Sportsliter Solutions Integral System User Manual

INTEGRAL SYSTEM

INSTALLATION INSTRUCTION GUIDE

WARNINGS, DIRECT & ANCHOR BOLT, CONCRETE & STEEL POLES, EQUIPMENT ASSEMBLY

REMOTE SYSTEM

INSTALLATION

Installation Instructions

See warnings on carton

Read all of the following instructions prior to installation and
formulate an action plan for installation of your SLS system. Different

foundation/pole/crossarm combinations require their own unique plan.
Ensure that these instructions are available for future servicing of this
installation.

WARNING!

• Disconnect power before installation or servicing.

• Install, operate and maintain to meet all applicable codes.

• This system is to be installed and maintained by qualified personnel only.

• Cover all open ground holes for direct burial poles at job site when not erecting poles.

• Supply voltage must match that of ballasts in remote ballast boxes.

• Ensure that all supply and ground wiring is sized to meet the requirements of

the installation.

• All plugs are to be connected and disconnected only when the power is turned off.
Failure to do so could result in personal injury or damage to the plugs.

• Check junction box wiring to verify single or three-phase layout.

• Proper equipment, procedures and personal safety gear must be utilized per the

requirements of the task to ensure safety.

• Read and follow the lamp manufacturer’s warnings and use information before
installing lamps. Wear safety glasses and protective gloves while working with lamps.

• Use only mounting hardware furnished by Hubbell Lighting, Inc. to assemble
components together.

• Do not alter structural members in any manner such as by drilling, welding,
bending, etc.

• Additions to the installed SLS system such as flags, banners, etc. are prohibited unless
approved by Hubbell Lighting, Inc.

• Use extreme caution when working near overhead power lines or underground
utilities. Verify the existence and location of all underground utilities at or near the job
site prior to proceeding with installation.

• When handling poles or pole sections, remember that they are tapered and thus require
that the lifting device be secured in a manner as to prevent slippage.

• For concrete poles, a thru-hole is provided at the proper 1-point pick-up location to
enable a steel bar to be inserted as a safety stop for the sling during the erection
process, (this bar is NOT a lifting device).

• Recommended lifting point for complete steel pole/crossarm assemblies is at pole top
just under the cap plate.

• Do not lift complete pole/crossarm assemblies by any of the crossarm members. Secure
lifting device to the pole only. Take care to not damage or misalign the reflectors during
the erection process.

• Slings for handling poles and crossarms should be made of or covered with nylon or
some other nonmetallic material to protect the pole finish. The lifting capacity of the
sling must be verified. Avoid damage or misalignment of SLS system components during
handling and storage operations.

• If the galvanized finish on any component is damaged in field, touch-up area with
spray-on galvanizing.

Soil Analysis/Foundation Design

• It is recommended that soil-boring samples be taken at the job site and
the information then submitted to a Registered Professional Engineer for
evaluation and issuance of a foundation design. Contact SLS for
foundation designs if needed.

• Refer to Fig. 1 for an example.

Field Layout/Pole/Crossarm Alignment

• Identify pole locations on site per
Hubbell Application Engineering documentation.
Refer to Fig. 2

• Refer to Fig. 3 for pole elevations.

• Refer to Figs. 2, 4 & 5 to align and plumb each pole/crossarm to the field

Foundations (direct burial and anchor bolt)

• The foundation is to be constructed in accordance with the design
supplied for your installation and per applicable code requirements.

• Underground supply wire entry into poles are as follows:

• Concrete and steel (direct burial) – 18” below ground line on sides of pole,
parallel to field.

• Steel (anchor bolt) – bottom, center of pole.

• For installations with the lightning rod (LR) option, install components that
will be covered during backfilling. (See installation instructions provided
with the LR (lightning rod) option.

Direct Burial Foundations

• Bore hole per required diameter and depth.

• If a footing with steel rebar cage is required, center the cage in the bottom
of the hole and pour concrete to the level specified on the foundation
design drawings.

• Concrete must cure 24 hours before proceeding with installation.

• Place the pole (or pole bottom section for steel pole when concrete backfill
is required) in the center of the hole; align and plumb.

• See light position check in Final Notes section prior to backfilling.

• Make provisions for underground supply wiring entry into pole before
completion of backfilling. For installations with the lightning rod (LR)
option, install components that will be covered during backfilling. (See
installation instructions provided with the LR option)

• Avoid damage to the protective coating on steel pole bottom section
during backfilling.

• Backfill per foundation design drawings. Poles must be supported until
backfilling has been completed.

• If concrete backfill is required, the concrete must be allowed to cure 7 days
prior to assembling remaining pole sections or sports lighting equipment
to them. Full strength concrete cure takes at least 28 days, so evaluate
anticipated weather conditions that may involve severe winds and plan
installation accordingly.

Anchor Bolt Foundations

• Anchor bolts, hardware and anchor bolt setting templates are furnished by
pole supplier.

• Construct foundation per design drawings.

• Ensure that the concrete has cured a minimum of 28 days prior to
installation of poles.

• Thread one bottom nut and insert one flat washer onto each anchor bolt.

• These bottom nuts should be set so that when the pole base plate is set
on top of them the base plate will be level and as close as practical to
the foundation.

• Lift the pole onto the anchor bolts while routing the underground supply
wiring into the pole bottom.

• Insert one flat and lock washer and thread one top nut onto each
anchor bolt.

• Check the pole to ensure that it is aligned and plumbed correctly.

• Tighten all anchor bolt nuts on the top side of the base plate snug then an
additional one quarter turn

• Check to make sure that hardware is bearing completely against the
base plate.

• It is common practice to secure anchor bolt nuts in some manner to
prevent unauthorized turning or removal. Refer to Fig. 12 & 13 for
anchor bolt detail.

INTEGRAL SYSTEM

INSTALLATION

Poles (concrete and steel)

• When unloading poles from freight carrier:

• Verify that all required materials have been received.

• Check all poles or pole sections for possible damage incurred

during shipping.

• Use proper pick-up points and equipment for lifting poles or pole sections
to prevent damage.

• Match pole ID mark with that described on the lighting layout provided by
Hubbell Lighting Applications Engineering and unload at these locations
on the job site. Unload with the pole base as close as possible to
the foundation.

• For concrete poles with cap plate, do not store pole with cap plate
supporting the pole weight. Blocks and chocks should be placed under
the pole or pole sections to aid in assembly and lifting.

• If the job site permits, it is recommended to assemble the sports lighting
equipment to the pole before erection. The pole should be oriented so
that attachment points are accessible without requiring rotation
of the pole.

• For installations that require front and back aimed fixtures, it will be
necessary to elevate the top end of the pole to provide clearance for the
reflectors if the assembly is completed prior to erection.

• Hoisting must be smooth and continuous without abrupt jerks.

• Tag lines can be used to guide the pole to the foundation during erection.

Concrete Poles

• Refer to the cast-in nameplate on the pole for information about pole
length, weight & ID mark.

• Poles must be lifted, stored and erected using only the following points
marked on the pole or indicated on documentation shipped with
each pole:

• C.G. (center of gravity) – This location is shown for informational purposes
only, it is not a pick-up point.

• 2 Point Pick-Up – These locations are the proper 2 point pick-up points.
Equal length slings are required. The pole will hang horizontally when
using these points. No sports lighting equipment is to be attached to the
pole before it is erected using the 2-point pick-up.

• 1 Point Pick-Up – This location is to be used for pole erection. A thru­ hole is provided at this point to enable a steel bar to be inserted as a
safety stop for the sling. Sports lighting equipment may be attached to
the pole before it is erected using the one-point pick-up.

• Storage – These locations are the points at which the pole must be
supported for storage at the job site. The pole must be stored in a straight
and level condition so that no bowing or bending occurs. While the sports
lighting equipment is being attached to the pole, support the pole using
these storage points. If the weight of the equipment at the pole top could
cause undesirable deflection during erection, the pole top must
also be supported.

• Ground Line – This location indicates the level to which the pole should
be embedded in the ground. Verify foundation design
embedment requirements.

Steel Poles

• Check each pole section’s straightness to ensure that there was no
damage incurred during shipping. Manufacturing tolerances permit a
variance from a string line by up to ¼ inch in 20 feet.

• Avoid damage to the pole surfaces during handling operations.

• Pole sections should be laid flat and blocked for storage and assembly.

• Pole sections may be assembled horizontally or be vertically depending on
job site requirements.

• Slip-fit the pole sections together by the following sequence:

• Match pole ID numbers to identify shaft sections that make up one
complete assembly.

• Ensure that there are no projections or dirt in the telescoping areas.

• If a lubricant is needed to slip sections together, soapy water
is recommended.

• Refer to Fig. 6 for shaft alignment and slip-fit tolerances.

15

•

⁄16” diameter holes are provided in each section for attachment of a

pulling device.

• Force the sections together snugly using devices such as come-alongs,
hydraulic jacks, etc.

• Ensure adherence to slip-fit tolerance described in Fig. 6

• All joints must be lashed securely together to prevent slipping apart
during erection. Listed below are some methods to do this:

• Come-alongs with tight cable lashings.

• A single, full length cable, fastened at the base (or bottom hand hole) and

the top of the pole.

• Plumbing of the pole should be done early in the morning when there is
minimum heat effect from the sun and when there is no appreciable
wind. The heat from the sun on one side of the pole can cause a visible
bow to occur.

Sports Lighting Equipment Assembly to Poles

Refer to Figs. 7 for component matching at each pole location.
Components must be installed at locations identified on the Hubbell
Application Engineering documentation. Verify all labeling.

Refer to Figs. 8 for standard crossarm system layouts.
Refer to Fig. 10 for clamp-on component mounting to concrete poles.
Refer to Fig. 11 for cap plate component mounting to steel or concrete poles.
Refer to Fig. 9 integral fixture mounting to crossarm.
Refer to Hubbell Application Engineering documentation and instruction sheet
shipped with integral fixture for detailed aiming and axial reflector mounting
instructions. Verify if protective hulls are required. Install proper lamps
Install lens assemblies to reflectors.

Final Notes

Supply wiring to be furnished by the Contractor. Refer to instruction sheet
shipped with integral fixture for detailed instructions on installing, aiming and
servicing the integral fixtures. Feed supply wiring through the pole base into the
remote ballast boxes and make electrical connections to the terminal blocks.
Ensure that each pole/remote box is properly grounded. Check one light position
on each crossarm assembly to verify that it aligns with the requirements specified
on the Hubbell Applications Engineering documentation. Locate the spot on the
field where this light should be aimed. To allow for your height, take two steps
toward the pole from this spot. Using binoculars, look at the lamp and reflector
of the light aimed at this spot.

• If the light is aligned properly:
Axial optics: The lamp and the back of the reflector will form a

perfect bull’s-eye.
Horizontal optics: The center of the lamp arc tube will be centered
in the reflector.

• If adjustments must be made, the following is required:

Steel base plate poles: Crossarm must be rotated.
Steel direct burial pole: Pole or crossarm must be rotated.
Concrete pole with cap plate components: Pole or crossarm must be rotated.
Concrete pole with clamp-on components: Pole must be rotated.

These instructions are not intended to be a comprehensive guide to every possible
installation issue. Always put safety first. If in doubt, call us.

2