Wiring standards, ferrules, colors, and testing.
Clean wiring accelerates fault-finding and approvals. Define conductor types/gauges, ferrule/numbering and color codes, loom/routing practices, and separation/shielding for EMC (347, 515). Standardize terminal labels and earthing/bonding, then embed inspection/test forms and required photo records for the ITP (714) and submission packs (938). These rules protect uptime for crash rated bollard sites in harsh climates (337). Include one-sentence context that naturally links upward to the parent hubs (this section and the chapter hub). Add SIRA context with a link to SIRA Bollards (UAE) when relevant. Link installation pages only if helpful: What to Expect and Installation Guide.
Important: This is a general guide. For live projects we develop a tailored
Method Statement & Risk Assessment (MS/RA) and align with authority approvals (e.g., SIRA) where in scope.
527.1 Wire types & gauges
Specify heat/UV-rated conductors (337). Proper wire sustains HVM bollard panels.
Choose conductor insulation and temperature class to match enclosure conditions from hot-climate design (337). In motor/solenoid circuits, size cross-sections for voltage-drop and inrush; for controls, follow your I/O list tag types and specify SELV/PELV where required.
In hydraulic lanes, consider cable jackets resistant to oil mist and sand abrasion; for outdoor pulls use UV-stable LSZH where local code permits. Record cable type in the Cable & Routing schedule (515) and cross-reference terminations in Enclosure Layout & Access (528).
| Aspect | What matters | Where to verify |
|---|---|---|
| Thermal rating | Conductor & insulation class vs enclosure heat | Enclosure heat-load estimator |
| Volt-drop | Cross-section vs run length & duty | Volt-drop calculator |
527.2 Ferrules & numbering
Use printed ferrules and consistent schemes. Numbering speeds crash rated bollard service.
Adopt machine-printed ferrules for all control and power cores. Tie the ferrule text to the tag in your I/O list template (523) and the terminal mapping sheet. For multi-core cables, include cable ID + core number (e.g., CB12-07) and mirror at both ends.
Reserve ranges by subsystem (power, safety, field devices) so future upgrades don’t collide. Enforce QC: a ferrule mis-print is a documented NCR and is reworked before the SAT witness (638).
527.3 Color codes
Adopt clear DC/AC/safety colors. Codes prevent HVM bollard errors.
Use a consistent color policy (e.g., green/yellow for PE, blue for neutral in AC, brown/black/grey for phases, and distinct colors for DC+ and DC-). For safety circuits and safety relays, set a contrasting sheath color and apply red ferrule backgrounds for emergency chains. Document the palette in the Integration Documentation pack (539) to keep third-party works aligned.
Where local codes differ, add a “legacy mapping” table inside the door card so maintenance teams can translate old colors to the new standard without mistakes.
527.4 Looming & routing
Neat looms, segregated paths (347). Routing reduces crash rated bollard EMI.
Route looms with service loops, drip loops, and strain relief at device entries; avoid tight radii. Keep power, motor, and encoder runs separate; cross at 90° when paths must meet. Use markers on trunking and DIN rails to show subsystem zones for rapid fault tracing during Power-On & Controls Health (632).
In doorways, protect looms with grommet plates or cable glands and specify an IP-rated gland plate. Reference Cables & Routing (515) for ducting and draw-pit tie-ins.
527.5 Separation & shielding
Distance and shields for noisy runs (515). Separation protects HVM bollard sensors.
Apply minimum clearances between noisy (VFD, motor, HPU contactor) and sensitive (loops, encoders, photo-eyes) circuits. Use twisted, shielded pairs for low-level signals and bond shields at one designated end to a clean reference.
Where VFDs are used for electromechanical drives (513), specify EMC-rated glands and filters; add ferrites only as last resort after measuring. Capture the rule set in the project’s EMC plan and verify during Loop & Sensor Proving (633).
527.6 Terminal labeling
Legible, durable markers (528). Labels aid crash rated bollard troubleshooting.
Use engraved or UV-stable terminal strips and device labels. The terminal ID must match the terminal mapping and the wiring diagrams. Add arrow markers for feed direction and keep a laminated legend inside the door.
For field terminations, show torque values and test points on the label or adjacent tag to speed interlock verification (634) and reduce rework.
527.7 Earthing/bonding
Bond doors, DIN, and sleeves (514). Earthing protects HVM bollard users.
Provide a dedicated PE bar; bond door, back-pan, DIN rails, and all gland plates with verified continuity. For outdoor HPUs and panels, ensure a low-impedance bond to the site earthing network per Electrical Supply & Protection (514). Label the bond points and test with results recorded in the ITP.
Where interface devices (e.g., loops) are remote, specify RCD/RCBO policies and surge protection; document earthing type (TN/TT) and include a simple schematic on the door card for maintenance teams.
527.8 Inspection/test forms
Standard forms in the ITP (714). Forms prove crash rated bollard quality.
Create panel-specific checklists: ferrule scheme, color compliance, torque, continuity, insulation resistance, shield terminations, and device function checks. Include a section for corrective actions and re-test. File the signed sheets under the project’s ITP (714) and reference them in the Submission-Pack Guidance (938).
Align the sequence with Power-On & Controls Health (632) → Loop & Sensor Proving (633) → Interlock Matrix Verification (634).
527.9 Photo records
Before/after panel shots (716, 938). Photos give HVM bollard traceability.
Capture wide→detail sets: overall enclosure, PE bar, terminal rows, device labels, cable entries, and each subsystem loom. Take “before close” and “after corrections” shots, then store in the Photo/Redline Logbook (937) with filenames matching the File Index & Naming Rules (911).
For UAE authority submissions, include a compact photo index in the submission pack (938) and add a SIRA-specific note where applicable, linking to the SIRA Bollards (UAE) hub.
Related
External resources
- NPSA — HVM guidance (design assurance context)
- ASTM F2656 — Crash testing overview (system dependencies)
- BSI — VSB impact test specifications (terminology)
527 Panel Wiring Standards — FAQ
What wire colors should I use for AC, DC, and safety circuits in HVM panels?
Use a consistent scheme: green/yellow for PE, blue for AC neutral, brown/black/grey for AC phases, and dedicated contrasting colors for DC+ and DC−. Give safety circuits a clearly distinguishable sheath or marker, and document the palette on the door card and in Integration Documentation.
How do ferrules and numbering link to the I/O list and terminal mapping?
Ferrule text mirrors each tag in the I/O list (e.g., LS-PE1, ENC-A), plus cable ID/core. The terminal mapping table shows exactly where the tag lands (panel/row/position). Both ends must match, and any change triggers an update to the I/O list and a reprint of ferrules.
What separation rules prevent EMC issues with loops and encoders?
Keep noisy runs (VFD, motor, contactor) physically distant from sensitive circuits (loops, encoders, photo-eyes). Cross at 90°, use twisted/shielded pairs, bond shields at one designated end, and install EMC glands/filters at VFDs. Verify during Loop & Sensor Proving.
Which test records and photos should be in the ITP and submission pack?
Include torque, continuity, insulation resistance, shield termination checks, color/ferrule compliance, and functional tests. Add wide→detail photo sets (overall, PE bar, terminal rows, cable entries, device labels). File in the ITP and index them in the submission pack for approvals.