Musco Sports Lighting SportsCluster Green User manual

©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
Installation Instructions: SportsCluster Green™Lighting System
MKT-4245
Cover Illustration,
SCG LED Ground, Wedge2
RWS
25 June 2015
Diode Light Source—LED

Installation Instructions: SportsCluster Green™Lighting System
2
www.musco.com · [e-mail]
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
Contents
MKT-3045-1
SCG LED Installation
RWS
23 June 2015
Before You Begin.....................................................................3
Safety Information ..................................................................................... 3
About These Instructions ........................................................................ 3
Standard Tools/Supplies .......................................................................... 4
Components of SportsCluster Green Lighting System................. 4
Unloading Instructions............................................................................. 5
Electrical System Requirements............................................................ 5
Documents We Provide............................................................................ 6
Electrical Components Enclosure..........................................7
Hardware Sorting ....................................................................................... 7
Overview ....................................................................................................... 9
Installation Procedure............................................................................... 9
Poletop Luminaire Assembly...............................................12
Overview .....................................................................................................12
Assembly Procedure................................................................................12
Setting Poletop Luminaire Assembly .................................15
Hardware Sorting and Preassembly..................................................15
Overview .....................................................................................................20
Installation Procedure.............................................................................20
Wiring ....................................................................................24
Overview .....................................................................................................24
Installation Procedure.............................................................................24
Lightning Ground.................................................................29
Overview .....................................................................................................29
Installation Procedure.............................................................................29

Installation Instructions: SportsCluster Green™Lighting System
www.musco.com · [e-mail]
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
3
Before You Begin
Safety Information
Electrical Safety Guidelines
Use extreme caution near overhead power lines or underground utilities. Observe all safety precautions for high-voltage
equipment. Only qualified personnel may perform wiring. Follow all applicable building and electrical codes.
General Safety Guidelines
Follow proper safety procedures during installation. Installers must wear the appropriate personal protective equipment
including:
•Hard hat
•Steel-toed shoes
•Fall protection
•Leather work gloves
•Eye protection
Locate all underground utilities prior to digging.
All tools and equipment supplied by Musco are designed for specific use as described in these instructions. Do not use them
in any other manner. Do not alter structural members in any way, such as bend, weld, or drill, without prior authorization
from Musco.
About These Instructions
These instructions outline basic assembly procedures for the SportsCluster Green lighting system. They are not a comprehensive
guide to all possible situations. Direct any questions to [phone] or call your local Musco representative.
Throughout this manual note these important symbols:
The safety alert symbol alerts you of situations that
require care and caution to avoid serious personal injury.
The stop and check symbol signals you to stop and
verify conditions before proceeding.
The contact Musco symbol appears in special situations
where you may need to contact Musco for further
information.
The go-to arrow indicates a branch in a procedure for
special situations. In case of optional equipment, the
instructions may be in another document.
The tip symbol points out advice that makes
installation easier.
The recycle symbol identifies recyclable materials.

Installation Instructions: SportsCluster Green™Lighting System
4
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Before You Begin
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
Standard Tools/Supplies
Contractor/installer supplies Function Page
Hammer, pry-bar, banding cutters Unloading equipment 5
Measuring tape, 25 ft (7.5 m) Identifying brackets and straps, locating components at proper height on pole 7, 8, 9, 15
Torque wrench Torquing pole clamping hardware 10
Sockets: ½, ⁄ in standard and deepwell Torquing pole clamping hardware 10
Screwdrivers, standard and Phillips Landing power, tightening enclosure hub screws 11, 26, 28
Marker Marking hanger bracket mounting locations on pole 9
Paint, chalk, flags Marking aiming points on field 20
Measuring tape, 300 ft (90 m) Locating aiming points on field 20
⁄ in open-end torque wrench or torque wrench
with ⁄ in crows-foot
Torquing pole clamping hardware, torque nuts 21, 23
⁄ in open-end wrench Tightening pole clamping hardware 16–19, 21, 23
Stepped drill, hole saw, or die set Cutting conduit entryways 26
Conduit, fittings, clamps, etc. Conduit and supplies as needed for wiring routing 26
Electrical fish tape Pulling conductors 27, 28
Main power disconnect and distribution panels Power to lighting system 28
Electicians pliers 28
Grounding electrode and driving sleeve* Pole lightning ground 30, 30
Grounding conductor, AL to CU splice (if required),
saddle clamp, bonding jumper, exothermic weld kit*
Pole lightning ground 29, 30
Shovel Excavating grounding electrode 29, 30
Musco supplies Function Page
Snips Cutting steel strapping 10
½, ⁄ in offset combination wrench Tightening strap hardware 10, 11, 29
⁄ in ratcheting combination wrench Tightening luminaire captive bolts 14, 28
5 mm hex key Landing primary feed wires on 125 A disconnect switch 28
⁄ in hex key Ground bar 26, 28, 29, 30
⁄ in hex key Grounding lug 27, 29, 30
Wago brand LEVER-NUTS® wire connector Connecting pole harness 27
Equipment needed Function Page
Load-rated crane and rigging Unloading, lifting crossarm assembly 5, 21, 22
Aerial work platform Attaching crossarm assembly to pole and other aerial work 21, 22
10 ft (3 m) stepladder or small line truck Attaching crossarm assembly to pole and other aerial work 9, 24–30
Components of SportsCluster Green Lighting System
* May be supplied by Musco.
MKT-3040-1
SCG LED Assembly
RWS
23 June 2015
F1
Poletop luminaire assembly
and mounting hardware
Electrical components enclosure
and mounting hardware
Wire harness
(contractor supplied)*
Lightning ground equipment
(contractor supplied)*

Installation Instructions: SportsCluster Green™Lighting System
www.musco.com · [e-mail]
Before You Begin
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
5
Unloading Instructions
A typical shipment includes electrical components enclosures, crossarm assemblies, luminaire cartons, attachment hardware,
and may include wire harnesses. Unload and uncrate equipment. Stage for assembly placing all matched components and
hardware at the proper pole location as noted on Field Aiming Diagram.
Tools/Materials Needed
❑Crane or forklift
❑Hammer
❑Pry bar
❑Banding cutters
As you unload, do the following:
•Check bill of lading to verify you have all materials.
•Inspect all materials for shipping damage.
•Store electrical components enclosures in a dry location or cover with tarp until ready to install.
If you need additional information, contact your local Musco representative.
Please recycle.
Luminaires, hardware, and other components are shipped in recyclable cardboard packaging.
Electrical System Requirements
While portions of the SportsCluster Green™ lighting system can be assembled by non-professionals, a qualified electrician must
handle the electrical supply installation and hook-up in accordance with national, state, and local codes. Your electrician should
review this information before installation begins.
The electrician is generally required to provide these items:
•Service entrance
•Main power disconnect and distribution panel(s)
•Supply wiring and equipment grounding conductors
•Lightning grounding conductor and electrode, one per pole
Ensure supply wiring is rated for 90° C. Review the label inside the electrical components enclosure door and Control System
Summary for voltage and phase requirements. All entrance hubs must be rated NEMA 3R (IP44) or better.
Other features that may affect the wiring supply requirements for this project include:
•Lighting contactor cabinets — refer to the supplemental installation instructions and the Musco Control System
Summary.
•Control-Link® control system — refer to the supplemental installation instructions and Musco Control System Summary.
Always dispose of electronic waste in accordance with all applicable laws and regulations.

Installation Instructions: SportsCluster Green™Lighting System
6
www.musco.com · [e-mail]
Before You Begin
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
Documents We Provide
Field Aiming Diagram
The Field Aiming Diagram is your map for locating all poles on
your project. It gives this information:
•Pole IDs, locations, and heights
•Luminaire IDs
•Field origin for coordinate measuring
•Aiming points for each pole
•Poletop luminaire assembly mounting height
•Full load current for each luminaire
Control System Summary
Projects with a control system include a Control System
Summary. It gives this information:
•Control system diagram and details
•Contactors and cabinets
•Lighting circuits
•Voltage, phase, and frequency
•Full load current for each circuit

Installation Instructions: SportsCluster Green™Lighting System
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©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
7
Electrical Components Enclosure
Hardware Sorting
Electrical components enclosure hardware will require sorting
before assembly.
Round Poles
Item Description Quantity
(per stack)
Note
A Strap assembly 2 – 4 See strap selection table.
B Strap bracket 2 – 4
C Hanger bracket (short) 0 – 2
D Hanger bracket (tall) 1 Select hanger bracket
approximately 3 in (76 mm)
shorter than enclosure height.
Hanger bracket arm width is
14 in (356 mm).
Strap Selection
Diameter Strap Length
0 – 19 in (0 – 483 mm) 45 in (1143 mm)
19.1 – 24 in (483 – 610 mm) 60 in (1524 mm)
24.1 – 30 in (610 – 762 mm) 78 in (1981 mm)
30.1 – 36 in (762 – 914 mm) 96 in (2438 mm)
36.1 – 42 in (914 – 1067 mm) 114 in (2896 mm)
42.1 – 48 in (1067 – 1219 mm) 132 in (3353 mm)
A
C
D
B
(If present)
(If present)

Installation Instructions: SportsCluster Green™Lighting System
8
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Electrical Components Enclosure
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
Square Poles
Item Description Quantity
(per stack)
Note
A Strap assembly 2 – 4 See strap and bracket
selection table.
B Strap bracket 2 – 4
C Hanger Bracket (short) 0 – 2 See strap and bracket
selection table.
D Hanger bracket (tall) 1 Select hanger bracket
approximately 3 in (76 mm)
shorter than the enclosure
height.
See strap and bracket
selection table.
Strap and Bracket Selection
Pole Width Strap Length Bracket Arm Width
0 – 11 in (0 – 280 mm) 45 in (1143 mm) 14 in (356 mm)
11.1 – 16 in (280 – 406 mm) 45 in (1143 mm) 18.5 in (470 mm)
16.1 – 20 in (406 – 508 mm) 60 in (1524 mm) 22.5 in (572 mm)
20.1 – 24 in (508 – 610 mm) 78 in (1981 mm) 26.5 in (673 mm)
24.1 – 28 in (610 – 711 mm) 96 in (2438 mm) 14 in (356 mm)
28.1 – 32 in (711 – 813 mm) 114 in (2896 mm) 14 in (356 mm)
32.1 – 36 in (813 – 914 mm) 132 in (3353 mm) 14 in (356 mm)
A
C
D
B
(If present)
(If present)

Installation Instructions: SportsCluster Green™Lighting System
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©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
9
Installation Procedure
Verify pole ID on electrical components enclosure
matches pole location on Field Aiming Diagram. If
assembling pole on ground, determine final grade
level on pole for proper measurement.
Measure and mark hanger bracket locations on pole.
Bracket Positioning
Stacker (Upper) Box Height Dimension A
28⁄ in (724 mm) 19⁄ in (494 mm)
40⁄ in (1029 mm) 31⁄ in (799 mm)
Dimension A in chart allows for approximately 0.75 in
(20 mm) gap between upper and lower enclosures.
1
MKT-3051_E
Hanger Bracket Locations
RWS
1 June 2015
10 ft (3 m)
to ground
A
Electrical Components Enclosure
Overview
The electrical components enclosure is factory-wired and tested. It contains lamp ballasts, capacitors, fusing, and other essential
components of the lighting system in an accessible location. It is ideally mounted on the pole about 10 ft (3 m) above grade to
discourage tampering. You may mount it in another accessible location, however limitations on conductor length and size apply.
Tools/Materials Needed
Musco Supplied
❑½ and ⁄ in offset
combination wrenches
❑Snips
❑Field Aiming Diagram
Contractor Supplied
❑Torque wrench with ½ and ⁄ in sockets
❑Large Phillips-head screwdriver
❑Measuring tape
❑Marker
❑10 ft (3 m) stepladder or small line truck

Installation Instructions: SportsCluster Green™Lighting System
10
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Electrical Components Enclosure
©2015, 2016 Musco Sports Lighting, LLC · LED ECE 9 · M-1933-en04-2
Cut straps to required length. Pull tight around pole
and trim excess within 1 in (25 mm) of strap bracket.
Cut across square holes, not between them.
Attach hanger brackets to pole. Torque ⁄in strap
bracket hardware A to 12 ft•lb (16N•m) using ½in
socket and torque wrench. Torque all ⁄ in tensioning
nuts B to 20ft•lb (27N•m) using ⁄ in socket and
torque wrench.
Caution
Falling equipment hazard.
Ensure you meet torque values specified on all
tensioning hardware.
If tensioning bolt is fully seated and strap is not yet
tight, trim strap at next set of holes and repeat step 3.
2
MKT-3035_B
Hanger Bracket Strap
RWS/BD
4 Jun 2012
A
B
Tensioning
bolt
9⁄16 in
20 ft•lb
(27 N•m)
Hanger
bracket
Strap
½ in
12 ft•lb
(16 N•m)
Strap
bracket
Sketch #6
3