Service Information Form for each lighting service on the project. A sample of this form is included in the Appendix. The contractor is required to calculate available fault current at the meter socket in accordance with the NEC Article Required contractor supplied labels are defined in contract documents. Photoelectric Controls (mounted inside service cabinets) Currently MnDOT uses a photoelectric control inside the service cabinets for turning "ON" and "OFF" the roadway luminaires on signal and roadway lighting systems. The photoelectric controls are installed in a 3-wire locking type mounting receptacle located inside the cabinet at the PEC windows. 14-6

7 MnDOT approved photoelectric controls are listed on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting. Standard photoelectric controls used on MnDOT projects must be an ANSI Multi-volt Volt (colored Blue) photocontrol. Position the photoelectric controls to face north. The photoelectric control may face east or west only if facing it north is not an option due to service cabinet orientation. 14-7

8 DIRECT BURIED LIGHTING CABLE 3815 Most MnDOT lighting projects require direct buried 4 conductor No. 4 AWG cable. Direct buried lighting cable must be in accordance with contract documents. Within 15 days after the Contract approval notice mailing date, the Contractor must furnish evidence to the Engineer, in writing, that orders have been placed for all direct buried lighting cable required for the project. WIRE AND CONDUCTOR INSTALLATION G Underground Wiring Direct Buried Lighting Cable Direct buried lighting cable must be installed in accordance with MnDOT G. The lighting cable must be installed at the same distance behind the bituminous shoulder or back of curb as the light foundations. 14-8

9 When an obstruction has been encountered in the path of the direct buried lighting cable, re-route the direct buried lighting cable around the obstruction away from the roadway. Direct buried lighting cable must be installed in rigid PVC or HDPE conduit under paved surfaces G.2 Install direct buried lighting cable in rigid PVC or HDPE conduit if located under bituminous, concrete, or other material not considered a top soil. Provide 3 in conduit if the contract does not specify size of conduit. Use a vibratory plow with a plow blade chute to reduce stresses on the cable during installation. Place plastic warning tape meeting the following characteristics at least 12 inches (300 mm) above the direct buried lighting cable: 1. 3 inch (75 mm) wide, 2. Permanent Red 3. Stretchable 4. Non-biodegradable 5. Imprinted with the inscription, CAUTION-MnDOT LIGHTING CABLE BELOW Install direct buried lighting cable from the reel or spool immediately into the ground. Do not lay direct buried lighting cable for the new lighting system on the ground and use as temporary. 14-9

10 Provide 2 feet of slack cable in an S pattern (within the width of the foundation) before cable enters the light foundation.. On a project where guardrail is also being installed, locate and/or install the guardrail before placing the lighting cable in order to help reduce or eliminate cable hits. METAL GUARDRAIL POST 14-10

11 Above Ground Splices Where above ground splices are allowed (pole base), the splices must be either split-bolt connectors or insulated wire splice connector blocks. SPLIT-BOLT CONNECTOR Use split-bolt connectors or insulated wire splice connector blocks to splice together the direct buried lighting cable and the light pole wiring in the light pole base in accordance with contract documents. MnDOT approved Insulated Wire Splice Connector Blocks are listed on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting. INSULATED WIRE SPLICE CONNECTOR BLOCK Light Pole Wiring Install light pole wiring in accordance with MnDOT G The wires connecting the luminaire to the direct buried lighting cable must be one continuous length without splice 12-2 UF cable with ground and a breakaway fuse holder installed with a cartridge type fuse. Terminate the individual black Hot conductor of the 12-2 UF cable directly to the barrel terminal on Load side of the fuse holder. Do not use wire nuts for light pole wiring. Place the breakaway fuse holder at the level of the access opening in the pole base. The fuse holder must be a MnDOT approved breakaway fuse holder as listed on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting. Use a 6 Amp 1.5 in X.406 in [38.1mm X 10.31mm] time delay cartridge fuse

12 The Contractor must provide sufficient excess conductor length to allow withdrawal of the connected fuse holder. The fuse holder must be properly orientated with respect to the line side and the load side. The neutral and grounding wires must not be fused. LOAD SIDE (Luminaire) LINE SIDE (Supply Side) Provide a MnDOT approved luminaire wire holder that supports the luminaire cable/conductors within the end of the light pole tenon near the connection point of the luminaire. MnDOT approved Wire Holders are listed on the MnDOT Approved/Qualified Products List (APL) for Roadway lighting. Luminaire Wire Holders 14-12

13 SIGNALS LIGHTING There are two types of MnDOT approved luminaire wire holders. One is designed for traffic control signal systems and the other for roadway lighting systems. Traffic control signal system luminaries require MnDOT approved luminaire wire holders that accommodate a round 3 conductor #14 AWG cable assembly that runs one continuous length without splice from the signal service cabinet to the luminaire atop the signal pole luminaire davit. Roadway lighting system luminaries require a MnDOT approved luminaire wire holder that accommodates a flat 12-2 UF cable

14 Underground Cable Splices No underground splices will be permitted that are not called for in the contract or approved in writing by the District Traffic Engineer. When direct buried cable splices are permitted install in accordance with G.4.b. Two Way Direct Buried Handhole Cable Splice When required, use a two way direct buried handhole cable splice in accordance with contract documents 14-14

15 Three Way Direct Buried Handhole Cable Splice When required use a three way direct buried handhole cable splice in accordance with contract documents. General MnDOT roadway light poles: ROADWAY LIGHT POLES ) Must be in accordance with the current edition of AASHTO Standard Specifications of Structural Supports for Highway Signs, Luminaires, and Traffic Signals. 2) If providing breakaway poles, the poles must be certified from the manufacturer that the pole meets specifications as specified in the current edition of AASHTO Standard Specifications of Structural Supports for Highway Signs, Luminaires, and Traffic Signals. 3) Must have a nominal 2 3/8 in schedule 40 tenon for slip fit luminaire installation. 4) Davit or mast arm must have an upward angle from horizontal of 3 degree +/- 2 degrees. There are several of types of light poles MnDOT uses. The most common types of poles used on MnDOT roadway lighting systems are: Coated (Galvanized) Steel Bridge and Barrier 40 foot and 49 foot nominal height Non- Breakaway Stainless Steel 40 Foot and 49 Foot Breakaway Aluminum Alloy 40 Foot and 49 Foot Breakaway High Mast Light Towers 14-15

16 Bridge and Barrier Poles 40 Foot and 49 Foot Galvanized Steel Non-Breakaway High Base 6-Bolt Base Plate 2 Access Door Assembly Single and Double Davit Mounted on Barrier (Center Median and Bridge Barrier Foundations) 14-16

17 Breakaway Roadway Light Poles 40 Foot and 49 Foot (Stainless Steel and Aluminum Alloy) Aluminum Alloy Pole: Transformer Base (Bolt On) Typically Single Davit (6 FT- 12 FT) Mounts on Design E and H Foundations Stainless Steel Pole: Slip Fit High Base 16 Sided Typically Single Davit (6 FT 12 FT) Mounts on Design E and H Foundations 14-17

18 High Mast Towers COR-TEN Steel (Weathering Steel) H Base Design Typically 100 FT or 120 FT Typically Ring Assembly Holds 3 to 4 Luminaires 14-18

19 A lighting unit is defined as follows: Includes the light pole, internal wiring with fuse holder and fuse to the luminaire, above ground splices, wire holder, stainless steel woven wire cloth, and luminaire. Underpass luminaires are lighting units even though they do not include some of these components. The foundation is not considered as part of this definition. The type of light pole required for each project will be shown in contract documents. Light poles that are specified by MnDOT are fabricated from stainless steel, high strength steel, or aluminum. Light poles fabricated from aluminum must have a factory installed vibration dampener. Light poles must be fabricated in accordance with MnDOT Within 15 days after the contract approval notice mailing date, the contractor must furnish evidence to the Engineer, in writing, that orders have been placed for all components of the lighting units required for the project. The Contractor must submit to the Engineer, for approval by the District s Traffic Engineer, four complete sets of shop detail drawings of the light poles and anchor rods, in accordance with B1 and B3. For high mast lighting installations, the Contractor must submit final reproducible drawings in accordance with B. The drawings must be distributed after approval, to the following: (a) (b) (c) (d) Contractor Contractor s Fabricator Engineer District Traffic Engineer All light poles must be approved before installation

20 Rodent Intrusion Prevention Stainless Steel Light Poles Install stainless steel woven wire cloth in accordance with MnDOT H in stainless steel light poles between the base plate and the foundation and use 100% clear silicone sealant to fill voids between the woven wire cloth and the pole base plate to protect against rodent intrusion. WOVEN WIRE CLOTH AND SILICONE SEALANT Aluminum Light Poles For aluminum light pole bases do not install stainless steel woven wire cloth. Instead, fill any gaps as a result of using leveling shims that exceed 1/8 in between the foundation and the aluminum light pole base with 100% clear silicone sealant. Do not completely seal around the perimeter between the foundation and the aluminum light pole base

21 LUMINAIRES All LED Luminaires listed on MnDOT s APL have a minimum Ten (10) year warranty. These luminaires will operate in a range of VAC (rms) with an integral power supply, pre-wired in the factory with terminal blocks or color coded pigtails for field connections. All MnDOT approved luminaires must have an ANSI C standard 7-terminal twist-lock type photoelectric control mounting receptacle with shorting cap and a dimmable electronic driver (power supply). MnDOT approved luminaires are listed on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting. LED Roadway Luminaires (40 foot mounting height) Light emitting diode (LED) luminaires for mounting at 40 feet are replacements for the existing 250 watt HPS luminaire. The housing must be adaptable to the nominal 2 3/8 inch (50 mm) diameter tenon on the end of the luminaire mast arm. This class of LED luminaire is used in both roadway lighting and at traffic control signal systems. LED Roadway Luminaires (49 foot mounting height) Light emitting diode (LED) luminaires for mounting at 49 feet are replacements for the existing 400 watt HPS luminaire. The housing must be adaptable to the nominal 2 3/8 inch (50 mm) diameter tenon on the end of the luminaire mast arm

22 Vertical Mount Luminaires LED Replacements (Replaces 250 and 400 HPS Luminaires) LED replacements for vertical mount luminaires are LED roadway luminaires for mounting at 49 feet. A 90 degree tenon mount adaptor must also be used. The 90 degree pole adaptor must be MnDOT approved adaptors listed on MnDOT s Approved /Qualified Products List (APL) for Roadway lighting. LED Underpass Luminaires LED underpass luminaires are replacements for 250 watt high pressure sodium luminaires. The housing of the luminaire is anodized aluminum. Underpass luminaires are usually installed on the abutment of a bridge or on a pier a minimum of 17 feet above the traveled roadway. If such mounting would place a luminaire more than about 20 feet from the edge of the traveled roadway, the luminaire is usually mounted on a metal mounting bracket bolted under the bridge deck. Bird spikes are now required to be installed on underpass luminaires. A full size instruction sheet can be found in the appendix

23 LED Luminaires on Signal Poles (40 foot mounting height) Luminaires are mounted on signal poles to provide intersection illumination. They are LED luminaires found on MnDOT s APL under LED Roadway Luminaires for mounting at 40 feet. High Mast Luminaires (Tower Lights) High mast luminaires are 1000 watt high pressure sodium symmetrical or asymmetrical luminaires with ballasts. High mast luminaires must be MnDOT approved luminaires as listed on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting

24 LUMINAIRE INSTALLATION Q Install and level luminaires in accordance with MnDOT Q, the manufacturer s installation requirements and to the satisfaction of the Engineer. Luminaires need to be installed in accordance with manufacturer s installation requirements. Tightening of the bolts that hold the luminaire on the tenon have specific tightening torque requirements that must be followed. Over tightening of these bolts can cause damage to the luminaire or the tenon

25 Place a level on the area provided on the top of the luminaire, and level side to side and front to back direction. Adjust the luminaire as required to completely level the luminaires. Luminaires must be level in order to perform properly. Lighting Controls Lighting controls (smart photocontrols) are becoming more popular with the introduction of the LED Luminaire. MnDOT Luminaires come standard with a 7 pin photocontrol receptacle with shorting cap and a dimmable electronic driver (power supply). These features make the luminaires lighting controls ready by simply replacing the shorting cap with a smart photocontrol. On some MnDOT roadway lighting projects smart photocontrols may be required. The Department may supply the smart photocontrols to the contractor for installation on the 14-25

26 luminaire prior to the luminaire being installed on the pole. Refer to the project s special provsions. It s important that the photocontrol window be faced north as required by the manufacturer. If a north facing node is not achievable then facing east or west is an acceptable alternative. Lighting Control Systems monitor and provide the following; 6. Energy measurement at revenue grade per luminaire 7. Luminaire voltage. 8. Luminaire wattage. 9. Luminaire type LED or HPS. 10. Luminaire dimming (0 to 10 Volts). 11. Dayburner. 12. No communication. 13. Global Positioning System (GPS) location. Smart photocontrols are not listed on the MnDOT s APL for Roadway lighting. There is a state contract in place where CPV members can purchase smart lighting controls. A modification in the lighting service cabinet will be required when lighting controls are installed. The contactor must be bypassed and de-energized. The luminaire and pole wiring will be energized 24 hours a day. Continuous powering of the lighting control allows the lighting control and the luminaire to report their status 24 hours a day 7 days a week. (photocontrols cont. next page) 14-26

27 Since luminaires and wiring in the light pole bases will be energized 24 hours a day, a Hazardous Voltage warning label will be placed on light poles and on the lighting service cabinet. Refer to the special provisions for the project on how to procure and apply the warning labels

28 AIR OBSTRUCTION LIGHTS 3816 MnDOT has Light Emitting Diode (LED) Air Obstruction Lights listed on MnDOT s Approved/Qualified Products List for Roadway lighting. MnDOT approved air obstruction lights include infrared light to aid pilots using night vision goggles. Air Obstruction Light Installation When the project requires air obstruction lights be installed on a roadway light pole the Plans and Special Provisions will require each pole requiring air obstruction lights to have a ¾ inch (N.P.T.) nipple welded to the horizontal portion of the light pole facing skyward. 3 conductor 14 AWG signal control cable must be pulled up from the pole base to the air obstruction light in addition to the required 12-2 UF with ground luminaire conductors. A separate breakaway fuse holder will be required in the pole base for the air obstruction light. NAVIGATION LANTERNS 3817 MnDOT has Light Emitting Diode (LED) navigation lanterns listed on MnDOT s Approved/Qualified Products List for Roadway lighting. Navigation Lantern Installation Install navigation lanterns in accordance with contract documents

29 LIGHT SYSTEM COMPONENT LABELING and NUMBERING P Lighting System Numbering The Contractor must number the light poles or the luminaires when light poles are not required (underpass luminaires, tunnel luminaires, special luminaires, etc.) and lighting service cabinets as specified in contract documents. FEEDPOINT NUMBER ASSETT TAG POLE NUMBER LIGHTING SERVICE CABINET Lighting service cabinets must have two feed point labels 4 feet above the concrete foundation. One label is required on the front door and one on the side of the cabinet that faces the roadway. MnDOT approved labels are listed on MnDOT s Approved/Qualified Products List (APL) for Roadway lighting

30 Labeling Lighting Cable and Conductors Label the direct buried lighting cable in service cabinets and lights pole bases indicating the next termination point in accordance with MnDOT P.2.b

31 Labeling Luminaires LED roadway luminaires require two types of labels be added by the contractor. One label defines the mounting height in feet 40 or 49 for the luminaire. The labels can be found on the MnDOT APL for lighting. Affix a machine printed label showing the month and year the LED luminaire was installed. Two of these labels are required, one on the outside of the luminaire facing the ground and one on the inside of the luminaire. CONTRACTOR SUPPLIED The contractor may also be required to install luminaire asset tags. See contract documents if asset tags are required on the project. LED underpass luminaires do not require a mounting height label be applied however the installation date label and the light unit number are required

32 ELECTRICAL SYSTEM TESTING AND ACCEPTANCE K General testing and acceptance requirements must be in accordance with K. CHECKLIST FOR ELECTRICAL SYSTEMS *The following list is a minimum and does not replace applicable specifications in The National Electrical Code (NEC) All Specification References are from the current Spec Book 1. Check SOP A. Meg all cables. Isolate neutral and ground. (2545.3K) B. All wires must meg greater than 100 meg ohms to earth ground. (2545.3K) C. All breakers labeled to indicate what poles are included in system per (NEC) D. Make sure wiring is neat. (2545.3G) E. Feedpoint number and MnDOT ESS labels should be on the cabinet. (2545.3P) F. Available Fault Current Calculations and Cabinet Label. (2545.3A.1) (2565.3CC) 2. Check Random Poles A. Check no less than 5 poles or up to one-third of system. B. Check fuse holder and fuse. (2545.3G3) C. Conduits right length. (Standard Plates 8127 and 8128) D. Splices insulated as per specs. (2545.3G4) E. Outside jacket of Direct Buried Lighting Cable striped back flush to 4 inches above the conduit opening. (2545.3G2) F. Cable depth consistent no less than 24 inches direct buried and conduit depth no less than 18 inches below finished grade. (2545.3G2) (2565.3D2b) G. Direct buried cable must be approximately 24 inches up into pole. (2545.3G.2) H. Handholes and lighting foundations to finish grade. (2545.3F2 and E) I. Feed point and light poles numbers should be put on all poles. (2545.3P) J. Cable routing changes must be noted on prints. K. Check wiring diagram for accuracy. L. Poles and system must be effectively grounded. (2545.3R) M. Poles plumb and luminaires are level. (2545.3H and Q) I certify that this project has met the above checklist criteria. Locating responsibility will be taken over when final is done and as-built is received. (Name) (Date) 14-32

33 LIGHTING SYSTEM TESTING AND ACCEPTANCE Prior to completion of the work, the Contractor must test the entire system for unwanted grounds and conduct a 12 hour burn test for each feed point (2545 3K). Megohm meter test (Test for unwanted grounds) A megohm meter test, at 500 volts DC, indicating the insulation resistance of each circuit must be made. The Contractor must furnish the Engineer with a written report of the megohm meter readings for the permanent record. The report must contain the following information: (1) PROJECT NUMBER AND LOCATION (2) FEEDPOINT NUMBER - As indicated in the Plans. (3) BRANCH CIRCUIT - Identify each lighting branch circuit being tested by indicating the number of the first light connected to that circuit, as indicated in the Plans. (4) PHASE CONDUCTOR INSULATION RESISTANCE - Measure the resistance between the phase conductors and between each phase conductor and the equipment ground bar in the service cabinet with the fuses removed from the in-line fuse connectors in the lighting poles. The resistance must not be less than 100 megohms. (5) NEUTRAL CONDUCTOR INSULATION RESISTANCE - Measure the resistance between each neutral conductor and the equipment ground bar in the service cabinet with the fuses removed from the in-line fuse connectors in the lighting poles. The resistance must not be less than 100 megohms. (6) CIRCUIT INSULATION RESISTANCE - Measure the resistance between each phase conductor and the equipment ground bar in the service cabinet with all fuses in place in the lighting poles. The resistance must not be less than 5 megohms. The contractor must make sure that the two circuit conductors are connected to the circuit breaker of the opposite phases. All tests must be made at the service cabinet, in the presence of the Engineer, with all grounding connections in place. THE PHASE AND NEUTRAL CONDUCTORS MUST BE DISCONNECTED AT THE SERVICE CABINET FOR THE INSULATION RESISTANCE TESTS

34 12 Hour Burn Test K.2 Upon completion of a lighting system and before no more than 90% of the lighting system cost is paid, the lighting cabinet must be energized and the entire lighting system must operate successfully without interruption for 12 hours, during daylight hours only. The 12 hour burn test is conducted during daylight hours to ensure that the system is fully functional prior to it being placed into service. Where test results indicate faulty insulation or a faulty connection within the circuit, all necessary corrections must be made and the circuit retested, all at no expense to the Department. No additional payment will be made for replacing any part of or the entire circuit as required to make the circuits meet the test requirements