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Outcome
When you have completed this module you will be able to:
State the proper lock-out procedures that must be followed before working
on a circuit.
Identify the correct equipment bonding methods.
Describe installation methods for sign related electrical equipment.
Describe the installation methods that apply specifically to signs.
List the safe limit of approach distances from power lines.
Describe conductor stress
In the sign industry we often refer to a circuit that supplies the power to
the sign only. By definition the correct terminology for that part of the
electrical system that supplies the sign is called a branch circuit. The
definition clearly states that a branch circuit is the part of the circuit that starts
at the last breaker or fuse and goes to the load.
Safety Procedures
There are several terms used with reference to grounding that have
similar meanings and are sometimes used interchangeably. These include the
following terms: ground, bond, and equipment bond. For example, when
describing a circuit that is properly wired we could use this terminology;
The current path under normal conditions would be; through the breaker
at the electrical panel, into the sign through the live conductor, through the
ballast, and back to the panel through the identified conductor.
The sign would operate fine with no apparent danger unless a fault
occurred in the wiring system. This potentially hazardous situation could take
place if the connection to the ballast, shown in Figure 6-2, was to come loose
and make contact with any of the metal portions of the sign. Now the entire
sign would be energized and at a potential of 120 volts.
fluorescent fixture
identified conductor
Figure 6-2
metal enclosure of
the sign is now
"hot"
Figure 6-3
The CEC outlines the proper method for installing the equipment
ground. In many cases, the ground wire for a circuit is already part of the
cable assembly. For example, #14 armored cable (i.e. BX) has a bare #14
ground conductor included in its construction. Should an equipment ground
be used that is not included in a cable assembly, the conductor insulation must
be green or a green/yellow combination.
Some metal raceways are only used to provide mechanical protection for
the conductors (flexible metal conduit and liquid-tight flexible metal conduit
for example). For the purpose of equipment grounding, these raceways do not
meet the requirements of a bonding conductor. There is an exception to this
rule. When flexible metal conduit or liquid-tight flexible metal conduit is used
to protect high-voltage cables between a neon electrode and a neon supply or
between neon electrodes, the flexible conduit is considered to be an adequate
bonding means if it is secured properly into a connector and all locknuts are
tight.
SKELETON NEON
METAL TRANSFORMER
ENCLOSURE
WIRE
CONNECTOR
1 2 3 4 5 6 7 8 BUILDING WALL
To answer that question one must follow the bonding path. The neon
supply enclosure is bonded to ground. The flex can be used to bond through-
wall housings number 1 and 8. That is where the bonding path stops. A
bonding conductor must be run to housings 2 or 3 to bond these through-wall
housings. The same is true for numbers 4 and 5, and numbers 6 and 7. These
groups (2 and 3, 4 and 5, and 6 and 7) are isolated from the bonding path. The
minimum number of bonding conductors required here would be three. A
sign installer can install a separate green bonding conductor to all eight
housings, but only three are required. The flex can be used as a bonding path.
If metal channel letters were used to enclose the neon, the metal letter can be
used to continue the bonding path from housing 1 to housing 2. This would
eliminate the need for a green wire to be run to housing 2 (the same could be
said for groups 4 and 5, and 6 and 7). To make a good connection between
the housing and the letter, the housing must be fastened with a screw, bolt,
rivet, or similar device, and paint must be removed to allow bare metal-to-
metal contact.
Figure 6-5 shows how a potential hazard can occur. In this case, the
metal enclosure of the sign is connected to ground through the ground
conductor that originates in the electrical distribution panel inside a building.
The metal parts of the generator and the truck are isolated from ground by the
truck tires. It is not uncommon for a difference in potential to exist between
the sign ground and the generator ground. If you come between the sign and
the casing of the generator there could be a voltage dropped across you,
resulting in electrocution.
The CEC uses Table 16 to size the equipment ground for electrical
installations. The size of equipment ground chosen is determined by the rating
of breaker or fuse protecting the load. According to Table 16, any circuit that
is supplied by an overcurrent device which does not exceed 20 A, requires:
Armored cables that are run between boxes and fittings must be strapped
in intervals of not more than 300 mm of every box or fitting and at intervals of
not more than 1.5 meters. Armored cable shall not be bent to a radius that
puts undo stress on the cable assembly (the inner edge of the bend shall be at
least 6 times the external diameter of the cable) as this could damage the
conductors inside the cable. The integrity of the outer shell of the cable
should not be jeopardized.
Neutral supported cable is not used to wire the neon letters of neon
signs. The insulation of most neutral supported cable is not rated for the
high voltages of a neon supply.
Raceways
The CEC dictates the maximum number of wires that can be pulled into
a raceway. Table 6 lists different wire types and the number of each wire that
can be drawn into a conduit. The key factors in determining conduit fill are
AWG wire size and type (thickness) of the insulation on the conductor. Table
6 has been designed so that when wires are pulled into a raceway, the wires
will not be damaged or overheat.
The CEC also states that not more than 360 degrees of bends are to be
allowed between junction boxes. The intent of this rule is to make sure that
high mechanical stresses are not placed on the conductors when they are being
installed.
Electrical metallic tubing must also have adequate supports. All runs
must be strapped within 1 meter of any junction boxes, couplings or fitting
and spacing of supports shall not be more than one meter for 1/2 inch and 3/4
inch conduits. Equipment should not be installed so that the EMT provides the
support for that device.
In addition to the general wiring methods listed above, there are several
wiring methods that apply specifically to the installation of electrical signs.
Detailed information on sign wiring methods can be found in the Canadian
Standards Association Booklet # 207 and relevant sections in the CEC. Some
of the more significant rules are discussed below.
Enclosures.
Openings In Enclosures.
Bushings
A hole made in the sheet metal of a sign that is to be used for conductors
to pass through must be fitted with a bushing to protect the conductor
insulation from the sharp edges. However, if the hole edges are rolled over
smoothly to at least 180 degrees, a bushing is not required. Holes for
conductors in materials other than sheet metal such as cast metal, extruded
metal, wood or thermoplastic shall be free of sharp edges, burrs or fins. Where
bushings are used, they must be installed so that they are securely held in
place.
High-Voltage Conductors
High-voltage cables run between neon tubing and the secondary of the
neon transformer, or between sections or letters must be installed to ensure
personal safety and proper operation of the equipment. All conductors shall
be the type specified by Table 19 in the CEC (i.e. GTO, GTOL, or an
equivalent) and must not be smaller than stranded #14 AWG.
If the GTO cable is run inside of rigid or flexible metallic conduit, or
electrical metallic tubing, the cable must be of the type that is resistant to the
Since GTO wire is not shielded, the high voltage Figure 6-6
will put stress on the conductor insulation when it is
installed near grounded metal. See Figure 6-6. If the GTO cable is installed in
metal flex, one side of the cable will be closer to ground. This side will have
more stress put on it. Stress will lead to insulation breakdown. There is no
way of eliminating this stress unless shielded cable is used; however, the
effect of the stress can be reduced if the length of the cable can be reduced.
The highest voltage-to-ground stress occurs on the cable run from the
transformer to the first unit of glass. This cable should be as short as possible.
The cable run between subsequent units of glass will have lower voltage-to-
ground stress. The cables with a lower voltage-to-ground stress could be
longer if necessary, as long as the total length of cable does not exceed the
maximum allowed. When deciding on the location of the transformer, the
length of the cable runs must be considered. Again, to reduce the stress on the
GTO cable, keep the cable run from the transformer to the first neon unit as
short as possible.
neon transformer
90 mm minimum 90 mm minimum
Figure 6-7
In CSA Standard 207 there is a Table 4 that lists the required spacing for
high-voltage conductors. Some of the distances listed are:
The installer should also ensure that there are no sharp bends in the
conductor and that no part of any conductor is connected to a door or a cover
of a sign.
Enclosures for portable signs may have the power cord come directly
from the sign body as long as the body of the sign acts as an enclosure for the
power connection.
Rule 12-310 in the CEC outlines the wiring method required when
overhead conductors are used to supply power to a sign. These conductors
must be installed so that no person can reach them while standing on a fire
escape or flat roof. They also must be at least 2.5 meters above a flat roof or a
roof that can be readily walked on. Conductors crossing peaked roofs must
have a clearance of at least 1 meter. By special permission conductors
crossing flat roofs may be less than 2.5 meters but never less than 2 meters.
Table 2-1
0-750 V
Insulated or Polyethylene 300 mm
Covered Conductors (1)
Above 750 V
Insulated Conductors (1)(2) 1.0 m
0 - 40 kV 3.0 m
69 kV, 72 kV 3.5 m
138 kV, 144 kV 4.0 m
230 kV, 240 kV 5.0 m
500 kV 7.0 m
NOTES: (1) Conductors must be insulated or covered throughout
their entire length to comply with these groups.
(2) Conductors must be manufactured to rated and
tested insulation levels.
Figure 6-8
• Always follow the five steps for locking out electrical equipment.
• Table 19 of the CEC outlines the types of wires suitable for certain
installations.
• The key factors involved in determining conduit fill are the AWG size of
the conductors and the type of wire insulation.
• High voltage cables shall be the type specified by Table 19 in the CEC.
• High voltage cable must not be smaller than #14 stranded. (GTO type)
• High voltage conductors must have a space between them and other
conductors as dictated by the CSA manual #207
• Overhead connections to signs must be in accordance with Rule 12-310 of the CEC.