Lightning Protection International Stormaster ESE Installation Manual

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Stormaster Install, lắp đặt kim thu sét ESE, Stormaster ESE Installation,
Installation Stormaster ESE
Stormaster ESE
Installation Manual
www.banhay.com; [email protected]; Hotline 24/7: 0986 219 626 - 0903 070 686Stormaster-ESE-15,
Stormater-ESE-15-GI, Stormaster ESE 15, Stormater ESE 15 GI, Stormaster ESE15, Stormater ESE15 GI, ESE
15, ESE 15 GI, ESE-15, ESE-15-GI, LPI Stormaster-ESE-15, LPI Stormater-ESE-15-GI, LPI Stormaster ESE-15,
Stormater ESE-15-GI
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
ABN 11 099 190 897
Web: www.lpi.com.au
Email: [email protected]
STORMASTER ESE 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 Stormaster ESE system, installers should check with
LPI or an authorised distributor to confirm they have the most recent version of
the Stormaster ESE 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.
Stormaster ESE Lightning Protection System
System Owner:___________________________________________
Date Installed:___________________________________________
Installation Contractor:____________________________________
Supplied by:_____________________________________________
Location of Installation:____________________________________
Lightning Protection International Pty Ltd
ABN 11 099 190 897
Complex #1, 16 Mertonvale Circuit, Kingston,
Tasmania, Australia, 7050
Phone: +61 3 62271955
Fax:
+61 3 62291900
Email: [email protected]
Web:
www.lpi.com.au
Stormaster ESE
Installation Manual
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
ABN 11 099 190 897
Web:
Email:
www.lpi.com.au
[email protected]
1
Contents
Protection Performance
3
Routing
19
Warranty
4
Fixing the HVSC Downconductor
21
Lightning Protection
4
Recommended Order of Installation
5
Installation of Conventional
Downconductors
21
Quick Installation Guide
5
Step 1.
Installation of the Lightning Earth
Installation of Stormaster GI Terminal
to threaded pipe
22
5
Termination of the HVSC Lower End
24
5
Lower Termination of Conventional
Downconductor to the Lightning Earth
27
Termination of the HVSC Upper End
27
Connection of Factory Pre-Terminated
HVSC (Upper End) to Stormaster
Terminal
31
Labelling
31
Masts
32
Types of Mast Configurations
32
Mast Bases
33
Mast Couplings and Guying Points
34
Guying
34
Step 2.
Installation of the HVSC Downconductor
Step 3.
Lower Termination of the HVSC
Downconductor and connection to the
Lightning Earth
Step 4.
Upper Termination of the HVSC
Downconductor and connection to the
Stormaster ESE terminal
Step 5.
Preparation and Raising of the Mast into
position
6
6
7
Checking Lightning Protection
Components Supplied
14
Preparation and Raising of the Mast
into position
35
LPI Stormaster ESE Installation
14
Raising of Mast
36
Installation of the Lightning Earth
15
Lightning Strike Recorder (LSR1)
38
Ground Resistance Lowering Compounds 16
Certification
39
Bonding the Lightning Earth
16
Operation and Maintenance
39
Labelling
17
Testing the Stormaster Terminal
40
Installation of the HVSC Downconductor
17
Hauling the HVSC Downconductor
17
Testing the Lightning Earth and the
HVSC Downconductor
40
HVSC Downconductor Clearance Holes
19
2
PROTECTION RADIUS (M) - (Rp)
h = height of Stormaster terminal
above area to be protected (m)
2
4
5
6
10
15
20
45
60
Protection Level 1 (High Protection)
Stormaster 15
Stormaster 30
Stormaster 50
Stormaster 60
13
19
28
32
25
28
55
64
32
48
68
79
32
48
69
79
33
49
69
79
34
50
70
80
35
50
70
80
35
50
70
80
35
50
70
80
Protection Level 2 (Medium Protection)
Stormaster 15
Stormaster 30
Stormaster 50
Stormaster 60
18
25
35
40
36
50
69
78
45
63
86
97
46
64
87
97
49
66
88
99
52
68
90
101
55
71
92
102
60
75
95
105
60
75
95
105
Protection Level 3 (Standard Protection)
Stormaster 15
Stormaster 30
Stormaster 50
Stormaster 60
20
28
38
44
41
57
76
87
51
71
95
107
52
72
96
107
56
75
98
109
60
77
100
111
63
81
102
113
73
89
110
120
75
90
110
120
Protection
Performance
The protection radius (Rp) of a Stormaster ESE terminal is calculated
using the following formula as defined by the French National
Standard NF C 17-102 (July 1995).
Rp = √h(2D-h) + ∆T(2D + ∆T) for ≥5m where:
The following key parameters determine the calculation
of RP.
• ∆T as established during the test.
Stormaster-ESE-15 = �∆T (µs) 15
Stormaster-ESE-30 = �∆T (µs) 30
Stormaster-ESE-50 = �∆T (µs) 50
Stormaster-ESE-60 = �∆T (µs) 60
• h = actual height of Stormaster terminal above the
area to be protected (m).
• D (in m) depends on the selected level of protection,
protection levels are specified in annex B of the
standard NF C 17-102.
D = 20m for protection level 1 (High Protection)
D = 45m for protection level 2 (Medium protection)
D = 60m for protection level 3 (Standard protection)
3
Warranty
LPI’s Stormaster ESE terminals are 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 certified by LPI or its
distributor. All other costs such as freight, re-installation, loss of profit,
insurance premiums are not included.
Responsibility for other direct or indirect damages or death is also
specifically excluded from the warranty.
The range of Stormaster ESE terminals (or to our knowledge any other
lightning protection system) cannot provide 100% protection and
therefore it is not inferred.
As confirmation of the above paragraph we refer to French Standard NF
C 17-102.
Lightning
Protection
Comments on the French Standard NF C 17-102.
We refer to the section in the standard titled “foreward” where it states
the following:
“As in the case with anything related to the natural elements, a lightning
protection system designed and installed in accordance with the
standard, cannot guarantee absolute protection to structures, persons
or objects: however , applying this standard will significantly reduce the
risk of protected structures being damaged by lightning.”
Figure 1.
The LPI Stormaster ESE Terminal should only be installed during storm
free periods.
4
Quick Installation Guide
Recommended
Order of
Installation
To assist in the installation of the Stormaster ESE terminal and
accessories refer to drawings GA-1, SM-1, ST-1, SW-1, ST-2 & HVS-1 as
illustrated on pages 8-13.
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 Stormaster ESE terminal.
5. Preparation and raising of the mast into position.
Step 1.
Installation of
the Lightning
Earth
LPI recommends the installation of a radial lightning earth as illustrated
in figure 8 on page 15.
• Each radial will 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 and earth rod clamps.
• 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.
Refer to page 15 for more detailed information on installation of the
lightning earth.
Step 2.
Installation
of the HVSC
Downconductor
• It is very important to check that the correct length of HVSC has
been supplied.
• The HVSC may be installed internally or externally on the structure.
• The HVSC should be installed as close (flush) as possible to the
structure.
5
• The HVSC should be fixed to the structure every 2m for the entire
length of the run. (Use LPI supplied or recommended saddles,
fixings and cable ties).
• Most direct route to ground is recommended, avoid sharp bends.
• Be sure to allow for enough HVSC at the top end for connection to
the Stormaster ESE terminal and the raising of the mast. Refer to
drawing HVS-1 on page 13 when installing HVSC over the edge of a
structure.
·
Refer to page 17 for more detailed information on the installation of
the HVSC.
·
If installing conventional downconductor such as copper tape or
stranded copper cable refer to page 21 for further instructions.
·
If installing Stormaster-GI model for connection to 2 inch male
threaded pipe refer to drawing ST-2 on page 12. Further instructions
are also given on page 22.
• When installing the HVSC downconductor a lower termination kit
(Model Number: LTERMKIT) should have been supplied as part of
the system.
Step 3. Lower
Termination
•
of the HVSC
Downconductor
and connection ·
to the Lightning
Earth
Refer to page 24 for detailed instructions on completion of the HVSC
lower termination and connection to the lightning earth.
If installing a conventional downconductor such as copper tape
or stranded copper cable refer to page 27 for instructions on
connection to the lightning earth.
• When installing the HVSC downconductor the upper termination
may have already been completed at the LPI factory prior to
shipment. If so refer to page 31 for further instructions.
Step 4.
Upper Termination of the
•
HVSC Downconductor and
connection to
the Stormaster ·
ESE terminal
If the HVSC is supplied without the upper termination completed,
an upper termination kit (Model Number: UTERMKIT) should have
been supplied as part of the system. Refer to page 27 for detailed
instructions on completion of the HVSC upper termination and
connection to the Stormaster ESE terminal.
If installing a conventional downconductor such as copper tape or
cable refer to page 21 for detailed instructions on connection to the
Stormaster ESE terminal.
6
Step 5.
Preparation
and Raising of
the Mast into
position
• With the upper termination of the HVSC completed and the FRP mast
in position it is now time to finalise the mounting arrangement so
that the mast can be raised and secured into position.
• If using the recommended installation methods as per drawings
GA-1, SM-1, SW – 1 & ST-1 fit the inline coupling to the lower mast
material.
• Fit the HVSC downconductor in and out of the slot in the coupling.
Refer to figure 34 on page 37.
• Carefully fit the mast butt adaptor of the Stormaster terminal into
the top of the FRP.
• It may be necessary to pull back any slack of HVSC downconductor through the FRP support mast to achieve a tight fit for
the mast butt adaptor. This should be completed carefully so as to
not damage the upper termination.
• Now fix the FRP support mast firmly into the inline coupling and
tighten the coupling so that the FRP mast and lower mast material
are secured tightly into position.
• If a guy kit is to be installed the guys should be securely fixed to the
eyelets as provided on the inline coupling. See figure 34 page 37.
• Refer to page 35 for instructions on how to safely raise the mast.
·
Refer to page 32 onwards for more detailed information on
preparation and raising of the mast.
7
Figure 2.
8
Figure 3.
9
Figure 4.
10
Figure 5.
11
Figure 6.
12
Figure 7.
13
Checking
Lightning
Protection
Components
Supplied
The LPI Stormaster ESE 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.
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.
Lengths and quantities of HVSC (if multiple lengths on one drum), will be
shown on the side of the Cable Drum(s).
LPI STORMASTER ESE Installation
All site and safety requirements must be followed during the installation
of the LPI Stormaster ESE.
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
Stormaster ESE terminal.
5. Preparation and raising of the mast into position.
LPI Stormaster ESE should only be installed during storm-free
periods.
If the Stormaster ESE 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.
14
Installation of
the Lightning
Earth
Figure 8.
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.
Earth DC resistance (typically ‹10 ohms) and impendence (typically ‹30
ohms) is required for successful operation of LPI Stormaster ESE.
LPI recommends the installation of a radial lightning earth as shown in
figure 8.
• Recommended to install a 3 length radial trench.
• Each radial will 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 fix the tape to rods is
recommended.
15
• 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.
• A ground pit should be installed where the end of the downconductor terminates to the lightning earth as shown in figure 8.
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.
Methods for bonding the earthing system components are listed below:
• The use of the EXOWELD exothermic welding process is a safe
and efficient way of providing a permanent connection between
conductors. EXOWELD connections will not corrode or rust with age.
• DO NOT use aluminium lugs or couplings
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.
16
Before bonding of these earths takes place make sure proper
authorisation is gained.
Bonding cable must be 70mm (2/0AWG) minimum depending on local
standards. It may be necessary to use a Transient Earth Clamp (LPI
TEC) 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, AS1768-2003, NFPA 780. C22.1
-98 and NEC.
Labelling
Installation
of the HVSC
Downconductor
It is the responsibility of the customer/installer to label earth pits or
earthing systems to local requirements.
If installing LPI HVSC, the HVSC downconductors(s) may have had the
upper terminations completed at a pre-specified 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.
Hauling the
HVSC Downconductor
Place the HVSC downconductor cable drum close to where it is to be
installed.
Figure 9.
17
• Make sure that the cable drum is in a good 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.
• 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 lug, see
Figure 10.
• Protect the HVSC downconductor at all times when it is being
moved.
Figure 10.
18
HVSC Downconductor
Clearance
Holes
Before running the HVSC downconductor through any clearance holes,
ensure that:
• A minimum hole diameter of 60mm (23/8in.) is used.
• Enough protection is provided so that the HVSC downconductor is
not damaged.
A waterproofing 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 (flush) 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 bend radius maintained ›500mm (20in.).
• Parallel routing with other services – Minimum separation = 20cm.
See Figure 11 on page 20.
• 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 Stormaster ESE Terminal and the raising of the
mast.
• If it is necessary to isolate the HVSC downconductor from the
structure put the cable in an insulating conduit with a minimum wall
thickness of 3mm (1/8in.). The maximum length isolated from the
19
structure should be 2.5m (9ft). The entire length of the HVSC downconductor cannot be run in insulated conduit.
• HVSC Downconductor should be protected from damage at the
lower end by installing a sleave of no more than 2m from ground
level.
The HVSC downconductor must be checked by an LPI representative
if it is damaged during installation to see if the damage will affect
performance.
20cm
INCORRECT
Power and Communications Lines
Radius <500mm
2m Max.
20cm
CORRECT
Figure 11.
20
Power and Communications Lines
Radius >500mm
Fixing the
HVSC Downconductor
Using non LPI saddles can damage the downconductor outer sheath.
• The HVSC downconductor should be fixed to the structure every 2m
for the entire length of the run.
• For masonry walls or roofs, use the LPI saddles provided. These
can be used with masonry anchors, suitable fastenings for wood,
fibreglass and metallic surfaces or self tapper screws.
• Use cable ties when fixing to pipes, tower legs, masts, etc.
• If the HVSC downconductor is to be routed above a false ceiling,
ensure that it is fixed to the underside of the concrete floor slab.
• Do not use explosive fastening methods on LPI saddles or
HVSC downconductors.
Installation of
Conventional
Downconductors
In some installations the use of copper tape or insulated stranded
copper cable may be installed as the downconductor. In such cases it
may be necessary to install multiple downconductors in compliance
with local standards. (NFC 17-102, AS1768-2003, BS6651). See the
following dot points for further information.
The Stormaster ESE Terminal provides a bolt for the lug connection to
the lower finial connector of the mast butt adaptor. All conventional
downconductors should be lugged and fixed to the terminal as per
figure 12 below.
Figure 12.
21
The following are recommendations and points that should be
considered when installing conventional downconductors.
• Downconductors should be installed at each external corner of
the building and additional downconductors installed at spacing not
exceeding 20m.
• The most direct path to ground is recommended avoiding sharp
bends.
• Downconductors should be installed around the outside walls of the
structure. It is not recommended to install downconductors
internally to the structure.
• It is not recommended to locate downconductors in areas where
personnel are liable to congregate.
• Any extended metal running vertically through the structure should
be bonded to the lightning downconductor at the top and bottom of
the structure.
• Each downconductor should be connected to the earthing system.
• Where practical all structural steel and metallic reinforcement in the
structure should be bonded to the downconductor system.
• The use of copper conductors are recommended and should have a
cross sectional area of not less than 35mm2.
• Recommended copper conductor size is 25mm x 3mm.
• The copper should be of a grade normally used for commercial
electrical work.
• The use of PVC insulated copper, bare aluminium and stainless steel
can be used as downconductors.
• Suitable fasteners should be installed to adequately secure all
downconductors.
• Downconductors should be fastened at spacings not exceeding 1.0m
on horizontal runs and not exceeding 1.5m on vertical runs.
Installation
of Stormaster
GI Terminal to
threaded pipe
LPI offers within it’s range of Stormaster terminals a GI version which is
designed for a threaded connection to a 2 inch GI pipe. Please refer to
drawing ST-2 on page 12 and figure 13 for further details.
The Stormaster GI terminal is supplied with a threaded coupler (female
thread) fixed to the terminal and designed for connection to a 2 inch
pipe (Male thread).
22
Figure 13.
Figure 14.
23
• Following installation of the Stormaster GI terminal to the threaded
pipe as per drawing ST-2 and figure 13 it will be necessary to
connect the metallic pipe to a conventional downconductor in order
to convey the lightning energy to the earthing system.
• Ideally the connection between the metallic pipe and the
conventional downconductor should be completed by lugging
or exothermically welding (LPI EXOWELD) the downconductor at a
practical point somewhere along the length of the pipe.
• Particular care should be taken to ensure that compatible metals are
used when connecting the downconductor to the metallic pipe.
• For installation details of the conventional downconductor please
review instructions and comments as detailed under the heading
Installation of Conventional Downconductors on page 21.
Termination of the HVSC Lower End
Tools required for the completion of the HVSC Lower Termination
include:
•
•
•
•
•
Compression or Mechanical Crimping Tool
Sharp Knife
Insulation Friction Cutting Tool
Shifting Spanner
Rubber Gloves
Lower Termination Kit Consists of
1 x Roll Denso Tape
1 x 95mm Crimp Lug
2 x Warning Stickers
1 x Earth Clamp
1 x Insulation Friction Cutting Tool
The following steps outline the termination of the lower end of the High
Voltage Shielded Cable to the lightning earth.
The inner screen copper conductors and the outer screen copper
conductors should be connected to the earthing system.
24
Figure 15.
1. Remove the outer sheath for a length of 15cm from the lower end
of the HVSC by cutting radially around HVSC cable with the supplied
insulation friction cutting tool. (This is less likely to damage
individual copper conductors than by cutting radially with a knife).
The lengthwise cut can be completed with a knife.
2. Remove the binder tape (2nd layer) for a length of 15cm from the end
of the HVSC, this will expose the outer screen copper conductors as
shown in Figure 16.
Figure 16.
3. Fold outer screen conductors back without damaging them. For a
length of 5cm from the end of the HVSC remove XLPE insulation (4th
layer) and inner binding tape (5th layer) to expose inner screen
copper conductors. Be sure not to remove outer screen conductors
in this step. It is recommended to use the insulation friction cutting
tool in this step.
4. Fold inner screen conductors back without damaging them. For a
length of 5cm from the end of the HVSC remove the inner PVC
spacer under the inner screen copper conductor leaving the inner
screen copper conductor in place.
Figure 17.
25
5. Bunch together both inner and outer screen conductors. If connecting directly to the earth system as per figure 20 then the
bunched conductors should be connected to the earth rod clamp
and the clamp tightened holding the conductors firmly in place. To
avoid oxidisation of this connection seal it using the water resistant
(Denso Tape) as provided in the kit.
Figure 18.
6. If terminating the lower end of the HVSC to a bus bar then bunch
together both inner and outer screen conductors, crimp them
together in the crimp lug provided using a compression or
mechanical crimping tool and connect the bus bar as per Figure 19.
HVSC
LSR1
Compression
Lug
Figure 19.
To Earthing System
26
Copper
Bus Bar
STEP 1.
STEP 2.
Ground Level
HVSC
Downconductor
HVSC
Downconductor
Denso Tape
Earth Rod Clamp
Earth Rod
Earth Rod
Figure 20
Lower
Termination of
Conventional
Downconductor to
the Lightning
Earth
If a conventional downconductor such as copper tape or stranded copper
cable has been installed as the downconductor then the lower end of the
conductor should be directly connected to the lightning earth and sealed
with a water resistant Denso tape so as to avoid oxidisation.
• If installing stranded copper cable as a downconductor then the
lower end should be connected to the lightning earth through the
use of a earth rod clamp and then wrapped with water resistant
Denso tape to avoid oxidisation.
• If installing a copper tape (25mm x 3mm) as a downconductor then
the lower end should be directly connected to the lightning earth
through the use of a suitable earth rod clamp and then wrapped
with water resistant Denso tape to avoid oxidisation.
Termination of the HVSC Upper End
Tools Required for the completion of the HVSC Upper Termination
Include:
•
•
•
•
•
Compression or Mechanical Crimping Tool
Sharp Knife
Insulation Friction Cutting Tool
Shifting Spanner
Rubber Gloves
27
Upper Termination Kit Consists of:
1 x 2.25m/19mm Semi Conductive Tape
1 x 50mm Crimp Lug
1 x 0.5m /38mm Mastic Tape
1 x 15cm Cold Shrink
The following steps outline the terminating of the upper end of the High
Voltage Shielded Cable.
1. In preparation for the upper termination of the HVSC it is important
to feed the HVSC cable through the FRP Support mast prior to
starting the upper termination. Refer to figure 21.
Draw HVSC Downconductor through
FRP Mast before terminating upper end
Downconductor
Figure 21
FRP Mast
(2 or 3 metre)
2. Firstly remove the outer sheath material for a length of 1.2 metres
by cutting radially around HVSC cable with the supplied insulation
friction cutting tool. (This is less likely to damage individual copper
conductors than by cutting radially with a knife). The lengthwise cut
can be completed with a knife.
3. Cut and remove the outer screen copper conductors 3 cm above the
end of the outer sheath.
Figure 22.
28
4. Fold the outer screen copper conductors back over the outer sheath,
secure the outer screen conductors in place by wrapping 50cm of
the HV insulation tape provided (5cm covering XLPE insulation, 5cm
covering folded screen over the outer sheath).
Figure 23.
5. Remove XLPE insulation (4th layer) and inner binding tape (5th
layer) to expose inner screen copper conductors for a length of
5cm from the top end of the HVSC. It is recommended to use the
insulation friction cutting tool in this step.
6. Fold back inner screen copper conductors and for a length of 5cm
from the end of the HVSC, remove the inner PVC spacer under the
inner screen copper conductors and return these conductors to their
original position.
7. Crimp the inner screen copper conductors in the crimp lug provided
using a compression or mechanical crimping tool.
Figure 24.
8. Slide cold shrink onto the cable in preparation for later step (ensure
release strap is coming out from inside white tube at the lower end
i.e. The other end from the crimp lug so the cold shrink contracts
from top to bottom but with the strap being pulled out from the
inside of the bottom of the cold shrink).
29
Note: The cold shrink should be placed into position in this step,
however it should not be applied until step 11.
9. The lugged HVSC is now ready to be connected to the base of
the Stormaster ESE terminal. Take the mast butt adaptor as
supplied in the Stormaster box and screw the mast butt adaptor
firmly into the base of the Stormaster terminal. Connect the crimp
lug to the Stormaster terminal mast butt adaptor using the nut and
bolt as supplied with the mast butt adaptor. Ensure the connection
is tightly secured.
Figure 25.
10. Using the 19mm semi conductive tape (2.25m) apply the tape
starting at the white XLPE material and continue to the mast butt
adaptor. Build up as smooth a finish as possible from the insulation
to the bottom of the mast butt adaptor.
Figure 26.
11. Place the cold shrink up against the bottom of the mast butt
adaptor, pull the release strap away from the mast butt adaptor
(rotate around the cable as the release strap is pulled to ensure
30
semi conductive tape is not effected by cold shrink application
process). When the cold shrink is applied it should be situated hard
up against the mast butt adaptor and continue 15cm down the cable
covering the entire semi conductive taped connection.
Connection of
Factory PreTerminated
HVSC (Upper
End) to
Stormaster
Terminal
Tools required for the installation of the factory completed upper
termination include:
• Sharp Knife
• Medium size Phillips head screw driver
1. Firstly remove the protective packaging from the cable and upper
terminated end section taking care not to cut cable or associated
upper termination parts in the process.
2. Using Phillips head screwdriver remove screw holding mast butt
adaptor to lower connector and retain both screw and mast butt
adaptor.
3. In preparation for completion of the installation of the factory
completed upper termination it is important to feed the HVSC cable
through the FRP support mast.
4. Once the terminated HVSC has been carefully fed through the top
end of the FRP mast, slide the black plastic mast butt adaptor back
onto brass lower connector, line up holes and insert phillips head
screw into position tightly. Now screw the mast butt adaptor into the
Stormaster terminal.
Figure 27.
Labelling
Warning Labels are supplied with all Stormaster ESE terminals and
should be installed as per the following.
• In locations where personnel may be in close contact to the HVSC
Downconductor.
31
• Where the HVSC downconductor connects to the earthing system.
• At the base of the support mast.
There are 2 Warning Label’s supplied in the front cover of this manual and
also 2 supplied in the lower termination kit. If more labels are required,
contact your nearest LPI supplier or Distributor.
Masts
The mast chosen for the application must:
• Raise the terminal to a height of at least 2 metres (6.5ft.) higher
than the structure. (Minimum accepted).
• An (FRP) mast section of at least 2 metres (81 in.) must be used
below the air terminal, if using LPI HVSC.
• Be suitable for local weather conditions. Seek guidance from a local
civil engineer.
• Be guyed and securely attached to the dedicated mounting points if
required.
Types of Mast
Configurations
When mounting a Stormaster ESE terminal there
are generally three types of mast configurations
that can be used.
Cantilevered
Typically used for mounting to a tower or the side
wall of a plant room when a mast and base are not
suitable. See drawings ST-1, SW-1 and Figure 28 .
• 1/3 of the overall mast height must be
fixed to the structure for adequate mechanical
strength.
• Cantilevered masts can be guyed for
additional strength. If guying the use of a guy
ring and or the eyelets provided on the inline
coupling can be utilized.
32
Figure 28.
Cantilevered Mast
Guyed
When mounting a Stormaster ESE terminal a
typical guyed configuration would involve the
following. See drawing SM-1 and Figure 29.
• Two sections of mast (Aluminium mast
& FRP mast) coupled together with a
inline coupling. Securing of guy wires is
completed at the eyelets as provided on
the inline coupling.
• Alternatively a guy ring can be supplied
which is installed at the neck of the mast
in between the Stormaster terminal
and the top section of the FRP. The guy
ring provides eyelets for
connection of the guy wires.
Figure 29. Guyed Mast
Freestanding
A freestanding mast configuration is
typically used in situations where protection
by isolation is required. For example a
Stormaster ESE terminal is installed 5 metres
or more away from a fuel storage tank.
Prior to installing the freestanding mast
ensure that:
• A spigot has been supplied with the
freestanding mast which allows
for external or internal mounting of the FRP
mast.
• The downconductor can exit through the
base of the freestanding
mast if run internally.
• Adequate information is provided for mast
foundation requirements.
Mast Bases
Figure 30.
Freestanding Mast
LPI supplies a mast base welded directly onto the required length
of aluminium mast. The base has a hole in the bottom for the
downconductor to run if being routed inside the mast. Ordering Code:
ALUMB-3M.
33
Mast
Couplings and
Guying Points
There are two methods of coupling two sections of mast:
1. The U-Bolt set uses two stainless steel U-Bolts to clamp the two
masts together.
2. The inline coupling fixes the upper and lower mast sections
together and provides guying points and an exit point for the HVSC
downconductor.
Figure 31.
U-Bolts and Inline Couplings nuts must be tightened to no more than
55kg/cm (45in.lb).
A Guying Ring is supplied for guy points for any two piece masts that
require double guying. This fits on the terminals mast butt adaptor
between the Stormaster ESE terminal and the top of the mast. See Figure
32 under the heading titled Guying.
Guying
LPI offers a standard 4m (13 ft) guy kit made up of light weight plastic
coated fibreglass non-conductive cable. If using conductive guy lines
they must be connected at the lower anchor points to the downconductor
by a conductor, or alternatively use appropriate guying insulators.
34
Figure 32.
Important Recommendations:
• The guying angle must be no greater than 60° from horizontal.
• The inline coupling couples the upper and lower mast sections
and provides guying points and an exit point for the HVSC
downconductor.
• Minimum of 3 guying grips per guy end.
•
Guying grips spaced at a minimum of 30mm (1 in.).
• Grips are correctly orientated –saddle on the longer length side of
the guy and U-bolt over the tail side of the guy.
• Tighten grips to no more than 60cN.m (5Ibf.in) of torque.
• Customised guy kits can be supplied upon request.
Preparation
and Raising of
the Mast into
Position
• With the upper termination of the HVSC completed and the FRP mast
in position it is now time to finalise the mounting arrangement so
that the mast can be raised and secured into position.
• If using the recommended installation methods as per drawings
GA-1, SM-1, SW – 1 & ST-1 fit the inline coupling to the lower mast
material.
35
• Fit the HVSC downconductor in and out of the slot in the coupling.
Refer to Figure 34 on page 37.
• Carefully fit the mast adaptor of the Stormaster terminal into the top
of the FRP.
• It may be necessary to pull back any slack of HVSC downconductor
through the FRP support mast to achieve a tight fit for the
Stormaster terminal. This should be completed carefully so as to not
damage the upper termination.
• Now fix the FRP support mast firmly into the inline coupling and
tighten the coupling so that the FRP mast and lower mast material
are secured tightly into position.
• If a guy kit is to be installed the guys should be securely fixed to
the eyelets as provided on the inline coupling and or the guy ring.
See text and graphics as detailed under the heading Guying for
more information.
Raising of
Mast
When raising the mast.
• Guys to inline coupling and or guy ring must be properly secured.
• Guys must not be twisted, kinked or damaged.
• Guys must be able to be easily secured at the base when the mast
has been raised.
Turnbuckles or Rigging Screws are recommended at the base anchor
points of the guys.
Other guying methods such as conductive stainless steel can be used
only on aluminium masts or inline couplings below an FRP section.
Using a crane is recommended or other suitable equipment for anything
over 6 metres (20ft.) in height, or for hazardous areas such as heights.
• It is very important to keep the mast straight during the lift to avoid
damaging the mast.
• The Stormaster ESE terminal must NOT be used as a slinging point.
• When lifting the mast, ensure that the slings or ropes cannot
damage the Stormaster ESE terminal, see Figure 33.
• When lifting the mast the HVSC downconductor must be tied off
to the mast to remove any strain on the HVSC downconductors
termination to the Stormaster ESE terminal.
36
Figure 33.
• Protect the HVSC downconductor at the base of the mast when
lifting, maintain a minimum bending radius of 500mm (20 in.) and
ensure it does not drag over rough or sharp surfaces.
Figure 34.
37
Lightning
Strike
Recorder
(LSR1)
The Lightning Strike Recorder (LSR1) should be installed at a position
along the downconductor length where it can be accessed easily for
inspection. Typically the LSR1 should be installed approximately 1.5m
from ground level or alternatively within the ground pit at the lower
termination point of the HVSC.
When installing the LSR1 the following should be considered.
• The LSR1 should be mounted away from areas where damage may
occur due to theft, vandalism or damage from nearby operations.
• The LSR1 can be enclosed in a security enclosure but the display
should be kept visible to allow for the checking of recorded strikes.
Figure 35.
Lightning
Strike Recorder
installed on HVSC
Downconductor
Figure 36.
Lightning Strike
Recorder installed
on Rod.
38
Certification
The certification of the LPI Stormaster ESE installation should be
performed by an authorised LPI representative.
A certificate of compliance and warranty registration is provided with
the installation manual. This certificate should be completed in full
following the successful inspection and certification of the installation.
The following should be checked for quality of workmanship and
compliance to recommended installation instructions.
Certification checklist
• Correct mast and any associated brackets and fastenings have been
used for installation.
• Guying, anchor points and fastenings.
• HVSC Downconductor routing, fixing and weatherproofing.
• Lower termination of HVSC Downconductor.
• Earthing System.
• Labelling.
Operation and
Maintenance
The LPI Stormaster ESE Lightning Protection System is designed to
react to the rise in electric field which is present in approaching thunder
storms. The Stormaster ESE Terminal becomes active only during storm
activity.
• The system operates without the need for external power supply or
spare parts for standard operation.
• To keep the LPI Stormaster ESE Lightning Protection System
operating at optimum levels it needs to be regularly checked.
Maintenance checks must be done:
• After each known lightning strike to the terminal.
• Once every twelve months.
• If changes have been made to the structure.
Checks to be conducted in standard maintenance inspection:
• Is there any damage to Stormaster ESE system?
• Has the structure to be protected been modified since the last
maintenance check?
• Check finial tip for excessive pitting.
39
• Check all rigging, mast mounts, saddles and conductor fixings are
secure and tight.
• Ensure that no dirt or other matter is sitting in the air gap between
the finial tip and the surrounding panel edges.
• If conventional downconductors are used, check that all conductors
are securely fixed and not damaged.
• Check for damage to the LPI HVSC, the installed position of the
downconductor should not be able to be accessed by non
authorised people or machinery.
• All warning labels must still be in place.
• Check LSR1 for secure installation and record number of strikes.
Testing the
Stormaster
Terminal
Testing the
Lightning
Earth and the
HVSC Downconductor
LPI manufactures and supplies a terminal spark-over tester suitable
for testing the Stormaster ESE range of terminals. Contact your local
distributor for further details.
Use the table on page 41 to record the results following completion of
the following steps.
1. Remove the waterproofing denso tape from the lower termination.
2. Disconnect the HVSC downconductor from the lightning earth.
3. Disconnect the structure earth bonding cable from the earth system.
4. Measure the earth resistance of the lightning earth system and
record in column 1 under the heading Earth Resistance Readings in
the table provided on page 41.
5. Measure the earth resistance of the structure and record in column 2.
6. Reconnect the structure earth bonding cable to the lightning earth
and measure and record in column 3 the earth resistance reading.
7. Use a multimeter to measure the continuity between the inner and
outer conductors of the HVSC downconductor. The measurement
should exceed 10,000 ohms.
8. Reconnect the HVSC lower termination to the lightning earth and
re-seal the termination using denso tape to ensure that it is
waterproof.
9. Reconnect the structure earth bonding cable to the lightning earth.
10. Report any problems arising from the above tests to your local LPI
distributor for further advice.
40
HVSC Downconductor�
(Disconnected from�
LP Earth)
Ground Resistance�
Meter
Structure Earth Cable�
(Disconnected from�
LP Earth)
LP Earthing System
Figure 37.
Date of
Inspection
Inspected
by:
Earth
Resistance
Reading #1
Earth
Resistance
Reading #2
Earth
Resistance
Reading #3
LSR
Reading
Comments
IMSTORM-V4
41
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