Jomitek Lightning Sensor Classic User manual

www.jomitek.dk
Lightning Sensor
Guide for
Design-in,
Installation,
Maintenance
Lightning sensor classic
October 2018
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Content:
Chapter 1 – Design-in:
1.1 Design-in guidelines
1.2 Drawings and measures
Chapter 2 – Installation:
2.1 Who may perform the installation?
2.2 ool requirements.
2.3 Content of a complete sensor.
2.4 Installation.
2.5 est.
2.6 Relays.
2.7 Battery maintenance
2.8 Connections
2.9 Measures
2.10 Relay output
2.11 Antenna sensitivity
Chapter 3 – Maintenance:
3.1 Battery replacement
Page 2 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Chapter 1
Design-in
1.1 Design-in guidelines
Design engineers can easily include the lightning sensor to all types of wind turbines.
All strikes that hit's a turbine construction will pass the bottom of the tower. he lower 10-15 meters of the
tower is seen as safe installation area (rolling sphere model).
For towers made of concrete material and steel wires, please contact Jomitek for special and free advise.
he 2 antennas has to be placed on opposite sides of the tower. he signal from the two antennas is
summarized in the antenna box. Any strike current that passes inside the tower or through the tower wall
will be measured by the magnetic field generated. By having the antennas 180 degrees from each other,
any strike in nearby turbines will generate a pulse that will have opposite sign in the 2 antennas and
thereby become subtracted and will then not be able to generate an alarm. his gives a design rule of
thumb:
1 Place the 2 antennas 180 degrees +/- 5 degrees from each other
he magnetic field generated will form circular field lines around the tower and flow through the
antennas. It is important that these field lines will not become disturbed so the next rule:
2 Place the antennas at a level where no other iron part will disturb the cirkle +/- 1 meter
in the horizontal plane
If something big, like a platform structure or a transformer is placed nearby, please ask Jomitek
for an evaluation of the actual placement and disturbances.
o make sure that the magnetic field lines will not induce a damaging high voltage between the
antenna wires and other metal parts the wires should:
3 Place antenna wires in a horizontal plane +/- 0,5 meters of the antenna level
As any metallic surrounded hole perpendicular to the current direction will generate a voltage
when strike passes a rule that must apply inside the tower as well as outside the tower is:
4 Antenna wires must be kept as close to the tower wall as possible and preferable within
10cm
o make sure that the summation of the antenna signals works well it is preferred that
5 The antenna wires must be approx the same length for each of the 2 antennas
Page 3 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
As the lightning sensor works on measuring the changing magnetic field :
6 It is free to use permanent magnets for mounting any parts
And finally remember that
7 Jomitek always offers free design-in assistance
Page 4 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
1 2 Drawings and measures:
Antennas:
he antenna consist of following details:
A. Antenna frame
B. Colour label Red=left, Green=right
C. Nut's and washer's
2 nuts
4 steel washers
4 nylon washers
D. Antenna wire in specified length
E. Antennna connector, SMA type
Measures
Height, h 225 mm
Width, w 135 mm
Distance, d 90 mm
Antenna bolts M12
Length bolts 40 mm
Max diameter of connector 9,5 mm
All materials suitable for harsh off-shore use.
Mounting plates available by special request.
Page 5 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Boxes:
op view Bottom view
L W H D E
Antenna box: 130 85 44 113 52
Control box: 180 85 67 163 52
he antenna box is fixed in one of 2 ways:
1. Use 4 pcs M4 self-tapping bolts in the 4 small holes underneath the box
2. Use 2 pcs M4 bolts mounted from inside the box through the 2 big holes (see picture).
Page 6 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Chapter 2
Installation
2 1 Who may perform the installation?
he Lightning Sensor is advanced electronic equipment. he sensor may therefore only be installed by
persons adequately experienced in handling such equipment. In case of need for battery replacement, only
such professional persons may open the box.
2 2 Tool requirements
1. Strong drilling equipment
2. 13mm drill
3. Round file for shaping of the holes
4. 19mm open-ended spanner
5. Lubricant for stainless steel assembly
6. Anti oxidations for protection of the drilled holes
7. Strong aluminium tape or tubes for mounting of the antenna cables
8. Strips for fixing of vertical cables
9. Adhesive or bolts for mounting of the antenna box. he box thickness is approx. 3 mm.
10. Control cable with screening (the connector is included) or it is all included in separate cable kit.
2 3 Content of a complete sensor
- 2 pcs antennas, including antenna cable
- 1 pcs. antenna box (the small box)
- 1 pcs. optical cable
- 1 pcs. control box (the big box)
- 1 pcs. connector for remote control (or complete cable)
- 1 pcs. IEC cable for AC plug
Page 7 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
2 4 Installation
Only professional and trained personal may install the lightning sensor.
Antennas
1 Find suitable places on the tower (outside) for the 2 antennas. he antennas must be mounted opposite
each other in the same height above tower button. he exact height of placement is not critical. he
most important issue is that the antennas must not be damaged by ladder's or persons. As an example,
the antennas could be placed 1-2 meters above entrance door top level. It is very important, that both
antennas are mounted having the plastic ring pointing upwards and it is also very important that the
antennas are placed exactly diagonally across each other.
2
The antennas must have the plastic rings at the upward end See the drawing
below
3 Drill 2 holes for each antenna. he 2 holes must be drilled vertically with a centre distance of 90,0mm.
he drill size is minimum 12 mm, but due to tolerances of the material and the drilling process a hole
size of 13 mm is recommended.
4 Remove the burr at the holes with a round file.
5 Protect the holes against oxidations.
6 If needed, use 2 thin (fishing line) wires out through the holes. Connect the wires to the antenna legs
and drag the antennas carefully into position.
7 Remember to use stainless steel lubricant on the bolts and nuts before assembly. If not used there will
be a high risk of cold welding of bolt and not assembly. It is recommended to use a maximum torque
of 35NM due to the nylon washers.
8 Mount the antenna cable horizontally along the tower wall. You may use aluminium tape (3M) or
tubes.
Page of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Antenna box
9 he antenna box (the small box) must be mounted exactly in the middle between the 2 antennas, inside
the tower, and in approx. the same height. he connectors must point downwards.
10 Connect the antenna cables. he minimum bending radius is 5cm.
11 Connect the optical cable. Be careful not to bend the optical cable too much during installation. he
minimum bending radius is 5 cm. Make sure that the cable is fixed so that there is no pull force on the
optical connector.
Control box
12 he control box may be placed, where it is most appropriate. All connectors should point downwards.
13 Connect the optical cable and the mains IEC cable. Make sure that the mains IEC connector cannot
drop out due to vibrations.
14 Connect the control cable as shown later in this guide.
Page 9 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
2 5 Testing
If test of the complete system is required after final mounting on the turbine, special test equipment is
needed. est equipment is not a part of the lightning sensor itself.
esting may only be performed by trained personnel.
1. An electrical field is applied on one of the antennas.
2. Check that the LED for lightning is lit up and that the relay is activated.
3. Reset the lightning signal from the sensor by pressing the 2 from panel buttons at the same time in
approx. 10 sec. until the diode switches off again and the relay deactivates.
4. Repeat the test using reverse polarity on the antenna.
5. Repeat the above tests on the other antenna
6. Repeat the test with the mains supply switched off during the lightning field pulse on the antennas.
Page 10 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
2 6 Relays
From factory the output relays are switched on during normal operation (no lightning). he relay positions
during normal operation can be altered. Please see instruction later in this guide.
2 7 Battery maintenance
he expected lifetime of the battery is 10 years. he life time will be shortened dramatically during days
without mains supply. he battery may be exchanged with a corresponding 3,7V Lithium battery, if the
supervision circuit in the sensor signals power failure. Please observe that also errors on the mains supply
will give a power failure signal.
he power failure circuit will not give any alarm if the battery is disconnected.
he battery is NO connected from factory. When the battery is connected, make sure that the mains
supply is up.
Page 11 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
2 8 Connections
he control-cable must be connected to the control box, using the connector delivered ( ype C 091 D,
IEC130-9, and IP67):
Only screened cable may be used for the control cable.
he connector has to be assembled as follow:
Pin 1 and 2: Power-error relay
Pin 3 and 6: Reset of lightning relay (pin 3 = minus at DC)
Pin 4 and 5: lightning relay
Pin 1 white, pin 2 brown Power failure
Pin 3 green, pin 6 yellow Reset
Pin 4 grey, pin 5 pink Lightning strike
Shield must be connected to the connector housing through the clamp.
Connector seen from soldering side.
Page 12 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Recommendations for Control box cables:
Cable specification signal cable:
LIYCY, 3x2x0,25, twisted pair shielded. Outer diameter approx. 7mm.
Color code according to DIN 47100,
Operating temperature: -30 - +80 degree C
Flame retardant to IEC60332-1
esting voltage 1200V
Peak operating voltage 300V
Cable specification 230V cable:
Rated voltage 300/500V
H05VV-F 3x0,75
Color coding: brown(Phase), blue(Neutral), yellow/green(Earth)
Operating temperature: -30 - +60 degree C
Free wire ends: 2-3 cm.
Page 13 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
2 9 Measures
For more measures, please see chapter 1.
Page 14 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Antenna measures:
Bolt length may be 40, 50 or 80 mm.
he bolt tubes may be with 90 degree angle to the antenna.
See the Design-in chapter for specific measures
2 10 Relay output:
he relay configuration in the control box is placed inside the box and only requires a small flat
screwdriver for change of configuration.
Page 15 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
he connections on the 8-input cage clamp are:
Power failure:
leg 1 – erra
leg 2 - errab
leg 3 – errb (short circuit to errab during normal operation)
Lightning relay output:
leg 4 - outa (short circuit to outab during normal operation)
leg 5 - outab
leg 6 - outb
Reset:
leg 7 - reset
leg 8 - reset gnd
Power failure is changed by moving the wire on the top level PCB from ‘errb’ to ‘erra’ or vice versa
(factory connection is ‘errb’).
he lightning signal is changed by moving the wire on the top level PCB from ‘outa’ to ‘outb’ or vice
versa (factory connection is ‘outa’).
Page 16 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
he sensitivity may be adjusted by placing small wire jumpers into the cage clamp inside the antenna box.
Jumper settings:
Numbering from right to left 1 to 10
Level 1 (1kA): 10-1
Level 2 (2kA): 10-3, 2-1
Level 3 (4kA): 10-7, 6-5, 4-1
Level 4 (8kA): 10-9, 8-7, 6-5, 4-1
Page 1 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Chapter 3
Maintenance
It is recommended that the battery is exchange minimum every 10 years or if the turbine has been off
mains power for more than 3 weeks.
Introduction to battery maintenance
he expected lifetime of the battery is 10 years. he life time will be shortened dramatically during days
without mains supply. he battery may be exchanged with a corresponding 3,7V Lithium battery, if the
supervision circuit in the sensor indicates power
failure. Please observe that also errors on the mains supply will give a power failure signal.
he power failure circuit will not give any alarm if the battery is disconnected.
he battery is NO connected from factory. When the battery is connected, make sure that the mains
supply is up.
Tools required
Page 19 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72

www.jomitek.dk
Battery Exchange Guide
1.
Unplug the 230V supply.
Open the Lightning Sensor Control box by loosening the 4 top screws. Start the unscrewing by loosening
slightly all 4 before the final unscrewwing of the top.
2.
Carefully loosen the top and be careful about the ribbon cable that connects the fronpanel.
Slide the top of the box left as shown on the right picture.
Page 20 of 24
Jomitek ApS – Electrical Engineering
Skovlytoften 22, DK-2 40 Holte 

 Tel. [phone] 

 Fax [phone] 

 CVR-nr. 20 01 99 72