CHAPTER 14
ROADWAY LIGHTING
ROADWAY LIGHTING SYSTEMS (2545)
GENERAL LIGHTING MATERIAL REQUIREMENTS
General material requirements must be in accordance with MnDOT 2545.2.
ROADWAY LIGHTING 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
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 3wire locking type mounting receptacle is located inside the cabinet at the PEC windows for the
photoelectric control device.
14-1
CHAPTER 14
ROADWAY LIGHTING
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
CHAPTER 14
ROADWAY LIGHTING
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
CHAPTER 14
ROADWAY LIGHTING
14-4
CHAPTER 14
ROADWAY LIGHTING
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 2545.3 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 2545.3 L.
Position the cabinet door from 90 degrees to 180 degrees to the roadway, away from traffic.
14-5
CHAPTER 14
ROADWAY LIGHTING
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 2545.3P.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 110.24. 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
CHAPTER 14
ROADWAY LIGHTING
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 105-305
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
CHAPTER 14
ROADWAY LIGHTING
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 2545.3 G
Underground Wiring Direct Buried Lighting Cable
Direct buried lighting cable must be installed in accordance with MnDOT 2545.3 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
CHAPTER 14
ROADWAY LIGHTING
When an obstruction has been encountered in the path of the direct buried lighting cable, reroute 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.
2545.3G.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.
2.
3.
4.
5.
3 inch (75 mm) wide,
Permanent Red
Stretchable
Non-biodegradable
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
CHAPTER 14
ROADWAY LIGHTING
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.
14-10
METAL
GUARDRAIL POST
CHAPTER 14
ROADWAY LIGHTING
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.
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.
SPLIT-BOLT
CONNECTOR
INSULATED WIRE SPLICE
CONNECTOR BLOCK
Light Pole Wiring
Install light pole wiring in accordance with MnDOT 2545.3 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.
14-11
CHAPTER 14
ROADWAY LIGHTING
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
CHAPTER 14
ROADWAY LIGHTING
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.
14-13
CHAPTER 14
ROADWAY LIGHTING
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 2545.3G.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
CHAPTER 14
ROADWAY LIGHTING
Three Way Direct Buried Handhole
Cable Splice
When required use a three way direct
buried handhole cable splice in
accordance with contract documents.
ROADWAY LIGHT POLES - 3811
General
MnDOT roadway light poles:
1) 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 NonBreakaway
Stainless Steel 40 Foot and 49 Foot Breakaway
Aluminum Alloy 40 Foot and 49 Foot Breakaway
High Mast Light Towers
14-15
CHAPTER 14
ROADWAY LIGHTING
Bridge and Barrier Poles 40 Foot and 49 Foot







14-16
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)
CHAPTER 14
ROADWAY LIGHTING
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
CHAPTER 14
ROADWAY LIGHTING
High Mast
Towers




14-18
COR-TEN Steel
(Weathering Steel)
H Base Design
Typically 100 FT or 120 FT
Typically Ring Assembly
Holds 3 to 4 Luminaires
CHAPTER 14
ROADWAY LIGHTING
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 3811.
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
2471.3B1 and 2471.3B3. For high mast lighting installations, the Contractor must submit final
reproducible drawings in accordance with 2471.3B. 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.
LIGHT POLE INSTALLATION 2545.3 H
Follow the light pole installation requirements in accordance with MnDOT 2545.3 H.
Steel and stainless steel lights poles, and high mast light towers are fastened to the foundation
anchorages using a top nut and a leveling nut with flat washers called a “double-nut moment
connection”. This connection essentially clamps the pole base plate with the required flat
washers in position between the top nut and the leveling nut. Both the top nut and leveling nut
must be tightened with a wrench.
14-19
CHAPTER 14
ROADWAY LIGHTING
Aluminum light poles use a single nut connection or a heavy hex top nut to fasten the pole base
to each foundation anchorage. In this connection the pole base rests directly on top of the
foundation.
Bridge and Barrier Galvanized Steel Light Poles with 6 Anchor Bolts
2- JAM NUTS
2- FLAT WASHERS
LEVELING HEAVY HEX NUT
Typically galvanized steel light poles are installed on bridges and barrier with 6 anchor bolts.
Light poles mounted on bridges and barrier are non-breakaway.
Ensure the clearance between the bottom of the leveling nut and the top of foundation or
“standoff distance” is less than one bolt diameter.
Bridge and barrier mounted poles require two heavy hex jam nuts in place of one standard
heavy hex nut for top nuts only. Do not use jam nuts in place of leveling heavy hex nuts. Heavy
hex jam nuts are thinner than a standard heavy hex nut but have the same dimensions across
the flats and corners. 2 heavy hex jam nuts = 1 standard heavy hex nut. Refer to Standard
Plate 8332 for more information.
Information on bridge and barrier mount pole foundations can be found in Chapter 10
Foundations & Equipment Pads.
14-20
CHAPTER 14
ROADWAY LIGHTING
Stainless Steel Light Poles
Typically stainless steel light poles are breakaway, mounted on Design E or Design H Light
Foundations. Contract documents will indicate which foundation design to install.
The stainless steel light pole manufacturer requires a ½ in min. gap between the bottom of the
pole base and the top of foundation. Set the leveling nuts to the correct “standoff distance”
(distance between bottom of leveling nut and top of foundation) before setting the light pole.
Refer to MnDOT 2545.3 H for standoff distances according to the design of the foundation. Use
the minimum standoff distance when possible. Tighten the leveling nuts with a 30 degree tight
access open-end wrench.
30° OPEN-END WRENCH
½ IN MIN GAP REQUIREMENT
Information on light pole foundations can be found in Chapter 10 Foundations & Equipment
Pads.
Install stainless steel woven wire cloth in accordance with MnDOT 2545.3 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
14-21
CHAPTER 14
ROADWAY LIGHTING
Aluminum Light Poles
Typically aluminum light poles are breakaway, mounted on Design E or Design H Light
Foundations. Contract documents will indicate which foundation design to install.
If leveling is required install aluminum light poles with leveling shims (not leveling nuts). See
Standard Plate 8129 for leveling shim requirements.
Install holddown ½ in thick washers supplied with the aluminum light pole base with top nuts in
accordance with MnDOT 2545.3 H. Do not use standard flat washers under the top nuts.
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.
USE ½ IN THICK HOLDDOWN WASHERS
LEVELING SHIMS
14-22
CHAPTER 14
ROADWAY LIGHTING
High Mast Lighting Towers
Install high mast lighting towers and tower foundations in accordance with contract documents.
Ensure the clearance between the bottom of the tower base plate and the top of foundation is 3
in. If leveling is required turn the leveling nuts that need adjustment downward towards the
foundation.
Install stainless steel woven wire cloth in tower lighting base between the base plate and the
foundation and use 100% clear silicone sealant to fill voids between the woven wire cloth and
the tower base plate to protect against rodent intrusion.
WOVEN WIRE CLOTH AND
SILICONESEALANT
14-23
CHAPTER 14
ROADWAY LIGHTING
LUMINAIRES
All LED Luminaires listed on MnDOT’s APL have a minimum Ten (10) year warranty.
These luminaires will operate in a range of 120 - 277 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 C136.41-2013 standard 7-terminal twistlock 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.
14-24
CHAPTER 14
ROADWAY LIGHTING
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.
14-25
CHAPTER 14
ROADWAY LIGHTING
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
symmetrical or asymmetrical
luminaires must be MnDOT
MnDOT’s Approved/Qualified
lighting.
1000 watt high pressure sodium
luminaires with ballasts. High mast
approved luminaires as listed on
Products List (APL) for Roadway
14-26
CHAPTER 14
ROADWAY LIGHTING
LUMINAIRE INSTALLATION 2545.3 Q
Install and level luminaires in accordance with MnDOT 2545.3Q, 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.
14-27
CHAPTER 14
ROADWAY LIGHTING
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.
14-28
CHAPTER 14
ROADWAY LIGHTING
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
luminaire prior to the luminaire being installed on the pole.
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.
No smart photocontrols are listed on the MnDOT APL for 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. Power to each luminaire will be on 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.
14-29
CHAPTER 14
ROADWAY LIGHTING
AIR OBSTRUCTION LIGHTS 3816
MnDOT has Light Emitting Diode (LED) Air Obstruction Lights listed on MnDOT’s
Approved/Qualified Products List web site under Roadway lighting.
http://www.dot.state.mn.us/products/roadwaylighting/index.html
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 web
site under Roadway lighting.
http://www.dot.state.mn.us/products/roadwaylighting/index.html
Navigation Lantern Installation
Install navigation lanterns in accordance with contract
documents.
14-30
CHAPTER 14
ROADWAY LIGHTING
LIGHT SYSTEM COMPONENT LABELING and NUMBERING 2545.3P
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
POLE
NUMBER
ASSETT
TAG
LIGHT POLE
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.
14-31
CHAPTER 14
ROADWAY LIGHTING
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 2545.3 P.2.b.
14-32
CHAPTER 14
ROADWAY LIGHTING
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.
14-33
CHAPTER 14
ROADWAY LIGHTING
ELECTRICAL SYSTEM TESTING AND ACCEPTANCE 2545.3K
General testing and acceptance requirements must be in accordance with 2545.3K.
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.






2.













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)
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 2565.3E)
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 2545.3Q)
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)
14-34
CHAPTER 14
ROADWAY LIGHTING
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.
14-35
CHAPTER 14
ROADWAY LIGHTING
12 Hour Burn Test 2545.3K.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.
14-36
CHAPTER 14
ROADWAY LIGHTING
LIGHTING STANDARD PLATES AND BRIDGE STANDARD FIGURES
LIGHTING STANDARD PLATES:
Equipment Pad B ..................................................................................... ........ 8106
Handholes ............................................................................................... ........ APL *
Pulling Vaults ........................................................................................... ........ APL *
Light Foundation–Design E ..................................................................... ........ 8127
Light Foundation - Design H .................................................................... ........ 8128
Shim And Washer .................................................................................... ........ 8129
Roadway Lighting Service Cabinets ........................................................ ........ APL *
Reinforced Concrete Median Type F (Non-Glare Screen Type) ............. ........ 8308
LIGHT POLE FOUNDATION
Reinforced Concrete Median Type F and Glare Screen ......................... ........ 8309
LIGHT POLE FOUNDATION
Anchor Bolt Cluster and Base Plate for Light Poles ................................. ........ 8332
* Approved/Qualified Products List (APL)
BRIDGE STANDARD FIGURES:
Refer to http://www.dot.state.mn.us/bridge/ for current Bridge CADD Standards (Standard
Figures).
14-37
CHAPTER 14
ROADWAY LIGHTING
This
Page
Intentionally
Left
Blank
14-38