Section 3: Circuit Design
Introduction
Once the service type is determined, the circuits can be designed.
This section covers the major considerations in the design of roadway
lighting circuits. Designers should refer to the
National Electrical
Code (NEC) Handbook
for additional information.Voltage Drop
The primary limitation on the length of circuits is the voltage
drop. “Calculating Voltage Drop,” Section 4 of this chapter, explains
how to calculate voltage drop.
Circuit Length Limits
At 480 volts, a 4,000 foot circuit of twin-arm poles
can be served without unduly large conductors. At 240 volts, the
circuit is limited to about 2,000 feet. (Conductor size and voltage
drop are discussed in "Circuit Design" and "Calculating Voltage
Drop" of this chapter.).
Conductors and Conduit Size
Another consideration is the number of conductors that can
be installed in the various sizes of conduits. Annex C of the
National
Electrical Code
shows the maximum number of conductors
allowed in each conduit based on the capability of the wire to dissipate
heat. However, with conduit runs of any substantial length, it is
usually not practical to install the maximum number of conductors allowed
in the conduit. A good rule of thumb is to limit the number of conductors
to approximately one-half of the number shown in Annex C.For underground lighting conduit, TxDOT's standard
practice is to use 2 inch PVC. Although this is usually larger than
required by the NEC for typical TxDOT lighting circuits, the larger
size conduit is easier to clean and to pull conductors through.
Since the largest cost of trenched conduit is the trench, 2-inch
trenched conduit has a similar cost to smaller sizes of trenched
conduit.
For underground lighting conductors, TxDOT's standard
practice has previously been to use a minimum size of 8 AWG copper.
However, it is now recommended to use the smallest size conductor
that the NEC and voltage drop will allow, with a minimum size of
12 AWG. Using the minimum size conductor gives three advantages:
- Lower cost of installation
- Reduced consequences of copper theft. Smaller conductors reduce the scrap value of the copper and can help to reduce the incentive to steal it. If the conductors are stolen, the smaller conductors are less expensive to replace.
- Increased safety due to the possibility of reduced arc flash. Smaller conductors have higher resistance, which can reduce arcing if they are accidentally shorted or grounded during maintenance.
Conduit Run Length
As conduit run length and number of bends increases, the effort
required to pull conductors also increases. Generally continuous
conduit runs in excess of 700 feet are not recommended. Continuous
conduit runs in excess 500 feet are not recommended when bends total
180 degrees. The NEC limits total conduit bends between pulling
points to 360 degrees (no matter what the length of the run).
Overcurrent Protection
The ampacity of conductors is shown in Table 310.15(B)(16)
and accompanying notes of the
National Electrical Code
.
This ampacity should be observed in sizing overload protection for
the circuit.Lighting is considered a continuous load. NEC 210.20
requires that for continuous loads, the rating of the overcurrent
device shall be at least 125% of the actual lighting load. For example,
if the actual lighting load is 18 amps, then the minimum breaker
size would need to be at least 1.25 x 18 amps = 22.5 amps. Since
that is not a standard size, the next higher breaker size of 30
amps would be used.
When sizing overcurrent protection, the device closest to
the load should be the smallest size. Devices should increase in
size toward the service disconnect.
For example, a 10
amp fuse might be used in the pole base where the branch circuit breaker
is 20 amps, and the main breaker is a 60 amp circuit breaker.
Grounding Conductor Size
An equipment grounding conductor (EGC) should be
installed in every conduit. The EGC may be sized according to NEC
table 250.122, or it may be the same size as the largest current-carrying
conductor in the conduit. For traffic signal installations, the
minimum size of the EGC in every conduit is 8 AWG.
Copper Theft
Theft of copper conductors from roadway electrical
installations is an ongoing problem for TxDOT and many other public
entities. Replacing stolen conductors can have a high cost in materials
and manpower. Copper theft also leaves the installation inoperable, which
decreases safety for drivers.
Although there is no universal solution to prevent
all copper theft, three strategies can be used to help deter it.
Law enforcement can reduce theft by taking thieves off the street
and punishing those involved. Engineering methods can be used to
make it more difficult for thieves to access the wiring. Reducing
the value of conductors by using smaller sizes or alternate materials can
help reduce the incentive for theft. Details on the three strategies
follow.
Law Enforcement:
- Texas Penal Code, Section 31.03, makes it a state jail felony to steal aluminum, bronze, copper, and brass up to a value of $20,000. This includes aluminum and copper conductors.
- Texas Occupations Code, Chapter 1956, requires scrap and recycling yards to collect information on sellers of scrap wire, including driver's license or official ID, contractor license, thumbprints, vehicle information, and photos or videos of the person selling the scrap.
Engineering Methods:
- Locking ground box covers, handhole covers, and T-base covers are available from several manufacturers.
- Eliminate junction boxes during design to reduce the number of access points to conductors.
- Ground boxes can be hidden a few inches underground. If this is done, then a method to locate them for maintenance is needed.
- Tack weld bolts to metal junction box covers. The tack weld needs to be removed for maintenance inside the box.
Reduce Value of Conductors:
- Use the smallest size conductor that will work according to the design and the NEC. The smaller wire is less expensive to replace and has less scrap value.
- Aluminum conductors have lower scrap value than copper, but the NEC has restrictions on the use of aluminum conductors that makes it mostly unsuitable for underground wiring. NEC 250.120(B) does not allow bare aluminum equipment grounding conductors to come in contact with the earth or to be used in corrosive conditions. Also NEC 250.120(B) does not allow aluminum equipment grounding conductors to be terminated within 18 inches of the earth. For these reasons, aluminum conductors are usually not recommended for underground wiring of illumination.