Lightning Protection International Guardian System 5 User manual

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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
ABN 11 099 190 897
www.lpi.com.au
Guardian Install Manual V12.indd 1 22/9/08 4:25:18 PM

GUARDIAN SYSTEM 5 INSTALLATION MANUAL
As a result of continuing research and product development in the area of lightning and
lightning protection, LPI reserves the right to alter any detail contained within at any
time without notice.
Prior to installation of the Guardian System 5, installers should check with LPI or an
authorised distributor to conrm they have the most recent version of the Guardian
System 5 Installation manual.
It should be noted that 100% (100 percent) protection level for direct lightning strikes
is not possible and cannot be provided due to the lightning discharge process being a
natural atmospheric event.
Guardian System 5 Lightning Protection System
System Owner:_____________________________________________________
Date Installed:_____________________________________________________
Installation Contractor:______________________________________________
Supplied by:_______________________________________________________
Location of Installation:____________________________________________
Lightning Protection International Pty Ltd
ABN 11 099 190 897
PO Box 379 Kingston, Tasmania, Australia 7051
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.lpi.com.au
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI1
Lightning Protection International Pty Ltd
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2 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
Contents
Warranty 3
Lightning Protection 3
General Safety Guidelines 4
Recommended Installation Method 4
Checking Lightning Protection
Components Supplied 12
LPI Guardian System 5 Installation 12
Installation of the Lightning Earth 13
Ground Resistance Lowering Compounds 15
Bonding the Lightning Earth 15
Labelling 15
Installation of the HVSC Downconductor 15
Hauling the HVSC Downconductor 16
HVSC Downconductor Clearance Holes 18
Routing 18
Fixing of the HVSC Downconductor 20
Installation of Conventional
Downconductors 20
Installation of Guardian CAT GI Terminal
to threaded pipe 22
Termination of the HVSC Lower End 24
Lower Termination of Conventional
Downconductor to the Lightning Earth 27
Termination of the HVSC Upper End 28
Connection of Factory Pre-Terminated HVSC
(Upper End) to Guardian CAT Terminal 34
Labelling 34
Masts 35
Types of Mast Configurations 35
Mast Bases 36
Mast Couplings and Guying Points 37
Guying 38
Preparation for raising the Mast into
position 39
Raising of Mast 39
Lightning Strike Recorder (LSR1) 41
Certification 43
Operation and Maintenance 43
Testing the Guardian CAT Terminal 44
Testing the Lightning Earth and the
HVSC Downconductor 45
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI3
Warranty
LPI’s Guardian System 5 Lightning Protection System is guaranteed against defects in materials
and workmanship for a period of 5 years from the original sales date when it was purchased
from LPI or one of its authorised distributors.
The warranty is limited to the ex factory cost of replacement of equipment providing it has been
installed and or certied by LPI or its distributor. All other costs such as freight, re-installation,
loss of prot, insurance premiums are not included.
Responsibility for other direct or indirect damages or death is also specically excluded from
the warranty.
The range of Guardian CAT terminals (or to our knowledge any other lightning protection
system) cannot provide 100% protection and therefore it is not inferred.
As conrmation of the above paragraph we refer to Australian Standard AS 1768 (2007).
Lightning Protection
Comments on the Australian Standard AS 1768 (2007).
We refer to the standard where it states that it provides authoritative guidance of a general
nature only and it is not intended to become a mandatory set of regulations.
In general, it is not economically possible to provide total protection against all the possible
damaging effects for lightning, but the recommendations in this standard will reduce the
probability of damage to a calculated acceptable level and will minimise any lightning damage
that does occur.
Thunderstorms are natural phenomena and there are no proven devices and methods capable
of preventing lightning ashes. Direct and nearby cloud-to-ground lightning discharges
can be hazardous to persons, structures, installations and many other things in or on them.
Consideration should always be given to the application of lightning protection measures.
Users are warned that direct strike lightning protection is only one aspect of the overall
protection strategy required for comprehensive structural, personnel and equipment safety.
Correctly designed and installed low impedance earthing, elimination of earth loops, systems
engineering, surge protection on power lines and transient protection of communications, data
and telephone lines are also essential.
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4 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
Figure 1.
• Ensure safe working environments and practices to local codes.
• Use of personal protective equipment during installation.
• Use mechanical methods of raising and installing masts over 6m.
• Cordon off area below installation point.
• Check for overhead powerlines or any other obstructions before lifting or raising.
• Ensure enough man power to safely conduct all aspects of installation.
• The installation must conform to all relevant local standards and regulations.
Recommended Installation Method
General Safety Guidelines
To assist in the installation of the Guardian CAT terminal and accessories, refer to drawings
CTA-01, CTA-02, CTA-03, CTA-04, CTA-05, CTA-06 and HVC-1 as illustrated on pages 5 to 11.
1. Installation of the lightning earth.
2. Installation of the HVSC Downconductor.
3. Lower termination of the HVSC Downconductor and connection to the lightning earth.
4. Upper termination of the HVSC Downconductor and connection to the Guardian CAT
terminal.
5. Preparation and raising of the mast into position.
The LPI Guardian CAT Terminal should only be installed during storm free periods.
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI5
LPI GUARDIAN CAT TERMINAL
LPI UPPER TERMINATION KIT
LPI FRP SUPPORT MAST
LPI INLINE COUPLING
LPI GUY KIT
LPI CABLE TIES
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LOWER MAST ASSEMBLY WITH BASE
LPI SADDLES AND FIXINGS
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LIGHTNING STRIKE RECORDER
LPI LOWER TERMINATION KIT
LPI INSPECTION PIT
LPI EARTHING SYSTEM
LPI GROUND
RESISTANCE
IMPROVEMENT
POWDER
BUILDING
IMPORTANT:
Guardian CAT terminal to
be a minimum of 2
metres above the highest
point of the building.
Recommended clearance
height = 5 metres.
ORDERING CODE: CAT I-G
CAT II-G
CAT III-G
ORDERING CODE: UTERMKIT-Mk2
ORDERING CODE: ILCOUPLING
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
FRP-4.6M
ORDERING CODE: GUYKIT-4M
GUYKIT-4M-SS
GUYKIT-7M
GUYKIT-7M-SS
ORDERING CODE: S/S-CABTIES-STD
S/S-CABTIES-LONG
ORDERING CODE: HVSC-PM
ORDERING CODE: ALUMB-3M
ALUMB-4M
ALUMB-5M
ALUMB-6M
ORDERING CODE: SAD/FIX
ORDERING CODE: LSR1
ORDERING CODE: LTERMKIT
ORDERING CODE: EPIT-P
ORDERING CODE: GRIP-10
EPIT-C
TYPICAL PRODUCTS REQUIRED FOR RADIAL LP EARTH
4 X CBER458
4 X RTC1625A
1 X EPIT-P
1 X GRIP-10
30 X CT253
Lightning Protection International Pty Ltd
Drawn
Date
Scale
Title
File
Version
CTA-01
Guardian CAT terminal assembly
component details
CAT Installation Type 1.dwg
NTS
9/4/2008
John Davey V1.00
Figure 2.
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6 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
LPI GUARDIAN CAT TERMINAL
LPI UPPER TERMINATION KIT
LPI FRP SUPPORT MAST
LPI CABLE TIES
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LOWER MAST ASSEMBLY
LPI SADDLES FOR CANTILEVERING MAST
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LIGHTNING STRIKE RECORDER
LPI LOWER
TERMINATION KIT
LPI INSPECTION PIT
LPI EARTHING SYSTEM
EXISTING STRUCTURE
LPI GROUND RESISTANCE IMPROVEMENT POWDER
IMPORTANT:
One third of the mast height
must be securely fixed to the
structure.
Guardian CAT terminal to be a
minimum of 2 metres above the
highest point of the building.
Recommended clearance
height = 5 metres.
LPI SADDLES AND FIXINGS
ORDERING CODE: CAT I-G
CAT II-G
CAT III-G
ORDERING CODE: UTERMKIT-Mk2
ORDERING CODE: ILCOUPLING
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
FRP-4.6M
ORDERING CODE: S/S-CABTIES-STD
S/S-CABTIES-LONG
ORDERING CODE: HVSC-PM
ORDERING CODE: ALUM-3M
ALUM-4M
ALUM-5M
ALUM-6M
ORDERING CODE: CANTSAD
ORDERING CODE: LSR1
ORDERING CODE: LTERMKIT
ORDERING CODE:EPIT-P
ORDERING CODE: GRIP-10
EPIT-C
TYPICAL PRODUCTS REQUIRED FOR
RADIAL LP EARTH
4 X CBER458
4 X RTC1625A
1 X EPIT-P
1 X GRIP-10
30 X CT253
ORDERING CODE: SAD/FIX
LPI INLINE COUPLING
(3 PER SET)
Lightning Protection International Pty Ltd
Drawn
Date
Scale
Title
File
Version
CTA-02
Guardian CAT terminal assembly
component details
CAT Installation Type 2.dwg
NTS
9/4/2008
John Davey V1.00
Figure 3.
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI7
LPI GUARDIAN CAT TERMINAL
LPI UPPER TERMINATION KIT
LPI FRP SUPPORT MAST
LPI CABLE TIES
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LOWER MAST ASSEMBLY
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LIGHTNING STRIKE RECORDER
LPI LOWER TERMINATION KIT
LPI INSPECTION PIT
LPI EARTHING SYSTEM
TYPICAL TOWER
LPI GROUND RESISTANCE IMPROVEMENT POWDER
IMPORTANT:
One third of the mast height
must be securely fixed to the
structure.
Guardian CAT terminal to be
a minimum of 2 metres
above the highest point of
the building.
Recommended clearance
height = 5 metres.
LPI BEAM AND CLAMP
SUPPORT
LPI U-BOLT
ORDERING CODE: CAT I-G
CAT II-G
CAT III-G
ORDERING CODE: UTERMKIT-Mk2
ORDERING CODE:ILCOUPLING
ORDERING CODE:FRP-2M
FRP-3M
FRP-4M
FRP-4.6M
ORDERING CODE: S/S-CABTIES-STD
S/S-CABTIES-LONG
ORDERING CODE:HVSC-PM
ORDERING CODE: ALUM-3M
ALUM-4M
ALUM-5M
ALUM-6M
ORDERING CODE: U-BOLT
ORDERING CODE: LSR1
ORDERING CODE: LTERMKIT
ORDERING CODE:EPIT-P
ORDERING CODE: GRIP-10
EPIT-C
TYPICAL PRODUCTS REQUIRED FOR
RADIAL LP EARTH
4 X CBER458
4 X RTC1625A
1 X EPIT-P
1 X GRIP-10
30 X CT253
ORDERING CODE: BEAM CLAMP/CABLE
SUPPORT-HSVC
LPI INLINE COUPLING
(2 PER SET)
Lightning Protection International Pty Ltd
Drawn
Date
Scale
Title
File
Version
CTA-03
Guardian CAT terminal assembly
component details
CAT Installation Type 3.dwg
NTS
8/4/2008
John Davey V1.00
Figure 4.
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8 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
LPI GUARDIAN CAT TERMINAL
LPI UPPER TERMINATION KIT
LPI FRP SUPPORT MAST
LPI CABLE TIES
LPI HIGH VOLTAGE SHIELDED CABLE
LPI LOWER MAST ASSEMBLY
WITH BASE
LPI LIGHTNING STRIKE RECORDER
LPI LOWER TERMINATION KIT
LPI INSPECTION PIT
LPI EARTHING SYSTEM
LPI GROUND RESISTANCE IMPROVEMENT POWDER
IMPORTANT:
Guardian CAT terminal to be a minimum of 2 metres
above the highest point of the building.
Recommended clearance height = 5 metres.
LPI GUY RING
LPI GUY KIT
DO NOT OVER TENSION GUY
WIRES (SLIGHTLY SAGGING)
GUY WHERE
NECESSARY
PREFERRED ANGLE 60-45
DEGREES
60-45
ORDERING CODE: CAT I-G
CAT II-G
CAT III-G
ORDERING CODE: UTERMKIT-Mk2
ORDERING CODE:ILCOUPLING
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
FRP-4.6M
ORDERING CODE:S/S-CABTIES-STD
S/S-CABTIES-LONG
ORDERING CODE:HVSC-PM
ORDERING CODE: ALUMB-3M
ALUMB-4M
ALUMB-5M
ALUMB-6M
ORDERING CODE:GUYKIT-4M
ORDERING CODE:LSR1
ORDERING CODE: LTERMKIT
ORDERING CODE: EPIT-P
ORDERING CODE: GRIP-10
EPIT-C
TYPICAL PRODUCTS REQUIRED FOR RADIAL
LP EARTH
4 X CBER458
4 X RTC1625A
1 X EPIT-P
1 X GRIP-10
30 X CT253
ORDERING CODE:GUY RING
GUYKIT-7M
GUYKIT-4M-SS
GUYKIT-7M-SS
LPI INLINE COUPLING
Lightning Protection International Pty Ltd
Drawn
Date
Scale
Title
File
Version
CTA-04
Guardian CAT terminal assembly
component details
CAT Installation Type 4.dwg
NTS
9/4/2008
John Davey V1.00
Figure 5.
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI9
LPI GUARDIAN CAT TERMINAL
THREADED GI ADAPTOR (FEMALE
THREAD 2 INCH BSP)
LPI SADDLES FOR
CANTILEVERING MAST
MAST ASSEMBLY WITH GI ADAPTOR
SUITABLE MOUNTING SADDLES
IMPORTANT:
One third of the mast height must be
securely fixed to the structure.
Guardian CAT terminal to be a minimum
of 2 metres above the highest point of
the building.
Recommended clearance height = 5
metres.
BASE OF MAST PIPE
EXISTING
STRUCTURE
MOUNTING BOLTS &
STAINLESS STEEL WASHERS
COMPRESSION LUG
COPPER CABLE
ORDERING CODE: CAT IGI-G
CAT IIGI-G
CAT IIIGI-G
ORDERING CODE: CATGI-ADPT
ORDERING CODE: ALUM3M-MGI
ALUM4M-MGI
ALUM5M-MGI
ALUM6M-MGI
ORDERING CODE: CANTSAD (3 PER SET)
Lightning Protection International Pty Ltd
Drawn
Date
Scale
Title
File
Version
CTA-05
Guardian CAT terminal assembly
component details
CAT Installation Type 5.dwg
NTS
28/7/2008
John Davey V1.01
Figure 6.
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10 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
Figure 7.
LPI GUARDIAN CAT TERMINAL
THREADED GI ADAPTOR
(FEMALE THREAD 2 INCH BSP)
MAST ASSEMBLY AND BASE
WITH GI ADAPTOR
LPI GUY KIT ORDERING CODE:
GUYKIT-4M
GUYKIT-4M-SS
GUYKIT-7M
GUYKIT-7M-SS
IMPORTANT:
GUARDIAN CAT terminal to be a minimum of 2 metres above the highest
point of the building.
Recommended clearance height = 5 metres.
BASE OF MAST PIPE
EXISTING
STRUCTURE
MOUNTING BOLTS &
STAINLESS STEEL
WASHERS
COPPER TAPE
ORDERING CODE: CAT I-GI
ORDERING CODE:CATGI-ADPT
ORDERING CODE: ALUMB3M-MGI
ALUMB4M-MGI
CAT II-GI
CAT III-GI
ALUMB5M-MGI
ALUMB6M-MGI
COPPER TAPE (OR COPPER CABLE)
DC TAPE CLIPS
Lightning Protection International Pty Ltd
Drawn
Date
Scale
Title
File
Version
CTA-06
Guardian CAT terminal assembly
component details
CAT Installation Type 6.dwg
NTS
20/8/2008
John Davey V1.00
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI11
Figure 8.
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12 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
Checking Lightning Protection Components
Supplied
The Guardian System 5 components received should be checked against the “Bill of materials”
for loss during shipping and for damage.
Check the following:
Terminal (s)
• Terminals have not been dented or damaged in any way during transit.
• Instructions, Warning Labels, Warranty, Test Certicate and relevant mast base components
supplied.
Downconductor(s)
• The HVSC cable drum (if supplied) is not damaged.
• The correct HVSC length(s) have been supplied.
• No obvious damage to the HVSC cable.
• If a factory completed upper termination is supplied, check to see that the termination is
not damaged and conrm inside or outside termination(s).
• Order of lengths and quantities of HVSC (if multiple lengths on one drum), will be shown
on the side of the Cable Drum(s).
All site and safety requirements must be followed during the installation of the LPI Guardian
System 5.
The correct order of installation is as follows:
1. Installation of the lightning earth.
2. Installation of the HVSC downconductor.
3. Lower termination of the HVSC downconductor and connection to the lightning earth.
4. Upper termination the HVSC downconductor and connection to the Guardian CAT terminal.
5. Preparation and raising of the mast into position.
LPI Guardian System 5 Installation
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI13
LPIGuardianSystem5shouldonlybeinstalledduringstorm-freeperiods.
If the Guardian CAT terminal needs to be raised prior to connection to the lightning earth or
immediate connection is not possible then connect the lower end of the downconductor to
structural steel reinforcing or other suitable earth point.
Installation of the Lightning Earth
Before installation of the lightning protection earth, consult site drawings of underground
services so that these are not damaged during installation of the earthing system.
Figure 9.
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14 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
Earth DC resistance (typically ‹10 ohms) and impedance (typically ‹30 ohms) is required for
successful operation of LPI Guardian System 5.
LPI recommends the installation of a radial lightning earth as shown in gure 9.
• Recommended to install a 3 x 10 metre length radial trench.
• Each radial should consist of a trench (Approx: 500mm Deep x 200mm wide x 10m length).
• An earth rod should be driven at the end of each trench.
• All rods should be interconnected through the use of 25mm x 3mm copper tape. The use of
earth rod clamps to x the tape to rods is recommended.
• Use waterproong mastic on all mechanical connections.
• The application of earth enhancing compounds such as LPI RESLO and GRIP assists to
reduce soil resistivity to the recommended level of less than 10 ohms.
• An earth pit should be installed where the end of the downconductor terminates to the
lightning earth as shown in gure 9. This gives an access point for disconnection
and future testing.
• Do not lower terminate (connect) the downconductor to the earthing system at this point in
time.
Note: If due to space constraints it is not possible to install a radial earth as recommended,
consult with LPI or an authorised distributor for further advice.
When using earth rods:
• Use driving heads to prevent mushrooming on top of rod.
• Use driving heads when using coupled rods.
• Use a post or picket driver.
Recommendations for bonding the earthing system components are listed below:
• The use of the EXOWELD exothermic welding process is a safe and efcient way of
providing a permanent connection between conductors. EXOWELD connections will not
corrode or rust with age.
• DO NOT use aluminium lugs or couplings.
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI15
Ground Resistance Lowering Compounds
• Ground resistance lowering compounds (such as LPI RESLO and GRIP) are supplied when
the existing soil mass has a high resistivity.
• Using the compounds can lower earth resistance/impedance.
• Compounds will require water and a mixing container.
• Follow all installation and safety instructions as supplied with products when applying the
compounds.
Bonding the Lightning Earth
Where separate earths exist eg. Structure, Power, Communications and Lightning Protection,
they need to be bonded to form an equipotential ground plane. This will stop ground loops and
potential differences arising under transient conditions.
Before bonding of these earths takes place, make sure proper authorisation is gained.
Bonding cable must be 70mm2 (2/0 AWG) minimum depending on local standards. It may be
necessary to use a Transient Earth Clamp (TEC 100) which bonds all earths to the same potential
under transient conditions.
For further information, it is advisable that local applicable standards are used, ie. IEC 61024-1,
BS 6551, AS1768-2007, NFPA 780, C22.1-98 and NEC.
Labelling
It is the responsibility of the customer/installer to label earth pits or earthing systems to local
requirements.
Installation of the HVSC Downconductor
If installing LPI HVSC, the HVSC downconductors(s) may have had the upper terminations
completed at a pre-specied end of the cable by the LPI factory before being shipped.
When removing HVSC downconductor packaging, do not use a knife or cut in any way as this can
damage the outer layer of termination.
LPI’s HVSC has an outer layer which is approximately 2mm (1/16in.) thick. Be careful not to
damage this layer.
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16 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
Hauling the HVSC Downconductor
Place the HVSC downconductor cable drum close to where it is to be installed.
• Make sure that the cable drum is in a servicable condition.
• Check that the correct length of HVSC downconductor has been supplied. The length of
HVSC will be marked on the drum.
• If the HVSC downconductor has been upper terminated on the outside of the drum, then
the HVSC downconductor will need to be hauled up the structure with the drum staying on
the ground.
Figure 10.
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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI17
Figure 11.
• If the HVSC downconductor has been upper terminated on the inside of the drum, then
the drum has to be taken to the top or near the top of the structure, then the HVSC
downconductor can be hauled downwards from the drum to the ground.
• Any lifting slings or ropes must be securely attached.
• DO NOT haul the HVSC downconductor from the termination, see Figure 11.
• Protect the HVSC downconductor at all times when it is being moved.
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18 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI
HVSC Downconductor clearance holes
Before running the HVSC downconductor through any clearance holes, ensure that:
• A minimum hole diameter of 60mm (2 3/8”) is used.
• Enough protection is provided so that the HVSC downconductor is not damaged during or
after installation.
• A waterproong sealant or sealing gland should be used if the hole needs to be
weatherproof.
Routing
The routing of the HVSC downconductor needs to follow these guidelines:
• The route of the HVSC downconductor should be as set out in the original design. Ensure
no structural changes such as new antenna or mast installations, air conditioning
towers or ducting has been installed.
• DO NOT double the HVSC downconductor back against itself after changes of direction, ie.
180°.
• The HVSC downconductor may be installed internally or externally on the structure.
• The HVSC downconductor should be installed as close (ush) as possible to the structure.
• Minimise the number of bends and use the most direct route to ground.
• Minimise strain on the HVSC downconductor.
• Ensure minimum bend radius maintained ›500mm (20in.).
• Parallel routing with other services – Minimum separation = 2m. See Figure 12 on page 19.
• If the HVSC downconductor has to cross other services make sure it crosses at right angles
using a conduit that extends at least 1m past either side of the existing service.
• The lower end of the HVSC downconductor must terminate close to the initial injection
point of the lightning earth.
• Be sure to allow for enough slack in the HVSC at the top end for connection to the Guardian
CAT Terminal and the raising of the mast.
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