Manual
Traffic and Road Use Management
Volume 4 – Intelligent Transport Systems and Electrical Technology
Part 4: Rate-3 Road Lighting Junction Box Assembly
May 2016
Copyright
http://creativecommons.org/licenses/by/3.0/au/
© State of Queensland (Department of Transport and Main Roads) 2016
Feedback: Please send your feedback regarding this document to: tmr.techdocs@tmr.qld.gov.au
Traffic and Road Use Management, Transport and Main Roads, May 2016
Contents
1
Introduction ....................................................................................................................................1
2
Definition of terms .........................................................................................................................1
3
Referenced Documents .................................................................................................................1
3.1
Australian Standards ...................................................................................................................... 1
3.2
Transport and Main Roads Specifications ...................................................................................... 1
3.3
Transport and Main Roads Standard Drawings ............................................................................. 1
4
Items included in the kit (ensure all the kit contents are available) .........................................2
5
Closure (entry ports) preparation ................................................................................................5
6
Install heat shrink sleeves onto base ..........................................................................................5
7
Prepare cable ends to be inserted into junction box as follows ..............................................6
7.1
XLPE cable ..................................................................................................................................... 6
7.2
HDPE cable .................................................................................................................................... 6
7.3
Earth cable ...................................................................................................................................... 6
8
Cable installation ...........................................................................................................................7
8.1
Main port multiple cable entries ...................................................................................................... 7
8.2
Auxiliary port ................................................................................................................................... 7
8.3
Earth cable ...................................................................................................................................... 8
8.4
Single cable entry installation ......................................................................................................... 8
8.5
Sleeve recovery .............................................................................................................................. 9
9
Installation Instructions – Active Joint ........................................................................................9
9.1
Active Connector ............................................................................................................................ 9
9.2
Remove insulation and clean cables .............................................................................................. 9
9.3
Make Connection ............................................................................................................................ 9
9.4
Push sealing cap onto connection ................................................................................................ 10
10
Installation Instructions – Neutral Joint ................................................................................... 10
10.1 Remove Insulation and Install Lugs .............................................................................................. 10
10.2 Termination ................................................................................................................................... 11
10.3 Push sealing cap onto connection (same process as with active joint) ....................................... 11
11
Finishing off ................................................................................................................................ 11
11.1 Install Joint enclosure support bracket ......................................................................................... 11
11.2 Apply sealant to enclosure ports after termination ....................................................................... 12
12
Warning ........................................................................................................................................ 13
12.1 Safety directions ........................................................................................................................... 13
12.2 First aid ......................................................................................................................................... 13
13
Closing joint closure .................................................................................................................. 13
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
1
Introduction
The purpose of this technical instruction is to detail the installation and maintenance of a Rate-3 road
lighting junction box used by the Department of Transport and Main Roads.
The road lighting junction box function is to connect and disconnect the wiring connections in electrical
system for the road lighting technology. This device also acts as a sub-switchboard by providing
flexibility to connect or isolate the circuit at every nodes for both single and three phase circuits as per
arrangements outlined in the departmental drawings SD1624, SD1625, SD1626 and SD1699.
All Electrical Works shall comply with the requirements of the Electrical Safety Act 2002.
2
Definition of terms
Term
The Act
RPM
Nm
3
3.1
Meaning
Electrical Safety Act 2002, Regulation and Codes of Practice
Revolutions Per Minute
Newton metre
Referenced Documents
Australian Standards
The table below lists Australian Standards referenced in this technical document.
Table 3.1
Referenced Australian Standards
Reference
AS/NZS 3000
3.2
Title
Australian / New Zealand Standard Wiring Rules
Transport and Main Roads Specifications
The table below lists Transport and Main Roads Specifications referenced in this technical document.
Table 3.2 – Referenced Transport and Main Roads Specifications
Reference
MRTS228
3.3
Title
Electrical Switchboards
Transport and Main Roads Standard Drawings
The table below lists Transport and Main Roads Technical Standard Drawings referenced in this
technical document.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Table 3.3 – Referenced Transport and Main Roads Standard Drawings
Drawing Number
4
Title
1624
Road Lighting – Junction Box Single Phase Wiring Details
1625
Road Lighting – Junction Box Three Phase Wiring Details
1626
Road Lighting – Junction Box Active, Neutral and Earth Bolting
Arrangements
1699
Parts List
Items included in the kit (ensure all the kit contents are available)
The items included in the Rate-3 road lighting junction box kit are as shown in Table 4.
In order to achieve the best installation and maintenance practice, the following changes
were applied to the existing rate-3 road lighting junction box kit and are all shown in
Table 4.
•
Lug covers and bolting arrangements replaced with Active connectors and Gel caps for
easy and quick installation.
•
To stop galling changed from Glenloch lock to Nylock nuts to further reduce likelihood
tighten by hand tools maximum at 20 RPM with 7 Nm.
•
Labels introduced to comply with the requirements of MRTS228 and AS 3000.
•
Polyols and Diicocyanate sealants replaced with the Magic Power Gel which is reusable
thus providing flexibility during maintenance.
Table 4 - Items included in junction box assembly kit
Dome
Sealing clamp
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Sealing
O-Ring
Heatshrink
Sleeves
Base
Mounting
Bracket
Cleaning
Sachet
Branch Clip
Instruction
Guide
Sealing Tape
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Abrasive
Strip
Gel cap with
clamp
Main
Earth
Conductor
Label
Main Switch
Label Fitted
To Isolator
Fuse
holder,
Fuse &
Padlock
2 Part Resin
Neutral
Connector
kit
Active
Connector
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
5
Closure (entry ports) preparation
•
Remove the moulded caps on the cable ports as required using appropriate tools and wipe
them with clean cloth.
•
Abrade ports with abrasive strip.
•
Preheat port using hot air gun (260º).
Note: Heat source can be a hot air gun producing a temperature of at least 260ºC or a soft butane gas
lame approximately 300 mm long, with a 200 mm soft yellow tip.
Figure 5 – Install heat shrink sleeves onto base
6
Install heat shrink sleeves onto base
•
Place heat-shrink sleeve on prepared port, aligning glue free end correctly.
•
Using an approved heat source, recover the glue free end first before proceeding with gluelined section (take care not to concentrate heat in one spot).
•
Allow cooling for ten minutes before installing cables.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Figure 6 – Install heat shrink sleeves onto base
7
Prepare cable ends to be inserted into junction box as follows
7.1
XLPE cable
•
Clean cable for 500 mm using clean cloth.
•
Remove 300 mm of outer sheath.
•
Wearing the mittens provided, use the alcohol wipe from sachet to clean cable 150 mm back
from the sheath cut and 16 mm onto the conductor insulation.
7.2
HDPE cable
•
Clean cable for 600 mm using a clean cloth.
•
Remove 300 mm of outer sheath.
•
Wearing the mittens provided, use the alcohol wipe from sachet to clean cable 150 mm back
from the sheath cut and 16 mm onto the conductor insulation.
7.3
Earth cable
•
Clean cable for 600 mm using a clean cloth.
•
Remove 30 mm of sheath 400 mm from the end of the cable.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Figure 7.3 – Prepare cable ends to be inserted into junction box
8
Cable installation
8.1
Main port multiple cable entries
•
Insert cables through heat shrink sleeve into base so sheath removal point is level with the
bottom port opening.
•
Pinch the heat shrink tube together, separating the two cables to form a Figure 8.1, slide the
branch clip fully in at the pinched position.
Figure 8.1– Multiple cable entries
8.2
Auxiliary port
•
Wrap one turn of sealing tape around each cable 10 mm from the sheath cut point, cutting the
tape to join ends without overlap. Do not stretch tape.
•
Press both cables together at taped sections.
•
Wrap one turn of tape around the two cables over the sealing tape section and join ends
together without over-lapping.
•
Squeeze and smooth tape to remove air passages.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
•
Insert into base so sheath removal point rests against opening.
Figure 8.2 – Auxiliary port
8.3
Earth cable
•
This cable must be installed with either SDI or the TPS cables. See Figure 8.3.
•
Wrap sealing tape 10 mm from end, once around main cable as per Section 4 b).
•
Flatten and spread conductors in earth cable at the stripped section.
•
Wrap sealing tape at this point working it between the strands in the earth conductor.
•
Place both cables together.
•
One final wrap around both, taking care to squeeze and smooth the tape together to remove
air paths.
Figure 8.3 – Earth cable
8.4
Single cable entry installation
•
Install single cables into base as per Section 8.1 and 8.2, omitting the use of sealing tape and
branch clip.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
8.5
Sleeve recovery
•
Secure base to a stable support.
•
Cables to prevent movement.
•
Heat source start to recover sleeve from the base towards the open end making sure the heat
kept moving so as not to concentrate heat in one spot.
i.
Where the branch clip is used, ensure that enough heat applied to make the orange glue
block flow.
Note: Heat source can be a hot air gun producing a temperature of at least 260ºC or a soft butane gas
lame approximately 300 mm long, with a 200 mm soft yellow tip.
Figure 8.5 – Sleeve recovery
9
Installation Instructions – Active Joint
9.1
Active Connector
“Holes A” can accommodate cables 2.5-70 mm2, “Hole B” can accommodate cables 2.5-10 mm2
Figure 9.1 – Active connector
9.2
Remove insulation and clean cables
Insulation removal length equals connector insertion depth (16 mm) allowing gap between insulation
and connector
9.3
Make Connection
Insert conductors into connector and, using a torque wrench, tighten screws to appropriate torque
value.
Hole A: 13.6 - 20.3 Nm
Hole B: 13.6 – 17.0 Nm
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Figure 9.3 – Make connection
9.4
Push sealing cap onto connection
Install clamp on cap. Verify proper placement of clamp by ensuring the two pins on the bottom edge of
the clamp are mated with the holes of the cap, as shown in the figure opposite.
Install cap by holding all wires and pushing the cap over the connection assembly until it goes no
further.
Snap clamp closed. If necessary use pliers to snap clamp closed. Clamp pressure points should fit
into opposing grooves of cap and apply pressure between the cables.
Figure 9.4 – Sealing cap onto connection
10 Installation Instructions – Neutral Joint
10.1 Remove Insulation and Install Lugs
•
Ensure copper extends fully into lug
•
Insulation must not extend into lug (1 mm clearance)
•
Select crimping tool for secure connection
•
Install crimp lugs onto conductor
•
***Place ”Main Earth Do Not Disconnect” warning label over earth conductor going to earthing
point on the pole foundation cage, prior to bolting lugged joint together.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Figure 10.1 – “Main Earth Do Not Disconnect” warning label
10.2 Termination
•
Install Neutral and Earth bolting arrangements required as per SD1626.
•
Torque all nuts on setscrew assembly to a minimum of 20 Nm.
•
Use Bellville washers for spacers if required.
•
Setscrew lengths vary – see bolting details.
•
Leads must run parallel for at least 40 mm to accommodate the insulating shroud.
•
Arrange the wiring neatly within the joint, use cable ties if necessary.
•
Do not connect MEN connection until earth continuity and polarity is established.
Figure 10.2 – Neutral and Earthing bolting arrangements
10.3 Push sealing cap onto connection (same process as with active joint)
•
Install clamp on cap. Verify proper placement of clamp by ensuring the two pins on the bottom
edge of the clamp are mated with the holes of the cap.
•
Install cap by holding all wires and pushing the cap over the bolted assembly until it goes no
further.
•
Snap clamp closed. If necessary use pliers to snap clamp closed. Clamp pressure points
should fit into opposing grooves of cap and apply pressure between the cables.
11 Finishing off
11.1 Install Joint enclosure support bracket
Install bracket at a height to allow clearance from pit lid (suggest 400 mm from top of pit to centre of
bracket).
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
Figure 11.1 – Joint enclosure supporting bracket
11.2 Apply sealant to enclosure ports after termination
•
Sealant comes in two separate solutions. A clear solution and a blue solution.
•
Pour entire contents of bottle A (clear) into bottle B (blue).
•
Shake mixture vigorously for 1-2 minutes until well combined
•
POUR IMMEDIATELY
Figure 11.2 – Sealant application to enclosure ports
•
Apply liquid sealant by pouring into ports being careful not to overfill ports and flood the base
•
At an ambient temperature of 25 Degrees Celsius, the solution will take approximately 1520 minutes before it starts to congeal. Curing time is faster at warmer ambient temperatures,
and slower at lower ambient temperatures. Be careful not to move the cables around in the
sealant prior to it setting - to avoid compromising the seal.
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Volume 4: Part 4 – Rate-3 Road Lighting Junction Box Assembly
12 Warning
12.1 Safety directions
•
Avoid contact with skin and eyes.
•
Wear protective gloves and safety glasses.
12.2 First aid
•
If poisoning occurs contact, a doctor or Poisonous information centre.
•
If swallowed, do not induce vomiting. Seek immediate medical attention.
•
If in eyes, rinse eyes with water
•
If on skin, wash with soap and water.
13 Closing joint closure
•
Clean all sealing surfaces with a clean cloth.
•
Clean and fit 'O' ring as shown in Figure 13 (a).
•
Place closure dome over joint and seat unto base as in Figure 13 (b)
•
Fit clamp to base and dome so base and dome fit into 'V' grove of clamp.
•
Push clamp together until locking ring of latch fits into position as in 13 (c).
•
Push locking latch with palm of hand until fully closed. (A locking device may be used to
secure the clamp to stop unauthorised opening).
•
Place closure into proposed vertical mounting position using the wall bracket as perfect as in
Figure 13 (d).
Figure 13 – Closing joint closure
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