Installation Instructions
WARNING:
Personnel installing or servicing the Light-Structure Green™
system should observe all safety precautions related to high
voltage equipment.
All personnel performing installation should wear proper safety
equipment: hard hat, steel-toed shoes, gloves and eye protection
as necessary; and follow proper procedures for the requirements
of the task to ensure safety.
All wiring should be done by qualified personnel in accordance
with applicable local, state and federal electrical codes.
Extreme caution should be exercised when working near
overhead power lines or underground utilities. Verify location of
any underground utilities around the job site prior to installation.
These instructions are not intended to be a comprehensive guide
to all situations or problems which might arise. Any questions
should be directed to the manufacturer at 800/825-6020.
800/825-6020
www.musco.com
lighting@musco.com
100 1st Avenue West / P.O. Box 808
Oskaloosa, Iowa 52577
641/673-0411 • Fax: 641/672-1996
Warranty Fax: 888-397-8736
©1991, 2006 Musco Lighting · I-200-6
Installation Instructions
Table of Contents
Before You Begin
Tools Checklist .........................................................................................2
Documents You Need...............................................................................2
Components Matching and Labeling ........................................................3
Electrical System Requirements...............................................................4
Unloading Instructions .............................................................................5
Assembly Instructions
Precast Concrete Base .............................................................................6
Galvanized Steel Pole and Poletop Luminaire Assembly ........................10
Electrical Components Enclosure ...........................................................12
Wire Harness..........................................................................................14
Luminaire Attachment ............................................................................16
Installation Instructions
Pole Setting and Alignment ....................................................................18
Grounding and Underground Wiring ......................................................22
Special Situations (provided separately as needed)
Painted Pole Handling Instructions ..........................................................A
Bolt-on Crossarms ...................................................................................B
Separating Steel Pole Sections/Concrete Base.........................................C
Optional Features (provided separately as needed)
Auxiliary Bracket Mountings ....................................................................D
Platform, Climbing Steps and Safety Cable..............................................E
Installation Instructions
...in 5 Easy Pieces™
Designed for fast, trouble-free installation
1
4
1
3
2
5
2
3
1
Poletop Luminaire Assembly
4
2
Wire Harness
3
Electrical Components Enclosure
4
Galvanized Steel Pole
5
Precast Concrete Base
5
1
Before You Begin
Standard Tools/Supplies Checklist
*Refer to Special Situations/Optional Features
flyers for any additional tools required.
Contractor/Installer Supplied Tools:
Function:
Hammer, 3' or 4' pry bar, banding cutters, gloves
Pump
Duct tape
Dishwashing liquid
Two 11⁄2 ton chain type come-alongs
9
⁄16" wrench
Unloading equipment
Removing water from base holes (as needed)
Sealing underground conduit and cover plate
Lubricating pole slip-fit connections
Jacking together pole sections
Tightening poletop set screw
Tightening electrical enclosure bolt
Tightening captive screws to seal ECE to pole hub
Feeding wire harness through pole
Loosening / tightening pole cap bolt
Marking grid points on field to sight in aiming
Marking grid points on field to sight in aiming
Guiding pole onto base
Guiding pole onto base
Connecting underground wires to electrical enclosure
Large standard or Phillips-head screwdriver
Electrical fish tape, electrician's tape
25 ft.-lb. min. capacity torque wrench with 9⁄16" socket
Spray paint, chalk or flags
300' tape measure
12' to 16' 2"x4" or bar
10' stepladder or small line truck
Page:
5
8
9
10, 11, 18
10-11, 12
11
13
13
14
14-15
18
18
21
21
22
Musco Provided Tools:
Wooden base wedges
Level (adjusted for base taper)
Steel bar (13⁄8, 17⁄8, or 2 3⁄8" dia., depending on base size)
5
⁄32" Allen wrench
Wooden shipping blocks
7
⁄16" ratchet and 7⁄16" universal socket wrench
Steel chain
6 mm Allen wrench
3
⁄16" Allen wrench
3
⁄8" Allen wrench
Setting base
Plumbing base
Setting base, setting pole on base
Attaching handhole covers on base and steel pole
Elevating pole sections off ground during assembly
Tightening captive bolts to secure luminaire assembly
Setting pole on base
Attaching primary feed wires inside electrical enclosure
Attaching grounding wires inside electrical enclosure
Attaching grounding lugs at auxiliary bracket mounts
Attaching grounding conductors inside pole at handhole
7
7
7, 21
9, 16, 22
10
17
21
22
22
D
22
Machinery Needed:
Small line truck or forklift with nylon strapping (13,000 lb.)
and 8' sling (sized to weight of base)
Auger or auger attachment
Concrete truck with concrete backfill
Load-rated crane, nylon slings and shackles
Unloading equipment, setting bases
Boring holes for bases
Backfilling bases per requirements of pole jacking drawing
Setting poles
About These Instructions
Throughout this manual look for these important symbols:
2
Situations which may
cause serious
personal injury
Further instructions for
special situations or
optional features
Situations that may
cause equipment
damage or failure
Watch for these tips to
make installation easier
5, 7
6
8
19
Documents You Need
• Pole Jacking Detail Drawings
• Field Aiming Diagram
• Foundation Design (optional, as needed)
• Control System Switching
Schedule (if applicable)
If you do not have all of these documents, contact Musco at 800/825-6020.
Contractor/Customer provides:
• Grounding wire and grounding rod
• Underground wiring and conduit
• Electrical service entrance
• Main power disconnect
Before You Begin
Components Matching and Labeling
Each Light-Structure Green™ system is clearly labeled for fast,
trouble-free installation.
5 Easy Pieces™ Matching
Light-Structure Green pole locations are identified
by a letter-number combination (A1, A2, B1, B2, etc.
— see photo at right) on the Field Aiming Diagram and
each of the 5 Easy Pieces for each pole’s location:
• Poletop Luminaire Assemblies and Luminaire
shipping cartons
• Wire Harnesses
• Electrical Components Enclosures
• Galvanized Steel Pole sections
• Precast Concrete Base
Photometric System Matching
Luminaires will be individually labeled, identifying the
correct crossarm location (see photo at right.). The luminaire
comes completely assembled. Each luminaire is also identified
on the Field Aiming Diagram.
2
6
3
15 Pin
13
10
7
4
1
14
11
8
5
2
15
12
9
6
3
7
2
5
8
3
6
9
4
7
10
13
2
5
8
11
14
3
6
9
12
15
11
9
7
3
1
Fuses
9
10
11
12
13
12
10
13
11
12
9
10
8
6
Fuses
5
6
7
8
7
5
8
6
4
2
Fuses
1
2
3
4
Capacitors
1
Color
–
Black
White/Black
Red
White/Red
Blue
White/Blue
Brown
White/Brown
Orange
White/Orange
Purple
White/Purple
–
–
First fixture is always the top left
fixture as you’re facing the fixtures
Ballasts
15 Pin
4
Fixture#
–
1
1
2
2
3
3
4
4
5
5
6
6
–
–
7
13
Capacitors
9 Pin
1
Pin#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
6
12
13
5
Pole Wire Harness Pin Identifier
5
11
Ballasts
5
9
4
10
First fixture number
on this pole
Lamp
Control
8
3
9
Ballasts
1
2
8
Lamp
Control
4
1
Color
–
Black
White
Black
White
Black
White
Black
White
Black
White
Black
White
–
–
Ballasts
7
Fixture#
–
1
1
2
2
3
3
4
4
5
5
6
6
–
–
Ballasts
Wire Harness conductors are
color-coded and labeled to provide
easy luminaire reference. (See chart
on the right.)
9 Pin
Pin#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Capacitors
All wires in the Electrical Components
Enclosure are color-coded and labeled
by luminaire. The pair of wires for each
individual luminaire is taped together.
(See wire ID chart on page 12.)
Not Applicable
Ballasts
Ballasts, capacitors, fuses and fixtures
are each labeled with a number that
corresponds to the luminaire’s location
on the Field Aiming Diagram. (See
typical fixture location diagram.)
Ballast Enclosure/Pole Fitter Wire Harness Pin ID
Lamp
Control
Electrical Components and
Wire Labeling
3
4
1
2
Typical fixture location diagram
3
Before You Begin
Electrical System Requirements
While the majority of the Light-Structure Green™ system can be assembled by non-professionals, a qualified
electrician must handle the electrical supply installation and hook-up in accordance with national, state
and local codes. Your project’s electrician should review the following before the installation begins:
The electrician is generally required to provide:
• Individual pole lightning protection grounding systems in accordance with NFPA 780.
Refer to page 22 and the project specifications for additional information.
• Service entrance
• Main power disconnect
• Underground wiring
Supply wiring must be rated for 90 degrees C.
Voltage required to operate this system is listed on the label inside Electrical Component Enclosure doors.
Three-phase wiring is typically required at each pole, unless the project has been specified with
single-phase wiring.
Other features may affect the wiring supply requirements for this project:
• Lighting Contactor Cabinets – refer to the supplemental installation instructions and the Musco
Contactor Cabinet Summary Sheet if applicable.
• Control-Link® – facility management system – refer to the supplemental installation instructions and
Musco Control System Summary Sheet .
• Auxiliary Bracket option – refer to Auxiliary Bracket Installation flyer for required wiring.
Volunteer Installation: If you are utilizing volunteers to install your project, you will need to have a qualified electrician
review and complete the following installation steps:
1. Electrical system design – prior to installation.
2. Verify trenches, underground wiring and conduit properly installed (See concrete base installation,
steps 9 to 11 on page 9).
3. Complete grounding and connecting to underground wiring steps 1 to 5 on page 22.
4. Test complete lighting system.
4
Before You Begin
Unloading Instructions
A typical Light-Structure Green™ shipment includes
Precast Concrete Bases, Galvanized Steel Poles, Electrical
Components Enclosures, Wire Harnesses, and Poletop
Luminaire Assemblies with Luminaires.
For ease of installation, set all matched components
by the proper pole location as noted on the Field
Aiming Diagram.
Tools/Materials Needed
❑
❑
❑
❑
❑
❑
Use proper pick-up procedures when lifting.
Hammer
Nylon strapping (13,000 pound)
3-foot or 4-foot pry bar
Banding cutters
Forklift or crane
Four people
WARNING!
To Avoid Personal Injury or Equipment Damage:
• DO NOT cut shipping bands or un-chock concrete
bases or poles until ready to unload. Product is heavy
and may roll.
• Use proper pick-up procedures and equipment for lifting
concrete bases and poles. Balance point may not be at
midpoint of base or pole.
• Check bill of lading to verify that all materials have
been received.
• Look over all materials for possible damage during
shipping.
• Do not alter structural members in any way, such as
bending, welding, drilling, etc. without prior authorization
by Musco Lighting.
A typical Light-Structure Green™ shipment.
• Luminaire Assembly shipping cartons come in three pieces:
top, center and bottom. Make sure box is upright before
cutting shipping straps; then lift off box top, interior panels
and center wall section before removing Luminaire
Assembly from remaining box bottom.
• Painted poles require special handling. For painted pole
unloading instructions separate flyer included.
NOTE: Specific component sizes and weights for each project
will vary.
NOTE: If additional information is needed, please
contact Musco’s shipping department at 800/756-1205.
5
Assembly Instructions
Precast Concrete Base
Wireway
Overview
The Precast Concrete Base is set directly into the ground, backfilled and allowed
to cure for 12 to 24 hours. Base is designed for easy slip-fit connection to the
Galvanized Steel Pole. The remaining components – Steel Pole Poletop
Luminaire Assembly, Electrical Components Enclosure and Wire Harness – are
assembled and set onto the base.
Top tapers
downward to
hollow center
Epoxy coating
(top edge)
Tapered upper
section for slip-fit
Tools/Materials Needed
Musco Supplied:
Contractor Supplied:
❑
❑
❑
❑
❑
❑
❑
❑ Conduit for underground
wiring
❑ Concrete backfill
❑ Method for pumping out
water (if any) from base hole
Field Aiming Diagram
Pole Jacking Drawing
Steel bar
Wooden base wedges
Tapered level for base
5
⁄32" Allen wrench
Foundation design
(if required)
Verify that the letter-number (example A1) identification on the concrete
base corresponds to the proper location on the Field Aiming Diagram.
Lifting hole
Handhole, above
grade
Ground line
Conduit
adapter
plate
Access hole,
below grade
Foundation designs and requirements may differ based on local governing
authority criteria and building codes. Only project-owner approved,
project-specific foundation designs should be utilized.
Refer to Musco pole jacking drawing for project-specific information.
For options on poor soil conditions or alternative installation methods, call
Musco at 800/825-6020 for more information.
1
Lay out trenches for underground wiring and determine orientation of
base’s wire access hole for proper base installation. Refer to the
Field Aiming Diagram for pole locations.
2
Bore hole for each Concrete Base. Refer to the Field Aiming Diagram
for the pole locations. Refer to the Pole Jacking Drawing or Foundation
Design from structural engineer for the size and depth of the holes, and
for the approximate weight of each of the bases. The hole depth must
be no more than eight inches deeper than the recommended depth. If a
deeper hole is bored, backfill with compacted rock or concrete to
proper depth per your project requirements.
Cover each hole if you will not be immediately installing Concrete Bases.
6
Epoxy coating
(bottom edge)
Assembly Instructions
Precast Concrete Base
3
Sling and lower Precast
Concrete Base into hole.
Run 8-foot sling through the
top of the Concrete Base.
Remove covers of top
handhole and lifting bar hole.
Run steel bar through the 11⁄2inch to 21⁄2-inch bar hole,
sling loop and out the top
handhole. Slide other sling
loop over the forklift fork or
line truck hook and lower
base into hole until lower
handhole is just above
ground level.
4
Lifting hole
Top handhole
Align wire access hole with
future trench and lower
Concrete Base into center
of hole until it rests on the
bottom. Keep the underground
access hole lined up with the
future wiring trenches as
determined by the electrician.
5
6
Wedge Concrete Base
into position.
Plumb Concrete Base, using
the supplied level. This level
has been designed to
compensate for the taper of
the base. Place the end of the
level with the attached shim
beginning approximately
1 foot from the top of the
base. Shift wedges until
base is plumb.
7
Assembly Instructions
Precast Concrete Base
7
Release forklift, remove
steel bar and 8-foot sling.
Recheck plumb of Precast
Concrete Base.
Do not allow concrete to enter
underground wire access hole.
If there is any water in the
hole, it MUST be removed
prior to backfilling with
concrete. The water will mix
with the concrete and flood
into the inside of the base,
filling the inside conduit and
making underground wiring
impossible, as well as
weakening foundation. Refer
to the Pole Jacking Drawing or
foundation design for the
required amount of backfill.
8
Keep concrete backfill level
below the underground wire
access hole
Assembly Instructions
Precast Concrete Base
Backfill requirements may
vary for your project.
Where a conflict occurs,
owner-approved drawings
take precedence over these
printed instructions.
8
Backfill with concrete in
2-foot to 3-foot increments
to just below the underground
wire access hole. Check
plumb after each increment.
If Concrete Base gets out of
plumb, simply push it back
into plumb before the concrete sets. Check plumb of Concrete
Base a final time. Allow concrete to cure until it can no longer
be readily penetrated with a 1⁄2-inch diameter rod and hammer.
Normally 12 to 24 hours is required. Backfill should reach to
approximately 2 feet from surface, unless foundation design
requires backfill to grade. If backfilling to grade, complete step 10
before following backfilling instructions.
9
After Concrete Bases are installed, dig conduit trenches to NEC
or local code depths and install individual pole grounding rods.
Refer to the grounding system information on page 22 for specifics
on installing ground rods.
10
Insert conduit and attach cover plates to Concrete Base with
5
⁄32 -inch Allen wrench. (Base is shown out of ground for clarity.
Electrician will run underground conduit and wiring after base
has been set.) Center handhole cover plates are provided with
knockouts that can be folded back to help support conduit for
underground access.
11
Have your electrician install all underground wiring, including
grounding system wiring, through the conduit and out the top of the
Concrete Base. The equipment ground will need to run through the
below grade access hole outside of the conduit and out the top
of the base.
12
Remove wedges and backfill the remaining space with compacted dirt
to ground level, when the electrical work is complete.
9
Assembly Instructions
Galvanized Steel Pole and Poletop Luminaire Assembly
Overview
While concrete is curing, you may assemble the remaining components.
The Galvanized Steel Pole and Poletop are designed to slip fit together.
Tools/Materials Needed
Musco Supplied:
❑ Wooden shipping blocks
❑ Pole jacking drawing
Contractor Supplied:
❑ Two 11⁄2-ton chain-type come-alongs
❑ Dishwashing liquid
❑ 9⁄16" wrench
Jacking ear
Jacking ear
Verify that the letter-number (example A1) identification on each of the
Steel Pole sections corresponds to the proper location on the Field
Aiming Diagram. Stencil is on the inside of the bottom ends and outside of
the top ends of each section.
1
Assemble Steel Pole sections. Position
bottom section of steel pole on wooden
shipping blocks. Place attaching
brackets for Electrical Components
Enclosure facing up and jacking ears on
sides of pole sections aligned.
Electrical Components
Enclosure attachment
brackets
Stainless steel nuts
welded in hub
Grounding lug
(inside pole)
Lubricate top two (2) feet of bottom
pole section with dishwashing liquid.
Slide upper section onto the lower
section as far as possible.
Jacking ear
Slip-fit
attachment
to Precast
Concrete Base
2
Pull pole sections together by attaching
two (2) 11⁄2-ton come-alongs to jacking
ears and pulling together evenly from
each side. See Pole Jacking Drawing for
section overlap dimensions.
Steel Pole section should overlap 1 1⁄2
times the pole’s diameter for proper
seating and reliability.
For larger poles with additional sections,
repeat above procedure for each section.
10
Wire access
handhole
Assembly Instructions
Galvanized Steel Pole and Poletop Luminaire Assembly
Verify that the letter-number
(example: A1) identification
on the Poletop Luminaire
Assembly corresponds to the
proper location on the Field
Aiming Drawing and the steel
pole sections it is being
attached to.
Pole cap
securing bolt
Pole cap
Crossarm
Pole cap
safety
cable
Quick
connect
plug-in
Snap hook
for wire
support grip
Crossarm wiring
3
Place Poletop Luminaire
Assembly on wooden blocks.
Luminaire
Mounting
Plate
Aim setscrew facing up if
the Electrical Components
Enclosure is designed to be
mounted on the field side.
Aim setscrew facing down if
enclosure is to be mounted
facing away from field, and
place poletop assembly on
wooden blocks. Lubricate
the top two (2) feet of the
top pole section with
dishwashing liquid prior
to sliding together.
4
Pole shaft
Jacking ears
Set screw
Slide Poletop Luminaire Assembly onto Steel
Pole as far as possible. Align crossarms,
either facing up or down as specified for
your project, with the front face of
Electrical Components Enclosure.
5
Pull Poletop onto Luminaire Assembly Steel Pole
section by attaching two 11⁄2-ton come-alongs to
jacking ears and pulling together evenly from each
side. See Pole Jacking Drawing for section
overlap dimensions.
Pole sections should overlap 1 1/2 times the pole’s
diameter for proper seating and reliability.
6
Tighten set screw with 9⁄16-inch wrench.
Do not over-tighten.
Step 6 drawing.
Refer to Bolt-on Crossarms installation flyer if you are installing bolt-on crossarms on your poletop assemblies.
Refer to Auxiliary Bracket Mountings installation flyer if you are installing auxiliary equipment on your system.
11
Assembly Instructions
Electrical Components Enclosure
Overview
The Electrical Components Enclosure is factory-wired and tested. Built-in hardware allows for easy, accurate attachment to
Galvanized Steel Pole. The quick-connect plug-in assures trouble-free connection to Poletop Luminaire Assembly via the
Wire Harness.
Tools Needed
Contractor Supplied:
Stainless steel bolt
Pole identification
label on front
❑ 9⁄16" wrench
❑ Large standard or Phillips-head screwdriver
Pole mounting bracket
Common (white/left)
Stainless steel latches
coated with clear
thermoset polymer
Voltage (black/center)
Capacitor (red/right)
Verify that the letter-number (example: A1)
identification on the Electrical Components
Enclosure corresponds to the proper location
on the Field Aiming Diagram.
Ballast
Ballast
attachment
Wire Identification
Wire access hub/
captive stainless steel
attachment screws
(not shown)
Wire Color
Purpose
Gauge
Black
Power lead*
12 or 10
Red
Power lead*
12 or 10
Blue (for 3-phase)
Power lead*
12 or 10
Ballast wire
access
White
Neutral on 120 or 277 VAC
12 or 10
Terminal block
Black & White
Lamp leads to crossarms
14
Green
Grounding jumper wire
6
Wiring
schematics
Fuses
Smart Lamp™ control
Capacitors
Landing lugs
Disconnect
switch
*The pair of wires for each individual light are taped together
All wires are labeled with a fixture number that corresponds to the light’s location
on the aiming diagram
Electrical Components Enclosures may be heavy!
Use care in lifting to avoid personal injury.
Electrical Components Enclosure Weights
Enclosure Type
Measurements
1
1
Mount the Electrical Components Enclosure on the
pole. Remove the label covering the wire access
hole on the back of the enclosure. Slide the hinge
hanger bracket bolt on the top of the enclosure
onto the mounting bracket on the pole. The wire
access hole in the back of the enclosure mounts
onto the wire access hub on the pole.
12
Weight Range
2PX-4P
W 14" X H 28 ⁄2" X D 9"
(36cm) X (72cm) X (23cm)
70-100 lbs
(32Kg)-(45Kg)
4PX-6P
W 14" X H 401⁄2" X D 9"
(36cm) X (103cm) X (23cm)
100-175 lbs
(45Kg)-(79Kg)
6PX
W 14" X H 521⁄2" X D 9"
(36cm) X (134cm) X (23cm)
150-225 lbs
(68Kg)-(102Kg)
Assembly Instructions
Electrical Components Enclosure
2
Open the Electrical Components Enclosure door.
The weight of the door may cause the Electrical
Components Enclosure to lean toward the door.
Prop the enclosure up on the door side with your
knee until the captive screws line up with the nuts
in the hub.
3
Tighten the two captive screws inside the Electrical
Components Enclosure to seal onto the hub with
the standard or Phillips-head screwdriver.
Go to the section below, Stacked Electrical
Components Enclosure Mountings, and at the top of
next page, Back-to-Back Electrical Component
Enclosure Mountings, if you have more than one
Electrical Components Enclosure per pole.
4
Tighten the bolt that slides into the Electrical
Components Enclosure mounting bracket with
the 9⁄16-inch wrench.
To protect the interior of the electrical enclosure,
the customer will need only to supply a lock.
Stacked Electrical Components Enclosure Mountings
Each Electrical Components Enclosure has a separate Wire Harness
and plug-in connection in the Poletop Luminaire Assembly.
Components are labeled indicating the correct combination.
Each Electrical Components Enclosure is mounted on the one below,
aligning the enclosure wire access port and tightening the bolt resting
in the mounting bracket on the Galvanized Steel Pole. The Wire
Harnesses are labeled for correct connection at the poletop.
NOTE: Each Electrical Components Enclosure must be grounded at lug
located in the bottom enclosure using the grounding wires provided.
NOTE: All connections should be made in the bottom box near the
disconnect switch. Plug-in connectors should then be placed behind the
disconnect switch sub-panel.
13
Assembly Instructions
Back-to-Back Fixture and Enclosure Mountings
Back-to-Back Fixture Mountings are used to light two fields from one
common pole. The Electrical Components Enclosure for each side is
mounted facing the same direction as the luminaires, and otherwise are
installed in the same way as a single-sided pole.
For Back-to-Back Fixture Mountings, it will be necessary to lift the
end of the pole for assembly, to provide clearance for the luminaires,
prior to setting the pole.
Wire Harness
Overview
The factory-built Wire Harness connects the Electrical
Components Enclosure to the Poletop Luminaire Assembly.
Pole cap fastener
Top plug-in
conductor circuits
Wire Harnes
quick conne
Wire tie
Tools/Materials Needed
Wire suppo
snap hook
Wire support grip
Musco Supplied:
Wiring to Electrical
Components Enclosure
Wiring to
Luminaires
❑ 5⁄32" Allen wrench
Contractor Supplied:
❑ Fish tape
❑ Electrical tape
❑ 9⁄16" wrench
Spiral wound cable
consisting of 14 gauge
copper wire
Flexible protective
sleeve
Verify that the letter-number (example: A1)
identification on the Wire Harness corresponds to
the proper location on the Field Aiming Diagram.
14
Lower plug-in
conductor circuits
MKT-2561
Assembly Instructions
Wire Harness
1
Fish the Wire Harness through the pole. Remove
pole cap from the Poletop Luminaire Assembly
with 9⁄16-inch wrench. Remove the cover from the
handhole located in the pole just below the
Electrical Components Enclosure with 5⁄32-inch
Allen wrench.
Insert fish tape down through the top of the pole
and out the bottom of the pole. Attach the top of
the Wire Harness (the end WITH the wire support
grip). Using electrical tape to hold it on, pull top
end of Wire Harness through to the poletop. Using
the handhole next to the Electrical Components
Enclosure, feed the bottom Wire Harness
connector into the Electrical Components
Enclosure through the hub.
2
3
Attach the Wire Harness support grip to the snap
hook inside the top of the poletop assembly. Poles
taller than 80 feet have an additional wire support
grip at the midpoint of the pole. Access to attach
this grip is provided by an additional handhole.
Plug in the Poletop Luminaire Assembly wiring
connector to the Wire Harness connector. Replace
the pole cap (using 25 ft.-lb. min. capacity torque
wrench with 9⁄16-inch socket). Torque to 15 in.-lb.
and back off 1⁄4 turn.
4
Plug in the Electrical Components Enclosure
connector to the Wire Harness connector, making
sure the wire numbers match.
Plug-in connector and excess wiring should be
placed behind the disconnect switch subpanel, with
the wire harness flexible protective sleeve
extending through the pole hub into the enclosure.
Do not allow wire harness or plug-in connectors into
the upper part of the enclosure.
15
Assembly Instructions
Luminaire Attachment
Overview
The luminaires are central to Musco's energy-efficient lighting. The optics system redirects what would be wasted light
back onto the field, increasing the light output from each luminaire and reducing off-site spill light and glare. The lamp’s
special design maintains the most energy-efficient position for the lamp arc while allowing the optimum field aiming angle.
Tools/Materials Needed
Die-cast aluminum
mounting plate
Musco Supplied:
Die-cast aluminum
knuckle
❑ 7⁄16" ratchet or 7⁄16" universal socket
Die-cast aluminum
lamp cone
Contractor Supplied:
❑ Gloves
The luminaire is factory built and assembled
complete with optics system and lamp. The
luminaire is shipped in individual cartons, ready
for quick attachment to the crossarm.
Lamp
Do NOT disassemble the knuckle cone!
Verify that the letter-number (example A1)
identification on the luminaire carton(s) corresponds
to the proper location on the
Field Aiming Diagram.
Refer to Platform, Climbing Steps and Safety Cable
installation flyer if you are installing these items.
If you are installing Back-to-Back Fixtures, go to
page 14.
1
2
3
Remove orange protective caps for each luminaire
position on the crossarm and discard.
Remove orange protective cap from the luminaire
knuckle and discard.
Match each luminaire to its location on the
crossarm. The unique number/ID on the
luminaire will match the same number/ID
on the crossarm.
Each luminaire is designed for a specific location
on the crossarm. The number/ID on the luminaire
and crossarm must match.
16
Orange protective caps
Assembly Instructions
Luminaire Assembly
4
Install luminaire knuckle into mounting plate on
crossarm. (See photo series 1-4 below.)
The rectangle slot in the mounting plate will be
facing the same direction as the reflector.
1. Insert back of knuckle into mounting
plate first.
5
2. Lock back of luminaire knuckle into
position on mounting plate.
3. Rotate front of knuckle into position
and hold. Finger tighten captive bolts
to hold luminaire in place.
Tighten (2) two captive
mounting bolts with 7⁄16"
ratchet or 7⁄16" universal
socket wrench. Do not
exceed 20 ft-lbs torque.
Do not over-tighten!
The wire connectors will
automatically connect when
luminaire is rotated into its
final position.
6
4. Tighten two captive bolts.
Two captive bolts per luminaire knuckle
Repeat process for all
remaining luminaires.
17
Assembly Instructions
Pole Setting and Alignment
Overview
All luminaires are factory aimed to their exact position on the field. To ensure the proper pole orientation, a simple eye-safe pole
alignment beam completes the precision field aiming. The pole alignment sight is factory attached to one luminaire per pole.
Tools/Materials Needed
Musco Supplied:
Contractor Supplied:
❑
❑
❑
❑
❑
❑
❑
❑
❑
Field Aiming Diagram
Steel chain
Steel bar
Pole Alignment Sight
(attached to one
luminaire per pole)
❑ Load-rated nylon slings as required
❑ Spray paint (or other method to
mark aiming points on the field)
❑ 2 11⁄2-ton chain-type come-alongs
Tape measure
Dishwashing liquid
Thick black marker
12' to 16' 2" x 4" or bar
Shackles as required
Verify letter-number (example: A1) identification on Galvanized Steel Pole and Concrete Base prior to setting pole.
Utilizing the pole alignment beam is critical to proper field aiming. If you have questions, contact 800/825-6020.
Pole alignment beam utilizes an intensity that is safe for viewing and will not harm eyesight if viewed from a
distance of three feet or more. DO NOT STARE INTO BEAM OR LOOK INTO BEAM FROM CLOSER THAN THREE
FEET. DO NOT USE BINOCULARS, CAMERA OR TELESCOPE TO VIEW ALIGNMENT BEAM FROM ANY DISTANCE.
Pole alignment beam is designated as a Class 2M laser during operation and all procedures of operation. This
device should not be modified, dismantled, serviced or repaired. Do not operate if device is defective or the cover
or seal is damaged.
“Caution — use of controls or adjustments or performance of procedures other than those specified herein may
result in hazardous radiation exposure.”
1
Use the Field Aiming
Diagram to determine the
beam aiming point on the
field for each steel pole.
39ºR 13ºR 27ºL 46ºL 64ºL
38ºV 31ºV 30ºV 28ºV 26ºV
15MZ 15MZ 15MZ 15MZ 15MZ
1
2
3
4
5
5
4W 4W 4M 4M
Mark the location on the
field. Use the point to
aim in the pole.
Project
S1
126'
S1
110'
2
Field Name
Pole
I.D.
S1
Aiming Points
X
Y
I.D.
4
-30
18
S2
6
-4
S3
11
67
1
S4
17
3
-51
Apply dishwashing liquid
to the top five feet of the
Concrete Base and inside
the bottom pole section
to lubricate the
slip-fit connection.
6
5
1
4
20
21
2
7
3
19
18
Portion of Field Aiming Diagram (example)
18
49
12
Assembly Instructions
Pole Setting and Alignment
3
Sling Galvanized Steel Pole using this recommended method. Attach shackles to lower jacking ears of pole lower
section, and continue up sides of pole until slings reach beyond the entire pole structure’s center of gravity.
Two or even three slings may be required per side for taller poles, to ensure the cradle point remains above the
pole assembly’s center of gravity.
Cradle point must be above the center of
gravity of the pole assembly.
Attach slings to bottom jacking ears using
shackles with 5⁄8 inch minimum bolts.
Join eyes of short sling
and attach to crane hook.
Feed short sling through eye of
sling and loop under pole shaft.
All slings must be rated for complete pole weight.
Crane head must be kept below bottom crossarm.
Explanatory label
4
Activate beam by turning the "ON" switch located at the end of the
pole alignment sight device body. Beam will provide 11⁄2 hours of
strong light for aiming alignment before dimming. Less intense
light will be visible for 3–4 hours. Pole alignment sight projects a
narrow vertical beam of light along luminaire’s aiming line.
LASER LIGHT
DO NOT STARE INTO THE BEAM OR VIEW DIRECTLY
WITH OPTICAL INSTRUMENTS (MAGNIFIERS)
CLASS 2M LASER PRODUCT, 635nm 1mW Max CW
CLASSIFIED PER IEC 60825-1, Ed. 1.2, 200-08
Pole Alignment Site labels and locations.
Manufacture date label
DO NOT USE BINOCULARS, CAMERA OR TELESCOPE TO VIEW AIMING
BEAM. Beam is safe to view from three feet or more distance from device
with the unaided eye. Product labeled next to alignment sight (see right).
All beam alignment devices are quality checked in the factory. If beam does
not activate when turned on, the batteries will need to be replaced. Extra
batteries are located in a plastic bag in the hardware / tools kit shipped
with your project. Follow the instructions with the replacement batteries.
5
“Complies with FDA performance standards for laser products except
for deviations pursuant to Laser Notice No. 50, dated July 26, 2001”
Manufactured by Musco Sports Lighting, LLC; Muscatine, Iowa
Mfg. Date: 2306
“On” switch is
located on back end
of pole alignment sight
Connect crane hook to sling and slowly lift pole.
Hoisting must be smooth and continuous without abrupt jerks.
Do not lift complete pole / crossarm assemblies by any of the crossarms.
Secure slings to pole only. Take care to avoid damaging or misaligning
luminaires during the lifting process.
The crane sling should be attached to the lowest pole section being
lifted below the separating point. If the sling is higher up on the pole,
all pole sections above the separation point must be secured together
to prevent separation during lifting.
19
Assembly Instructions
Pole Setting and Alignment
Do not stand under assembled steel pole sections. The pole may rotate quickly during the lifting operation. To avoid
potential personal injury and possible damage to the lighting equipment, position two people, one gripping each
side of the crossarm bar. The personnel should be equipped with appropriate safety equipment including hard hats,
gloves and protective eyeglasses. Hold the crossarm level until the pole is raised enough to allow the crossarms to
clear the ground, as well as the electrical components enclosure. Steady the crossarms until pole stops rotating or
until the pole is raised sufficiently to allow crossarms to clear the ground if rotating continues.
For back-to-back fixture mounting, refer to page 14 for luminaire adjustment.
6
Maneuver the Galvanized
Steel Pole using a 12-foot to
16-foot 2" x 4" wood pole or
metal bar inserted into the
lower handhole of the pole.
7
Lower pole assembly onto
Concrete Base.
Keep hands clear when setting
Steel Pole over Concrete Base.
Avoid pinching the wires. Do
not allow pole assembly to
rest on the Concrete Base until
final alignment is complete
(steps 8 & 9).
8
Turn the pole so the fixtures
are approximately aligned
with the field. Refer to the
Field Aiming Diagram for
crossarm orientation.
9
Figure 9a: Circle shows Field Aiming Diagram aiming point
Align pole to its aiming point using the pole alignment beam. The pole
alignment device projects a narrow vertical beam of light easily
detected by the eye when directly in line with its aiming. Standing
on the field, look at the
luminaire with the device.
Walk parallel to the pole's
crossarm until you see the
beam “flash” in your eyes.
Direct the pole's rotation
until the “flash” is visible
when standing on the
aiming point, and hold
position. (See Figure 9a.)
Pole Aligning Sight is Class 2M during
operation & all procedures of operation.
Laser Emission Parameters
Operation Accessible Radiation Fields:
Wavelength:
635-660 nm
Laser Power for Classification:
Beam Diameter:
Divergence:
<5mm at aperture
<1.5mrad x 1 radian
Transverse Beam Mode:
20
<1mW CW
TEM00
Assembly Instructions
Pole Setting and Alignment
When you start seeing red from the beam the pole is close; when the light “flashes” in your eye, you are directly in line with
the aiming line.
If the sun is directly behind the luminaire, shield glare with your hand to see luminaire with the aiming sight. Beam will be
visible if the luminaire is visible.
If beam is turned on prematurely, or pole setting is delayed, using red-lensed glasses may aid in seeing the decreased
strength beam. Do not use binoculars.
Red beam lines may still be visible on the field surface the first evening after installation. Within a few hours, beam
lights will extinguish.
10
Mark a vertical line on the base of
the Steel Pole and also about twothirds down the Concrete Base.
This will provide a visual sign if
the pole rotates during the
following lowering process.
Galvanized
Steel Pole
Or: Mark the Steel Pole at the seam
in the Concrete Base, then follow
the seam down during the
lowering process.
Alignment marks
11
Lower the Steel Pole onto the
Concrete Base, making sure the
Precast
Concrete Base
vertical line on the pole and base
stay aligned.
12
Seat the Steel Pole onto the Concrete
Base. Reinsert steel bar through the
Concrete Base. If the steel bar does
not align with the jacking ears on
the lower pole section, wrap a chain
around the base below the bar.
Attach the 11⁄2-ton chain-type comealongs to the jacking ears and the
steel chain. Make sure the comealongs are positioned vertically on
each side of the pole. Pull together
tightly using even force from each
side. Remove come-alongs, steel
bar and chain.
Do not attempt to pull the pole down
if come-alongs are twisted around
the Steel Pole. The pole will rotate
and misalign fixtures.
If the pole becomes seated before being aligned, the pole will require separating tools. Contact Musco to request these tools.
If you are installing the Safety Cable option, go to the Platforms, Steps and Safety Cables Flyer for tightening instructions.
21
Pole Setting and Wiring
Grounding and Connecting to Underground Wiring
Tools/Materials Needed
1
Musco Supplied:
Contractor Supplied:
❑
❑
❑
❑
❑
❑
❑
❑
3
⁄16" Allen wrench
3
⁄8" Allen wrench
5
⁄32" Allen wrench
6 mm Allen wrench
10' x 5⁄8" ground rod
#2 or #2/0 copper wire
Underground wiring & conduit
Main power disconnect
Adjust excess wiring as necessary. The plug-in connector(s) must
remain in the bottom Electrical Components Enclosure under no
tension. Plug-in connector(s) and excess wiring should be placed
behind disconnect switch subpanel, with the wire harness flexible
protective sleeve extending through the pole hub into the enclosure.
Ground lug in
Electrical Components
Enclosure
Do not allow wire harness or plug-in connectors into the upper part of
the enclosure.
2
3
Adjust system phase if necessary.
All Electrical Components Enclosures
are shipped from the factory wired three
phase unless specified single phase,
but are field adaptable to single phase
systems. All necessary equipment is
installed in the enclosure to readily and
easily make this modification. Refer to
the wire identification chart on page 12.
Jumper grounding
wire
Underground wire,
brought into Electrical
Components Enclosure
through wire access
hole in Galvanized
Steel Pole.
Ground lug in
Galvanized
Steel Pole
Individual pole
ground, attached to
ground lug inside
Galvanized Steel
Pole and ground
rod in soil.
Connect underground power supply.
Bring underground wire into the
Electrical Components Enclosure
through the access hub. Attach primary
feeds to the landing lugs, on the
disconnect switch in the Electrical
Components Enclosure, with 6 mm
Allen wrench.
See page 13 and 14 for multiple Electrical Component Enclosures connections.
22
10' x 5⁄8"
Ground rod,
supplied by
contractor
Pole Setting and Wiring
Grounding and Connecting to Underground Wiring
4
5
6
Connect primary system ground jumper wire in Electrical Components Enclosure to
grounding lug inside Galvanized Steel Pole, opposite the handhole, with 3⁄8-inch
Allen wrench.
Each pole must be grounded for lightning protection per the National Fire
Prevention Association (NFPA) code 780. Poles 75 feet or shorter should use
a #2 copper conductor to the ground rod, and poles taller than 75 feet should
use #2/0. For standard clay soil, the ground rod must be not less than 5⁄8-inch
diameter and 10 feet long, driven vertically into the soil until the point is 10'
below grade. Do not encase the ground rod in the concrete foundation. For
other soil conditions, consult NFPA 780, Section 3-16.
Replace handhole covers and base covers
with 5⁄32-inch Allen wrench.
23
Installation Instructions
24
Installation Instructions
Notes
25
Installation Instructions
800/825-6020
www.musco.com
lighting@musco.com
100 1st Avenue West / P.O. Box 808
Oskaloosa, Iowa 52577
641/673-0411 • Fax: 641/672-1996
Warranty Fax: 888/397-8736
©1991, 2006 Musco Lighting · I-200-6
Musco products referenced or shown are protected by one or more of the following patents. U.S. Patents: 4725934; 4729077; 4816974; 4947303; 4994718; 5075828; 5134557; 5161883; 5211473;
5229681; 5377611; 5398478; 5423281; 5426577; 5600537; 5707142; 5800048; 5816691; 5856721; 6036338; 6203176; 6250596; 6340790; 6398392; 6676277; 6681110; 6833675; 6969034; D337168;
D353797; D353911; D411096. Canada Patents: 70479; 73755; 74939; 89366; 2009749; 2026850; 2027033; 2035014; 2058261; 2110014; 2200511; 2200515; 2378279; 2378283. EPC Patents: 440531.
Mexico Patents: 175863; 183225. Other patents pending.