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TS Traffic Installation Testing

Traffic Solutions, Siemens Mobility 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

Signature Signature

Issue : Change Ref : Date : Approved By


1 5/7/89
2 83/16446 28/4/92
3 83/16563 22/6/92
4 83/16700 14/9/93
5 ANL00102 13/11/96
6 January 1999
7 February 2001
8 TS000669 September 2001
9 February 2003
10 October 2003
11 TS001616 December 2003
12 TS004023 September 2007
13 TS004922 February 2009
14 TS004944 December 2009

This is an unpublished work the copyright in which vests in Siemens plc.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.

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SAFETY WARNING

HEALTH AND SAFETY AT WORK

Note by the Health and Safety at Work Executive

BS 7671 and the IEE 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 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 IEE 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.

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(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) Any personnel working on site must wear the appropriate protective clothing, e.g.
reflective vests, etc
(vi) 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 exposed-
conductive-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).
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 the
safety of pedestrians, especially children, who may come into contact with the equipment
metalwork.

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CONTENTS
SAFETY WARNING 2

1. INTRODUCTION 6
1.1 PURPOSE 6
1.2 SCOPE 6
1.3 RELATED DOCUMENTS 6
1.4 QUALIFICATIONS 6
1.5 GLOSSARY 7

2. INSTALLATION TESTING 9
2.1 TEST GEAR REQUIREMENT 9
2.2 CORE TO CORE TESTING 9
2.2.1 Equipment 10
2.2.2 Method 10
2.3 VISUAL INSPECTION 11
2.4 CIRCUIT PROTECTIVE CONDUCTOR (CPC) TEST 11
2.4.1 Provision of cable cores for test purposes 12
2.4.2 Loop Resistance of Two “Test” Cable Cores on Each Cable Run 12
2.4.3 Loop Resistance of Cable Core (R1) and CPC (R2). For Poles without push buttons. 12
2.4.4 Loop Resistance of Cable Core and CPC. For Poles with push buttons. 13
2.4.5 CPC Continuity Resistance 13
2.5 BASIC POLARITY TEST (ADDITIONAL) 14
2.6 SITE INSULATION TEST 15
2.6.1 Preparation 15
2.6.2 Test 16
2.7 POLARITY TEST 16
2.8 EARTH LOOP IMPEDANCE TESTS (ZS) 17
2.8.1 General Information 17
2.8.2 Preparation 18
2.8.3 Fuse Replacement 19
2.8.4 Measuring Earth Loop Impedance at The Origin, Prospective Short Circuit Current and Prospective
Fault Current. 19
2.8.5 Measuring Earth Loop Impedance at Poles and Push buttons 21
2.8.6 Calculating the ELI value for ELV only poles 21
2.8.7 Measuring Earth Loop Impedance within the Controller Cabinet 22
2.8.8 Controller RCD Fitted To Incoming Power 22
2.8.9 Maximum Allowable Earth Loop Impedance With in-line RCD 22
2.9 RCD TEST 22
2.9.1 30mA Trip Current RCD Protecting Maintenance Socket 23
2.9.2 300 mA RCD Protecting Whole Installation (If fitted) 23
2.10 DETECTOR LOOP TEST 23
2.10.1 Tests 24
2.11 NEUTRAL CONDUCTOR VOLTAGE DROP TEST 24
2.12 COMMISSIONING 24
2.13 VERIFICATION OF ELI RESULTS 24
2.14 COMPLETION OF CERTIFICATES 25

3. TESTING TO CLEAR PROBLEMS 26


3.1 PURPOSE 26
3.2 TEST EQUIPMENT 26
3.3 TOTAL SITE/JUNCTION INSULATION TEST 27
3.3.1 Preparation 27

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3.3.2 Test 27
3.4 EARTH LOOP IMPEDANCE TEST (ZS) 28
3.4.1 Preparation 28
3.4.2 Tests 28
3.4.3 Maximum Allowable Impedance (fuse protected) 29
3.4.4 Maximum Allowable Impedance (RCD protected) 29
3.4.5 Fuse Replacement 29
3.4.6 Signal Head Poles 29
3.5 TESTING OF RCDS 30
3.5.1 Preparation 30
3.5.2 30mA trip current RCD protecting maintenance socket 30
3.5.3 300mA RCD protecting whole controller (if fitted) 30
3.6 CORE INSULATION TESTING 31
3.6.1 Preparation 31
3.6.2 Test 31
3.7 CORE TO CORE LOOP RESISTANCE CONTROLLER TO POLE 31
3.7.1 Preparation 31
3.7.2 Tests 32
3.8 DC RESISTANCE CHECKS ON LAMP TRANSFORMERS (TS SUPPLIED SIGNAL HEADS ONLY)32
3.8.1 Preparation 32
3.8.2 Tests 32
3.9 NEUTRAL CONDUCTOR VOLTAGE DROP TEST 33

4. PERIODIC INSPECTION AND TESTING 34


4.1 INTRODUCTION 34
4.2 CONTENT OF WORK 34

5. MINOR WORKS 38
5.1 INTRODUCTION 38

APPENDIX A - PRECAUTIONS TO BE TAKEN WHEN PLANNING THE INSTALLATION


AND MAINTENANCE OF TRAFFIC CONTROL EQUIPMENT IN THE VICINITY OF LIGHT
RAPID TRANSPORT SYSTEMS. 39

APPENDIX B - COMPLETION CERTIFICATE AND TEST RESULTS 41

APPENDIX C - P.I. ELECTRIC TEST CERTIFICATE 50

APPENDIX D - MINOR ELECTRICAL INSTALLATION WORKS CERTIFICATE 57

APPENDIX E - START UP ROUTINE 59

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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 IEE wiring regulations (BS7671) as amended 2008.

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 IEE 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.

1.3 RELATED DOCUMENTS


Detectors and Cable Terminations Handbook 667/HE/20663/000
Above Ground Detectors Handbook 667/HE/20665/000
Helios Signals and Poles Handbook 667/HB/30000/000
ST4R Detector Handbook 667/HB/27663/000
ST700 General Handbook 667/HB/27880/000
ST750 General Handbook 667/HB/33750/000
ST750 ELV General Handbook 667/HB/32750/000
ST800 Installation Commissioning and Maintenance Handbook 667/HE/27000/000
ST900 Installation Commissioning and Maintenance Handbook 667/HE/33900/000
ST900 ELV Installation Commissioning & Maintenance Handbook 667/HE/32900/000
BS 7671: 2008 Requirements for Electrical Installations. IEE Wiring regulations 17th
Edition

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.

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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 the ST900 ELV Controller should have completed the
following training courses:

• HA Sector Scheme Sector 8 Modules 5XX


• M609 – Junction Traffic Controller Maintenance for ST900 ELV

Training requirements for non UK users may be different.

1.5 GLOSSARY
CPC Circuit Protective Conductor
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
IEE Institute of Electrical Engineers
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.
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.
PME Protective Multiple Earthing
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).

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TT supply Where no earth is provided by the supply authority and an earth electrode
is used as the method of earthing.

Note:
For full definitions of FELV, PELV and ELV, see IEE Regulations 17th Edition (BS7671)

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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 IEE 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 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).

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 IEE Wiring regulations 17th Edition for insulation resistance testing between live
conductors and each live conductor to earth.

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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 20MΩ.
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.

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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.

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 Traffic Solutions, Siemens Mobility chooses 2mm
maximum.

2.4 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 ST900 ELV controller. 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 of a 250m long 1.0mm2 cable (8 core), but
offers a degree of protection against an accidental short-circuit from a third party’s

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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.

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 Approximate length of loop


o o
@ 25 C @ 25 C
36.92Ω 24.68Ω 1 Km
18.46Ω 12.34Ω 500 metres
9.23Ω 6.17Ω 250 metres
4.61Ω 3.08Ω 125 metres
2.77Ω 1.87Ω 75 metres
1.85Ω 1.25Ω 50 metres
0.74Ω 0.5Ω 20 metres
0.37Ω 0.25Ω 10 metres
TABLE 1

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.
(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. This gives (R1 + R2).

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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
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)

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= (R2 + Rt) – Rt (calculated from Table 1)

Connections at
top of pole

Rt

Low resistance Luminaire


Meter Post

R1

controller
CPC R2

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 should be in the region of 1.5Ω per
80m of cable length. If the resistance is greater than 1.5 Ω per 80 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 IEE Wiring Regulations 17th Edition. This includes ST900, ST800 and ST700
Controllers (Controller Factory test documentation can be supplied on request).
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.

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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).
Ensure all other switches are ON, i.e. controller switch, signals ON/OFF switches,
maintenance socket, maintenance socket RCD and Controller RCD if fitted.
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 certain types of 13 Amp Socket with built in RCD, the RCD requires to be tripped
before insulation testing e.g. CONTACTUM, B & R H22 (B & R double socket RCD).

ENSURE THEY 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.
Maintenance Sockets with integral RCD can be sensitive to the Insulation Test, and
may need to be disconnected.
Surge Protection Devices such as the TS DIN rail mounted 516/4/00136/000 contain
275VAC varistors. Disconnect these before the Insulation Test.
The Gemini2 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/Gemini modules are correctly re-connected after the Insulation
Test.

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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
IEE regulations allow for testing at 500 Volts defined in BS 7671 Table 61 IEE Wiring
Regulations 17th Edition, with a minimum insulation resistance of 1MΩ. It should be
noted that Insulation resistance values are usually much higher than this, and will
typically exceed 10MΩ.

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 1MΩ. (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)
• Gemini2 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).

ELV circuits do not need to be subject to an Insulation Test,

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.

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

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than 10V AC. Isolate the controller using the master switch (if not already so) and
repeat the measurements on the out going / controller side, there should be no voltage
measured.

2.8 EARTH LOOP IMPEDANCE TESTS (Zs)

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.

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 pelican 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 a 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 (IEE 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 IEE regulations 17th
Edition is 5 seconds and for equipment connected via sockets the specified
disconnection time is 0.4 seconds.

Table 2 on page 19 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.

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 2 is not
possible, or in doubt. Then the fuse and Earth Loop Impedance tables in the IEE
Regulations 17th edition section 411.4.6 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 IEE 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.

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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 IEE 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 lamp supply circuits.

These figures can be given in the appropriate box for 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.

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 earth stud, Rear door earth stud, Front panel earth stud,
Maintenance socket Earth pin.

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Table 2

Controller fuses and allowable Earth Fault Loop Impedance Zs @ 20°C


compensated for 70°C operation by Rule of Thumb Method from IEE Regs
Master fuse Controller fuse Signal fuse
230v 160v 140v 120v
240v 167.2v 146.3v 125.4v
ST700 Part number 518/4/90352/005 518/4/97056/012 518/4/90301/013
BS No BS88 NF C 93-435 EN 60127 – 2/1
Amps 16 16 10
Max earth loop imp. 3.34 3.07 6.19 4.31 3.78 3.24
ST700 Part number 518/4/97056/012 518/4/90301/013
MCB BS No MCB type C NF C 93-435 EN 60127 – 2/1
Master
Amps 20 16 10
Switch
Max earth loop imp. 0.92 3.07 6.19 4.31 3.78 3.24
ST700 Part number 518/4/90637/007 518/4/97056/012 518/4/90301/013
TfL BS No BS 88 NF C 93 435 EN 60127 – 2/1
Amps 16 16 10
Max earth loop imp. 3.34 3.07 6.19 4.31 3.78 3.24
ST800 Part number 518/4/90637/003 518/4/90638/005 518/4/97056/010
BS No BS1361 BS1361 BS 88
Amps 45 30 10
Max earth loop imp. 0.76 1.47 6.19 4.31 3.78 3.24
Part number 518/4/90637/003 518/4/90638/005 518/4/97020/120
T400 BS No BS1361 BS1361 BS 88
Amps 45 30 10
Max earth loop 0.76 1.47 6.19 4.31 3.78 3.24
imp.

NB The values for dimmed voltages are based on the ratio of the open circuit supply
voltage used for calculation of ELI in BS7671 i.e. 230V, and the open circuit value for
the dimming supply i.e. dim supply + 4.5% e.g. 160V Uo is 167.2V Uoc.
Note as this is the installation section, the above only contains those controllers that
may still currently be being installed, for older controllers please see section 4.

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

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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.

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 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 this value as
after repeating this test Line to Neutral in the next test the larger values calculated is to
be recorded as Ze. Note that Zs = Ze + (R1 + R2).

If Earth Loop Impedence Zs measurement exceeds the values shown in Table 2 for the
appropriate specification of supply fuse, do not proceed with further testing and report
the supply as out of specification to the customer concerned.

If the value of Earth Loop Impedance exceeds the value shown in Table 2, and the
supply authority can not improve the characteristics of the supply to improve Ze, then a
permissible solution is to fit a 300mA RCD to protect the whole installation.

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)

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If this value exceeds 16000 amps refer to Engineering.

If the main earth has been disconnected from the controller


during ‘Initial Installation test’, ENSURE IT IS NOW RE-
CONNECTED.

Record the highest fault current either Line to Neutral OR Line to Earth on the record
sheets against ‘Max Prospective Fault Current’.

2.8.5 Measuring Earth Loop Impedance at Poles and Push buttons

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 the pole earthing point.

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
19.

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
not possible, or in doubt. Then the fuse and Earth Loop Impedance tables in the IEE
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

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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.

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 earth stud, Rear door
earth stud, Front panel earth stud, Maintenance socket Earth pin.

To test, Connect the Red probe to the line supply 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 switch. The values measured at poles should be below those noted
under lamp supply 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 IEE 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
IΔn.

Note: For a 300 mA RCD, it is recommended that Zs does not exceed 100Ω; and for a
30 mA RCD, it is recommended not to exceed 1000Ω. Note, however, that the
ELI should be as low as possible. Values over 200Ω 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.

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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. IΔn/2

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. IΔn

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. 5IΔn

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.

Note IEE 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.

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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 8Ω.

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 10MΩ.

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 30μH, and the maximum value 500μH.

2.11 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.

(a) With 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.

2.12 COMMISSIONING

The standard commissioning procedure should now be followed, as specified for the
particular controller. For example, see 667/HE/33900/000 ST900 Installation
Commissioning and Maintenance Handbook; 667/HE/32900/000 ST900 ELV Installation
Commissioning and Maintenance Handbook; 667/HE/27000/000 ST800 Installation
Commissioning and Maintenance Handbook; or 667/HB/27880/000 ST700 General
Handbook.

In general, complete the Traffic Signal Installation Completion Certificate sheet 2 and,
where the client requires certification for the design aspect, the second form Electrical
Installation Certificate 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.

2.13 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 controller lamp supply fuse, and that those for
elements within the controller cabinet, are below the minimum allowed values for the
appropriate controller master switch fuse.

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2.14 COMPLETION OF CERTIFICATES

The certificates in appendix B must be completed. Please note there are two different
pages which start with “comments in existing installation”, one 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.

If required, additional forms only documents are available in the following documents: -

667/SF/20664/001 Installation Completion Certificates (No Design)

667/SF/20664/002 Installation Completion Certificates (Including Design)

667/SF/20664/003 P.I. Electrical Test Certificates.

667/SF/20664/004 Minor Electrical Installation Works Certificates.

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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 D 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 IEE Regs 17th Edition. (e.g. Megger CBT3, Robin KMP 5404,
ISO TECH IRT 1900, Metrohm 16R, Seaward RC750).

vi) Inductance tester (LCR bridge): 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).

Note that all test equipment must be within its calibration period.

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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).
Ensure all other switches are ON, i.e. controller switch, signals ON/OFF switches,
maintenance socket, maintenance socket RCD and Controller RCD if fitted.
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 certain types of 13 Amp Socket with built in RCD, the RCD requires to be tripped
before high voltage testing e.g. CONTACTUM, B & R H22 (B & R double socket RCD).

ENSURE THEY 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.

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
IEE 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 1MΩ. (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.

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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).

3.4 EARTH LOOP IMPEDANCE TEST (Zs)

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.

Test Points:
Main Earth Terminal
Distribution panel
Castellated bar or CET bar as fitted
Front door earth stud
Rear door earth stud
Front panel earth stud
Maintenance socket Earth pin
(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.)

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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 2.8.1.

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
IΔn.

Note: For a 300 mA RCD it is recommended that Zs does not exceed 100Ω, and for a
30 mA RCD it is recommended not to exceed 1000Ω. Note, however, that the
ELI should be as low as possible. Values over 200Ω 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. 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
Earth terminal of pole
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. 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

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TS Traffic Installation Testing
fuse - for the purposes of this test treat as BS1361. For other controllers it
may be the controller fuse. See table 2 on page 19 for values.
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
100Ω

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. IΔn/2

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. IΔn

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. 5IΔn

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.

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).
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.
IΔn/2

Reset the RCD. Set the test trip current to 300mA and perform test, maximum allowable
trip time 0.2 seconds (i.e. 200msecs). IΔn

If test fails replace RCD.

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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 12MΩ. 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
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.

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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 Approximate length of loop


o o
@ 25 C @ 25 C
36.92Ω 24.68Ω 1 Km
18.46Ω 12.34Ω 500 metres
9.23Ω 6.17Ω 250 metres
4.61Ω 3.08Ω 125 metres
2.77Ω 1.87Ω 75 metres
1.85Ω 1.25Ω 50 metres
0.74Ω 0.5Ω 20 metres
0.37Ω 0.25Ω 10 metres

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 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. A reading of between 35Ω and 50Ω - typically 42Ω should be
obtained. Any transformer with a reading outside these limits should be replaced.

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3.9 NEUTRAL CONDUCTOR VOLTAGE DROP TEST


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.

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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.

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.
For the duration of this test, switch the mains supply Master Switch to the
OFF position. See Appendix D for the suggested method. Ensure local
procedures are observed when switching the mains supply off.
All signal fuses to be 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.
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 IEE 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. 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

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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 1MΩ.

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
2.8.4 2.8.5. (Do this for all poles and push buttons).
xiii) 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).
Repeat above tests for all poles

Please see next page for table and completion of procedure.

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Table 3
Controller fuses and allowable Earth Fault Loop Impedance Zs @ 20°C
compensated for 70°C operation by Rule of Thumb Method from IEE Regs
Master fuse Controller fuse Signal fuse
230v 160v 140v 120v
240v 167.2v 146.3v 125.4v
P110 Part number Circuit Breaker Type B
BS No BS EN 60898
Amps 10
Max earth loop imp. 3.68
P125 Part number Rewireable
BS No 3036
Amps 5
Max earth loop imp. 7.71
T70 Part number Rewireable Rewireable
BS No 3036 3036
Amps 30 30
Max earth loop imp. 1.15 1.15
Part number Rewireable Rewireable 518/4/97020/118
7A BS 3036 BS3036 ULE 10480 and CSA LR29862
Amps 30 30 6.3
Max earth 2.11 2.11 10.73 7.46 6.53 5.6
loop imp.
Part number 518/4/97020/120
10A ULE 10480 and CSA LR29862
Amps 10
Max earth 6.75 4.69 4.1 3.51
loop imp.
T200

Part number 518/4/90624/015


15A EN60127-2/4
Amps 15
Max earth 3.99 2.77 2.42 2.08
loop imp.
Part number 518/4/90624/016
20A EN60127-2/4
Amps 20
Max earth 2.33 1.62 1.42 1.22
loop imp.
Part number 518/4/90638/003 518/4/90352/004
T500 BS No BS1361 BS 88
Amps 15 10
Max earth loop 4.0 5.93
imp.

xi) Check the Fuse in the Lucy Cut Out


xii) Perform an Earth Loop Impedance Test between the Line at the Lucy Cut Out
and Earth
xiii) 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.

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xiv) Close the controller door


xv) Complete the appropriate PI form. See Appendix C
xvi) 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.

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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 IEE 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.

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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 –
Metrolink Report on Touch Voltages for Phase 1 dated 19th 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.

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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 insulation of the cables should be adequate to withstand the maximum touch
voltage and the installation procedure should ensure adequate separation to prevent
chafing due to track movements.

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.

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APPENDIX B - COMPLETION CERTIFICATE AND TEST RESULTS
7 Pages Follow

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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: ...................…

Extent of installation 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 Earthed 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 .........................Ω 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 8 12 16 20
Armour CSA 20 34 38 41
Tick if used
1.5mm Nos Cores 8 12 16 20
Armour CSA 21 36 40 45

Master Supply fuse Type: BS…… Rating……..A


Lamp Supply fuse or circuit breaker Type: BS…… Rating……..A
Regulatory Signs fuse or circuit breaker Type: BS…… Rating……..A
Solar Cell supply fuse or circuit breaker Type: BS…… Rating……..A

Residual current device protecting:-


Whole installation 300mA Polarity Test OK

Maintenance socket only 30mA Basic Polarity Test OK

Traffic Solutions, Siemens Mobility


Sopers Lane, Poole, Dorset, BH17 7ER
Tel: +44 (0)1202 782000 Fax: +44 (0)1202 782331

Traffic Solutions, Siemens Mobility is a division of Siemens plc Certificate No FS000856


Registered office, Siemens plc, Faraday House, Sir William Siemens Square, Frimley, Camberley,
GU16 8QD, England. Registered No. 727817

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TRAFFIC SIGNAL INSTALLATION COMPLETION Sheet 2
COMME NTS ON EXIS TING INS TALLATION, IN TH E CASE OF A MODIFICATION

C ONSTRUCTION
I /W e b ein g th e pe rson s re sp onsible (as in dicat ed b y m y/our signat ures below) fo r the con stru ct ion of the ele ct rical
installa tio n, p articulars of which are de scrib ed o n pa ge 1 of this form CER TI FY t hat the sa id work for which I/W e ha ve
b een re sp onsib le is to the best of m y/our knowled ge a nd b elief in acco rd ance with BS 767 1 am en ded to … ….…. (d ate)
Re quire me nts fo r Electrical Insta llations e xcept for th e de partures, if a ny, state d in th is certifica te.

Details of de partures f ro m B S 767 1

Th e extent of liability of t he signa ture is limited to the work described on page 1 o f th is fo rm .

For the CON STRUCTION of the installation

N ame (BLOCK LETTERS):...................................… Position...................................

Signature................................................................. Date..........................................

For and on behalf of: Traffic S olutions, S iem ens Mobility


S opers Lane, P oole , Dorset. B H17 7ER

INS PECTION AND TES T

I /W e b ein g th e pe rson s re sp onsible (as in dicat ed b y m y/our signat ures below) fo r the inspe ct ion and testing of th e
e lectrica l installation, p articu lars of which are de scrib ed o n p age 1 of this form CER TIFY that the sa id work for which
I /W e h ave inspected and teste d is to th e be st of my/ou r kn owle dge and belief in accordance with
BS 767 1 am end ed t o … ….…. (d ate). Requirem ents f or Electrical In st allation s
e xcept for th e de partures, if any, stat ed in th is certifica te.

Th e extent of liability of t he signa ture is limited to the work described on page 1 o f th is fo rm .

For the INSPECTION a nd TESTING of the installatio n

N ame (BLOCK LETTERS):...................................… Position...................................

Signature................................................................. Date..........................................

For and on behalf of: Traffic S olutions, S iem ens Mobility


S opers Lane, P oole , Dorset. B H17 7ER

I /W e re co mm end this in st allation be further inspecte d an d te st ed a fter a n interval of n ot m ore t han 1 year.

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ELECTRICAL INSTALLATION CERTIFICATE (notes 1 and 2)
(REQUIREMENTS FOR ELECTRICAL INSTALLATIONS - BS 7671 [IEE 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, 120.4):

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, 120.4):

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 Traffic Solutions, Siemens Mobility, 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 de-
scribed 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, 120.4):

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 Traffic Solutions, Siemens Mobility, 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, 120.4):

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 Traffic Solutions, Siemens Mobility, Sopers Lane, Poole Dorset BH17 7ER
For INSPECTION AND TEST of the installation: Signature: ....................................................................................... Date:.............................................................
Name (BLOCK LETTERS): .............................................................................................................. Inspector
NEXT INSPECTION (notes 4 and 7)
I/We the designer(s), recommend that this installation is further inspected and tested after an interval of not more than 1 year.

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INSTALLATION TEST RESULTS
Test Equipment Used TGP Number Calibration date
Multimeter:
Low Resistance Ohmeter
Insulation Tester:
Earth Loop Impedance Tester:
RCD Tester:
Inductance tester:
Other:
Insulation Test of Complete Installation 30ma RCD Time 300ma RCD Time
(2.6.2) Test (2.9) Test (2.9)
500V 15mA mS 150mA mS
MΩ 30mA mS 300mA mS
150mA mS
Cable Test Results
Core to Core Loop Loop
Cable Run:
Insulation Resistance Resistance CPC Earth Loop
Min 20MOhm Core to Core Core to CPC Resistance Impedance
From To (2.2.2) (2.4.2) (2.4.3 or 2.4.4) (2.4.5) (2.8)
(R1 + R1) (R1 + R2) (R2) Zs
Main earth Distribution Ω
panel
Main earth Castellated Ω
bar or CET
bar as fitted
Main earth Front door Ω
earth stud
Main earth Rear door Ω
earth stud
Main earth Front panel Ω
/ Racking
earth.
Main earth Maintenanc Ω
e socket
Earth pin
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω

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Place an ‘*’ in the top left corner for an ELI value that has been calculated for
an ELV Pole.

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Cable Test Results


Core to Core Loop Loop
Cable Run:
Insulation Resistance Resistance CPC Earth Loop
Min 20MOhm Core to Core Core to CPC Resistance Impedance
From To (2.2.2) (2.4.2) (2.4.3 or 2.4.4) (2.4.5) (2.8)
(R1 + R1) (R1 + R2) (R2) (Zs)
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
MΩ Ω Ω Ω Ω
Place an ‘*’ in the top left corner for an ELI value that has been calculated for
an ELV Pole.

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TS Traffic Installation Testing
INSTALLATION DETECTOR TEST RESULTS (2.10.1)
Loop Series Resistance Resistance to Inductance
Designation of Loop Earth of Loop of Loop
and Feeder Cable and Feeder and Feeder
Max R = 8Ω Min R = 10MΩ 30-500μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH
Ω MΩ μH

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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)

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APPENDIX C - P.I. ELECTRIC TEST CERTIFICATE

6 Pages Follow

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TRAFFIC SIGNAL PERIODICAL INSPECTION


CERTIFICATE (BS7671 amended to …………………(date)
Customer: ............................................................… Site Reference No. …………….

Site Address ..............................................................................……………………………………………

………………………………………………………………………………………….......................................
Controller Type: …………………. Log Book present in controller Y or N
EM/STS No: .................……………… Supply: TN -C- S TN - C TN-S TT IT
Document present in controller Y or N
SUPPLY AND PROTECTION DETAILS
Site insulation @ 500V MΩ Supply Voltage V DIM Voltage V
Protection at Supply Cut Out
Fuse: Type BS………. Rating ………..A ELI Measurement ……………..…..Ω
Protection at Master Switch
Fuse: Type BS………. Rating ………..A ELI Measurement ……………………Ω
Protection Device at Final Sub Circuit (Pole) See Attached Sheet

Lamp Supply Type BS……..…. Rating……….A See Attached Sheet


Reg Sign Supply Type BS…..……. Rating……….A See Attached Sheet
Solar Cell Supply Type BS…..……. Rating……….A See Attached Sheet
Protection is provided by earthed equipotential bonding and automatic disconnection of the supply
Cabling Used
Tick If Used
1.0 mm Nos Cores 8 12 16 20
Armour CSA 20 34 38 41
Tick If Used
1.5 mm Nos Cores 8 12 16 20
Armour CSA 21 36 40 45
REMARKS

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:
Traffic Solutions, Siemens Mobility
Sopers Lane Poole Dorset BH17 7ER
Tel: +44 (0)1202 782000 Fax: +44 (0)1202 782331

Traffic Solutions, Siemens Mobility is a division of Siemens plc Certificate No FS000856


Registered office, Siemens plc, Faraday House, Sir William Siemens Square, Frimley, Camberley,
GU16 8QD, England. Registered No. 727817

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TS Traffic Installation Testing

P.I. TEST RESULTS


Test Equipment Used TGP Number Calibration date
Multimeter:
Low Resistance Ohmmeter
Insulation Tester:
Earth Loop Impedance Tester:
RCD Tester:
Other:
Insulation Test of Complete Installation (2.6.2) 30ma RCD Time 300ma RCD Time
Test (2.9) Test (2.9)
500V MΩ 15mA mS 150mA mS
30mA mS 300mA mS
150mA mS
Cable Test Results

Test Point
Pole Number
Wait/Ped. Signal Earth Loop Impedance


























CONTROLLER CABINET Ω

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TS Traffic Installation Testing
Cable Test Results Continued
Cable Test Results

Test Point
Pole Number
Wait/Ped. Signal Earth Loop Impedance





































CONTROLLER CABINET

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CABLE TEST RESULTS FOR ELV ONLY POLES


FOR PERIODIC INSPECTION
(Where CPC values are measured and the ELI value is calculated)
Cable Test Results
Loop Loop
Cable Run:
Resistance Resistance CPC Earth Loop
Core to Core Core to CPC Resistance Impedance
From To (2.4.2) (2.4.3 or 2.4.4) (2.4.5) (2.8)
(R1 + R1) (R1 + R2) (R2) (Zs)
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω
Ω Ω Ω * Ω

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CHECK LIST FOR PERIODIC INSPECTION


FOR ENGINEER TO COMPLETE DURING THE PERIODIC INSPECTION
TICK TO INDICATE SATISFACTION WITH INSPECTION - DELETE IF
NOT APPLICABLE
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 Y/N
8. Detectors Operational Y/N
9. RAM Battery date fitted
10. Checked no faults displayed Y/N
11. Log book and site configuration documents
present
12. Correct Controller operation verified
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. Check rating of fuse in Lucy cut out
18. Inspect Push Button housing
19. Connection of conductors
20. Identification of conductors

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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 signal 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 Electricity Board Cut Out fuse check for type
and rating.
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

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APPENDIX D - MINOR ELECTRICAL INSTALLATION WORKS CERTIFICATE

1 Page Follows

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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 pages 32 – 34 of 17 Edition of IEE regulations)
2. Method of protection against indirect contact: ............................................................................................................
3. Protective device for the modified circuit : Type BS ..................................... Rating ................ A
th
4. Comments on existing installation, including adequacy of earthing and bonding arrangements : (see IEE Regulation 17
Edition, regulation 131.8.)
...........................................................................................................................................................................
...........................................................................................................................................................................
PART 3 : Essential Tests
1. Earth continuity : satisfactory
2. Insulation resistance:

Line and Neutral/earth ......... MΩ


3......................................................................... Earth fault loop impedance Ω

4. Polarity : satisfactory
5. RCD operation (if applicable) : Rated residual operating current IΔn ..........mA and operating time of ..........ms
(at IΔn)

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 (IEE 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 2.

2. Name: ..................................................................... 3. Signature: ...............................................................


For and behalf of: ...................................................
Address: ................................................................. Position: .................................................................

................................................................................

................................................................................ Date: ......................................................................

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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 59 Issue 14


TS Traffic Installation Testing
Traffic Solutions, Siemens Mobility
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 Traffic Solutions, Siemens
Mobility, a division of Siemens plc. All rights reserved.

The information contained herein is the property of Traffic Solutions, Siemens Mobility 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.

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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.

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