667 Ds 20664 000

JUNCTION CABLING DESIGN CERTIFICATION 667/DS/20664/000
Siemens Traffic Controls,

Sopers Lane,
Poole,
Dorset,
BH17 7ER
SYSTEM/PROJECT/PRODUCT :
Traffic Signal Junction Cabling

Design Certification
THIS DOCUMENT IS ELECTRONICALLY APPROVED

AND HELD IN THE TS DOCUMENT CONTROL TOOL
Issue : Change Ref : Date : dd/mm/yy
Issue 3 TS004079 18/09/2007
Issue 4 TS006507 20/03/2012
Issue 5 TS006919 March 2013
Prepared By Checked and Released

Company/Dep Siemens Mobility, Traffic Solutions Siemens Mobility, Traffic
t.
Name Dave Brocklehurst Solutions
David Martin
Function Senior Product Engineer Product Engineering Manager
Signature
Date December 17 December 17

COPYRIGHT STATEMENT
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
Copyright ã Siemens plc2017 All Rights Reserved
Issue 5 Page i
Siemens Traffic Controls,

Sopers Lane,
Poole,
Dorset,
BH17 7ER
SYSTEM/PROJECT/PRODUCT :
Site Reference:
Site Address:
Prepared By:
Function :
This Document is fully issued when this page is at a FULL numeric issue and all
of the following pages are at the same full numeric issue below and is either
signed if provided in paper form, or has the name of the person preparing it added
above by the person who has edited the detail / designed the junction cabling
layout.
Issue : Change Ref : Date : dd/mm/yy
This is an published 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.
Site Reference: ?? Issue ? Page 1

CONTENTS
1...INTRODUCTION......................................................................................4
1.1 Purpose..................................................................................................4
1.2 Scope......................................................................................................4
1.3 Related Documents...............................................................................4
1.4 Glossary.................................................................................................4
1.5 Use..........................................................................................................4
2...GENERAL NOTES ON INSTALLATION WIRING......................................5

2.1 Neutral Connections..............................................................................5
2.1.1 Introduction......................................................................................5
2.1.2 Context.............................................................................................5
2.1.3 Procedure.........................................................................................5
3...CABLING.................................................................................................6
3.1 Cable Maximum Loading (Limited by the heating effect)....................6
3.2 Loading limited by Cable Voltage Drop (thus associated with cable length) 7
4...DUCTING................................................................................................8
4.1 Capacities..............................................................................................8
5...CABLE IMPEDANCES............................................................................11
5.1 1mm2 Armoured Cable........................................................................11
5.2 1.5mm2 Armoured Cable.....................................................................12
6...COMPLETION OF VERIFICATION CALCULATIONS...............................13
7...APPENDIX A VERIFICATION CALCULATIONS......................................14
8...APPENDIX B COMPLEX DUCTING CAPACITIES..................................16
LAST PAGE.................................................................................................20

Issue History

1 INTRODUCTION
1.1 Purpose
This document is intended to allow an assessment to be made on the suitability of the cabling design for a traffic
controlled junction installed by STC using STC provided cable. Providing all of the criteria noted in the subsequent
sections and sub sections are complied with within the junction design, the cable and terminations design can be
certified as complying with BS7671 and Electrical Installation Certificates signed off.
1.2 Scope
This document only applies to cables 998/4/70468 and 4/MC832 supplied by STC, and cable terminations supplied in STC
traffic controllers and Poles Caps.
1.3 Related Documents
BS 7671 IEE wiring Regulations

667/SA/20664/000 Design and Manufacturer Supplied Information.
1.4 Glossary
1.5 Use
The tables in the body of the document allow a quick check of the electrical design. For a more detailed check should
one be required or if the values or extent of the tables are exceeded the calculation form in the appendix should be
used.
The process is to edit the data in this document for the particular customer / site and then provide a paper or magnetic
copy to the customer, who should then forward it on to the appropriate installing company. To edit the forms in the
appendices of this document, you will need Microsoft Excel, double click on them and they will open up in Excel to
allow editing. When you have edited the data, click back on the body of the main word document and the modified
tables will be copied back to the word document. Then save the word document in the normal way. Please remember to
edit the document series number picking a base number appropriate to your STC base i.e. DEPOT and selecting the next

variant in order. The site reference must also be edited in the footer to ensure each page indicates the site for which it
is relevant.
2 GENERAL NOTES ON INSTALLATION WIRING
The standard size of cable drum used in the field by STC is 250M anything else is a special order.
STCs Recommendations are that LV, ELV and detector cabling are run in separate ducts, where ever possible.
1.6 Neutral Connections
2.1 Introduction
Street wiring faults can sometimes affect the display of traffic signals on-street. Poor connections, for example in pole
top termination blocks usually leads to the failure of signals to illuminate properly which may be detected by lamp
monitoring where this is implemented.
2.2 Context
Where common neutral connections are used it is possible for the failure of a neutral connection to cause unexpected
signal displays, where one or more signals within a given signal head are incorrectly illuminated simultaneously. This
lack of neutral connection is not detectable by the controller because the signal voltage presented at the controller
terminals does not exceed the required thresholds for conflict or correspondence monitoring.
When incandescent signals are used a cable fault of this type usually causes the signals to be illuminated at a low level
and is not particularly noticeable. For LED signals however it is possible for the signals to flash, at least at their 'dim'
level. Although the rate of signal flashing is such that they are only typically illuminated for a very short time, less than
the conflict / correspondence time defined in TR2500, it can be more noticeable than the display seen with
incandescent lamps.
2.3 Procedure
Normally this type of fault only affects a single signal head or pole and due to other signals displaying correctly is
unlikely to cause signalisations that could be considered dangerous, so retrospective action is not essential.
Therefore we are not mandating retrospective action on existing sites, however if the customer wishes to re-wire then
we can do this on a chargeable basis

However for new LED sites where it is desired to reduce the likelihood of incorrect displays, particularly involving green
signals, it is recommended that individual neutral returns are used for each green signal. For existing incandescent
sites where LED signals are being now fitted and spare cables cores are available these may be used to provide
additional neutral connections.

3 CABLING
1.7 Cable Maximum Loading (Limited by the heating effect)
The following is based upon the worst case with all cores carrying the specified current and the maximum number of
any type of cable possible, i.e. the worst case condition (thus removing the need to calculate all scenarios),whilst also
taking into account the controller maximum load per aspect drive. (See also LIMTS OF LOADING IMPOSED BY MAXIMUM
DUCT CAPACITIES). Provided that the loading per core is kept below the maximum number of heads / maximum current
value specified below, then the requirements of BS 7671 can be guaranteed. If loadings above these are required then
Engineering at Poole should be consulted. This later is extremely unlikely.
LOADING
Core Size Amps Reg Halogen LED
Signs Lamp Aspects
Aspects
1.00 mm2 3.5 10 12 24
1.50 mm2 4 12 14 28

1.8 Loading limited by Cable Voltage Drop (thus associated with cable length)
Note the following tables are based on the load of a normal tungsten halogen lamp, an LED aspect load, is generally half
that of a tungsten halogen lamp and therefore these tables provide a worst case scenario. If all LED aspect are used on
a cable run the after careful consideration as to the future use of the cables it is feasible that the lengths could be
doubled.
1.0mm2
Length Of Cable Run
aspect per cable core
Number of singal
10
15
20
25
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
1
2
3
4 2 2 2 2 2 2
5 2 2 2 2 2 2 2 2 2 2
6 2 2 2 2 2 2 2 2 2 2 2 2 2
1.5mm2
Length Of Cable Run
aspect per cable core
Number of singal
10
15
20
25
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
1
2
3
4
5 2 2
6 2 2 2 2 2 2

The voltage drop in the installation must be no more than 4% of the incoming supply, for a 230 volts supply this is 9.2
volts. The tables above should be checked to ensure that for the selected core size and loading the voltage drop is lower
than this maximum. If the voltage drop exceeds the 4% cores / conductors may be paralleled up to reduce it, note NO
MORE than 3 cores should be connected in parallel. The numbers in the cells within the tables indicate the number of
cores required to meet the voltage drop requirement.
4 DUCTING
1.9 Capacities
Based on BS 7671 ‘Selection and Erection’ Appendix A Cable capacities on conduit and trunking section e) the following
tables and rule of thumb has been produced.
Duct Cable Cores Number of Effect On Loading Effect On Loading

cables allowed in terms of aspects in terms of aspects
Per Core Allowed Per Core Allowed
1mm2 1.5mm2
50mm Armoured 8 3 33 36
50mm Un Armoured 8 4 28 31

It should be ensured that none of the conduits in the installation exceed these recommendations.
Ducts should not be over filled with a visual check of the above it would appear as a maximum of 50% filled.
For Detector Feeder Cables The following applies
Duct Cable Number of

cables allowed
50mm 1 Pair Armoured 4
50mm 1 Pair Unarmoured 7
A mixture of cable sizes i.e. a number of cables in a duct with different numbers of cores in the cables, becomes
complex calculation
(and appendix b can be used), however a rule of thumb whithout refering to the spreadsheet in appendix B, would be as
follows
Cable Type Duct 1 20 Core 1 16 Core 1 * 12 Core

Armoured 50mm + 1 other lower + 1 equal or lower + 1 equal lower
size Cable size Cable size Cable
Un 50mm + 2 other lower + 2 equal or lower + 2 equal lower
Armoured size Cable size Cable size Cable
Armoured 100mm + 7 other lower + 7 equal or lower + 9 equal lower
size Cable size Cable size Cable
Un 100mm + 11 other lower + 11 equal or lower + 14 equal lower
Armoured size Cable size Cable size Cable
NOTE some customers have there own requirements for DUCT capacities and these must be complied with on
contracts with those customers, check with customers and /.or their requirements specifications.

An Example would be.

50mm ducts should have no more than 2 armoured cables or 4 non armoured cables. If used in combination in the duct
it can be taken that an armoured cable is equivalent to 2 non armoured.
100mm ducts should have no more than 5 armoured cables or 10 non armoured cables. If used in combination in the
duct it can be taken that an armoured cable is equivalent to 2 non armoured.
Bend Radii in a Traffic Signal Junction Installation meet the requirements of IEE Regs On Site Guide, provided a) the
conduits are not over filled (see earlier paragraphs with reference to duct capacities and, b) standard ‘Slow bends’ are
fitted in conduits (e.g. for 50mm conduits 350mm radius, 100mm conduit 450mm radius), or chambers are fitted at such
bend points allowing cable minimum bend radii to be met.
Allowable bend Radii are
For Armoured cable min bend radius is 6 X Dia For Un Armoured Cable min bend radius is 4 X Dia
Armoured Cable Un-armoured Cable

Cores Diameter Min Bend Diameter Min Bend
8 15.4 93.00 12.6 76.00
12 18.6 112.00 15.8 95.00
16 20.2 122.00 17.4 105.00
20 21.1 127.00 18.3 110.00
1 Pair 13.5 81.00 9.9 60.00
2 Pair 15 90.00 11.4 69.00

5 CABLE IMPEDANCES
The approporiate impedances below should be combined and added with the Ze (earth loop impedance at origin)
supplied by the Electricity supply authority or Local Authority. Firstly the combined value should not be greater than the
required ELI value for the fuse in the controller. Finally these values should be used to cross check the Earth Loop
Impedances measured during the testing of the installation. The tables assume 1 core used, at measured at 20˚C, this
allows comparison with the max values allowed in 667/HE/20664, as the max values have been reduced by the IEE regs
‘Rule of Thumb’, 0.8 to take into account being measure at 20˚C. Note the impedances below are the loop of 1 core plus
the armouring.
1.10 1mm2 Armoured Cable
Length Of Cable Run

the cable
Number of Cores in
10
15
20
25
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
8
0.13
0.26
0.39
0.52
0.65
0.78
1.04
1.30
1.55
1.81
2.07
2.33
2.59
2.85
3.37
3.63
3.89
4.14
4.40
4.66
4.92
5.18
5.44
5.70
5.96
6.22
6.48
12 3.11
0.23
0.34
0.45
0.57
0.68
0.91
1.13
1.36
1.58
1.81
2.04
2.26
2.49
2.72
2.94
3.17
3.39
3.62
3.85
4.07
4.30
4.53
4.75
4.98
5.20
5.43
5.66
0.11
16
0.22
0.33
0.44
0.55
0.67
0.89
1.33
1.55
1.78
2.00
2.22
2.44
2.66
2.88
3.33
3.55
3.77
3.99
4.22
4.44
4.66
4.88
5.10
5.33
5.55
0.11
1.11
3.11
20
0.22
0.33
0.44
0.55
0.65
0.87
1.09
1.31
1.53
1.75
1.96
2.18
2.40
2.62
2.84
3.06
3.27
3.49
3.71
3.93
4.15
4.37
4.58
4.80
5.02
5.24
5.46
0.11

250 4.82 4.08 3.99 3.88
240 4.63 3.92 3.83 3.73
230 4.44 3.76 3.67 3.57
220 4.24 3.59 3.51 3.42
210 4.05 3.43 3.35 3.26
200 3.86 3.27 3.19 3.11
190 3.67 3.10 3.03 2.95
667/DS/20664/000
180 3.47 2.94 2.87 2.80
Issue ? Page 13
170 3.28 2.78 2.71 2.64
160 3.09 2.61 2.55 2.48
150 2.89 2.45 2.39 2.33
Length Of Cable Run
140 2.70 2.29 2.23 2.17

130 2.51 2.12 2.07 2.02
120 2.31 1.96 1.91 1.86
110 2.12 1.80 1.75 1.71
100 1.93 1.63 1.59 1.55
90 1.74 1.47 1.43 1.40
JUNCTION CABLING DESIGN CERTIFICATION
80 1.54 1.31 1.28 1.24

70 1.35 1.14 1.12 1.09
60 1.16 0.98 0.96 0.93
50 0.96 0.82 0.80 0.78
1.11 1.5mm2 Armoured Cable
40 0.77 0.65 0.64 0.62

30 0.58 0.49 0.48 0.47
25 0.48 0.41 0.40 0.39
Site Reference: ??
20 0.39 0.33 0.32 0.31
15 0.29 0.24 0.24 0.23
10 0.19 0.16 0.16 0.16
5 0.10 0.08 0.08 0.08
Number of Cores in
12
16
20
the cable
8
6 COMPLETION OF VERIFICATION CALCULATIONS
It is required that the Verification calculations sheet in appendix A is filled out for the longest cable run and the
shortest cable run. Double Click
On the form (this will open it in EXCEL to allow editing), answer yes to macros. Once completed Click back on the Word
document page to save it back to the word document. Once Complete the sheets should be checked for the following.
NB The TARGET ELI value given in the blank form is that for and ST700 or ST800 with 160 volt dimming, for other
scenarios please refer to 667/HE/20664/000
a) Volt drop does not exceed max limit shown.

b) MAX ELI does not exceed target max ELI.
c) Minimum conductor size is less than the size of the cores used (The Steel wiring Armouring will also sufficient).
Note for all of the above extra cores may be used to assist in bringing the design within requirements (no more than 3
dcores in parallel).
The completed sheets sheets should be signed and filed with the design.

7 APPENDIX A VERIFICATION CALCULATIONS

Notes on Design Certification:-
Note 1
Cabling and armouring impedances are based on worst case figures from STC cable
suppliers.
Note 2
For the Voltage drop for the designed installation to be acceptable it should be less
than 4% as noted in section 525 of the IEE Regs BS7671. The calculations for voltage
drop in this document are based on the worst case current for the aspects used in the
installtion and a RED/AMBER starting condition. If other than standard Tungsten
Halogen lamps are used then you may need to refer to the signal suppliers details to
obtain the current required. However if the voltage drop is within the acceptable 4%
limit using the figure given for Tungsten Halogen, you need not necessarily consider
other lamps types, as in general other lamps have lower current requirements.
Note 3 As noted in Note 1 above the IEE Regs sets the voltage drop limit within an
installtion at 4% (section 525) and the value highlighted in red (9.2 volts) is 4% of the
nominal 230 volt supply.
Note 4
For the earth loop impedance of the design to be acceptable, the calculated Earth Loop
impedance must be less than the target impedance selected from the Installation
Handbook for the particular controller and dimming voltage, (handbook
667/HE/20664/000 can be used for STC controllers). (NB As the dimming voltage is taken
into account in the target impedance design calculations do not need to consider this).
R1 Circuit Phase
Conductor
Resistance
Earth Loop Short

Ze Supply
Impedanc Circuit
Impedance
e = Ze +
Circuit
R1 + R2
R2 Circuit Protective
Conductor Resistance
In the IEE regs all earth loop impedance calculations are normalised to the likely
measurement temperature of 20 Celcius (as this allows for comparison when
measuring this value during the test and inspection phase of an installation), hence the
values calculated here are normalised to this same 20 celcius.
The figures calculated include the impedance as for the supply as given by the
electricity board supplier, and thus are higher by this same amount than the loop
impedances given in section 5 of this document.
Note 5
For the earth loop impedance of the design to be acceptable, the calculated Earth Loop
impedance must be less than the target impedance selected from the Installation

Handbook for the particular controller and dimming voltage, (handbook

667/HE/20664/000 can be used for STC controllers). (NB As the dimming voltage is taken
into account in the target impedance design calculations do not need to consider this).
Note 6
The minimum cross sectional area for a conductor is calculated as noted in the IEE
regs 543-01-03, and provided the conductor size in the cable used is greater than this
calculated figure, this part of the design is acceptable.
8 APPENDIX B COMPLEX DUCTING CAPACITIES

Detector Feeder
Armoured Unarmoured Armoured Unarmoured Allowed ?
Duct Size 8 12 16 20 8 12 16 20 1 Pr 2 Pr 1 Pr 2 Pr
1 100 1
2 100 1
3 100 1
4 100 1
5 100 1
6 100 1
7 100 1
8 100 1
9 100 1
10 100 1
11 100 1
12 100 1
13 100 1
14 100 1
15 100 1
16 100 1
17 100 1
18 100 1
19 100 1
20 100 1
21 100 1
22 100 1
23 100 1
24 100 1
25 100 1
26 100 1
27 100 1
28 100 1
29 100 1
30 100 1
31 100 1
32 100 1
33 100 1
34 100 1
35 100 1
36 100 1
37 100 1
38 100 1
39 100 1
40 100 1
41 100 1
42 100 1
43 100 1
44 100 1
45 100 1
46 100 1

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JUNCTION CABLING DESIGN CERTIFICATION 667/DS/20664/000

Siemens Traffic Controls,

Traffic Signal Junction Cabling

THIS DOCUMENT IS ELECTRONICALLY APPROVED

Issue : Change Ref : Date : dd/mm/yy

Issue 3 TS004079 18/09/2007

Issue 4 TS006507 20/03/2012

Issue 5 TS006919 March 2013

Prepared By Checked and Released

Date December 17 December 17

Siemens Traffic Controls,

Issue : Change Ref : Date : dd/mm/yy

Site Reference: ?? Issue ? Page 1

2...GENERAL NOTES ON INSTALLATION WIRING......................................5

6...COMPLETION OF VERIFICATION CALCULATIONS...............................13

7...APPENDIX A VERIFICATION CALCULATIONS......................................14

8...APPENDIX B COMPLEX DUCTING CAPACITIES..................................16

Site Reference: ?? Issue ? Page 2

Site Reference: ?? Issue ? Page 3

1.3 Related Documents

BS 7671 IEE wiring Regulations

Site Reference: ?? Issue ? Page 4

2 GENERAL NOTES ON INSTALLATION WIRING

1.6 Neutral Connections

Site Reference: ?? Issue ? Page 5

Site Reference: ?? Issue ? Page 6

1.7 Cable Maximum Loading (Limited by the heating effect)

Site Reference: ?? Issue ? Page 7

Site Reference: ?? Issue ? Page 8

Duct Cable Cores Number of Effect On Loading Effect On Loading

Site Reference: ?? Issue ? Page 9

Duct Cable Number of

Cable Type Duct 1 20 Core 1 16 Core 1 * 12 Core

Site Reference: ?? Issue ? Page 10

An Example would be.

Armoured Cable Un-armoured Cable

Site Reference: ?? Issue ? Page 11

1.10 1mm2 Armoured Cable

Length Of Cable Run

Site Reference: ?? Issue ? Page 12

180 3.47 2.94 2.87 2.80

140 2.70 2.29 2.23 2.17

80 1.54 1.31 1.28 1.24

40 0.77 0.65 0.64 0.62

6 COMPLETION OF VERIFICATION CALCULATIONS

a) Volt drop does not exceed max limit shown.

Site Reference: ?? Issue ? Page 14

7 APPENDIX A VERIFICATION CALCULATIONS

Site Reference: ?? Issue ? Page 15

Notes on Design Certification:-

Earth Loop Short

Site Reference: ?? Issue ? Page 16

Handbook for the particular controller and dimming voltage, (handbook

8 APPENDIX B COMPLEX DUCTING CAPACITIES

Site Reference: ?? Issue ? Page 17

Site Reference: ?? Issue ? Page 18

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