SIGNALS AND LIGHTING FIELD GUIDE

CHAPTER 14 – WIRING
WIRING
The installation of all wiring, including electrical cables and conductors, must conform to the
National Electrical Code (NEC). The Code represents the minimum required standard. MnDOT’s
requirements may exceed those of the Code.
14.1 Wiring Requirements
14.1.1 GENERAL REQUIREMENTS
Materials
All the material used in traffic control signal and lighting
system construction, including electrical wires, must be
inspected and approved before it is installed. It is the
contractor’s responsibility to provide the appropriate
wire for the project.
Electrical cables and conductors must be as specified in
the contract documents. The contract documents will
specify all requirements (including cable markings,
cable construction, color code, etc.) for electrical cables Figure 14-1: Cabinet Wiring Example
and conductors used for MnDOT traffic control signals
and lighting systems.

All electrical cable (except as otherwise indicated in the

contract documents) must be listed by a National
Recognized Testing Laboratory (NRTL) as defined by the
U.S. Department of Labor. The testing laboratory must
be listed by OSHA in its scope of recognition for the
applicable tests being conducted as required by the
contract documents.
Figure 14-2: Cable Markings

Single conductor wire must be stranded copper

conforming to the American National Standards
Institute (ANSI) and the NEC and shall be rated at 600
volts.

Figure 14-3: Single Conductor Wire

14-1
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

Inspection
Traffic control signal and lighting system cables are usually
inspected at the distributor by MnDOT. Documentation
(cut sheet) showing project number, reel number(s), and
MnDOT test number(s) will be included with each project
shipment. If this documentation is not with the shipment,
a sample of the cable must be sent to the MnDOT lab for
testing along with material certification from the
manufacturer. Testing at the MnDOT Materials Lab must
be completed before cable is installed on the project.
After MnDOT approves cable at the distributor and a
shipment is made to the project, a form is completed by Figure 14-4: Traffic Control Signal Cut Sheet
the MnDOT lab inspector and sent to the MnDOT
project engineer. The project engineer or MnDOT
field Inspector should compare this document to
the cut sheet provided by the contractor with the
shipment of cable to ensure that the cable arriving
on the job site has, in fact, been inspected and
approved by MnDOT.
It is the inspector’s responsibility to check the wire
and record the information on the Materials
Inspection Form as the wire is furnished to the job
site. A copy of the form is in the Appendix of this Figure 14-5: Materials Inspection Form
Field Guide.
Cables must be inspected and approved before installation and the contractor must be reminded
of this at the pre-construction meeting. Any cables, not having the inspection documentation
when furnished for installation, must be sampled and submitted to the MnDOT Materials Lab for
testing. Once the wire is approved by the MnDOT Materials Lab, the contractor can install it.
14.1.2 TRAFFIC CONTROL SIGNAL SYSTEMS WIRING REQUIREMENTS
Traffic control signal cable must be stranded copper with a conductor
size of number 14 AWG [3 conductor 14 AWG (3/C 14)], rated for 600
volts, and suitable for use at 90°C in wet or dry locations. This cable is
used for the luminaries atop the traffic control signal poles, cable from
the signal cabinet to the signal pole transformer base, emergency
vehicle preemption confirmation lights, and air obstruction lights.
Figure 14-6: Traffic Control
Consult the contract documents for detailed cable requirements. See Signal Systems Wiring
MnDOT Standard Specifications for Construction (Spec Book) 3815 for
more details.

14-2
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

14.1.3 LIGHTING SYSTEMS WIRING REQUIREMENTS

Type 12-2 UF (with ground) cable must run from the light pole base to the
luminaire on lighting system projects only.
Most MnDOT lighting projects require direct buried 4 conductor No. 4 AWG
cable. Direct buried lighting cable must be in accordance with contract
documents.
Figure 14-7: Type 12-2 UF
Within 15 days after the contract approval notice mailing date, the with Ground Cable
contractor must furnish evidence to the engineer, in writing, that orders
have been placed for all direct buried lighting cable required for the
project.
14.1.4 FIBER OPTIC COMMUNICATION CABLE
Many projects are now calling for fiber optic cable to be used for traffic
control signal interconnect. The benefits of using this type of back bone for
communications are large bandwidth or the ability to pass large amounts Figure 14-8: Lighting Cable
of data up and down the corridor. This type of interconnect allows easy
interconnection of field devices to a central office.
The two main types of fiber optic cable are multi-mode optical fiber
and single mode fiber.
Multi-mode optical fiber, which is used for short haul (short distances)
typically used in a building or on a campus. Patch cords will usually Figure 14-9: Multi-Mode Optical
Fiber
have an orange jacket.
Single mode fiber which is used for long haul distances like MnDOT traffic control signal
interconnect and the Regional Transportation Management
Center (RTMC) metro wide communications network (back
bone). Patch cords will usually have a yellow jacket.
Figure 14-10: Single-Mode Fiber

14.2 Wiring Installation

14.2.1 GENERAL REQUIREMENTS
All electrical cables and conductors (except loop detector conductors) must be continuous
(without splices) from the terminal appliances in the traffic control signal or lighting cabinet to
the terminal appliances in the mast arm pole bases, pedestal bases and junction boxes.
Installing splices that are not authorized by the contract are not allowed. If it becomes necessary
to splice a cable, the engineer must approve it in writing. Unless otherwise specified, splices must

14-3
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

be confined to handholes, control cabinets, junction boxes and

the bases of poles. If underground cable splices are specified,
they must be made using an approved epoxy splice kit listed on
MnDOT’s Approved/Qualified Products List (APL) for traffic
control signals or lighting. Additional details about splices are
listed in contract documents. See Spec Book 2545.3G.4.b and
2565.3J for more details.
The size and number of conductors in each cable and the
number of cables in a conduit run must conform to those
shown in the plan. The contractor must wire the electrical
system in accordance with the field wiring diagram shown in
the plans.
Approximately three feet of slack cable must be left in each
handhole that houses a cable run and approximately two feet
Figure 14-9: Field Wiring Diagram
of slack cable must be left in each mast arm pole base, light
standard base and pedestal base.
Field leads entering a traffic control signal or lighting system
cabinet must not be cut shorter than the furthermost terminal
in the cabinet. After all field connections are made to the
cabinet terminal facilities, field leads must be neatly dressed
and banded together to provide an orderly arrangement inside
the cabinet. The ends of all spares not terminated must be
taped to prevent moisture contamination of the wire. Figure 14-10: Service Conductors

Service conductors must be installed in a separate conduit

system and all conductors of a branch circuit must be run in a
single conduit.
Conduit must be cleaned before cables and wire are installed.
All electrical cables and wires must be pulled through the
conduit by hand so that no damage is done to the conductors
and insulation. The ends of all cables and conductors must be
Figure 14-11: Hand Pulling Cables
taped to prevent moisture entering the conductors until
spliced or terminated. Before direct buried cable enters or
exits handholes a bushing rigid steel (RSC) conduit or end bell
(NMC conduit) must be installed on the conduit to prevent
damage to the insulation of the cable.
Cable Labels
As presented in Figure 14-14, the labels used to identify cables
(except at the signal indication fuse panels) can be made of
white vinyl adhesive tape wrapped around the cable and be
hand written with a black permanent marker. They may also Figure 14-12: Cable Labels

14-4
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

be machine printed labels suitable for use in wet locations with

a minimum 1/10 inch overlap when installed on the cable
assembly.
Cables must be identified as shown in the field wiring diagram
in all handholes, junction boxes, traffic control signal pedestal
bases, mast arm pole bases and the cabinet.
Above Ground Wiring
All electrical cables and conductors installed above ground, Figure 14-13: Above Ground Wiring
except on overhead span wires, must be installed in conduit
attached to wood poles, in metal poles, in cabinets or in other
structures.
If electrical cables and conductors are to be installed overhead
unsupported and spanned between wood poles or supports,
sufficient slack must be furnished (generally five percent of the span
length). Cables and conductors installed overhead in conjunction with
a messenger wire (span wire) must be attached to the messenger wire
using approved straps with a maximum spacing as required by the
contract documents. Straps must be approved by the engineer prior Figure 14-14: Sufficient Slack
to installation.
14.2.2 TRAFFIC CONTROL SIGNAL
SYSTEMS WIRING INSTALLATION
Loop lead-in cable (2/C 14) must be
continuous from the splice in the
handhole to traffic control signal
cabinet.
Labels to identify the individual
conductors terminated at the signal Figure 14-15: Cable Labeling on the Fuse Panel
indication fuse panels must use
either machine printed labels embossed plastic labels, vinyl adhesive preprinted labels, or sleeve
type labels placed around each conductor.
As seen in Figure 14-17, in addition to labeling each cable within the cabinet, the contractor must
label, in a similar manner, each conductor of each cable terminated on the fuse panel or terminal
block (RED 2-1, YEL 2-1, GRN 2-1 and so on) indicating the signal indication and the signal head
number. The label must be applied within three inches of the terminal point.

If a battery back system is required then

the contractor must terminate wires on
the inverter.

Figure 14-16: Wire Termination Battery Backup Inverter

14-5
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

Pole base connectors are now the standard

termination device for all new traffic control signal
systems. These devices shall be installed in each
mast arm pole base, traffic control signal pedestal
base, etc. with vehicle and/or pedestrian signal
indications must have pole base connectors as
specified in the contract documents. Pole base
connectors, pins, sockets, sealing plugs, and hand
crimp tool must be MnDOT approved as listed on
MnDOT’s APL.
Figure 14-19: Labeling Requirements

Detailed requirements for terminal blocks are

provided in 2565.2GG of the Spec Book. When
required by the contract documents on retrofit
projects only where terminal blocks are already
installed, each mast arm pole base, traffic control
signal pedestal base, etc. with vehicle and/or
pedestrian signal indications must have a terminal
block for terminating field leads.
Terminal blocks, screws, and spade lugs must be
sprayed with approved electrical insulating coating. Figure 14-20: Labeling Requirements
MnDOT approved electrical insulating sprays are
listed on MnDOT’s APL.

If electrical cables and conductors are to be installed overhead

unsupported and spanned between wood poles or supports,
sufficient slack must be furnished (generally 5% of the span length).
There are two types of MnDOT approved luminaire wire holders.

Figure 14-18: Sufficient Slack

Traffic control signal system luminaries require MnDOT approved

luminaire wire holders that accommodate a round 3 conductor14 AWG
cable assembly that runs one continuous length without splice from the
signal service cabinet to the luminaire atop the signal pole luminaire davit.

Figure 14-17: Signals

Luminaire Wire Holder

14-6
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

14.2.3 LIGHTING SYSTEMS WIRING INSTALLATION

Underground Wiring Direct Buried Lighting Cable
Underground direct buried lighting cable must be installed in accordance with MnDOT 2545.3 G.
The lighting cable must be installed at the same distance behind the bituminous shoulder or back
of curb as the light foundations.
When an obstruction has been
encountered in the path of the direct buried
lighting cable, re-route the direct buried
lighting cable around the obstruction away
from the roadway. All changes to cable
location must be shown in the as-builts.
Direct buried lighting cable must be
installed in rigid PVC or HDPE conduit under Figure 14-19: Re-routed Cable
paved surfaces per 2545.3G.2.

2545.3G.2
Install direct buried lighting cable in rigid PVC or HDPE conduit if located under bituminous, concrete,
or other material not considered a top soil. Provide 3 in conduit if the contract does not specify size of
conduit.

Figure 14-21: Spec Book Section 2545.3G.2

Use a vibratory plow with a plow blade chute to reduce stresses

on the cable during installation.
Place plastic warning tape to meet the following characteristics at
least 12 inches above the direct buried lighting cable:
Use a vibratory plow with a plow blade chute to reduce stresses
on the cable during installation.
Place plastic warning tape meeting the following characteristics at
least 12 inches above the direct buried lighting cable:
1. 3-inch wide,
2. Permanent Red
Figure 14-20: Plastic Warning Tape
3. Stretchable
4. Non-biodegradable
5. Imprinted with the inscription,
“CAUTION-MnDOT LIGHTING CABLE BELOW”

Install direct buried lighting cable from the reel or spool immediately into the ground. Do not lay
direct buried lighting cable for the new lighting system on the ground and use as temporary.

14-7
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

Provide two feet of slack cable in an “S” pattern (within the

width of the foundation) before cable enters the light
foundation.
On a project where guardrail is also being installed, locate
and/or install the guardrail before placing the lighting cable
in order to help reduce or eliminate cable hits. Figure 14-25: "S" Pattern in Cable

Above Ground Splices

Where above ground splices are allowed (in the
pole base), the splices must be either split-bolt SPLIT-BOLT
CONNECTOR
connectors or insulated wire splice connector
blocks.
Use split-bolt connectors or insulated wire splice
connector blocks to splice together the direct
buried lighting cable and the light pole wiring in
the light pole base in accordance with contract
documents. MnDOT approved Insulated Wire INSULATED WIRE SPLICE
Splice Connector Blocks are listed on MnDOT’s CONNECTOR BLOCK

APL for roadway lighting. Figure 14-26: Above Ground Splices

Light Pole Wiring

Install light pole wiring in
accordance with MnDOT 2545.3 G
The wires connecting the luminaire
to the direct buried lighting cable
must be one continuous length
without splice 12-2 UF cable with
ground and a breakaway fuse holder
installed with a cartridge type fuse.
Terminate the individual black “Hot”
conductor of the 12-2 UF cable Figure 14-27: Time Delay Cartridge Fuse
directly to the barrel terminal on
“Load” side of the fuse holder. Do not use wire nuts for light pole wiring.
Place the breakaway fuse holder at the level of the access opening in the pole base. The fuse
holder must be a MnDOT approved breakaway fuse holder as listed on MnDOT’s APL.
Use a 6 amp 1.5 in X .406 in time delay cartridge fuse.
The contractor must provide sufficient excess conductor length to allow withdrawal of the
connected fuse holder. The fuse holder must be properly orientated with respect to the line side
and the load side. The neutral and grounding wires must not be fused.

14-8
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

LOAD SIDE LINE SIDE

(Luminaire) (Supply Side)

Figure 14-28: Fuse Holder

Luminaire Wire Holders

Provide a MnDOT approved luminaire wire holder that
supports the luminaire cable/conductors within the end of the
light pole tenon near the connection point of the luminaire.
MnDOT approved wire holders are listed on the APL for
roadway lighting.
Figure 14-29: Luminaire Wire Holders
Lighting system luminaries require a MnDOT approved
luminaire wire holder that accommodates a flat 12-2 UF cable.

Underground Cable Splices

No underground splices will be permitted that are not
called for in the contract or approved in writing by the
district traffic engineer. When direct buried cable splices
are permitted install in accordance with 2545.3G.4.b.

Figure 14-30: Splice Kit

14-9
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

Two-Way Direct Buried Handhole Cable Splice

When required, use a two-way direct buried handhole cable
splice in accordance with contract documents.

Figure 14-22: Two-Way Direct Buried Handhole

Cable Splice

Three-Way Direct Buried Handhole Cable Splice

When required use a three-way direct buried handhole cable
splice in accordance with contract documents.

Figure 14-23: Three-Way Direct Buried Handhole

Cable Splice

Labeling Lighting Cable and Conductors

Label the direct buried lighting cable in service cabinets and lights pole
bases indicating the next termination point in accordance with MnDOT
2545.3 P.2.b.

Figure 14-24: Labeling

Lighting Cable

14.2.4 FIBER OPTIC CABLE INSTALLATION

MnDOT prefers to install fiber optic cable in NMC conduit however if fiber optic cable must be
installed in RSC conduit the conduit should be close to approaching the 40% fill ratio.
If this is not the case an “Ice Crush” of the fiber may result potentially causing catastrophic failure
of the fiber interconnect.

This was a round conduit initially.

The fiber optic cable is inside.
Figure 14-25: Damaged Conduit

14-10
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

All MnDOT fiber is installed in a conduit system. Once the conduit is

properly installed with the required end bells in place there are two
approved methods for installing the fiber:
1. Hand pulling the cable with a break away pulling device so the
pulling tension on the fiber optic cable central strength member
is not exceeded.
2. Air assisted blowing the fiber in place. This method places the
least amount of stress on the cable. Figure 14-26: Break Away
Device
Fiber optic cable has a minimum bend radius that cannot be exceeded.
Failure to adhere to the bend radius during installation and final
placement of the cable can cause catastrophic failure of the individual
stands of glass. Pulling fiber optic cable in and out of a hand holes is
very difficult to do without exceeding the minimum bending radius.
Figure 14-36: Break Away
Optical cable bend radius limits are typically 10x and 15x the cable Device
diameter at no tensile load and at rated tensile load respectively.
Approved fiber optic cable can be found on MnDOT’s APL website:
http://www.dot.state.mn.us/products/trafficmgtsystems/index.html
Once the entire fiber optic back bone is fully installed and fully spliced,
extensive testing of the installed system must be completed and Figure 14-36: Fiber Optic
Equipment
documented. Consult the contract documents for testing and test
report requirements.
Fiber optic schematics are part of the contract documents when fiber interconnect is required. A
fiber optic schematic is available for review in the Appendix.

Figure 14-37: Signal Cabinet Fiber Optic Patch Panel

14-11
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

14.2.5 ETHERNET VIDEO INSTALLATION

When Ethernet based video is installed at an intersection the following details will be included in
the contract documents. As part of the Ethernet based video the contractor will be required to
terminate Category 6 Ethernet based copper cable. MnDOT requirements for Category 6
Ethernet cable (Outside Plant) are listed in Spec Book 3815.2C.6.d. Refer to the contract
documents for detailed requirements.

14-12
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

Figure 14-38: Camera Detail

14-13
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

Figure 14-39: IP Camera Wiring Detail

14-14
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

14.3 Chapter 14 Resources

 MnDOT Approved Products List (APL)
 National Electrical Code (NEC).
 MnDOT Standard Specifications for Construction 3815, 2565.3J, 2565.2GG, 3815.2C.6.d,
2545.3G, 2545.3 P.2.b.

14-15
Wiring
 SIGNALS AND LIGHTING FIELD GUIDE

This Page Intentionally Left Blank

14-16
Wiring