Directive Installation Lane Light MLK LED road marker V4 and V5; Version 2

Transcription

1 Directive Installation Lane Light MLK LED road marker V4 and V5; Version 2

2 Index 1 Surveying and Marking Milling the cable joint Core drilling for the LaneLight MLK Assembling bottom parts of MLK and cable tubes Filling the core holes with concrete Effuse gap of MLK and cable joint Electrical Installation Sealing the cable tube Electrical junction Potting- possible solutions Installation of top part Warranty Regulation Systems Concrete - recommendation Cable joint mass - recommendation Armoured tube - recommendation Single cable - recommendation Electrical junction - recommendation Casting compound - recommendation /13

3 1 Surveying and Marking Surveying and marking from the desired position of the MLK also the location of the cable joint. See Fig. 1 Fig. 1: Marking the positions for installation 2 Milling the cable joint The cable joint has to have a width of 21mm -0/+5 and a depth of 60mm -0/+5. Cable tube Fig. 2: Cutting the cable joint Layout: Cable joint 3/13

4 3 Core drilling for the LaneLight MLK 150 Drilling a core hole with a diameter of 200mm -10/+0 and a depth of 70mm -0/+10. Layout: core hole drilling Fig 3: drilling the core hole Fig. 4: break out the core Fig. 5: cleaned core hole Cleaning the joint and the core hole with water or compressed-air and then dry it. 4/13

5 4 Assembling bottom parts of MLK and cable tubes Assembling the installation plate with 2xM8 screws on the bottom. Cut the cable tube according to the drill distances and put it into the junction box. Save the cable tube from falling out with adhesive tape on the junction box. Tighten the screws of the junction box. Fig. 6: pull the screws thight Fig. 7: prepared installation Attention: If the cable tube shifts out of the junction box and if the junction box isn t tightened, concrete can get inside the MLK-bottom part and it is impossible to cable. Layout of the prepared bottom parts with cabling 5/13

6 5 Filling the core holes with concrete Before beginning of assembling the direction of LaneLight must be defined. Insert bottom part with installation plate. Fig 8: inserted bottom part with installation Advice: Do not use the enclosed screws (M8x25) for the adjustment procedure. They are foreseen to be used only once (screw securing compound!). Advice: Set direction of LaneLight before filling the bottom part with concrete. Attention: Don t forget to tighten the junction box after the direction is fixed. 6/13

7 The concrete must be chosen according to the ambient temperature. Effuse core hole till 1 cm below the border. During this process the installation plate has to lie flat on the road. Take off the installation plate not before 30 minutes. Consider processing time of the recommended installation materials. It is absolutely important to notice the processingtime of the used materials. Fig. 10: glued bottom part 6 Effuse gap of MLK and cable joint Fig. 9: bottom part before glued Take care that the glue can t get into the installation box at effusing the gap. Using bitumen potting or Epoxy cable joint potting in asphalt road installations. Using Epoxy concrete or bitumen in concrete road installations. At effusing the joint with hot bitumen the cable pipe has to be covered with a sand stratum of 1, 5 cm. Fig. 11: sand stratum on the pipe Fig. 12: cable joint potting 7/13

8 7 Electrical Installation LaneLight Version V4.0 obsolete LED technology, with separate error control Wire the electrical connections like displayed on the block diagram. (If using controller units without error detection the white cable can be cancelled.) LaneLight Version V5.0 new LED generation and electronic PCB hard and software PWM -green wire- signal for flashing frequency, brightness control and error detection. For all functions controller will be necessary! to error control e.g. ITEM, EBE controller Following the next steps how to accomplish the electrical junction. Providing and preparing the cables Pull in four single wires on V4 (red, black, white and green). Pull in three single wires on V5 (red, black and green). Fig. 13: cables pulled through the pipe 8/13

9 7.1 Sealing the cable tube To prevent that the casting compound flows out, you have to seal the tube end with silicone. For this purpose you have to inject silicone into the left and right half of the cable tube next to the cables. It is not necessary to wait until the silicone is hardened to continue to work. Fig. 14: Silicon injection 7.2 Electrical junction Fig. 15: 3M terminal wiring All three wires MLK V5 or four MLK V4 of one color get into the 3M clip and get press strong down. Attention: connect to controller - and control now all LaneLights if wirings are complete o.k. 9/13

10 7.3 Potting- possible solutions Warning: You must not prepare too much material, because look for processing time in technical datasheet from product! For one MLK compound should be ml enough. You have to mix the mass, with technical datasheet from product, otherwise the casting compound could not harden complete! The clip must be complete bordered! You have to wait of hardens like technical datasheet from product! Recommendation- solution 1-3M High Gel 8882 Scotchcast The advantage from 3M Gel over Macig Rubber is the clear color, if you can see position of terminal wirings on end result. Fig. 16: potting terminal wiring 10/13

11 Recommendation- solution 2 - Magic Rubber Fig. 17: Magic Rubber before mixed Fig. 18: potting terminal wiring 11/13

12 8 Installation of top part Place the Rubber Ring Against Freezing in the MLK- bottom part. Place in the LaneLight (= top part) and screw it with 2x M8x20 A4-70 DIN912 with Tuflok cover (hexagon socket). When you will open later please change the screw or get new Tuflok on windings! Tighten both screws equally (clamping torque 16Nm). Attention: Do not forget to insert the Rubber Ring against freezing! Inserting the top part do not bend cables! Fig. 19: Affixing the top part Fig. 20: finish! 12/13

13 9 Warranty Regulation See Document: warranty_lane_light_en_ Systems 10.1 Concrete - recommendation Dependent on the temperature one of the two concretes should be chosen! The following concretes are available at the company Possehl - Cds - concrete UW Cds - concrete UW is a free of dissolvent, filled with minerals, easily to cast, 2-components- Epoxidresinmaterial. Insertable within temperatures around degrees Celsius Cds - concrete UW-Rapid Cds - concrete UW-Rapid is a 2-components-Epoxidresinmaterial with minerals filled, easily to cast. Insertable within very low temperatures above the freezing point Cable joint mass - recommendation Cds - cable joint mass Cds cable joint mass is a reactive adapted, free of flexibiliser, thin fluid 2-componentsmaterial on Epoxidresin basis Armoured tube - recommendation Armoured flex tube flexible HFXP20SW 10.4 Single cable - recommendation Single cable FLR11Y 2,5 PUR 10.5 Electrical junction - recommendation 3M 314 Scotchlok Casting compound - recommendation 3M High Gel 8882 Scotchcast Magic Rubber /13