TS Traffic Installation Testing Siemens Mobility Division Traffic Solutions
667/HE/20664/000
Sopers Lane Poole Dorset BH17 7ER
SYSTEM/PROJECT/PRODUCT: Traffic Signals
INSTALLATION AND COMMISSIONING HANDBOOK INSTALLATION TESTING (GENERAL)
Prepared: David Martin
Approved: D.A.Martin
Function: Engineering Manager
Function: Engineering Manager
THIS DOCUMENT IS ELECTRONICALLY APPROVED AND HELD IN THE TS DOCUMENT CONTROL TOOL
Issue : 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Change Ref : 83/16446 83/16563 83/16700 ANL00102
TS000669
TS001616 TS004023 TS004922 TS004944 TS005821 TS007220 TS008004 TS008072
Date : 5/7/89 28/4/92 22/6/92 14/9/93 13/11/96 January 1999 February 2001 September 2001 February 2003 October 2003 December 2003 September 2007 February 2009 November 2009 December 2012 December 2014 June 2015 July 2015
This is an unpublished work the copyright in which vests in Siemens plc. All rights reserved. The information contained herein is the property of Siemens plc. and is supplied without liability for errors or omissions. No part may be reproduced or used except as authorised by contract or other written permission. The copyright and the foregoing restriction on reproduction and use extend to all media in which the information may be embodied.
667/HE/20664/000
Page
1
Issue 18
TS Traffic Installation Testing SAFETY WARNING HEALTH AND SAFETY AT WORK Note by the Health and Safety at Work Executive BS 7671 and the IET Wiring Regulations have been extensively referred to in HSE guidance over the years. Installations which conform to the standards laid down in BS 7671:2008 (and incorporating amendments) are regarded by HSE as likely to achieve conformity with the relevant parts of the Electricity at Work Regulations 1989. Existing installations may have been designed and installed to conform to the standards set by earlier editions of BS 7671 or the IET Wiring Regulations. This does not mean that they will fail to achieve conformity with the relevant parts of the Electricity at Work Regulations 1989. Safety of Installation and Maintenance Personnel In the interests of health and safety, when installing, using or servicing this equipment the following instructions must be noted and adhered to: (i)
Prior to any work being started a Risk Assessment must be completed.
(ii)
Only competent persons who possess sufficient technical knowledge, relevant practical skills and experience for the nature of the electrical work undertaken and are able to prevent danger and, when appropriate, injury to themselves and others, and who are also familiar with the safety procedures required when dealing with modern electrical/electronic equipment are to be allowed to use and/or work on the equipment. All work shall be performed in accordance with the Electricity at Work Regulations 1989.
(iii)
Electrical equipment shall be selected so as to withstand safely the stresses, the environmental conditions and the characteristics of its location. An item of equipment which does not by design have the properties corresponding to its location may be used where adequate further protection is provided as part of the completed electrical installation. As a minimum all equipment must be H.A. approved.
(iv)
Good workmanship by competent persons or persons under their supervision and proper materials shall be used on the erection of the electrical installation. Electrical equipment shall be installed in accordance with the instructions provided by the manufacturer of the equipment.
(v)
Competent personnel must take heed of all relevant notes, cautions and warnings in this Handbook and any other Document or Handbook associated with the equipment including, but not restricted to, the following: (a) The equipment must be correctly connected to the specified incoming power supply and earth protection installed and tested in accordance with current BS 7671 Wiring Regulations. (b) The equipment must be disconnected / isolated from the incoming power supply before removing any protective covers or working on any part from which the protective covers have been removed. (c) Any power tools and equipment must be regularly inspected and tested. (d) Any ladders used must be inspected before use to ensure they are sound and not damaged.
667/HE/20664/000
Page
2
Issue 18
TS Traffic Installation Testing (e) When using a ladder, before climbing it, ensure that it is erected properly and is not liable to collapse or move. If using a ladder near a carriageway ensure that the area is properly coned and signed. (f) (vi)
Any personnel working on site must wear the appropriate protective clothing, e.g. reflective vests, etc
When competent personnel are working within a confined space with restricted movement the following protective measures apply to circuits supplying the following current-using equipment: (a) For the supply to a hand-held tool or an item of mobile equipment: i. Electrical separation subject to only one item of equipment being connected to a secondary winding of the transformer or ii. SELV (b) For the supply to hand lamps: i. SELV. It is permissible for the SELV circuit to supply a fluorescent luminaire with a built-in step-up transformer with electrically separated windings. (c) For the supply to fixed equipment: i. Automatic disconnection of the supply with supplementary equipotential bonding. The supplementary bonding shall connect exposed-conductive parts of fixed equipment and the conductive parts of the location, or ii. By use of Class II equipment or equipment having equivalent insulation provided the supply circuits have additional protection by the use of RCDs having the characteristics specified in BS 7671,or iii. Electrical separation subject to only one item of equipment being connected to secondary winding of the isolating transformer, or iv. SELV, or v. PELV, where equipotential bonding is provided between all exposedconductive-parts, all extraneous-conductive-parts inside the conducting location with restricted movement, and the connection of the PELV system to Earth.
Safety of Road Users It is important that all personnel are aware of the dangers to road users that could arise during installation, repair and maintenance of traffic control equipment. Ensure that the junction area is coned and signed as necessary. Barriers and suitable warning signals/signs must be in place prior to work commencing and arranged to give clear warning to motorists and pedestrians of the electrical or mechanical hazards relating to the work being carried out on the traffic installation. Ensure adherence to safety requirements conforming to current BS 7671 17th Edition Wiring Regulations to help protect the personnel working on the site. (16th edition section 611”Highway Power Supplies” is now 17th section 559.10). Whilst repairing signals which are in an "all-out" condition, care must be taken to ensure that no spurious signals are lit during testing which could mislead drivers or pedestrians. Particular care is required where pedestrian audible devices are installed, to ensure that no false indications are given during, for example, cable testing. Personnel should also ensure 667/HE/20664/000
Page
3
Issue 18
TS Traffic Installation Testing the safety of pedestrians, especially children, who may come into contact with the equipment metalwork.
667/HE/20664/000
Page
4
Issue 18
TS Traffic Installation Testing
CONTENTS SAFETY WARNING
2
1.
7
1.1 1.2 1.3 1.4 1.5
2.
INTRODUCTION PURPOSE SCOPE RELATED DOCUMENTS QUALIFICATIONS GLOSSARY
7 7 8 9 10
INSTALLATION TESTING
12
2.1 TEST GEAR REQUIREMENT 12 2.2 CORE TO CORE TESTING 12 2.2.1 Equipment 13 2.2.2 Method 13 2.3 VISUAL INSPECTION 14 2.4 CIRCUIT PROTECTIVE CONDUCTOR (CPC) TEST 14 2.4.1 Provision of cable cores for test purposes 15 2.4.2 Loop Resistance of Two “Test” Cable Cores on Each Cable Run 15 2.4.3 Loop Resistance of Cable Core (R1) and CPC (R2). For Poles without push buttons. 15 2.4.4 Loop Resistance of Cable Core and CPC. For Poles with push buttons. 16 2.4.5 CPC Continuity Resistance 16 2.5 BASIC POLARITY TEST (ADDITIONAL) 17 2.6 SITE INSULATION TEST 18 2.6.1 Preparation 18 2.6.2 Test 19 2.7 POLARITY TEST 20 2.8 EARTH LOOP IMPEDANCE TESTS (ZS) 23 2.8.1 General Information 23 2.8.2 Preparation 24 2.8.3 Fuse Replacement 27 2.8.4 Measuring Earth Loop Impedance at The Origin, Prospective Short Circuit Current and Prospective Fault Current. 27 2.8.5 Measuring Earth Loop Impedance at Poles and Push buttons in LV installations 28 2.8.6 Calculating the ELI value for ELV only poles 29 2.8.7 Measuring Earth Loop Impedance within the Controller Cabinet 29 2.8.8 Controller RCD Fitted To Incoming Power 30 2.8.9 Maximum Allowable Earth Loop Impedance With in-line RCD 30 2.9 RCD TEST 30 2.9.1 30mA Trip Current RCD Protecting Maintenance Socket 30 2.9.2 300 mA RCD Protecting Whole Installation (If fitted) 31 2.10 DETECTOR LOOP TEST 31 2.10.1 Tests 31 2.11 ADDITIONAL INSULATION TESTS 33 2.12 NEUTRAL CONDUCTOR VOLTAGE DROP TEST 33 2.13 GUIDANCE FOR GENERATORS 33 2.14 COMMISSIONING 34 2.15 VERIFICATION OF ELI RESULTS 34 2.16 COMPLETION OF CERTIFICATES 34
3. 3.1
TESTING TO CLEAR PROBLEMS
35
PURPOSE
35
667/HE/20664/000
Page
5
Issue 18
TS Traffic Installation Testing 3.2 TEST EQUIPMENT 35 3.3 TOTAL SITE/JUNCTION INSULATION TEST 36 3.3.1 Preparation 36 3.3.2 Test 36 3.4 EARTH LOOP IMPEDANCE TEST (ZS) 37 3.4.1 Preparation 37 3.4.2 Tests 37 3.4.3 Maximum Allowable Impedance (fuse protected) 38 3.4.4 Maximum Allowable Impedance (RCD protected) 38 3.4.5 Fuse Replacement 38 3.4.6 Signal Head Poles 38 3.5 TESTING OF RCDS 39 3.5.1 Preparation 39 3.5.2 30mA trip current RCD protecting maintenance socket 39 3.5.3 300mA RCD protecting whole controller (if fitted) 40 3.6 CORE INSULATION TESTING 40 3.6.1 Preparation 40 3.6.2 Test 40 3.7 CORE TO CORE LOOP RESISTANCE CONTROLLER TO POLE 40 3.7.1 Preparation 40 3.7.2 Tests 42 3.8 DC RESISTANCE CHECKS ON LAMP TRANSFORMERS (TS SUPPLIED SIGNAL HEADS ONLY)42 3.8.1 Preparation 42 3.8.2 Tests 42 3.9 NEUTRAL CONDUCTOR VOLTAGE DROP TEST 43
4. 4.1 4.2
5. 5.1
PERIODIC INSPECTION AND TESTING
44
INTRODUCTION CONTENT OF WORK
44 44
MINOR WORKS
48
INTRODUCTION
48
APPENDIX A - PRECAUTIONS TO BE TAKEN WHEN PLANNING THE INSTALLATION AND MAINTENANCE OF TRAFFIC CONTROL EQUIPMENT IN THE VICINITY OF LIGHT RAPID TRANSPORT SYSTEMS. 49 APPENDIX B - COMPLETION CERTIFICATE AND TEST RESULTS
51
APPENDIX C - P.I. ELECTRIC TEST CERTIFICATE
61
APPENDIX D - MINOR ELECTRICAL INSTALLATION WORKS CERTIFICATE 71 APPENDIX E - START UP ROUTINE
667/HE/20664/000
Page
74
6
Issue 18
TS Traffic Installation Testing 1.
INTRODUCTION
1.1
PURPOSE This handbook contains details of test procedures designed to verify functional aspects of wiring and to ensure that an installation conforms to the requirements of the 17th edition of the IET wiring regulations (BS7671:2008) incorporating the following amendments: Amendment No. 1:2011 (issued on 1st July 2011, and effective from 1st January 2012) Amendment No. 2:2013 (issued on and effective from 1st August 2013) Amendment No. 3:2015 (issued on 1st January 2015, and effective from 1st July 2015)
1.2
SCOPE This handbook details testing procedures to be carried out as part of the installation for traffic signal controllers, poles, signals and associated equipment. It should be read in conjunction with the other Installation and Commissioning Handbooks - see section 1.3. It also contains procedures for electrical tests performed during fault location and routine maintenance visits but does not include service schedules, which are contained in the appropriate controller manual. Where a variance between Local Authority Specifications, Equipment Specifications and this document exist, the Local Authority and Equipment Specifications take precedence only when additional procedures or tests are identified. The resulting degree of safety of the installation shall be not less than that obtained by compliance with BS 7671 IET Wiring Regulations 17th edition. Note that although this handbook is arranged in the order that tests would normally be carried out, testing is not a continuous activity and takes place at various stages of installation as required.
667/HE/20664/000
Page
7
Issue 18
TS Traffic Installation Testing
1.3
RELATED DOCUMENTS Detectors and Cable Terminations Handbook Above Ground Detectors Handbook Helios Signals and Poles Handbook ST4R Detector Handbook ST700 General Handbook ST900 General Handbook ST750 General Handbook ST750 ELV General Handbook ST950 General Handbook ST800 Installation Commissioning and Maintenance Handbook ST900 Installation Commissioning and Maintenance Handbook ST900 ELV Installation Commissioning & Maintenance Handbook ST950 ELV Installation and Commissioning Handbook ST950 LV Installation and Commissioning Handbook UPS Solution General Handbook Traffic Signal Junction Cabling Design Certification (LV) Traffic Signal Junction Cabling Design Certification (ELV)
667/HE/20663/000 667/HE/20665/000 667/HB/30000/000 667/HB/27663/000 667/HB/27880/000 667/HB/32900/000 667/HB/33750/000 667/HB/32750/000 667/HB/46000/000 667/HE/27000/000 667/HE/33900/000 667/HE/32900/000 667/HE/45950/000 667/HE/46950/000 667/HB/47750/000 667/DS/20664/000 667/DS/20664/048
BS7671: AMD3: 2015 Requirements for Electrical Installations. IET Wiring regulations 17th Edition BS 7430:2011 Code of practice for protective earthing of electrical installations (see Section 7 covering Generators if applicable) Guidance Note 3: Inspection and Testing (from the IET)
667/HE/20664/000
Page
8
Issue 18
TS Traffic Installation Testing 1.4
QUALIFICATIONS Only skilled or instructed personnel with relevant technical knowledge and experience, who are also familiar with the safety procedures required when dealing with modern electrical/electronic equipment, are to be allowed to use and/or work on the equipment. All work shall be performed in accordance with the Electricity at Work Regulations 1989 or the relevant local, state and government regulations. Any personnel working on Siemens Traffic Controllers should have completed the following training courses: HA Sector Scheme Sector 8 Modules 5XX (for installation) M609 – Junction Traffic Controller Maintenance Any personnel completing and signing the certificates for installation and/or periodic inspection must hold the relevant National Highway Sector Scheme modules. Training requirements for non UK users may be different.
667/HE/20664/000
Page
9
Issue 18
TS Traffic Installation Testing 1.5
GLOSSARY CET
Central Earth Termination
CPC
Circuit Protective Conductor
DNO
Distribution Network Operator
ELI
Earth Loop Impedance
ELV
Extra Low Voltage - Normally not exceeding 50 V a.c. or 120 V ripple-free d.c., whether between conductors or to earth
FELV
Functional Extra Low Voltage
IET
Institute of Engineering and Technology (formerly IEE)
Line
A conductor of an a.c system for the transmission of electrical energy other than a neutral conductor, a protective conductor or a PEN conductor. The term also means the equivalent conductor of a d.c system unless otherwise specified in the regulations.
Live
Live conductor defined as any live part of the installation intended to be energised in normal use.
LRT
Light Rapid Transport
LV
Low Voltage – Normally exceeding extra low voltage but not exceeding 1000 V a.c. or 1500 V d.c. between conductors, or 600 V a.c. or 900 V d.c. between conductors and Earth
MET
Main Earth Terminal
PEN
A conductor combining the functions of both protective conductor and neutral conductor
PELV
Protective Extra Low Voltage. An extra low voltage system which is not electrically separated from earth.
PI
Periodic Inspection
PME
Protective Multiple Earthing
PPE
Personal Protective Equipment
RCD
Residual Current Device (Residual Current Circuit Breaker).
STS
Site Traffic Signals
TS
Traffic Solutions (part of the Siemens Mobility Division)
TN-C supply Where the neutral and protective functions are combined in a single conductor (known as PME). TN-C-S
A system where the supply is TN-C (neutral and protective functions are combined) and the arrangement of the system is TN-S (separate neutral and protective conductors).
TT supply
Where no earth is provided by the supply authority and an earth electrode is used as the method of earthing.
UPS
Uninterruptible Power Supply
Note: 667/HE/20664/000
Page
10
Issue 18
TS Traffic Installation Testing For full definitions of FELV, PELV and ELV, see IET Regulations 17th Edition (BS7671:2008 incorporating Amendment No 1:2011).
667/HE/20664/000
Page
11
Issue 18
TS Traffic Installation Testing 2.
INSTALLATION TESTING
2.1
TEST GEAR REQUIREMENT General: Test equipment and their leads must conform to the safety requirements as laid down in BS EN 61557 (Electrical safety in LV systems) and BS EN 61010 (Safety requirements for electrical equipment in measurement and control). i) A Low resistance ohm meter, or the continuity range of an insulation and continuity tester (see iii below). An instrument to BS EN 61557-4 will meet the requirements expressed in BS7671. ii) Digital Multimeter capable of reading 250V or greater, current to (10A). iii) Insulation Tester. Megger BM222 or similar. iv) Earth Loop Impedance Tester. Megger LT5 or similar v) RCD Tester capable of testing both positive and negative half cycles as required in IET Regs 17th Edition. (e.g. Megger CBT3, Robin KMP 5404, ISO TECH IRT 1900, Metrohm 16R, Seaward RC750). vi) Inductance tester (LCR bridge). Wavetek DM27XT or Beckman LM22A or similar. vii) A test lamp certified to meet the requirements of the HSE, Guidance note GS38 "Electrical test equipment for use by electricians". (This may be used in place of a multimeter to check polarity). For tests of earth electrode resistance where low values are required, it may be necessary to use a four-terminal earth tester (e.g. for use with generators, see IET Guidance Note 3: Inspection and Testing section 2.7.12). Note that all test equipment must be within its calibration period.
Note: The following sections, 2.2 to 2.6 inclusive, must be completed before connection to the mains supply.
2.2
CORE TO CORE TESTING The test will ensure that the insulation of the cable has not been compromised during the installation. It will also comply with minimum values obtained from table 61 of BS7671 IET Wiring regulations 17th Edition for insulation resistance testing between live conductors and each live conductor to earth.
667/HE/20664/000
Page
12
Issue 18
TS Traffic Installation Testing
2.2.1 Equipment 1
A terminal block may be made up which has shorting links between each terminal. For larger cables additional terminal blocks can be cascaded.
2
Insulation Tester
2.2.2 Method This test is to be carried out after all the cables have been run to the signal poles and terminated in the pole cap (sometimes connected through to adjacent poles). The lamp transformers and all ELV connections are to be left disconnected.
Cable to Pole
Armour Core 1 Measure Insulation
Controller End
Figure 1 - Test Block connected for testing
At the controller end, each cable is to be terminated in the test block with one core per termination and the armour in the last position (as shown in Figure 1). Remove the first core (Figure 1) and measure the insulation at 500V between this and all other cores, including the armouring, in the termination block. Minimum reading should be 20M . Remove the second core and repeat above. Proceed until all cores have been tested. The test is to include all cores including spare cores and cores reserved for ELV applications. Record the lowest reading obtained on each cable on the form in Appendix B.
667/HE/20664/000
Page
13
Issue 18
TS Traffic Installation Testing
2.3
VISUAL INSPECTION Before connection to the mains supply a visual inspection of the installation is to be undertaken. Visual inspections will consist of the following: i)
All lanterns are correctly aligned and securely fastened in accordance with the STS.
ii)
All push buttons are securely fastened and their doors tightened down. Ensure that the correct operating voltage of the wait lamp is clearly indicated on the label inside the push button box.
iii)
All pole caps are correctly installed and that no gaps exist to allow the ingress of water.
iv)
Controller base seal is not punctured, and is free from gaps around cables.
v)
Ensure all earth connections are securely made off: Main earth conductor to the mains supply. All cable armouring is secured correctly to the castellated bar or where applicable that all CET glands are correctly made off and secured to the earth bar. Controller doors have their earth straps correctly connected to the controller case. Castellated or earth bars are correctly bonded to the Main Earth Terminal.
2.4
vi)
Check that terminal block connections are securely made.
vii)
Check that terminal block connections are not loose, especially where more than one conductor uses the same terminal.
viii)
Check that conductor/wire insulation has not retracted from terminal connections. There must be no exposed conductor on new installations. The maximum allowable length of exposed conductor is 2mm in any circumstance. It is noted that Regulation 559.10.3.1 allows for a minimum degree of protection of IP2X (12mm diameter), but Siemens Mobility - Traffic Solutions chooses 2mm maximum.
CIRCUIT PROTECTIVE CONDUCTOR (CPC) TEST It is necessary to test and verify the continuity of the CPC of each cable run to the furthest earthed point, this may be a pushbutton or similar pole mounted item. The results of these tests will be recorded in the Test Results section of Appendix B. The following tests can be completed after the installation has been fully terminated, but before any power is applied to the installation. This test is also required for the ELV controllers. In this case, the Continuity Protective Conductor (CPC) resistance shall not be greater than 2.2 Ohms. This impedance is slightly higher than the CPC resistance of the armouring of a 250m long 1.0mm2 cable (8 core), but offers a degree of protection against an accidental short-circuit from a
667/HE/20664/000
Page
14
Issue 18
TS Traffic Installation Testing third party’s mains supply at the signal head. Any third party LV supply must be separated from the TS ELV supply in all instances; it is recommended that the installation is entirely ELV. 2.4.1 Provision of cable cores for test purposes During the termination of cables at signal poles two “spare cores” are selected for the purpose of testing and feed through poles to the furthest pole where they will be connected to the earth terminal. Where a cable run “loops” through other poles, it is essential to use two spare terminals at the pole top to connect through cores. These test cores must not be connected together at any pole other than the last pole on a cable run. At the controller end these cores will be identified as “Test Cores” and labelled to indicate to which cable run they are connected. 2.4.2 Loop Resistance of Two “Test” Cable Cores on Each Cable Run Using the low resistance test instrument identified in 2.1 i), zero the test leads, measure at the controller the loop resistance of the two test cores for each cable run. The results of these tests will be inserted in the “Core to Core Resistance” box in the Installation Test Results form. The resistance should be no greater than that stated in the following table, if greater, then all pole terminations should be checked for tightness. If all pole terminations are correct, perform further loop resistance checks at each pole, working out along the cable run from the controller until the particular cable at fault is isolated. Before testing, zero the meter. 1mm2 Resistance
1.5mm2 Resistance
@ 25oC (round trip)
@ 25oC (round trip)
Expected CPC resistance (armour)
36.92
24.68
7.8
1 Km
18.46
12.34
3.9
500 metres
9.23
6.17
1.95
250 metres
4.61
3.08
0.98
125 metres
2.77
1.87
0.59
75 metres
1.85
1.25
0.39
50 metres
0.74
0.5
0.16
20 metres
0.37
0.25
0.08
10 metres
Approximate distance to signal
TABLE 1 ‘Expected CPC resistance’ is the typical value of resistance of the metal cable sheath/armouring for 8-core 1mm2 cable. Larger cables have lower CPC values. 2.4.3 Loop Resistance of Cable Core (R1) and CPC (R2). For Poles without push buttons. Using the low resistance test instrument identified in 2.1 i), zero the test leads, measure the loop resistance between one cable core (R1) and the CPC (R2) for each cable run, as measured from the cable core to a local earth connection. (Unless there 667/HE/20664/000
Page
15
Issue 18
TS Traffic Installation Testing are exceptional circumstances the cable armouring would be used as the CPC). The results of these tests will be inserted in the "Core to CPC Resistance" box in the Installation Test Results form. This gives (R1 + R2). 2.4.4 Loop Resistance of Cable Core and CPC. For Poles with push buttons. This test is to be conducted even on poles which only have ELV. Connect the CPC (R2) at the pushbutton to one other core (Rt) in the drop cable. Then connect one of the test cores (R1) to the same core of the drop cable. This will create a loop including the CPC of the controller to pole cable(s), the CPC drop to the pushbutton, the other core in the drop cable and the test core. Using the low resistance test instrument identified in 2.1 i), zero the test leads, measure the loop resistance between one cable core (R1) and the CPC (R2) for each such cable run. (Unless there are exceptional circumstances the cable armouring would be used as the CPC). The results of these tests will be inserted in the "Core to CPC Resistance" box in the Installation Test Results form. As an alternative method two cores in the drop cable may be linked at the top cap together and with the CPC in the drop cable, and the tests performed to determine the impedance of the CPC in the drop to the push button. The tests are the same as those in 2.4.2 and 2.4.3. for the controller to pole, but in this instance it is pushbutton to pole. The test of the two ‘test cores’ should be entered in the core to core column (as in 2.4.2), the test between the two test cores and CPC should be entered in the core to CPC column (as in 2.4.3). The impedance of the CPC may then be calculated as in 2.4.5. and then added to the impedance measured for the pole to determine the overall impedance to the pushbutton. This overall impedance should be within the limits required. NB On older installations and modified ones there may be insufficient spare cores to perform the test. The client should be informed and requested to fund the installation of additional cores. The CPC impedance pushbutton to pole top should be shown on the test form as shown in the example below. example Cable Run: From
To PB1
Pole 1
2.4.5 CPC Continuity Resistance The value to be entered in the "CPC Resistance" box of the Installation Test Results is determined by the following method: i)
Divide the value of Core to Core resistance by 2. Core resistance = (R1 + R1) / 2 = R1
ii)
Subtract the resulting value from the value of Core to CPC resistance. CPC Resistance = (R1 + R2) - R1 = R2
iii)
If the measurement was to a pushbutton (2.4.4 above), then note that the drop cable Test Core, Rt, will add resistance to the measurement and therefore Table
667/HE/20664/000
Page
16
Issue 18
TS Traffic Installation Testing 1 should be used to determine Rt by calculating the length of the drop and the core size for subtraction from Core to CPC resistance. Note Figure 2. R2
= (R1 + R2 + Rt) – R1 – Rt (calculated from Table 1) = (R2 + Rt) – Rt (calculated from Table 1)
R1, R2, Rt connectivity to measure CPC value from controller to push button Figure 2 If the alternative method in 2.4.4 has been used the exact value of the CPC in the drop cable can be calculated and added to the Pole CPC value. iv)
This will leave the resistance value for the CPC, R2.
The determined value can then be entered in the "CPC Resistance" box in the Installation Test Results form. The figure for a typical armoured multi-cored cable (8 core) should be in the region of 0.78 per 100m of cable length. If the resistance is greater than 0.78 per 100 meter of cable length then it will be necessary to investigate the cause and remedy the problem. On completion of tests 2.4.2 and 2.4.3 or 2.4.4 the "Test Cores" are to be labelled and made off. The remote ends are to be connected to earth and the controller end tied back and insulated. These test cores may be used for testing if future earthing problems are discovered. 2.5
BASIC POLARITY TEST (ADDITIONAL) This test will have been carried out on all Controllers supplied as they are all required to meet IET Wiring Regulations 17th Edition. This includes ST950, ST900, ST800 and ST700 Controllers (Controller Factory test documentation can be supplied on request).
667/HE/20664/000
Page
17
Issue 18
TS Traffic Installation Testing However, if the client requires this further test to be performed or is in any doubt about the Controllers, then he may request this extra test which will be charged over and above the normal rate for this testing. With controllers having solid state or other lamp switch outputs and many having fuses mounted on PCBs or within the controller assemblies, which will have been tested as part of the controller manufacture, a polarity test of these is unnecessary and impracticable. A basic test to check fuse carriers and switches on the main and controller switch assemblies, (that may be rewired / altered during the controllers use / installation), shall be performed, as follows. Connect the phase (line) conductor to the Circuit Protective Conductor (Main Earth Terminal), at the input to the controller. Then for each of the following at the furthest point accessible before entering controller control modules, measure between earth and the phase (line) conductor (this should show short circuit / low impedance). Operate the single pole protective devices (remove fuses or operate circuit breakers), and any switches. Check that the circuit is broken i.e goes open circuit / high impedance. If the circuit does not break this would indicate a wiring fault / protective device fault and should be investigated. Check: Lamp Supply, Regulatory Sign supply, solar cell supply and auxiliary unit supplies. 2.6
SITE INSULATION TEST This test will be performed AFTER the completion of all signal cable terminations and BEFORE the controller is connected to the incoming mains supply. Where a controller has been connected to the mains supply, the Master Switch must be set to the OFF position during this test.
2.6.1 Preparation The controller must be isolated for this test (i.e. both LINE and NEUTRAL conductors disconnected by switching). This is normally accomplished by switching OFF the MASTER SWITCH. If in any doubt, then refer to the handbook for the type of controller being tested. (N.B. The MASTER SWITCH may be in the Haldo pillar). An Uninterruptible Power Supply (UPS) solution is available for ELV/LV LED Traffic Controllers with loads up to 2000W. Note that if a UPS is fitted to the controller, isolating the mains supply at the Haldo pillar will not remove power to the controller mains input unless the UPS is switched to BYPASS. Ensure all other switches are ON, i.e. controller switch, signals ON/OFF switches. Ensure all phase cable cores are connected up as required for normal operation. All phase switch/phase driver PCBs etc. are to remain fitted. With most types of 13 Amp Socket with built in 30mA RCD, it is ideal for the RCD to be tripped OFF before insulation testing. However this is not possible without applying power so for initial installation it is necessary to include them in the insulation test. If there are problems passing, it may be necessary to disconnect 30mA RCDs for the test. Ensure that the connections are restored after the test. After mains power is applied to the controller, the RCDs can be tripped off instead of being disconnected. Note that it is important that any RCDs which have been insulation tested while ‘ON’ should subsequently be tested and pass the RCD tests of section 2.9 below.
667/HE/20664/000
Page
18
Issue 18
TS Traffic Installation Testing Surge Protection Devices such as the TS DIN rail mounted 516/4/00136/000 contain 275VAC varistors. Disconnect these before the Insulation Test. The Gemini 2 unit also contains varistors, and should be disconnected before the Insulation Test. Varistors will not be damaged by the Insulation Test, but will affect the result. Ensure that all varistor/Gemini2 modules are correctly re-connected after the test. 2.6.2 Test The Insulation test instrument must be set to 500 Volts. This will avoid false low impedance readings that may be obtained using higher test voltages, which trigger the Surge Protection Devices (SPD) fitted to some modern equipment (including TS LED Signals). BS7987 / HD638 section 8.6 (the European standard for Traffic Signal systems) and IET regulations allow for testing at 500 Volts defined in BS 7671 Table 61 IET Wiring Regulations 17th Edition, with a minimum insulation resistance of 1M . It should be noted that Insulation resistance values are usually much higher than this, and will typically exceed 10M . Connect the Megger test instrument between the neutral (black) and line (red) (connected together), and earth (green/yellow) on the Panel where all site cables are terminated. Test insulation impedance. It must be greater than 1M . (Note that this test relies on line and neutral being connected together). During this test the insulation to earth of all cable cores, aspect cables, and aspect transformers are checked and the failure of any one item may be indicated by a lower than expected reading. If this test fails, disconnect signal cables and re-test. If the test now passes, the fault is in the cables; test the individual cores until the fault is traced. If test still fails, the fault is in the controller. Disconnect individual parts of the controller (re-testing each time) until the fault is traced. Controller parts that could give rise to low reading are: over voltage protection (see section 2.6.1 above) Gemini 2 unit (see section 2.6.1 above) lamp switch / lamp driver PCBs filters logic transformer modular power supplies maintenance sockets with integral RCD (see section 2.6.1 above) and any other item which is connected to earth and to which mains voltage is also connected). In an ELV controller, the Mains (LV) circuits in the Controller should be subject to the Insulation Resistance test. In an ELV controller, Earth is connected to the common connection of all ELV loads, so the Insulation Resistance test on the Mains circuits will test that the street wiring has appropriate Insulation Resistance to Mains. Core to Core testing described in 2.2.2 should have been completed prior to connection of signal heads. Where a customer requests cable core insulation tests as part of a periodic inspection on ELV signal circuits, to check for any degradation on a cable, then site 667/HE/20664/000
Page
19
Issue 18
TS Traffic Installation Testing spare cores in street wiring should be used, however it should be checked that they are not connected together or to earth at any point these can then be subjected to Insulation Resistance Testing to prove that the street wiring has not degraded. Fill in the inspection certificate as far as possible. The installation can now be connected to the mains supply and powered up ready for the commissioning tests to be completed. 2.7
POLARITY TEST The object of this test is to check that the controller is connected to Line and Neutral in the correct sense and there is isolation between all the phase conductors and the control equipment. The diagrams below show a TN-S supply connected to a Controller, and a TT supply connected to a Controller. TN-S Supply
L
Controller
L
N
N
E
E
300mA RCD
Load
Feeder Pillar Local Earth connections through Controller stool, poles etc.
DNO Supply
TT Supply
Controller
Feeder Pillar
L
L
N
N
300mA RCD
Load
E
DNO Supply
Earth electrode
Local Earth connections through Controller stool, poles etc.
For a TN-S supply or TT supply, the following simple polarity and isolation tests are suitable. Check that the polarity of the line phase conductor on the incoming / supply side of the Controller master switch is in the correct sense, i.e. the voltage measured from Line to Earth is approximately 230V AC and the voltage measured from Neutral to Earth is less than 10V AC. Isolate the controller using the master switch (if not already 667/HE/20664/000
Page
20
Issue 18
TS Traffic Installation Testing so) and repeat the measurements on the out going / controller side, there should be no voltage measured.
NOTE
A TN-S supply or TT supply can be successfully polarity tested without removal of the Earth connection. This does not apply to a TN-C-S supply!
The diagram below shows a TN-C-S supply connected to a Controller. TN-C-S Supply
L
Controller
L
N
N
300mA RCD
Load
E
Feeder Pillar Local Earth connections through Controller stool, poles etc.
DNO Supply
If the TN-C-S supply has the Line and Neutral connections reversed, the local Earth is connected to supply Line, instead of supply Neutral, as shown below.
This situation could go un-noticed, because all local Earth connections are made to supply Line. One evidence of wrong polarity is that the ground around locally earthed metalwork dries much more quickly than other ground after rain.
NOTE 667/HE/20664/000
A TN-C-S supply CANNOT be polarity tested without removal of the Earth connection. Page
21
Issue 18
TS Traffic Installation Testing ELI testing must not be carried out on a TN-C-S installation where there is reason to suspect wrong mains polarity. Supply polarity can only be tested by switching off the junction, so that the incoming Line and Neutral can be measured with respect to an independent known Earth (such as the CET bars with the incoming Earth connection removed). See the diagram below. This is a hazardous procedure, as the Local Earth connection is now connected to true Earth through the ground, and the earth wire from the Feeder Pillar is connected to the supply Line, if the supply polarity is reversed. This test must NOT be carried out by Siemens employees, due to the hazards involved. However at the beginning of a new installation, while the fuse in the feeder pillar is still unconnected and the controller earth has not yet been connected to the Feeder Pillar earth, it is advisable to check for supply reversal by carefully measuring the voltage of the earth wire from the Feeder Pillar with respect to local earth at the controller stool (must be less than 10V AC). Be aware that if there is reversed supply polarity, the earth from the Feeder Pillar is live and dangerous at this stage! Avoid touching the earth wires or Feeder Pillar enclosure during this test. This test is particularly advisable when installing a new controller on an old site with existing Feeder Pillar. In the unlikely event that there is a supply polarity reversal between the Feeder Pillar and Controller, this is Siemens responsibility, and needs to be corrected! Note that Controller Supply Polarity is tested in the Factory, and only needs to be re-considered when any changes have been carried out, such as adding extra switchgear to the Master Switch Assembly.
WARNING
TN-C-S supply polarity on an installed controller must only be tested by the DNO, when there is good reason to suspect wrong polarity. Diagram for information only, to highlight the electrical hazards.
BS7671:2008 now includes Amendment No. 1:2011, which shows a Supply Polarity check during Periodic Inspection. This test requires the junction to be switched off, so that the incoming Line and Neutral can be measured with respect to an independent known Earth.
667/HE/20664/000
Page
22
Issue 18
TS Traffic Installation Testing The traffic accident risk is increased when a junction is switched off. It is recommended that a Supply Polarity check on an installed controller is only performed by the DNO, when there is reason to suspect wrong polarity and a Risk Assessment indicates that the wrong supply polarity risks exceed the traffic accident risks. The Electrical Installation Condition Certificate includes the following in the Remarks box, “Risk assessment carried out. No known electrical work done to affect Supply Polarity, so polarity not checked. (Cross out, if inapplicable).” Risk Assessment includes, but is not limited to, inspection of the Feeder Pillar, base seal, incoming supply tails and Log Book. If in doubt, refer to your Supervisor, or the DNO supply authority. 2.8
EARTH LOOP IMPEDANCE TESTS (Z s)
2.8.1 General Information The ELV system only requires an Earth Loop Impedance test to be done on the Mains electrical supply to the controller cabinet, and not on the supply from the controller, which is less than 50VAC nominal. Consideration of ELI offers a degree of protection against an accidental short-circuit from a third party’s mains supply. Any third party LV supply must be separated from the TS ELV supply in all instances; it is recommended that the installation is entirely ELV. Ensure any UPS is switched to BYPASS before performing ELI tests on the controller. Earth Loop Impedance tests are carried out at any points in the system where mains and exposed metal work are present. The fault path within the installation comprises the live conductors (R1), control equipment (either a traffic or pedestrian controller) and the CPC (R2). The fault path external to the installation (Ze) contains the supply authority's transformer windings, the line conductor and CPC of the supply authority's distribution network, or the earth electrode. The Earth Loop Impedance test carried out at the end of each cable run in an LV traffic signal installation will include both elements described above. Note that:
Zs = Ze + (R1 + R2)
The Earth Loop Impedance test results are required to ensure that in the event of an earth fault (or a short circuit fault) the protection devices e.g. fuses to the appropriate circuit will disconnect within the time limit as specified in BS7671 (IET Wiring Regulations). For fixed equipment i.e. permanently wired traffic controllers, the specified disconnection time for a TN system as laid down by BS 7671 IET regulations 17th Edition is 5 seconds and for equipment connected via sockets the specified disconnection time is 0.4 seconds. Table 2 on page 23 indicates the maximum permissible Earth Loop Impedance values for the various fuse and circuit breaker types in use for traffic signal installations with a 5 second disconnection time (current controller types). Note: - There may also be other supplies associated with certain poles e.g. regulatory sign supply, Solar Cell supply. These are generally of a lower value than the lamp supply fuses and would therefore not affect the max value expected, however this should always be checked, if a direct comparison with other fuses noted in Table 2 is 667/HE/20664/000
Page
23
Issue 18
TS Traffic Installation Testing not possible, or in doubt. Then the fuse and Earth Loop Impedance tables in the IET Regulations 17th edition section 411.4.8 Table 41.4 for 5 second disconnection, should be consulted, remembering that temperature compensation needs to be applied using calculation or rule of thumb described in Appendix 14 of the IET Wiring Regulations 17th Edition as follows: Rule of Thumb Zs (m)
0.8 x Uo / Ia
Where Zs (m) is the measured impedance of the earth fault current loop up to the most distant point of the relevant circuit from the origin of the installation. Uo is the nominal a.c. rms voltage to Earth. Ia is the current causing the automatic operation of the protective device within the time stated in the IET regulations. When installing third party equipment it will be necessary to refer to the technical handbook to determine the fuse type and value protecting the relevant circuits. These figures should be given in the Particulars of the Installation portion of the completion form. The LT5 tester currently recommended for carrying out Earth Loop Impedance tests is only suitable for supply voltages in the range 200V to 260V. It is not possible to test circuits when supplied by a lower voltage than 200V i.e. dimmed lamp supply. The Earth Loop Impedance test measures the Earth Loop Impedance by connecting line to earth via a low resistance, causing a simulated fault current of approx. 25 Amps to flow for a period of approximately 10 - 20 milliseconds around the loop. SAFETY NOTE. It is therefore vital to ensure that NOBODY is in contact with the pole or cabinet during the Earth Loop Impedance test.
CAUTION
ELI testing must not be carried out on a TN-C-S installation where there is reason to suspect wrong mains polarity.
If satisfactory Earth Loop Impedance results cannot be obtained, then consideration should be given to fitting a 300mA RCD to the controller supply. 2.8.2 Preparation Ensure all phase cable cores are connected up as required for normal operation. The controller should be switched on and operational (signals illuminated). Ensure signal heads are covered at this time to prevent spurious signals to road users. Every pole, cabinet, wait indicator (230V) and controller door must be tested and recorded on the form in Appendix B. Within the cabinet at least the following shall be tested - Main Earth Terminal, Distribution panel, Castellated bar or CET bar as fitted, Front door on unpainted area around door catch, Rear door (if applicable) unpainted area or earth stud, Front panel earth stud, Maintenance socket Earth pin. The values measured within the controller cabinet (see also Appendix B ‘mains live’ list of tests) should be below the values for the master fuse. The values measured on phase outputs at poles should be below those noted under signal fuses (ELI 667/HE/20664/000
Page
24
Issue 18
TS Traffic Installation Testing values for the controller fuse are provided for completeness but are not used). Access to mains live within the controller cabinet requires removal of the fuse cover and connection into live on the output of the master switch – take care to avoid electric shock. Re-fit the fuse cover after the tests and fully secure it in place. If the ELI measurement within the cabinet exceeds the values shown in Table 2 for the appropriate specification of fuse, do not proceed with further testing and report the supply as out of specification to the customer concerned. If the supply authority cannot improve the characteristics of the supply to improve Ze (e.g. lower impedance earth return), then a permissible solution is to fit a 300mA RCD to protect the whole installation. For measurements at poles, a failure may indicate the need for larger cable size, use of additional parallel cores, or improved earth connection from cable armour to the pole.
667/HE/20664/000
Page
25
Issue 18
TS Traffic Installation Testing Table 2 Fusing and ELI for Current Controllers Controller fuses and allowable Earth Fault Loop Impedance Zs @ 20°C compensated for 70°C operation by Rule of Thumb Method from IET Regs Master fuse
Controller fuse
Signal fuse 230V
160V
140V
120V
ST900/ Part number ST950 Fuse standard LV Amps Max earth loop imp.
518/4/90637/003 BS1361/BS88 45 0.73
518/4/90638/005 BS1361/BS88 30 or 32 1.28
240V 167.2V 146.3V 125.4V 518/4/90301/013 EN 60127 – 2/1 10 5.44 3.78 3.31 2.83
ST900/ Part number ST950 Fuse standard LV LED Amps Max earth loop imp.
518/4/97092/020 IEC60269/BS88 20 2.24
518/4/90352/005 BS88/IEC60269 16 3.12
518/4/90301/013 EN 60127 – 2/1 10 5.44 3.78 3.31 2.83
ST900/ Part number ST950 Fuse standard ELV Amps Max earth loop imp.
518/4/90637/001 BS1361/BS88 30 or 32 1.28
516/4/02061/000 MCB type D 20
No PCB fuses on LSLS card HPU F4 30A 518/4/97079/001 6A type C MCB for AUX ELV – ELI is calculated
ST900/ Part number ST950 Fuse standard ELV low Amps inrush Max earth loop imp.
518/4/90637/007 BS88/IEC60269 16 3.12
516/4/02061/000 MCB type D 6
No PCB fuses on LSLS card HPU F4 30A 518/4/97079/001 6A type C MCB for AUX ELV – ELI is calculated
ST900/ Part number ST950 Fuse standard ELV Amps 40A Max earth loop imp.
518/4/90637/001 BS1361/BS88 30 or 32 1.28
516/4/02061/001 MCB type D 32
No PCB fuses on LSLS card HPU F4 30A 518/4/97079/001 6A type C MCB for AUX ELV – ELI is calculated
ST750 Part number LV Fuse standard Amps Max earth loop imp.
516/4/97053/002 BS1361/BS88 20 2.13
518/4/97056/012 IEC60068/GAM T1 16 3.12
518/4/90301/013 EN 60127 – 2/1 10 5.44 3.78 3.31 2.83
ST750 Part number ELV Fuse standard Amps Max earth loop imp.
516/4/97053/002 BS1361/BS88 20 2.13
ST800 Part number Fuse standard Amps Max earth loop imp.
518/4/90637/003 BS1361/BS88 45 0.73
518/4/97052/020 UL248 10 ELV – ELI is calculated 518/4/90638/005 BS1361/BS88 30 or 32 1.28
518/4/97056/010 IEC60068/GAM T1 10 5.44 3.78 3.31 2.83
NB The values for dimmed voltages are based on the ratio of the open circuit supply voltage (Uo) used for calculation of ELI in BS7671 i.e. 230V, and the open circuit value (Uoc) for the dimming supply i.e. dim supply + 4.5% e.g. 160V Uo is 167.2V Uoc. Pole and push-button ELI tests on LV controllers should use the Signal fuse values. The test is performed at 230V (test in bright) to obtain the ELI value. If the controller is able to run in dim, the maximum allowed ELI value must be taken from the dimmed voltage which applies to that installation. E.g. bright-only ST950LV is 5.44 max, but if dimming to 160V the maximum ELI value is reduced to 3.78 . 667/HE/20664/000
Page
26
Issue 18
TS Traffic Installation Testing BS1361 fuses may still be found, so values for these are taken from the 2008 version of the Regs, and multiplied by 0.8 (thermal) and then 0.95 (voltage tolerance). The ELI value given for 45A and 20A fuses applies to BS1361 and BS88 fuses, and the ELI value for ’30 or 32’ fuses applies to BS1361 30A fuses or BS88 32A fuses. For a 45A fuse, the value for BS88 is higher than for the older BS1361 so on a borderline case, it is permissible to check if the fuse is the BS88 type and if so to use the higher value of 0.8 . In this case a note should be made that only BS88 fuses are to be used. An auxiliary circuit supplied from a 6A Type C MCB should have an ELI below 2.91 . Note as this is the installation section, the above Table 2 only contains those controllers that may still currently be being installed, for older controllers please see section 4.2 (page 41). 2.8.3 Fuse Replacement Following any Earth Loop Impedance tests all fuses (with the exception of the supply authority's fuse) which have been placed under stress are to be changed. A fuse with a current rating of less than 10A will be considered to have been placed under stress. 2.8.4 Measuring Earth Loop Impedance at The Origin, Prospective Short Circuit Current and Prospective Fault Current. A TN-C-S supply should have the following characteristics quoted by the supply authority. Where the prospective fault current is available from the supply authority, it should be recorded in the appropriate area on the installation completion form, if unavailable, it may be left blank. However the following tests must always be conducted and the resulting maximum value entered on to the forms as measured value. Supply Volts:
230 V
Prospective Fault Current:
16KA
If the maximum prospective fault current of 16KA is exceeded then the equipment should not be connected to this supply without reference to Engineering. The Origin is the point where the Electricity Company equipment is terminated and the cables from this point belong to the customer. However for safe and easy access to test points, the test should be performed at the terminals on the incoming / supply side of the Controller master switch. This will also allow the inclusion of any cable between the electricity board cut-out and the controller switch in the calculations. Ensure any UPS is switched to BYPASS before performing ELI tests. INITIAL INSTALLATION TESTING If this is a test of the initial installation, then in order to avoid multiple paths to earth (i.e. through controller and poles installed in the ground), disconnect the earth point provided by the supplier from the controller, and then test the supplier’s earth point. For this test, ensure the Controller master switch is ‘OFF’ so that the temporarily unearthed controller is not powered. 667/HE/20664/000
Page
27
Issue 18
TS Traffic Installation Testing Warning: proceed with caution – inspect the incoming supply wiring before removing the earth, and ensure the period of time when earth is disconnected is minimised i.e. perform the test and reapply the earth as soon as possible. For subsequent testing during maintenance and/or periodic inspection and test, the main earth is not to be disconnected to reduce the likelihood of damage or poor re-connection. Connect the LT5 2-core adapter lead to the earthing point provided by the supplier and the main line feed. Measure and record (under Particulars of the Installation) the Earth Loop Impedance at the origin (Ze). The Prospective Fault current at the origin can be calculated from this reading using the following formula: Prospective fault current
=
___230V___ ZL-E at origin (Ze)
If this value exceeds 16000 amps refer to Engineering. Make a note of the value before continuing to the next test. Repeat the above test between the line and neutral conductors of the incoming supply, (ZL-N). The Prospective short circuit current at the origin can be calculated from this reading using the following formula: Prospective short circuit current = ___230V___ ZL-N at origin (Ze) If this value exceeds 16000 amps refer to Engineering. Record the highest fault current either Line to Neutral OR Line to Earth on the record sheets against ‘Max Prospective Fault Current’.
If the main earth has been disconnected from the controller during ‘Initial Installation test’, ENSURE IT IS NOW RE-CONNECTED. 2.8.5 Measuring Earth Loop Impedance at Poles and Push buttons in LV installations At all poles and wait boxes the Earth Loop Impedance is measured using any phase conductor feed to the pole, connecting the LT5 earthing test lead to the appropriate live feed and to the metal of the pole itself (to include pole earthing in the test). Measure and record the Earth Loop Impedance at each point of a cable run. Ensure that the value is less than the maximum permissible value detailed in Table 2 on page 23 under Signal fuses. Note: - There may also be other supplies associated with certain poles e.g. regulatory sign supply, Solar Cell supply. These are generally of a lower value than the lamp supply fuses and would therefore not affect the max value expected, however this 667/HE/20664/000
Page
28
Issue 18
TS Traffic Installation Testing should always be checked, if a direct comparison with other fuses noted in Table 2 is not possible, or in doubt. Then the fuse and Earth Loop Impedance tables in the IET Regulations, should be consulted, remembering that temperature compensation needs to be applied using calculation or rule of thumb described in 2.8.1. Where a mains supplied wait indicator is fitted, the Earth Loop Impedance of the push button box is measured by connecting the LT5 test cable between the centre pin of the lamp holder and the case of the push button. If the push button box is of the type fitted with a separate terminal block then it is preferable to take the live supply from this terminal. Note: It is not practicable to test Poles fitted only with equipment having less than 50V e.g. 24V detector poles or FELV wait indicators, as a live 230V supply is not available for the Earth Loop Impedance tester. They should however have been CPC continuity tested and the ELI (Zs) value can now be calculated by adding the measured CPC loop value to the measured Ze at origin for the point supplying the ELV pole e.g. this may be the controller cabinet or a LV pole see the following section. 2.8.6 Calculating the ELI value for ELV only poles As noted in 2.8.5 above without an LV supply to a pole (i.e. on an ELV only pole), the measurement of the ELI with an ELI meter is not practicable. However the value can be calculated from the CPC values measured in 2.4.5 earlier in the test procedures. Take the value noted in the ‘Loop Resistance Core to CPC (2.4.3 or 2.4.4)’ column of the CPC resistance test results, for the ELV pole(s), add to this the measured ELI value for the point from which the ELV pole is supplied (NB this may be the controller cabinet or an LV pole). Put the resultant value in the ELI column for the ELV pole and mark it with an * to indicate that it is a calculated value. On ELV controllers the CPC to signal poles etc should be measured and confirmed to be less than 2.2 in accordance with section 2.4. The calculated ELI value for pole connections in ELV controller installations should also be kept below the 230V value for a 10A fuse, i.e. 5.44 . The calculated ELI is the measured mains origin ELI Ze, plus the measured CPC of the armoured cable to the pole, plus the measured resistance of an ELV phase core from controller to pole.
2.8.7 Measuring Earth Loop Impedance within the Controller Cabinet Within the cabinet at least the following shall be tested - Main Earth Terminal, Distribution panel, Castellated bar or CET bar as fitted, Front door unpainted metal, 667/HE/20664/000
Page
29
Issue 18
TS Traffic Installation Testing Rear door unpainted metal/earth stud, Front panel earth stud, Maintenance socket Earth pin. Ensure any UPS is switched to BYPASS before performing ELI tests. To test, Connect the Red probe to the line supply on the output of the master switch and the earth test probe of the tester (Black probe) to each of the test points. Note: - the values measured within the controller cabinet should be below those values for the master fuse. The values measured at poles should be below those noted under Signal fuses. 2.8.8 Controller RCD Fitted To Incoming Power In some areas it will be found that an RCD has been specified to protect the whole installation. A 300mA RCD should not be affected by the LT5 test. It may be necessary for the RCD to be bypassed for the purpose of completing the Earth Loop Impedance tests, and reconnected before commissioning of the site. 2.8.9 Maximum Allowable Earth Loop Impedance With in-line RCD The maximum allowable Earth Loop Impedance Zs of an installation following an in-line RCD is calculated using the following formula derived from IET Wiring regulations 17th Edition 415.2.2: Zs =
50 X 1000 I (mA)
Where I (mA) is the operating current in milliamps of the protective device – for RCDs I n. Note: For a 300 mA RCD, it is recommended that Zs does not exceed 100 ; and for a 30 mA RCD, it is recommended not to exceed 1000 . Note, however, that the ELI should be as low as possible. Values over 200 should be investigated and reasons confirmed.. Note: 30mA RCD is not recommended on a junction as nuisance tripping can occur.
2.9
RCD TEST This test is performed with the RCD test meter see 2.1 Test Equipment. The test measures the actual disconnection time of the RCD. The following tests are required to be completed in both polarities. Some meters automatically change polarity for consecutive tests e.g. Seaward RC750, others will require a manual selection change.
2.9.1 30mA Trip Current RCD Protecting Maintenance Socket Nuisance trip test: Connect the RCD tester into the maintenance socket. Set the test trip current to 15mA (30mA / 2), select positive half cycle, press test button: The RCD should not trip. Reset the RCD, select negative half cycle and repeat test. (I n/2 test)
667/HE/20664/000
Page
30
Issue 18
TS Traffic Installation Testing Connect the RCD tester into the maintenance socket. Set the test trip current to 30mA, press test button: The maximum allowable trip time is 0.2 seconds. Reset the RCD, select negative half cycle and repeat test. (I n test) Reset the RCD. Set the trip current to 150mA and re-test: The maximum allowable trip time is 0.04 seconds. Reset the RCD, select negative half cycle and repeat test. (5I n test) If any test other than the first 15mA test fails, replace the RCD. If only the nuisance trip test fails, consult the client, if they use the socket to power permanently installed equipment, they may wish it to be replaced. Note IET regulations 17th Edition section 415.1 Additional Protection (RCD’s).
2.9.2 300 mA RCD Protecting Whole Installation (If fitted) WARNING: Tripping the RCD will switch off the signals. Ensure that the signals are switched off or covered prior to carrying out this test to avoid confusion to motorists. Trip the 300mA RCD using the test button. (The whole installation will switch off). Switch off the master switch and connect to the line and neutral terminals using an adapter lead. (Either use probes or connect into the line and neutral termination points). Connect the earth to the main earth terminal. Nuisance trip test: Connect the RCD tester into the maintenance socket. Set the test trip current to 150mA (300mA / 2), select positive half cycle, press test button: The RCD should not trip. Select negative half cycle and repeat test. The RCD should not trip. Reset the RCD. Set the trip test current to 300mA and perform the test: Maximum allowable trip time is 0.2 seconds. If test fails, replace RCD.
2.10
DETECTOR LOOP TEST For a new installation, the loops should be tested to ensure that the recommended limits in this section are achieved. Ensure the detector cards are disconnected for the test, and replaced afterwards.
2.10.1 Tests Using the Multimeter set to read continuity, measure at the controller the detector loops and feeder cable continuity resistance. Record the reading in the detector test results section of the completion certificate. The reading should be less than 8 . Using the insulation tester measure the loop insulation resistance to earth and record the reading in the detector test results section of the completion certificate. The reading should be greater than 10M . 667/HE/20664/000
Page
31
Issue 18
TS Traffic Installation Testing The inductance of each detector loop and feeder will be measured with the inductance meter. This test will be made at the controller after the joint has been made. The results will be recorded in the detector test results section of the completion certificate. The minimum value to be 30 H, and the maximum value 500 H.
667/HE/20664/000
Page
32
Issue 18
TS Traffic Installation Testing 2.11
Additional Insulation Tests In some cases the customer may require additional tests of cable sheath insulation. If additional tests are required they must be performed and recorded (use additional record sheets if required by the customer, appended to the appropriate Forms in the Appendix of this document). Example 1: From Series 1400 Highway Works: an insulation resistance test of 1000V direct current instead of 500V, applied and maintained for not less than one minute between the continuous cable armouring or earth conductor and the general mass of earth - the measured insulation resistance shall not fall below 1.0 M ohm for the full duration of the test. If this test is required, it shall be carried out after the cable has been laid and the trench backfilled, but before jointing has taken place. Example 2: Highways Agency (MCH1540F) detector loop additional tests to ensure no water ingress: With the two conductors of a loop tail, or complete circuit (comprising a loop and feeder) connected together, the insulation resistance between the cable conductors and a good earth point shall be >100 M Ohms measured at 500Vd.c. Any failures must be investigated and rectified.
2.12
NEUTRAL CONDUCTOR VOLTAGE DROP TEST This test only applies to non LED signals. The test relies on a lamp transformer in the signal head, so that the un-driven green ‘sees’ the signal head Neutral through the lamp transformer. The following test should be carried out on each phase green feed, using a digital Multimeter or voltmeter set to measure 250V AC (RMS) or greater. Select a phase and wait until its green has just terminated. Measure the voltage between the controller neutral and the green feed, the voltage should be no greater than 4V (RMS) throughout the controllers cycle, except when the phase next goes to green. If the voltage is over 4V, refer to section 3.9.
2.13
GUIDANCE FOR GENERATORS If a generator is connected to a traffic controller (as a temporary measure while mains power to the junction is unavailable), the requirements for a fixed installation of up to 10kW apply. A 300mA RCD must be present between the generator and the controller, with the neutral of the generator output connected to earth on the generator side of the RCD. Ensure the generator frame is also reliably connected to earth. If it is not certain at the time of connecting the generator that there is a known good earth connection supplied via the DNO supply wiring, a local earth electrode must be utilised which has a resistance to earth of under 167 . The relevant official publications contain detailed requirements, and take preference over the guidelines summarised here. For latest information refer to BS 7430 “Code of practice for protective earthing of electrical installations” (e.g. section 7), and IET
667/HE/20664/000
Page
33
Issue 18
TS Traffic Installation Testing document “Guidance Note 3: Inspection and Testing” (e.g. section 2.7.12 which describes how to test a low-impedance earth electrode).
2.14
COMMISSIONING The standard commissioning procedure should now be followed, as specified for the particular controller. See the handbooks referenced in section 1.3. If necessary, follow the UPS power-up sequence as defined in the UPS Handbook. Complete the Traffic Signal Installation Completion Certificate including the form Electrical Installation Certificate which should be completed with the client / junction design engineer completing the first part, and the second half being completed by a TS Engineer having verified junction cabling is as required in Junction Cabling Design Guide (see section 1.3).
2.15
VERIFICATION OF ELI RESULTS As a final verification of ELI results check that those for poles are below the minimum allowed values for the appropriate signal fuse, and that those for elements within the controller cabinet, are below the minimum allowed values for the appropriate master fuse (see Table 2).
2.16
COMPLETION OF CERTIFICATES The certificates in Appendix B must be completed. Please note the page which starts with “Comments on existing installation” contains a section for a signatory for “Design”. Certain customers who have not performed their own design verification may require this section to be completed by a TS engineer. In this case the installation should be checked against the generic design document 667/DS/20664/000 or 667/DS/20664/048 as applicable. If the customer requires their own forms to be filled in, complete the customers forms in addition to those in Appendix B. Also complete the checklist for new installations (schedule of inspections) at the end of Appendix C (which is shared with Periodic Inspections).
667/HE/20664/000
Page
34
Issue 18
TS Traffic Installation Testing 3.
TESTING TO CLEAR PROBLEMS
SAFETY Before performing any electrical tests requiring junction isolation (signals switched OFF) the permission of the relevant authorities must have been given. Signal heads must be covered or "SIGNALS UNDER MAINTENANCE" signs placed on ALL approaches. If the signals have to be switched off for any tests, refer to Appendix E for the suggested method.
3.1
PURPOSE Define the methods for Electrical tests required either during maintenance, or, if problems are found, during installation or maintenance. These tests should only be carried out when a specific test is requested in the Maintenance Handbook.
3.2
TEST EQUIPMENT
General: Test equipment and their leads must conform to the safety requirements as laid down in BS EN 61557 (Electrical safety in LV systems) and BS EN 61010 (Safety requirements for electrical equipment in measurement and control). i) A Low resistance ohm meter, or the continuity range of an insulation and continuity tester (see iii below). An instrument to BS EN 61557-4 will meet the requirements expressed in BS7671. ii) Digital Multimeter capable of reading 250V or greater, current to (10A) and continuity to 2 decimal places. iii) Insulation Tester: Megger BM222 or similar. iv) Earth Loop Impedance Tester. Megger LT5 or similar v) RCD Tester capable of testing both positive and negative half cycles as required in IET Regs 17th Edition. (e.g. Megger CBT3, Robin KMP 5404, ISO TECH IRT 1900, Metrohm 16R, Seaward RC750). vi) A test lamp certified to meet the requirements of the HSE, Guidance note GS38 "Electrical test equipment for use by electricians". (This may be used in place of a multimeter to check polarity).
Note that all test equipment must be within its calibration period.
667/HE/20664/000
Page
35
Issue 18
TS Traffic Installation Testing
3.3
TOTAL SITE/JUNCTION INSULATION TEST
3.3.1 Preparation The controller must be isolated for this test (i.e. both LINE and NEUTRAL conductors disconnected by switching). This is normally accomplished by switching OFF the MASTER SWITCH. If in any doubt, then refer to the handbook for the type of controller being tested. (N.B. The MASTER SWITCH may be in the Haldo pillar). Note that if a UPS is fitted to the controller, isolating the mains supply at the Haldo pillar will not remove power to the controller mains input unless the UPS is switched to BYPASS. Ensure all other switches are ON, i.e. controller switch, signals ON/OFF switches. Ensure all phase cable cores are connected up as required for normal operation. All phase switch/phase driver PCBs etc. are to remain fitted. With most types of 13 Amp Socket with built in 30mA RCD, the RCD should be tripped before insulation testing to avoid exceeding manufacturer’s specifications. This needs to done while power is still applied to the controller (e.g. immediately before isolating the power at the Master Switch). ENSURE ALL 30mA RCD DEVICES ARE TRIPPED BEFORE TESTING. PRESS TEST BUTTON (T) WHILST POWER IS APPLIED TO SOCKET. RCD SHOULD TRIP AND THE APPROPRIATE INDICATOR SHOULD INDICATE THIS ON THE SOCKET. Surge Protection Devices such as the TS DIN rail mounted 516/4/00136/000 contain 275VAC varistors. Disconnect these before the Insulation Test. The Gemini 2 unit also contains varistors, and should be disconnected before the Insulation Test. 3.3.2 Test The Insulation test instrument must be set to 500 Volts. This will avoid false low impedance readings that may be obtained using higher test voltages, which trigger the Surge Protection Devices fitted to some modern equipment (including TS LED Signals). BS7987 / HD638 section 8.6 (the European standard for Traffic Signal systems) and IET regulations allow for testing at 500 Volts. Connect the Megger test instrument between the neutral (black) and earth (green/yellow) on the Panel where all site cables are terminated. Test insulation impedance. It must be greater than 1M . (Note that this test relies on low impedance between line and neutral within the controller to effectively link line to neutral). During this test the insulation to earth of all cable cores, aspect cables, and aspect transformers are checked and the failure of any one item may be indicated by a lower than expected reading. If this test fails, disconnect signal cables and re-test. If the test now passes, the fault is in the cables; test the individual cores until the fault is traced.
667/HE/20664/000
Page
36
Issue 18
TS Traffic Installation Testing
If test still fails, the fault is in the controller. Disconnect individual parts of the controller (re-testing each time) until the fault is traced. Controller parts that could give rise to low reading are: over voltage protection (see section 3.3.1 above) lamp switch / lamp driver PCBs filters logic transformer modular power supplies and any other item which is connected to earth and to which mains voltage is also connected. Ensure any disconnected parts are reconnected, and any tripped RCDs are reset, after the insulation test before continuing.
3.4
EARTH LOOP IMPEDANCE TEST (Z s)
3.4.1 Preparation Ensure all phase cable cores are connected up as required for normal operation. The controller should be switched on and operational (signals illuminated) unless stated in the following subsections. SAFETY During test ensure that NOBODY is in contact with the pole or cabinet under test. Poles should be tested in sequence, working from the controller outward.
3.4.2 Tests Using an LT5 tester: Connect the Red probe to the line input and the earth test probe of the tester (Black probe) to each of the test points listed below in turn. Note that not all points are applicable to all types of controller. For in-cabinet tests, connect to the live line on the output of the master switch by removing the fuse cover. Replace the fuse cover after the tests and fully secure. Test Points: Main Earth Terminal Distribution panel Castellated bar or CET bar as fitted Front door unpainted metal Rear door unpainted metal/earth stud Front panel earth stud Maintenance socket Earth pin
667/HE/20664/000
Page
37
Issue 18
TS Traffic Installation Testing (Normally the earth fault loop impedance of the socket earth pin would only be that necessary to trip the RCD. However any item earthed by this socket may come into contact with a mains supply in the controller which is not disconnected by the RCD.)
3.4.3 Maximum Allowable Impedance (fuse protected) The maximum allowable Earth Loop Impedance (Zs) for fixed circuits (5 seconds disconnect) for controllers protected by fusing only is shown in Table 2 in section 2.8.2 for current controllers and Table 3 in section 4.2 for legacy controllers.
3.4.4 Maximum Allowable Impedance (RCD protected) The maximum allowable Earth Loop Impedance of an electrical installation following an in-line RCD is calculated by using the formula: Zs = 50 X 1000 I(mA) Where I (mA) is the operating current in milliamps of the protective device – for RCDs I n. Note: For a 300 mA RCD it is recommended that Zs does not exceed 100 , and for a 30 mA RCD it is recommended not to exceed 1000 . Note, however, that the ELI should be as low as possible. Values over 200 should be investigated and reasons confirmed..
3.4.5 Fuse Replacement Following an Earth Loop Impedance test, all fuses (with the exception of the Electricity Supplier's fuse in the cut-out) which have been placed under stress are to be changed. A fuse with a current rating of less than 10A will be considered to have been placed under stress.
3.4.6 Signal Head Poles This test must be performed on the pole in question where LV (230V) is present on the pole. After gaining access to the signal head terminations connect the Red probe of the test instrument to a phase conductor termination (either red or green aspect conductor). Connect the earth test probe (Black probe) to the test points listed below. When the aspect to which the instrument is connected illuminates read the earth fault loop impedance.
Test points Earthed metal of pole itself e.g. unpainted inside face 667/HE/20664/000
Page
38
Issue 18
TS Traffic Installation Testing Wait Indicator box Near sided signals Tactile indicators (if metal)
Maximum acceptable values This is based on the rating of the fuse protecting the pole and the dimming voltage, which is normally the signal fuse. For a T400 controller it is the 10Amp fuse on the lamp switch PCB: this is actually a fast acting fuse which blows faster than a BS1361 fuse - for the purposes of this test treat as a general purpose fuse under the IET Regulations. For some legacy controllers it may be the controller fuse. See Table 2 on page 23 for values (current controllers) or Table 3 on page 41 for legacy controllers. See also explanatory notes following Table 2. If the whole controller is protected by 300mA RCD, the maximum Earth Loop Impedance should be as calculated in section 3.4.4. and not exceed 100 .
3.5
TESTING OF RCDs
3.5.1 Preparation Controller should be switched on and operating normally. This test is performed with the RCD test meter, see 3.2 Test Equipment. The test measures the actual disconnection time of the RCD. The following tests are required to be completed in both polarities, some meters automatically change polarity for consecutive tests e.g. Seaward RC750, others will require a manual selection change. 3.5.2 30mA trip current RCD protecting maintenance socket Nuisance trip test: Connect the RCD tester into the maintenance socket. Set the test trip current to 15mA (30mA / 2), select positive half cycle, press test button: The RCD should not trip. Reset the RCD, select negative half cycle and repeat test. (I n/2 test) Connect the RCD tester into the maintenance socket. Set the test trip current to 30mA, press test button: The maximum allowable trip time is 0.2 seconds. Reset the RCD, select negative half cycle and repeat test. (I n test) Reset the RCD. Set the trip current to 150mA and re-test: The maximum allowable trip time is 0.04 seconds. Reset the RCD, select negative half cycle and repeat test. (5I n test) If any test other than the first 15mA test fails replace the RCD. If only the nuisance trip test fails consult the client, if they use the socket to power permanently installed equipment they may wish it replaced.
667/HE/20664/000
Page
39
Issue 18
TS Traffic Installation Testing 3.5.3 300mA RCD protecting whole controller (if fitted) Trip the 300mA RCD using test button on RCD. (The whole controller will switch off – check for relevant permissions). Switch off the Master switch and connect to the line and neutral terminals using an adapter lead. (Either use probes or connect into the line and neutral termination points.) Connect the Earth to a convenient good Earth. Nuisance trip test: Connect the RCD tester into the maintenance socket. Set the test trip current to 150mA (300mA / 2), select positive half cycle, press test button: The RCD should not trip. Select negative half cycle and repeat test. The RCD should not trip. (I n/2 test) Reset the RCD. Set the test trip current to 300mA and perform test, maximum allowable trip time 0.2 seconds (i.e. 200msecs). (I n test) If the test fails replace the RCD.
3.6
CORE INSULATION TESTING
3.6.1 Preparation Switch off the controller/isolate the signals. Disconnect both ends of the suspect core (controller and pole). If the core links between many poles it will be easier to disconnect the other side of the terminal blocks in each pole, e.g. disconnecting the lamp transformers. Then the whole cable run can be tested.
3.6.2 Test With the suspect core isolated, connect the red test lead of the Megger test instrument to the core. Then connect black test lead to each of the cores in the same cable in turn and test the impedance between the suspect core and other cores. It should be greater than 12M . If less, replacement of cable is recommended.
3.7
CORE TO CORE LOOP RESISTANCE CONTROLLER TO POLE
3.7.1 Preparation Switch the controller off and/or isolate the signals. If the fault is common to signals in all signal posts, start the tests described below from the signal post nearest the controller. Otherwise work on the post where the fault is present. Disconnect the two cores to be tested from the pole top, connect the two cores together into a spare terminal at the pole top. Disconnect any transformers or other equipment from the cores throughout the complete run. Disconnect the associated cores at the 667/HE/20664/000
Page
40
Issue 18
TS Traffic Installation Testing controller, if the cables radiate from one pole to many, the cores must be disconnected at all of the "many" before testing. (It may be necessary to perform further loop resistance tests to check all branches of cabling, if cables to other poles radiate from one pole rather than all in one long chain). If only one core is suspect, another suitable core should be selected to form the loop for this test.
667/HE/20664/000
Page
41
Issue 18
TS Traffic Installation Testing
3.7.2 Tests Connect a resistance meter between the two cores at the pole. The resistance should be no greater than those stated below. If it is, then all pole terminations should be checked. If all pole terminations are all right, perform further loop resistance checks at each pole, working out along the cable run from the controller until the particular cable at fault is isolated. Before testing, zero the meter. 1mm2 Resistance
1.5mm2 Resistance
@ 25 C (round trip)
@ 25 C (round trip)
Expected CPC resistance (armour)
36.92
24.68
7.8
1 Km
18.46
12.34
3.9
500 metres
9.23
6.17
1.95
250 metres
4.61
3.08
0.98
125 metres
2.77
1.87
0.59
75 metres
1.85
1.25
0.39
50 metres
0.74
0.5
0.16
20 metres
0.37
0.25
0.08
10 metres
o
o
Approximate distance to signal
TABLE 1 ‘Expected CPC resistance’ is the typical value of resistance of the metal cable sheath/armouring for 8-core 1mm2 cable. Larger cables have lower CPC values.
3.8
DC RESISTANCE CHECKS ON LAMP TRANSFORMERS (TS supplied signal heads only)
3.8.1 Preparation Disconnect the lamp transformer primary wires from the pole termination blocks.
3.8.2 Tests The lamp supply (signal) fuses in the controller may be blown if a lamp transformer begins to break down. The transformer may be checked as follows. Connect a meter set to measure resistance between the two primary leads of any suspect lamp transformer. Expect a reading of between 35 and 50 - typically 42 should be obtained. Any transformer with a reading outside these limits should be replaced.
667/HE/20664/000
Page
42
Issue 18
TS Traffic Installation Testing
3.9
NEUTRAL CONDUCTOR VOLTAGE DROP TEST This test only applies to non LED signals. The test relies on a lamp transformer in the signal head, so that the un-driven green ‘sees’ the signal head Neutral through the lamp transformer. Set the Multimeter or voltmeter to measure 250V AC (RMS) or greater. Select a phase and wait until its green has just terminated. Measure the voltage between the controller neutral and the green feed. The voltage should be no greater than 4V (RMS) throughout the controllers cycle, except when the phase next goes to green. If the voltage between the green feed and neutral is greater than 4V then do the following: i)
Check all joints in the appropriate cable run, ensure that they are all tight and none seriously corroded. Replace or tighten them as necessary. If the fault still persists, then:
ii)
Check all joints in the appropriate neutral cable run, ensure that they are all tight and none seriously corroded. Replace or tighten them as necessary.
iii)
Increase the number of conductors/cable cores used for the neutral, or
iv)
Replace the cable that has failed the test.
Re-test the cable to ensure that corrective action taken has removed the problem.
667/HE/20664/000
Page
43
Issue 18
TS Traffic Installation Testing 4.
PERIODIC INSPECTION AND TESTING
4.1
INTRODUCTION Periodic inspection and testing of installations is to be carried out at least annually. This work will comprise careful scrutiny of the equipment and shall be carried out without dismantling or with partial dismantling of equipment as required, supplemented by testing to comply with BS7671 17th edition incorporating the following amendments: Amendment No. 1:2011 Amendment No. 2:2013 Amendment No. 3:2015
4.2
CONTENT OF WORK The work shall consist of the following: i)
Check the condition of the outer case, posts and signals, base seal and the earth bonding and wiring. These should be recorded as ‘good’, ‘poor’ or ‘requires work’.
ii)
Check all signal heads for correct alignment with their respective approaches, and that they are tightened to the appropriate suppliers specification.
iii)
Check all pole top cable connections; ensure that they are sound, secure and not seriously corroded.
iv)
Check that all top caps are fitted and are not damaged.
v)
Open the controller door and verify presence of Log Book and Site configuration documents.
vi)
Verify correct operation, i.e. no fault lamps are displayed. If required by the customer, download site data to the handset.
vii)
Check the bonding of all cables where connected via terminations. This is to be done visually, checking for any fraying, discolouration and corrosion and by giving each tail a short pull.
viii)
Cover the Solar Cell, wait for the signals to dim and measure the dim voltage.
ix)
Allow the controller to cycle, check the detectors are operating correctly by waiting for demands and ensuring correct results from the demands.
x)
Allow Signals to cycle and check all lamps operate correctly.
xi)
Site Insulation Test and fuse inspection. For the duration of this test, switch the mains supply Master Switch to the OFF position. See Appendix E for the suggested method. Ensure local procedures are observed when switching the mains supply off. If the customer dictates that the P.I. should be completed without powering off the controller then the tests in this section (insulation test and fuse inspection) cannot be performed and this must be clearly recorded on the P.I. form under ‘Agreed limitations including reasons’. All fuses to be checked to ensure that the correct type and value is fitted e.g. the DNO Fuse (in the Lucy Cut Out), master fuse, controller fuse, signal supply fuse(s), box signs fuse and other fuses.
667/HE/20664/000
Page
44
Issue 18
TS Traffic Installation Testing Cartridge fuses in DIN-rail style fuse-holders should be marked with the fuse value and the fuse standard. For fuses in DIN-rail style holders record the BS standard marked on the fuse under ‘Type’. Note that PCB-mounted fuses (32x6.3mm, 20x5mm, blade fuses) are not marked with the fuse standard, only the fuse value, but PCB-mounted fuses must be replaced with the correct characteristic (e.g. quick-acting F or time-lag T, and ceramic-bodied highbreaking capacity if applicable). For PCB-mounted fuses, enter the fuse size under ‘Type’. Note: for accessing and/or checking the DNO fuse specific training and wearing of appropriate PPE are required. The Insulation test instrument must be set to 500 Volts. This will avoid false low impedance readings that may be obtained using higher test voltages, which trigger the EMC protection devices fitted to some modern equipment (including TS LED Signals). BS7987 / HD638 section 8.6 (the European standard for Traffic Signal systems) and IET regulations allow for testing at 500 Volts. All switches and circuit breakers other than the Master Switch in the controller will be set to the ON position (but note 30mA RCDs must be tripped off and varistor modules will need to be disconnected for this test (see section 2.6 for details). Using the insulation tester set to the 500V range, connect the test leads; one to both the line and neutral supply tails and the other to the earth tail. Test the insulation resistance and record the result in the appropriate box on the P.I. Test Results form (Appendix C). The minimum acceptable value for these tests is 1M . The installation can now be connected to the mains supply and powered up ready for the P.I. tests to be completed. SAFETY During the following test, ensure that NOBODY is in contact with the pole or cabinet under test. Poles should be tested in sequence working from the controller outward. xii)
Perform an Earth Loop Impedance Test of a single Live Core, as described in 2.8.5 (note connection of the earth test lead to the metal of the pole). Do this for all poles and push buttons with LV supply. See Table 2 or Table 3 for acceptable values.
xiii)
Perform an Earth Loop Impedance Test at the origin of supply in accordance with section 2.8.4.
xiv)
For ELV only pole(s), calculate the ELI. Firstly measure the loop resistance of cable core and CPC as described in 2.4.4, then calculate the ELI value for the ELV only pole as described in 2.8.6 (do this for all poles and push buttons). Confirm the calculated value is below 5.44 (value for 10A fuse at 230V). Repeat above tests for all poles
Please see below for a table giving legacy controllers (see section 2.8.2 for current controllers) followed by completion of the procedure 667/HE/20664/000
Page
45
Issue 18
TS Traffic Installation Testing Table 3 Fusing and ELI of Legacy Controllers Controller fuses and allowable Earth Fault Loop Impedance Zs @ 20°C compensated for 70°C operation by Rule of Thumb Method from IET Regs Master fuse
Controller fuse
Signal fuse 230v 240v 125.4v
518/4/90352/005 or 518/4/97056/012 ST700 Part number 518/4/90637/007 (TfL/ BS88/IEC60269 IEC60068/GAM T1 TCUG) Fuse standard Amps 16 16 Max earth loop imp. 3.12 3.12 ST700 /ST750 MCB Master Switch P110
P125
T70
Part number BS No Amps Max earth loop imp.
516/4/97076/010 MCB type C 20 0.87
Part number BS No Amps Max earth loop imp. Part number BS No Amps Max earth loop imp. Part number BS No Amps Max earth loop imp.
Circuit Breaker Type B
Part number 7A Amps Max earth loop imp.
518/4/97056/012 IEC60068/GAM T1 16 3.12
BS EN 60898 10 3.5 Rewireable BS 3036 5 7.28 (for 0.4s) Rewireable BS 3036 30 2
Rewireable BS 3036 30 2
Rewireable BS 3036 30 2
Rewireable BS3036 30 2
Part number
T200
Amps Max earth loop imp. Part number Amps Max earth loop imp. Part number Amps Max earth loop imp.
667/HE/20664/000
167.2v 146.3v 518/4/90301/013
EN 60127 – 2/1 10 5.44 3.78 3.31
2.83
518/4/90301/013 EN 60127 – 2/1 10 5.44 3.78 3.31 2.83
518/4/97020/118 ULE 10480 and CSA LR29862 6.3 9.6 6.67 5.84 5
518/4/90624/016 EN60127-2/4 20 2.24 1.55 1.36 1.16
20A
T500
120v
518/4/90624/015 EN60127-2/4 15 3.12 2.17 1.9 1.62
15A
Part number Fuse standard Amps Max earth loop imp. Part number BS No Amps
140v
518/4/97020/120 ULE 10480 and CSA LR29862 10 5.44 3.78 3.31 2.83
10A
T400
160v
518/4/90637/003 BS1361/BS88 45 0.73 518/4/90638/003 BS1361/ BS88 15 or 16
Page
518/4/90638/005 BS1361/BS88 30 or 32 1.28 518/4/90352/004 BS 88 10
46
518/4/97020/120 EN 60127 – 2/1 10 5.44 3.78 3.31 2.83
Issue 18
TS Traffic Installation Testing Max earth loop imp.
3.12
5.44
Note: Table 3 only covers legacy controllers - for current (more recent) controllers see Table 2 in section 2.8.2 on page 23. Only Siemens controllers are covered in this document. Third party controllers need the equivalent information to be obtained from the third party manufacturer.
xv)
Open Push Button Housing, inspect and if 230V lamp, switch signals on and perform an Earth Loop Impedance Test at the lamp socket, or if 50V, switch signals on.
xvi)
Close the controller door
xvii)
Complete the appropriate PI form (see Appendix C). If the customer requires their own forms to be filled in, complete the customers forms in addition to those in Appendix C.
xviii) Inspect site to ensure that there are no hazards, check signals are cycling correctly. The check list in Periodic Inspection Forms is to be completed, at the back of this document in Appendix C.
667/HE/20664/000
Page
47
Issue 18
TS Traffic Installation Testing 5.
MINOR WORKS
5.1
INTRODUCTION The minors works certificate (Appendix D), may be used for those works considered minor and in general these are Pole Knockdowns, Vandalised Pushbuttons, Change of Pole Cap assembly and Change of Controller case. Local authorities may have different views on what is to be considered minor so the local requirements should be checked first. The IET define minor works as additions, alterations or replacements that do not add new circuits. The addition of a new phase would mean the provision of a new circuit and could therefore not be covered using a minor works certificate.
667/HE/20664/000
Page
48
Issue 18
TS Traffic Installation Testing APPENDIX A - PRECAUTIONS TO BE TAKEN WHEN PLANNING THE INSTALLATION AND MAINTENANCE OF TRAFFIC CONTROL EQUIPMENT IN THE VICINITY OF LIGHT RAPID TRANSPORT SYSTEMS. Introduction The details given in this Appendix are designed to assist in the planning of installation and maintenance of traffic control equipment in the vicinity of LRT systems. Advice is given on the prevention of accidental contact between LRT track or vehicles and street furniture, which would permit traction current to return through the Traffic control equipment earthing system. Reference Documents The following documents were consulted in the preparation of this Appendix: GEC Alsthom Transportation Projects Limited report no. TPL25/S/026 – Earthing and Bonding Policy for Manchester Metrolink. GEC Alsthom Transmission and Distribution Projects Limited report no. S/Sdq 856 – th Metrolink Report on Touch Voltages for Phase 1 dated 19 October 1990. Reference 732/XREP27. Background LRT track and the vehicles running on it may be at a potential other than the local earth potential. This is due to track resistance and the return traction current flowing through it. In the Manchester Metrolink system the highest track/vehicle potential, known as the “touch voltage” is estimated to be 34.9V for trains crush loaded on minimum headway and 109V under short circuit fault conditions. The fault is said to persist for a maximum of 100ms. The traction current is DC and the resulting track/vehicle potential is said to be safe for humans from the touch voltage point of view. However, the source impedance could be low and it is desirable to prevent the touch voltage coming into contact with traffic control equipment street furniture and cables that are bonded to the electricity supply earth. Any contact could cause heavy currents to flow, which would give rise to excessive temperatures in the earth conductors of the traffic control equipment, with resultant fire and explosion risk. The recommendations that follow are aimed at preventing this. Spacing of Street Furniture from LRT Track and Vehicles It is recommended that 3 metres separation should always be maintained between the nearest points on street furniture and LRT track and vehicles. This nearest point should take into account that the separation can be reduced when vehicle and equipment doors are open.
667/HE/20664/000
Page
49
Issue 18
TS Traffic Installation Testing The installation manuals for all street furniture including cabinets, poles, signals, detectors, key switches and push buttons should be amended where necessary to include this information. Spacing of Cables from LRT Track Vehicle detector loops and feeder cables may have to be laid under LRT tracks to detect the passage of light rail vehicles. The cables should be fully insulated and the installation procedure should ensure adequate separation to prevent chafing due to track movements. Pantograph zones There are special requirements for insulation of top cap brackets and wait units on ELV controllers situated close to Pantograph overhead power installations. See 667/CC/46150/000, 667/CC/46150/001 and 667/CC/46150/002 for details. Refer also to BS EN50122-1 ‘Railway applications – Fixed Installations – Electrical safety, earthing and the return circuit’. Avoiding Accidental Contact with Tools and Test Equipment It is common practice to connect power tools and test equipment to the controller maintenance socket. The case of the tools or test equipment will therefore be connected to the controller earth and should not come into contact with the LRT track or vehicles. Neither the RCD if fitted, nor the mains supply fuse will provide protection against the possible heavy current resulting from accidental contact. Care must be taken when using metal ladders to gain access to above ground detectors and signals heads to prevent making contact between the street furniture and LRT track or vehicles. Installation and maintenance manuals should be amended where necessary to include this information. Isolation of Interface between LRT and Traffic Control Equipment The design of the interface between remote LRT outstations and traffic control equipment should be isolated so that it is not affected by different earth potentials at the two sites. The isolation should apply to the signals conductors and any cable armour or screen, so that earth leakage current cannot flow between the cabinets.
667/HE/20664/000
Page
50
Issue 18
TS Traffic Installation Testing APPENDIX B - COMPLETION CERTIFICATE AND TEST RESULTS (ELECTRICAL INSTALLATION CERTIFICATE)
6 Pages Follow NOTE. The latest edition of BS7671 was issued on 1st January 2015 (BS7671: AMD3: 2015). Enter this date in the form where it shows “BS7671 amended to …… (date)”.
667/HE/20664/000
Page
51
Issue 18
TS Traffic Installation Testing
TRAFFIC SIGNAL INSTALLATION COMPLETION CERTIFICATE (BS7671) amended to ……………...(date) Customer's Name / Title: .............................................................…
DETAILS OF THE INSTALLATION
Site Address: ..............................................................................…………………………………………………. ……………………………………………………………………………………………………………………………..
EM/STS No: .................….
Customer Drawing No: ...................… E xtent of installat ion covered by this certificate.
New Installation Modification to Installation
PARTICULARS OF THE INSTALLATION Type of Supply: TN-C-S
TN-S
TN-C
TT
IT
Protection is provided by Earthe d Equipotential bonding and automatic disconnection of the supply Characteristics of the supply at the origin: Nominal Voltage………....….V Electricity Board Fuse Rating……….A ELI (Ze) at origin ......................... Max prospective fault current measured .......................…A Max Prospective Fault Current Provided by the supply Authority………….……….A Cabling used Tick if used 1. 0mm Nos Cores Armour CSA
8 20
12 34
16 38
20 41
8 21
12 36
16 40
20 45
Tick if used 1. 5mm Nos Cores Armour CSA
Master Supply fuse or circuit breake r
Type: BS………..…… Rating…….…..A
Lamp Supp ly (signal) fuse
Type: …………...…… Rating…….…..A
Regulatory Signs fuse or circuit breaker
Type: …………...…… Rating…….…..A
Solar Cell supply fuse or circuit breaker
Type: ……………...… Rating………...A
Residual current device protecting:Whole installation 300mA
Supply Pola rity
- Tested
Maintenance socket only 30mA
- Risk assessed, not tested Basic Polarity Test OK
Siemens Mobility - Traffic Solutions Sopers Lane, Poole, Dorset, BH17 7ER Tel: +44 (0)1202 782000
Fax: +44 (0)1202 782331
Siemens Mobility - Traffic Solutions is a division of Siemens plc Registered office, Siemens plc, Faraday House, Sir William Siemens Square, Frimley, Camberley, GU16 8QD, England. Registered No. 727817
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing ELECTRICAL INSTALLATION CERTIFICATE (REQUIREMENTS FOR ELECTRICAL INSTALLATIONS - BS7671 [IET WIRING REGULATIONS]) COMMENTS ON EXISTING INSTALLATION IN CASE OF MODIFICATION
DESIGN FOR Junction design including positioning of equipment and equipment Selection
I/We being the person(s) responsible for the design of the electrical installation (as indicated by my/our signatures below), particulars of which are described above for Junction design including positioning of equipment and equipment Selection, having exercised reasonable skill and care when carrying out the design hereby CERTIFY that the design work for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with BS 7671, amended to................................(date) except for the departures, if any, detailed as follows: Details of departures from BS 7671 as amended (Regulations 120.3, 133.5):
The extent of liability of the signatory or the signatories is limited to the work described above as the subject of this Section and Certificate. For the DESIGN of the installation: For and on Behalf of Client Signature: .............................................
Date: ...........................
Name (BLOCK LETTERS):......................................................... Designer No 1
DESIGN FOR Selection of Cable, Cable Routing and Installation of said Junction cabling
I/We being the person(s) responsible for the design of the electrical installation (as indicated by my/our signatures below), particulars of which are described above for Selection of Cable, Cable Routing and Installation of said Junction cabling, having exercised reasonable skill and care when carrying out the design hereby CERTIFY that the design work for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with BS 7671, amended to................................(date) except for the departures, if any, detailed as follows: Details of departures from BS 7671 as amended (Regulations 120.3, 133.5):
The extent of liability of the signatory or the signatories is limited to the work described above as the subject of this Section and Certificate. For the DESIGN of the installation: For and on Behalf of Siemens Mobility - Traffic Solutions, Sopers Lane, Poole Dorset BH17 7ER Signature: .............................................
Date: ...........................
Name (BLOCK LETTERS):......................................................... Designer No 2
FOR CONSTRUCTION / Installation
I/We being the person(s) responsible for the construction of the electrical installation (as indicated by my/our signatures below), particulars of which are described above, having exercised reasonable skill and care when carrying out the construction hereby CERTIFY that the construction work for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with BS 7671, amended to ................................(date) except for the departures, if any, detailed as follows: Details of departures from BS 7671 as amended (Regulations 120.3, 133.5):
The extent of liability of the signatory is limited to the work described above as the subject of this Certificate. For CONSTRUCTION of the installation: For and on Behalf of Siemens Mobility - Traffic Solutions, Sopers Lane, Poole Dorset BH17 7ER Signature .................................................................................................................................................. Date Name (BLOCK LETTERS) .........................................................................................................................
Constructor
FOR INSPECTION & TESTING
I/We being the person(s) responsible for the inspection & testing of the electrical installation (as indicated by my/our signatures below), particulars of which are described above, having exercised reasonable skill and care when carrying out the inspection & testing hereby CERTIFY that the work for which I/we have been responsible is to the best of my/our knowledge and belief in accordance with BS 7671, amended to ..............................(date) except for the departures, if any, detailed as follows: Details of departures from BS 7671 as amended (Regulations 120.3, 133.5):
The extent of liability of the signatory is limited to the work described above as the subject of this Certificate. For and on Behalf of Siemens Mobility - Traffic Solutions, Sopers Lane, Poole Dorset BH17 7ER For INSPECTION AND TEST of the installation: Signature: ............................................................................ Date: ....................................................... Name (BLOCK LETTERS): ................................................................................................... Inspector NEXT INSPECTION
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing I/We the designer(s), recommend that this installation is further inspected and tested after an interval of not more than 1 year.
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing INSTALLATION TEST RESULTS Test Equipment Used
TGP Number
Multimeter: Low Resistance Ohmeter Insulation Tester: Earth Loop Impedance Tester: RCD Tester: Inductance tester: Other: Insulation Test of Complete Installation (2.6.2) 500V M
30mA RCD Test (2.9) 15mA 30mA 150mA
Next Calibration due
Time
300mA RCD Time Test (2.9) ms 150mA ms 300mA ms
ms ms
Cable Test Results Cable Run: From
To
Core to Core Insulation Min 20MOhm (2.2.2)
Loop Resistance Core to Core (2.4.2) (R1 + R1)
Loop Resistance Core to CPC (2.4.3 or 2.4.4) (R1 + R2)
CPC Resistance (2.4.5) (R2)
Earth Loop Impedance (2.8) Zs
Mains Main Earth Live Terminal Mains Distribution Live panel Mains Castellated Live bar or CET bar as fitted Mains Front door Live bare metal Mains Rear door Live bare metal Mains Front panel Live / Racking earth
Mains Maintenance Live socket Earth pin
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing Place an ‘*’ in the top left corner for an ELI value that has been calculated for an ELV Pole.
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing
Cable Test Results Cable Run: From
To
Core to Core Loop Insulation Resistance Min 20MOhm Core to Core (2.2.2) (2.4.2) (R1 + R1)
Loop Resistance Core to CPC (2.4.3 or 2.4.4) (R1 + R2)
CPC Resistance (2.4.5) (R2)
Earth Loop Impedance (2.8) (Zs)
Place an ‘*’ in the top left corner for an ELI value that has been calculated for an ELV Pole.
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing
INSTALLATION DETECTOR TEST RESULTS (2.10.1) Loop Designation
Resistance to Earth of Loop and Feeder Min R = 10M
Series Resistance of Loop and Feeder Cable Max R = 8
Inductance of Loop and Feeder 30-500 H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing
NEUTRAL CONDUCTOR VOLTAGE DROP TEST (2.11) Phase
Voltage Drop
1 (A) 2 (B) 3 (C) 4 (D) 5 (E) 6 (F) 7 (G) 8 (H) 9 (I) 10 (J) 11 (K) 12 (L) 13 (M) 14 (N) 15 (O) 16 (P) 17 (Q) 18 (R) 19 (S) 20 (T) 21 (U) 22 (V) 23 (W) 24 (X) 25 (Y) 26 (Z) 27 (A2) 28 (B2) 29 (C2) 30 (D2) 32 (E2) 32 (F2) Results of additional tests if required by the customer:
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing APPENDIX C - P.I. ELECTRIC TEST CERTIFICATE (ELECTRICAL INSTALLATION CONDITION REPORT)
6 Pages Follow NOTE. The latest edition of BS7671 was issued on 1st January 2015 (BS7671: AMD3: 2015). Enter this date in the form where it shows “BS7671 amended to …… (date)”.
667/HE/20664/000
Page
61
Issue 18
TS Traffic Installation Testing TRAFFIC SIGNAL ELECTRICAL INSTALLATION CONDITION CERTIFICATE (BS7671 amended to …………………(date) Customer: ............................................................…
Site Reference No. …………….
Site Address ..............................................................................…………………………………………… …………………………………………………………………………………………....................................... Log Book present in controller Y or N Controller Type: …………………. Supply: TN -C- S TN - C TN-S TT EM/STS No: .................……………… Document present in controller Y or N
SUPPLY AND PROTECTION DETAILS
Supply Polarity - Tested
IT
- Risk assessed, not tested
Agreed limitations including reasons: (e.g. if customer mandates no switch-off of supply)
Site insulation @ 500V
Supply Voltage
Protection at Supply Cut Out Fuse: Type BS………….. Rating ………..A
ELI Measurement
V
DIM Voltage
V
……………..…..
Protection at Master Switch Fuse:
Type BS………….. Rating ………..A
Protection Device at Final Sub Circuit (Pole) Lamp Supply (Signal) Type……..…. Rating……….A Reg Sign Supply Type ….…..……. Rating……….A Solar Cell Supply Type ….…..……. Rating……….A
ELI Measurement
……………………
See Attached Sheet for ELI measurements See Attached Sheet for ELI measurements See Attached Sheet for ELI measurements See Attached Sheet for ELI measurements
Protection is provided by earthed equipotential bonding and automatic disconnection of the supply
REMARKS Risk assessment carried out. No known electrical work done to affect Supply Polarity, so polarity not checked. (Cross out, if inapplicable).
Remarks need to be classified with one of the following codes: C1 = Danger present. Risk of injury. Immediate action required. C2 = Potentially dangerous – urgent remedial action required. C3 = Improvement recommended.
Overall assessment of suitability of installation for continued use:
SATISFACTORY
UNSATISFACTOR Y
(tick one)
I/we certify that the said work as indicated on this form has been carried out Name (Block Letters)................................................
Position .......................................................
Signature................................................................ Date.............................................................. .. For and on behalf of:
Siemens Mobility - Traffic Solutions Sopers Lane Poole Dorset BH17 7ER
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing Tel: +44 (0)1202 782000
Fax: +44 (0)1202 782331
Siemens Mobility - Traffic Solutions is a division of Siemens plc Registered office, Siemens plc, Faraday House, Sir William Siemens Square, Frimley, Camberley, GU16 8QD, England. Registered No. 727817
Subject to any necessary remedial action being taken, I/we recommend that the installation is further inspected and tested after an interval of not more than 1 year.
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing P.I. TEST RESULTS Test Equipment Used
TGP Number
Multimeter: Low Resistance Ohmmeter Insulation Tester: Earth Loop Impedance Tester: RCD Tester: Other: Insulation Test of Complete Installation (2.6)
M
500V
Cabling Used Tick If Used 1.0 mm Nos Cores Armour CSA
30mA RCD Test (2.9) 15mA 30mA 150mA
Next Calibration due
Time
300mA RCD Test (2.9) ms 150mA ms 300mA ms
Time ms ms
Tick If Used 8 20
12 34
16 38
20 41
1.5 mm Nos Cores Armour CSA
8 21
12 36
16 40
20 45
Cable Test Results Test Point Pole Number Wait/Ped. Signal
Earth Loop Impedance
Results of additional tests if required by the customer:
CONTROLLER CABINET
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing Cable Test Results Continued Cable Test Results Test Point Pole Number Wait/Ped. Signal
667/HE/20664/000
Earth Loop Impedance
Page
of
Issue 18
TS Traffic Installation Testing CONTROLLER CABINET
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing CABLE TEST RESULTS FOR ELV ONLY POLES FOR PERIODIC INSPECTION (Where CPC values are measured and the ELI value is calculated) Cable Test Results Cable Run: From
To
Loop Resistance Core to Core (2.4.2) (R1 + R1)
Loop Resistance Core to CPC (2.4.3 or 2.4.4) (R1 + R2)
CPC Resistance (2.4.5) (R2)
Earth Loop Impedance (2.8) (Zs)
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing CHECK LIST FOR NEW INSTALLATION OR PERIODIC INSPECTION (INSPECTION SCHEDULE) FOR ENGINEER TO COMPLETE DURING THE INSPECTION TICK TO INDICATE SATISFACTION WITH INSPECTION - DELETE IF NOT APPLICABLE TYPE OF INSPECTION (tick one): NEW INSTALLATION
PERIODIC INSPECTION
1.
Outer Case Condition
2.
Condition of Posts & Signal heads
3.
Condition of Base Seal
4
Protection against direct contact
4.1
Check all insulation is in good condition
4.2
Check all covers are in place and not damaged in any way
4.3
Check that all barriers and enclosures are in place and not damaged e.g. the cabinet, all pole caps, pushbuttons housings, signal heads / housings, feeder pillars etc.
5.
Condition of Earthing as protection against indirect contact. ADS (Automatic Disconnection of Supply).
5.1 Main Earth Terminal 5.2 Main Equipotential Earth Bonding Conductors Earthing between panels etc within the cabinet, and to Pushbuttons etc 5.3
CPC (Armouring terminations etc)
6.
Condition of Internal Wiring
7.
Dimming Functioning
8.
Detectors Operational
9.
RAM Battery date fitted
10.
Checked no faults displayed
11.
Log book and site configuration documents present
12.
Correct Controller operation verified
667/HE/20664/000
Y/N Y/N
Y/N
Page
of
Issue 18
TS Traffic Installation Testing 13.
Check security of connections
14.
Check results from demands
15.
After signals cycle, check all lamps are ok
16.
Switch Signals Off and then On again
17.
Earth Loop Impedance tests
18.
Inspect Push Button housing
19.
Connection of conductors
20.
Identification of conductors
21.
Routing of cables in safe zones or protected against mechanical damage
22.
Connection of single-pole devices for protection or switching in phase conductors only
23.
Adequacy of access to switchgear and equipment
24.
All fuses checked to ensure that the correct type and value is fitted e.g. master fuse, controller use, signal supply fuse, box signs fuse and other fuses.
25.
Site insulation test
26.
Labelling of protective devices, switches and terminals
27.
Presence of danger notices and other warning signs
28.
Controller door closed
29.
Complete PI Form
30.
Inspect for hazards and that signals are cycling correctly
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing APPENDIX D - MINOR ELECTRICAL INSTALLATION WORKS CERTIFICATE
1 Page Follows NOTE. The latest edition of BS7671 was issued on 1st January 2015 (BS7671: AMD3: 2015). Enter this date in the form where it shows “BS7671 amended to …… (date)”
667/HE/20664/000
Page
71
Issue 18
TS Traffic Installation Testing
PART 1 : Description of minor works 1.Description of the minor works : ............................................................................................................... 2.Location/Address : ................................................................................................................................... 3.Date minor works completed : .................................................................................................................. 4.Details of departures, if any, from BS 7671 (as amended)…………………(Date) ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... PART 2 : Installation details 1. System earthing arrangement (where known):
TN-C-S
TN-S
TN-C
TT
IT
th
(For an illustration of earthing system arrangements see regulation 312.2 of 17 Edition of IET regulations) 2. Method of protection against indirect contact: ...................................................................................................... 3. Protective device for the modified circuit :
Type BS .....................................
Rating ................ A
4. Comments on existing installation, including adequacy of earthing and bonding arrangements : (see IET Regulations 17th Edition, regulation 132.16.) ................................................................................................................................................................... ................................................................................................................................................................... PART 3 : Essential Tests 1. Earth continuity :
satisfactory
2. Insulation resistance:
Line and Neutral/earth ...................... ……….M 3. Earth fault loop impedance ............................. …..……
4. Polarity :
satisfactory
5. RCD operation (if applicable) : Rated residual operating current I n ............mA and operating time of ............ms (at I n)
PART 4 : Declaration 1. I/We CERTIFY that the said works do not impair the safety of the existing installation, that the said works have been designed, constructed, inspected and tested in accordance with BS 7671 (IET Wiring Regulations), amended to ..........................(date) and that the said works, to the best of my/our knowledge and belief, at the time of my/our inspection, complied with BS 7671 except as detailed in Part 1 above.
3. Signature: ...........................................................
2. Name: .................................................................. For and on behalf of: ............................................
Position: ..............................................................
Address: ..............................................................
.............................................................................
Date: ...................................................................
.............................................................................
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing
667/HE/20664/000
Page
of
Issue 18
TS Traffic Installation Testing APPENDIX E - START UP ROUTINE The following pages contain the text of document 4/CC/1057/000 incorporated into this handbook.
667/HE/20664/000
Page 74
Issue 18
TS Traffic Installation Testing Siemens Mobility - Traffic Solutions Sopers Lane, Poole, Dorset, BH17 7ER
METHOD STATEMENT
FOR
JUNCTION SWITCH OFF AND START-UP ROUTINE
Prepared: T.R. Lelliott
Approved: J.P. Burgess
Function: Technical Services Manager
Function: Engineering Manager
THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED
Issue: 2.00
Change Ref:
Date: 25 July 2001
This is an unpublished work the copyright in which vests in Siemens Mobility - Traffic Solutions, a division of Siemens plc. All rights reserved.
The information contained herein is the property of Siemens Mobility - Traffic Solutions and is supplied without liability for errors or omissions. No part may be reproduced or used except as authorised by contract or other written permission. The copyright and the foregoing
667/HE/20664/000
Page 75
Issue 18
TS Traffic Installation Testing restriction on reproduction and use extend to all media in which the information may be embodied.
667/HE/20664/000
Page 76
Issue 18
TS Traffic Installation Testing 1
Introduction
1.1
Purpose
This document defines the procedure for switching off and starting up Traffic Signal controllers in the presence of live running traffic. This procedure is not appropriate for installations which are being commissioned to be put into service for the first time.
1.2
Scope
This procedure is relevant for use on both Intersection and Pedestrian Controllers, and will be applied in the event that signals are to be switched off to allow maintenance activity to be undertaken.
In the event that the owners/operators of the signals (normally the Local Authority) have local instructions covering this activity, then those instructions take precedence over this document.
2
Training and Safety
2.1 This procedure is to be carried out only by competent persons. Satisfactory completion of the appropriate TS training course, or extensive work experience to the satisfaction of the Regional Line Manager are necessary pre requisites.
2.2 High visibility clothing to the required TS standards is to be worn at all times when working on the highway.
3
Procedure
To Switch Off and /or Start Up a traffic signals installation the following sequences apply:
Switch Off:
Switch controller to manual
Establish main traffic flow Switch off signals.
Start-Up:
Switch “Signals On/Off” switch to OFF
Switch main controller supply ON, make sure automatic control is selected, Switch main controller supply OFF. Switch “Signals On/Off” switch to ON Switch main controller supply ON.
This ensures that for all makes of controllers, they will start up in the start up stage
4
Risk Assessment
Risk assessment for this procedure is deemed to be generic, and the procedure defined in section 3 above has been identified as the safest method for all installation configurations.
It is inappropriate to attempt to identify risks related to driver behaviour.
667/HE/20664/000
Page 77
Issue 18
