Lightning Protection International Stormaster ESE 60 Installation Manual

LIGHTNING PROTECTION INTERNATIONAL PTY LTD
Stormaster ESE Installation Manual
Comprehensive Lightning, Surge Protection & Earthing Solutions
www.lpi.com.au
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 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
PO Box 379 Kingston, Tasmania, Australia 7051
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
www.lpi.com.au
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
1
Contents
Protection Performance
3
Warranty
5
Lightning Protection
Upper Termination Instructions for
UTERMKIT-Mk3 (Heatshrink)
30
6
Termination of the HVSC Plus Upper
End
30
General Safety Guidelines
7
Upper Termination Instructions for
UTERMKIT-Mk3 (Heatshrink)
31
Recommended Installation Method
7
Connection of Factory Pre-Terminated
HVSC Plus (Upper End) to Stormaster
ESE Terminal
36
Checking Lightning Protection
Components Supplied
16
Labelling
36
LPI Stormaster ESE Installation
16
Installation of the Lightning Earth
17
Masts
36
Earth Enhancing Compounds
18
Types of Mast Configurations
37
Bonding the Lightning Earth
18
Cantilevered
37
Labelling
19
Guyed
37
Freestanding
37
Mast Bases
38
Mast Couplings and Guying Points
38
Guying
39
Installation of the HVSC Plus
Downconductor
19
Hauling the HVSC Plus
Downconductor
19
HVSC Plus Downconductor Clearance
Holes
21
Routing
21
Preparation for Raising the Mast into
Position
40
Fixing the HVSC Plus Downconductor 22
Raising of the Mast
40
Installation of Conventional
Downconductors
Lightning Strike Recorder (LSR1)
42
Certification
44
Operation and Maintenance
44
Testing the Stormaster Terminal
45
23
Installation of Stormaster GI Terminal
to Threaded Pipe
25
Termination of the HVSC Plus
Lower End
Lower Termination of Conventional
Downconductor to the Lightning
Earth
26
30
Testing the HVSC Plus Downconductor 45
Testing the Lightning Earth
Record of Earth Resistance Readings
Table
48
Installation Notes
2
46
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
48
www.lpi.com.au
Rp3
Protection Performance
h1
The protection radius (Rp) of a Stormaster
ESE terminal is calculated using the formula
as defined in NF C 17-102 (September 2011),
namely:
Rp1
Rp2
h3 h2
(1) Rp(h) = √2rh − h2 + Δ(2r + Δ) for h ≥ 5 m
and
(2) Rp = h x Rp5 / 5 for 2 ≤ h < 5 m
where h
=
Rp5 =
r
=
Stormaster height relative
to the area being protected (m)
value of Rp from Eqn. (2) when h = 5 m
20 m for protection level I (Very High protection)
30 m for protection level II (High protection)
45 m for protection level III (Medium protection)
60 m for protection level IV (Standard protection)
and
Δ
= Stormaster time and height advantage according to the Stormaster model installed:
Choices:
Stormaster ESE 15:
Stormaster ESE 30:
Stormaster ESE 50:
Stormaster ESE 60:
www.lpi.com.au
Δ = 15 µs
Δ = 30 µs
Δ = 50 µs
Δ = 60 µs
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
3
PROTECTION RADIUS, Rp (m)
h = height of Stormaster
ESE terminal above the
area to be protected (m)
2
4
5
6
10
15
20
45
60
80
100
13
19
27
31
25
38
55
63
32
48
68
79
32
48
69
79
34
49
69
79
35
50
70
80
35
50
70
80
35
50
70
80
35
50
70
80
35
50
70
80
35
50
70
80
15
22
30
35
30
44
61
69
37
55
76
86
38
55
76
87
40
57
77
88
42
58
79
89
44
59
79
89
44
59
79
89
44
59
79
89
44
59
79
89
44
59
79
89
18
25
35
39
36
51
69
78
45
63
86
97
46
64
87
97
49
66
88
99
52
69
90
101
55
71
92
102
60
75
95
105
60
75
95
105
60
75
95
105
60
75
95
105
20
29
38
43
41
57
76
85
51
71
95
107
52
72
96
107
56
75
98
109
60
78
100
111
63
81
102
113
73
89
109
119
75
90
110
120
75
90
110
120
75
90
110
120
Protection Level I
(Very High)
Stormaster ESE 15
Stormaster ESE 30
Stormaster ESE 50
Stormaster ESE 60
Protection Level II
(High)
Stormaster ESE 15
Stormaster ESE 30
Stormaster ESE 50
Stormaster ESE 60
Protection Level III
(Medium)
Stormaster ESE 15
Stormaster ESE 30
Stormaster ESE 50
Stormaster ESE 60
Protection Level IV
(Standard)
Stormaster ESE 15
Stormaster ESE 30
Stormaster ESE 50
Stormaster ESE 60
Contact LPI for Protection Radius for Level I+ and Level I++
4
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
www.lpi.com.au
WARRANTY
This product has a limited manufacturer’s warranty given by Lightning Protection
International Pty Ltd (LPI) to the original purchaser. The warranty covers any
manufacturing defects, material defects and workmanship for a period of five (5)
years from the date of dispatch from the manufacturer. This warranty is only valid if
the purchaser sends a copy of the dulyfilled warranty card back to LPI within 30 days
of purchase.
The purchaser acknowledges 100% protection for direct strike lightning is not
possible and cannot be provided due to the lightning discharge process being a
natural atmospheric event with statistical variation in behaviour and energy levels,
which may exceed product ratings. Hence, the manufacturer’s liability is limited to
repair or replacement of the faulty product with an equivalent product. The option
to repair or replace the product will be at manufacturer’s sole decision. The repaired
or replacement product will be warranted under the terms of this warranty for the
remainder of the warranty period for the product originally supplied. This warranty
does not indemnify the purchaser of the product for any consequential claim for
damages or loss of operations or service or profits.
This warranty only covers products supplied by LPI or its authorized distributor.
The manufacturer also confirms that the warranty will not be applicable (in its
judgement) under the following conditions:
(a) The product being connected to equipment and accessories not authorised by
LPI.
(b) Improper handling, misuse, abuse, neglect, accident, improper installation or
non-compliance with the direction of use.
(c) Any alteration or modification which in the opinion of LPI will affect the
performance of the product.
(d) The product not earthed (where ever applicable) according to LPI’s recommendations.
www.lpi.com.au
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
5
Lightning Protection
Comments on the French Standard NF C 17-102 (2011).
Refer to the section in the standard titled “foreward” which states the following:
Installations for protection against lightning designed and made according to this document,
may not, like everything about the natural elements, ensure the absolute protection of structures,
people or objects; however, the application of this document must reduce significantly the risk
of damage due to lightning on protected structures.
The LPI Stormaster ESE terminal should only be installed during storm free periods.
Figure 1.
6
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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General Safety Guidelines
∆
∆
∆
∆
∆
∆
Ensure safe working environments and practices to local codes
Use personal protective equipment during installation
Use mechanical methods of raising and installing masts over 6 m
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
Recommended Installation Method
∆
The installation must conform to all relevant local standards and regulations.
To assist in the installation of the Stormaster ESE terminal and accessories, refer to drawings
as illustrated on pages 8 to 15.
1. Installation of the lightning earth.
2. Installation of the HVSC Plus downconductor.
3. Lower termination of the HVSC Plus downconductor and connection to the lightning earth.
4. Upper termination of the HVSC Plus downconductor and connection to the Stormaster ESE
terminal.
5. Preparation and raising of the mast into position.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
7
LPI® STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15
STORMASTER-ESE-30
STORMASTER-ESE-50
STORMASTER-ESE-60
LPI® UPPER TERMINATION KIT
ORDERING CODE: UTERMKIT-Mk3
LPI® FRP SUPPORT MAST
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
LPI® INLINE COUPLING
ORDERING CODE: ILCOUPLING
LPI® GUY KIT
ORDERING CODE: GUYKIT-4M
GUYKIT-4M-SS
GUYKIT-7M
GUYKIT-7M-SS
LPI® CABLE TIES
ORDERING CODE: S/S-CABTIES-STD
S/S-CABTIES-L
LPI® HVSC PLUS DOWNCONDUCTOR
ORDERING CODE: HVSCPLUS-PM
OR LPI COPPER TAPE
ORDERING CODE: FL6T253C
LPI® LOWER MAST ASSEMBLY
ORDERING CODE: ALUMB-3M
ALUMB-4M
ALUMB-5M
ALUMB-6M
LPI® SADDLES AND FIXINGS
ORDERING CODE: SAD FIX
LPI® LIGHTNING STRIKE RECORDER
ORDERING CODE: LSR1
TYPICAL PRODUCTS 4 x CBER1214
4 x RTC253
REQUIRED FOR
1 x EPIT-P
RADIAL LP EARTH:
1 x GRIP-10
SRIM-20
RESLO-20
30 x FL6T253C
LPI
INSPECTION PIT
ORDERING CODE:
EPIT-P
®
LPI® LOWER TERMINATION KIT
ORDERING CODE: LTERMKIT-MK3
LPI® EARTHING SYSTEM
LPI® EARTH ENHANCING MATERIAL
ORDERING CODE: GRIP-10
SRIM-20
RESLO-20
Figure 2.
8
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
www.lpi.com.au
LPI® STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15
STORMASTER-ESE-30
STORMASTER-ESE-50
STORMASTER-ESE-60
IMPORTANT:
One third of the mast
height must be securely
fixed to the structure.
Stormaster ESE
terminal to be a
minimum of 2 metres
above the highest point
of the building or
rooftop objects.
Recommended
clearance height = 5
metres.
LPI® FRP SUPPORT MAST
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
LPI® INLINE COUPLING
ORDERING CODE: ILCOUPLING
LPI® CABLE TIES
ORDERING CODE: SS-CABTIES-STD
SS-CABTIES-L
LPI® HVSC PLUS DOWNCONDUCTOR
ORDERING CODE: HVSCPLUS-PM
OR LPI® COPPER TAPE
ORDERING CODE: FL6T253C
LPI® SADDLES FOR CANTILEVERING MAST
ORDERING CODE: CANTSAD
LPI® LOWER MAST ASSEMBLY
ORDERING CODE: ALUM-3M
ALUM-4M
ALUM-5M
ALUM-6M
LPI® SADDLES AND FIXINGS
ORDERING CODE: SAD FIX
LPI® LIGHTNING STRIKE RECORDER
ORDERING CODE: LSR1
LPI® LOWER TERMINATION KIT
ORDERING CODE: LTERMKIT-MK3
LPI® INSPECTION PIT
ORDERING CODE: EPIT-P
LPI® EARTH ENHANCING
MATERIAL
ORDERING CODE: GRIP-10
SRIM-20
RESLO-20
LPI® EARTHING SYSTEM
TYPICAL PRODUCTS REQUIRED FOR RADIAL LP EARTH:
4 x CBER1214
4 x RTC253
1 x EPIT-P
1 x GRIP-10 / SRIM-20 / RESLO-20
30 x FL6T253C
Figure 3.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
9
IMPORTANT:
One third of the mast
height must be securely
fixed to the structure.
Stormaster ESE
terminal to be a
minimum of 2 metres
above the highest point
of the building or
rooftop objects.
Recommended
clearance height = 5
metres.
LPI® STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15
STORMASTER-ESE-30
STORMASTER-ESE-50
STORMASTER-ESE-60
LPI® FRP SUPPORT MAST
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
LPI® INLINE COUPLING
ORDERING CODE: ILCOUPLING
LPI® CABLE TIES
ORDERING CODE: SS-CABTIES-STD
SS-CABTIES-L
LPI® HVSC PLUS DOWNCONDUCTOR
ORDERING CODE: HVSCPLUS-PM
OR LPI® COPPER TAPE
ORDERING CODE: FL6T253C
LPI® U-BOLT
ORDERING CODE: U-BOLT (2 PER SET)
LPI® LOWER MAST ASSEMBLY
ORDERING CODE: ALUM-3M
ALUM-4M
ALUM-5M
ALUM-6M
LPI® U-BOLT
ORDERING CODE: U-BOLT (2 PER SET)
LPI® BEAM CLAMP AND CABLE SUPPORT
ORDERING CODE: BEAM CLAMP /
CABLE SUPPORT - HVSC
LPI® LIGHTNING STRIKE RECORDER
ORDERING CODE: LSR1
LPI® LOWER TERMINATION KIT
ORDERING CODE: LTERMKIT-MK3
LPI INSPECTION PIT
ORDERING CODE: EPIT-P
®
LPI® EARTH ENHANCING
MATERIAL
ORDERING CODE: GRIP-10
RESLO-20
SRIM-20
LPI® EARTHING SYSTEM
TYPICAL PRODUCTS REQUIRED FOR RADIAL LP EARTH:
4 x CBER1214
4 x RTC253
1 x EPIT-P
1 x GRIP-10 / RESLO-20 / SRIM-20
30 x FL6T253C
Figure 4.
10
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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IMPORTANT:
Stormaster ESE Terminal to
be a minimum of 2 metres
above the highest point
of the building or rooftop
objects. Recommended
clearance height = 5
metres.
LPI® STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15
STORMASTER-ESE-30
STORMASTER-ESE-50
STORMASTER-ESE-60
LPI® GUY RING
ORDERING CODE: GUY RING
LPI® GUY KIT
ORDERING CODE: GUYKIT-4M
GUYKIT-4M-SS
GUYKIT-7M
GUYKIT-7M-SS
LPI® FRP SUPPORT MAST
ORDERING CODE: FRP-2M
FRP-3M
FRP-4M
GUY WHERE
NECESSARY
LPI® INLINE COUPLING
ORDERING CODE: ILCOUPLING
LPI® CABLE TIES
ORDERING CODE: SS-CABTIES-STD
SS-CABTIES-L
DO NOT OVERTENSION
GUY WIRES (SLIGHTLY
SAGGING)
LPI® GUY KIT
ORDERING CODE: GUYKIT-4M
GUYKIT-4M-SS
GUYKIT-7M
GUYKIT-7M-SS
LPI® HVSC PLUS DOWNCONDUCTOR
ORDERING CODE: HVSCPLUS-PM
OR LPI® COPPER TAPE
ORDERING CODE: FL6T253C
LPI® LIGHTNING
STRIKE RECORDER
ORDERING CODE: LSR1
LPI®
INSPECTION
PIT
ORDERING
CODE: EPIT-P
LPI® LOWER MAST ASSEMBLY
ORDERING CODE: ALUMB-3M
ALUMB-4M
ALUMB-5M
Preferred Angle
ALUMB-6M
60 - 45 Degrees
LPI® LOWER TERMINATION KIT
ORDERING CODE: LTERMKIT-MK3
LPI® EARTHING SYSTEM
LPI® EARTH ENHANCING
MATERIAL
ORDERING CODE: GRIP-10
SRIM-20
RESLO-20
TYPICAL PRODUCTS
REQUIRED FOR RADIAL
LP EARTH:
4 x CBER1214
4 x RTC253
1 x EPIT-P
1 x GRIP-10 / SRIM-20 / RESLO-20
30 x FL6T253C
Figure 5.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
11
IMPORTANT:
One third of the
mast height must be
securely fixed to the
structure. Stormaster
ESE terminal to be a
minimum of 2 metres
above the highest
point of the building
or rooftop objects.
Recommended
clearance height = 5
metres.
LPI STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15-GI
STORMASTER-ESE-30-GI
STORMASTER-ESE-50-GI
STORMASTER-ESE-60-GI
MAST ASSEMBLY WITH GI ADAPTOR
ORDERING CODE: ALUM3M-MGI
ALUM4M-MGI
ALUM5M-MGI
ALUM6M-MGI
LPI® SADDLES FOR CANTILEVER MAST
ORDERING CODE: CANTSAD
BASE OF MAST PIPE
MOUNTING BOLT &
STAINLESS STEEL
WASHER
COPPER TAPE
BASE OF MAST PIPE
MOUNTING BOLT &
STAINLESS STEEL
WASHER
COMPRESSION LUG
COPPER CABLE
LPI® INSPECTION PIT
ORDERING CODE: EPIT-P
LPI® EARTH ENHANCING MATERIAL
ORDERING CODE: GRIP-10
SRIM-20
RESLO-20
LPI® EARTHING SYSTEM
LPI® LOWER TERMINATION KIT
ORDERING CODE: LTERMKIT-MK3
TYPICAL PRODUCTS REQUIRED
FOR RADIAL LP EARTH:
4 x CBER1214
4 x RTC253
1 x EPIT-P
1 x GRIP-10 / SRIM-20 / RESLO-20
30 x FL6T253C
Figure 6.
12
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
www.lpi.com.au
IMPORTANT:
LPI® STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15-GI
STORMASTER-ESE-30-GI
STORMASTER-ESE-50-GI
STORMASTER-ESE-60-GI
Stormaster ESE
terminal to be a
minimum of 2
metres above the
highest point of
the building or
rooftop objects.
Recommended
clearance
height = 5
metres.
LPI® GUY RING
ORDERING CODE: GUY RING
MAST ASSEMBLY WITH GI ADAPTOR
ORDERING CODE: ALUMB-3M-MGI
ALUMB-4M-MGI
ALUMB-5M-MGI
ALUMB-6M-MGI
BASE OF MAST PIPE
MOUNTING BOLT &
STAINLESS STEEL
WASHER
COPPER TAPE
BASE OF MAST PIPE
MOUNTING BOLT &
STAINLESS STEEL
WASHER
COMPRESSION LUG
COPPER CABLE
LPI® SADDLES AND FIXINGS FOR
COPPER TAPE
ORDERING CODE: FL3DCTC253C
LPI® LIGHTNING STRIKE RECORDER
ORDERING CODE: LSR1
LPI INSPECTION PIT
ORDERING CODE: EPIT-P
®
LPI® EARTH ENHANCING
MATERIAL
ORDERING CODE: GRIP-10
SRIM-20
RESLO-20
LPI® LOWER TERMINATION KIT
ORDERING CODE:
LTERMKIT-MK3
LPI® EARTHING SYSTEM
TYPICAL PRODUCTS 4 x CBER1214
4 x RTC253
REQUIRED FOR
1 x EPIT-P
RADIAL LP EARTH:
1 x GRIP-10
/ SRIM-20
/ RESLO-20
30 x FL6T253C
Figure 7.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
13
LPI® STORMASTER ESE TERMINAL
ORDERING CODE: STORMASTER-ESE-15
STORMASTER-ESE-30
STORMASTER-ESE-50
STORMASTER-ESE-60
LPI® FRP SUPPORT
MAST
ORDERING CODE:
FRP-2M
FRP-3M
FRP-4M
LPI® HVSC PLUS
DOWNCONDUCTOR
OR LPI COPPER
TAPE
(DOWNCONDUCTOR
TO BE RUN
INTERNALLY)
ORDERING CODE:
HVSCPLUS-PM OR
FL6T253C
M6 x 10 PAN HEAD
SCREWS 3 PLACES
AT 120°
3 HOLES DRILLED
ON SITE, Ø 6.5 SPACED
AT 120°
INTERNAL SPIGOT
59 mm OD FOR SLIDING
FIT
WELDED LUG
SPIGOT
DETAIL
SHACKLE
FREESTANDING
MAST
TYPICAL PRODUCTS 4 x CBER1214
REQUIRED FOR
4 x RTC253
RADIAL LP EARTH: 1 x EPIT-P
1 x GRIP-10
/ SRIM-20
/ RESLO-20
30 x FL6T253C
CABLE SOCK LOCATED
INSIDE FREESTANDING
MAST, ATTACHED TO
WELDED LUG AT TOP
VIA SHACKLE
CABLE SOCK
DETAIL
LPI® LOWER TERMINATION KIT
ORDERING CODE: LTERMKIT-MK3
LPI® INSPECTION PIT
ORDERING CODE: EPIT-P
LPI® EARTHING SYSTEM
FOOTING
TERMINATION OF
DOWNCONDUCTOR
TO EARTH
LPI® EARTH ENHANCING MATERIAL
ORDERING CODE: GRIP-10
SRIM-20
RESLO-20
Figure 8.
14
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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NOTE: IF SUPPORT MAST ASSEMBLY IS
INSTALLED CLOSER TO EDGE OF STRUCTURE,
MINIMUM BENDING OF 0.43 m SHOULD BE
MAINTAINED
STAINLESS STEEL
CABLE TIES
3M
ETR
STAINLESS STEEL
SADDLES
FIX EVERY 1-2 METRES
ES M
INIM
UM
THIS TYPE OF ROUTING
TO BE AVOIDED. SHARP
BENDING RADIUS MAY
DAMAGE HVSC PLUS
REQUIRED “ANGULAR”
ROUTING OF THE HVSC.
NOTE: MINIMUM BEND
RADIUS 0.43 m
Figure 9.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
15
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
Instructions, warning labels, warranty, test certificate and relevant mast base components
are supplied
Downconductor(s)
∆
∆
∆
∆
The HVSC Plus cable drum (if supplied) is not damaged
∆
Order of lengths and quantities of HVSC Plus (if multiple lengths on one drum), will be
shown on the side of the cable drum(s)
The correct HVSC Plus length(s) have been supplied
There is no obvious damage to the HVSC Plus cable
If a factory completed upper termination is supplied, check to see that the termination is
not damaged and confirm inside or outside termination(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 Plus downconductor.
3. Lower termination of the HVSC Plus downconductor and connection to the lightning earth.
4. Upper termination of the HVSC Plus 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.
16
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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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.
Earth DC resistance (typically ‹10 ohms) and impedance (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 10.
∆
∆
∆
∆
It is recommended to install a 3 x 10 metre length radial trench
Each radial should consist of a trench (Approx: 500 mm Deep x 200 mm wide x 10 m length)
An earth rod should be driven at the end of each trench
All rods should be interconnected through the use of 25 x 3 mm copper tape. The use
of earth rod clamps to fix the tape to rods is recommended
Earth Rod Clamp
Ordering Code: RTC253
Earth Pit (Polymer)
Ordering Code: EPIT-P
Lower Termination
Ordering Code: LTERMKIT - MK3
Earth Rods
Ordering Code: CBER1214
25 x 3 mm typically
3 radial lengths of 10 m,
with 500 mm depth.
Ordering Code: FL6T253C
Each radial trench is treated
with earth enhancing compounds
Ordering Code: GRIP-10
RESLO-10
SRIM-20
Figure 10.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
17
∆
∆
Waterproofing mastic tape should be used on all mechanical connections
It is recommended to apply earth enhancing compound such as LPI RESLO-20, GRIP-10 or
SRIM-20 to reduce soil resistivity to less than 10 ohms
∆
An earth pit should be installed where the end of the downconductor terminates to the
lightning earth as shown in figure 10. 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
Earth Enhancing Compounds
∆ Earth Enhancing Compounds (such as LPI RESLO-20, GRIP-10 or SRIM-20) 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 e.g. 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 70 mm2 (2/0 AWG) minimum depending on local standards. It may be
necessary to use a transient earth clamp (TEC100-2L) which bonds all earths to the same
potential under transient conditions.
For further information, it is advisable that local applicable standards are used, i.e. IEC 62305,
AS1768, NFPA 780, C22.1-98 and NEC.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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Labelling
It is the responsibility of the customer/installer to label earth pits or earthing systems to local
requirements.
Installation of the HVSC Plus Downconductor
If installing LPI HVSC Plus, the HVSC Plus 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 Plus downconductor packaging, do not use a knife or cut in any way as
this can damage the outer layer of termination.
LPI’s HVSC Plus has an outer layer which is approximately 2 mm (1/16 in.) thick. Be careful not
to damage this layer.
Hauling the HVSC Plus Downconductor
Place the HVSC Plus downconductor cable drum close to where it is to be installed.
Pre-terminated end of HVSC Plus
hauled from the ground
to the top of the structure
Pre-terminated end
of HVSC Plus on the
inside end when
wound on the drum
Pre-terminated end of
HVSC Plus wound on to
the outside of the drum
Lower un-terminated
end to the ground
Figure 11.
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Cable pre-termination and drum locations
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
19
∆
∆
Make sure that the cable drum is in a serviceable condition
∆
If the HVSC Plus downconductor has been upper terminated on the outside of the drum,
then the HVSC Plus downconductor will need to be hauled up the structure with the drum
staying on the ground
∆
If the HVSC Plus 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
Plus downconductor can be hauled downwards from the drum to the ground
∆
∆
∆
Any lifting slings or ropes must be securely attached
Check that the correct length of HVSC Plus downconductor has been supplied. The length
of HVSC Plus will be marked on the drum
DO NOT haul the HVSC Plus downconductor from the termination. See Figure 12
Protect the HVSC Plus downconductor at all times when it is being moved
Figure 12.
Correct method of hoisting
HVSC Plus
20
Incorrect method of hoisting
HVSC Plus
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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HVSC Plus Downconductor Clearance Holes
Before running the HVSC Plus downconductor through any clearance holes, ensure that:
∆
∆
A minimum hole diameter of 60 mm (2 3/8”) is used
∆
A waterproofing sealant or sealing gland should be used if the hole needs to be weatherproof
Enough protection is provided so that the HVSC Plus downconductor is not damaged
during or after installation
Routing
The routing of the HVSC Plus downconductor needs to follow these guidelines:
∆
The route of the HVSC Plus 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 Plus downconductor back against itself after changes of
direction, i.e. 180°
∆
∆
The HVSC Plus downconductor may be installed internally or externally on the structure
∆
∆
∆
∆
Minimise the number of bends and use the most direct route to ground
∆
If the HVSC Plus downconductor has to cross other services make sure it crosses at right
angles using a conduit that extends at least 1 m past either side of the existing service
∆
The lower end of the HVSC Plus downconductor must terminate close to the initial injection
point of the lightning earth
∆
Be sure to allow for enough slack in the HVSC Plus 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 Plus downconductor from the structure, run the cable
in an insulating conduit with a minimum wall thickness of 3 mm (1/8 in.). The maximum
length isolated from the structure should be 2.5 m (9 ft). The entire length of the HVSC
Plus downconductor cannot be run in insulated conduit
The HVSC Plus downconductor should be installed as close (flush) as possible to the
structure
Minimise strain on the HVSC Plus downconductor
Ensure minimum bend radius maintained ›430 mm (20in.)
Parallel routing with other services – Minimum separation = 2 m. See Figure 13 on
page 22
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∆
HVSC Plus downconductor should be protected from damage at the lower end by installing
a “Top Hat” surface mount cover of no more than 2 m from ground level
Radius < 430 mm
INCORRECT
<2m
Radius
> 430 mm
Power and Communication Lines
The HVSC Plus downconductor must be checked by an LPI representative if it is damaged during
installation to see if the damage will affect performance
ax.
CORRECT
2m
Figure 13.
Power and Communication Lines
2mM
Fixing the HVSC Plus Downconductor
Using non LPI saddles can damage the downconductor outer sheath.
∆
∆
∆
The HVSC Plus downconductor should be fixed to the structure every 2 m for the entire
length of the run. (Use LPI supplied or recommended saddles, fixing and cable ties)
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 selftapping screws
The most direct path to ground is recommended. Avoid sharp bends (refer to Figure 9 on
page 15)
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∆
∆
∆
Use cable ties when fixing to round sections, such as pipes, tower legs, masts, etc.
If the HVSC Plus 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 Plus 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 and/or international standards such as NFC 17-102, AS1768, and
IEC 62305. 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 per Figure 14 on page 24.
The following are recommendations and points that should be considered when installing
conventional downconductors.
∆
For structures made of combustible materials, downconductors must be separated from
the structure by a distance of at least 0.1 m and they must have a cross-sectional area of
100 mm2
Installation on structures:
∆
Minimum of two downconductors are required, preferably on opposite sides of the
structure
∆
At least one of these downconductors must be a dedicated downconductor per
EN 50164-2 and the other can be the natural components of the structure (i.e., both
downconductors cannot be natural components)
∆
For installations where multiple Stormaster terminals are installed, the requirement for
two downconductors per terminal is waived
Standalone / isolated installation:
∆
∆
Only one downconductor is required
The “structure” may be used if metallic and complies with the requirements for
downconductors
Note: EN 50164-2 has a requirement for copper and aluminium downconductors to have a
cross-sectional area of at least 50 mm2
Routing and installation:
∆
Install externally wherever possible. Internal installation requires routing inside a nonflammable insulating pipe
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23
MAST BUTT ADAPTOR
MAST BUTT ADAPTOR
Figure 14.
∆
∆
∆
∆
∆
As direct and straight as possible
Avoid sharp bends. Bend radius must not be smaller than 20 cm
Avoid routing along or across electrical conduits
Use three fasteners per metre
Protect against the risk of mechanical impact damage with guard tubes up to a height
of at least 2 m above the ground level
Natural components:
∆
24
External interconnected steel frames (metal structures) may be used in place of
dedicated downconductors if it is shown that the electrical continuity / resistance is
≤ 0.1 W
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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∆
Internal metallic structures, concrete reinforcements, metal structures inside walls,
metal sheets and pipes at least 2 mm thick may be used to supplement dedicated
downconductors(s)
Equipotential bonding:
Dangerous sparking may occur between the external Stormaster system and the following
components:
∆
∆
∆
Metal installations
Internal systems
External conductive parts and lines connected to the structure
The dangerous sparking can be avoided by means of:
∆
∆
Equipotential bonding, using conductors and/or SPDs or
Electrical insulation between the parts (must comply with separation distance
requirements)
Installation of Stormaster GI Terminal to Threaded Pipe
LPI offers within its range of Stormaster terminals a GI version which is designed for a threaded
connection to a 2 inch BSP GI pipe. Please refer to drawings on pages 12 and 13 along with
Figure 15 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).
∆
Following installation of the Stormaster GI terminal to the threaded pipe as per Figure 15
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 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 per “Installation of Conventional Downconductors” on page 23
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
25
Figure 15.
Termination of the HVSC Plus Lower End
Note: This Document is to be used in conjunction with the LTERMKIT-MK3 on HVSC
Plus cable only. Using the following guide, check the cable first prior to performing the
termination to ensure the use of the correct lower termination kit.
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HVSC Plus cable has an outer diameter of approximately 35 mm and has an aluminium
stranded centre conductor and copper tape screen (which can be easily seen from the
end of the cable).
This termination kit will not work with any other cable.
Tools and parts required for the completion of HVSC Plus lower termination include:
∆
∆
∆
∆
∆
Compression or mechanical crimping tool (for 70 mm² crimp lug)
Sharp knife
Shifting spanner (or 17 mm A.F. spanner/socket)
Rubber gloves
Tape measure (metric)
Lower Termination Kit consists of:
∆
∆
∆
∆
∆
∆
Instructions
1 x Roll of waterproofing mastic tape
1 x 70 mm² crimp lug
2 x Warning labels
U-Bolt earth clamp
1 x Tube of conductive paste
The following steps outline the termination of the lower end of the HVSC Plus to the
lightning earth.
The diagram below shows the different layers of the HVSC Plus cable and indicates
their names as referred to in the following instructions:
Black Inner
Filler
Black Insulation
with Semiconductive Outer
Inner Aluminium
Conductors
Black
Outer Sheath
Outer Copper
Screen Tape
Figure 16.
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27
1. First, remove the black outer sheath for a length of 15 cm by cutting radially round the
HVSC Plus cable with a sharp knife. The lengthwise cut can also be completed with a knife,
but take great care not to score or damage the copper tape. Cut and remove the material
lining over the copper tape (Figure 17).
15 cm
Figure 17.
2. Carefully unwind the copper tape to expose about 7 cm of the sheath underneath. Again,
be careful not to damage the copper tape during this process. Measure 5 cm from the
end of the cable and remove the black insulation section of the sheath over the aluminium
conductors (Figure 18). Note: There are many valid ways of removing this layer, but it is
very important that the aluminium conductor strands are not scored or damaged in any
way as this will decrease their strength and may lead to breakage when bending them for
insertion into the crimp lug.
5 cm
Figure 18.
3. Cut and remove the black binding tape from over the aluminium strands. Remove at least
3 cm of the black lnner filler core under the inner aluminium conductors by carefully
bending back the conductor strands to expose the filler core then cut and remove the
core with a knife. Carefully bend the conductors back to allow them to be fed into the lug.
Figure 19.
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4. Using a rubber glove, apply all conductive paste evenly over the 5 cm length of aluminium
strands prior to re-wrapping the copper tape.
5. Re-wrap the copper tape back into its original position neatly over the aluminium conductors. Wrap the tape as tight as possible over the aluminium strands and place
both the tape and strands into the supplied 70 mm² crimp lug and crimp securely using
a suitable compression or mechanical crimping tool (Figure 19). Note, this will require
crimping at 70 mm² to obtain a secure compression.
6. If terminating the lower end of the HVSC Plus to a bus bar, connect to the bus bar as per
Figure 20.
7. Connect the crimp lug to the earthing system using the supplied U-Bolt earth clamp if
necessary (Figure 21). Ensure the connection is aligned correctly and tightly secured
using a 17 mm spanner, socket or shifting spanner.
8. Use the waterproofing mastic tape to completely cover all exposed conductive areas of the
lower termination and to seal the termination from moisture ingress where it connects to
the earthing system (Figure 21).
9. Place the warning labels on or next to the HVSC Plus cable where they can be easily seen
and read by anyone with access to that area.
Figure 20.
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29
Lower Termination of Conventional Downconductor to the
Lightning Earth
∆ If installing stranded copper cable as a downconductor then the lower end should be
connected to the lightning earth through the use of an earth rod clamp and then wrapped
with waterproofing tape to avoid oxidisation
∆
If installing copper tape (25 x 3 mm) 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 waterproofing tape to avoid oxidisation
Figure 21.
Upper Termination Instructions for UTERMKIT-Mk3
(Heatshrink) for HVSC Plus
Termination of the HVSC Plus Upper End
Note: This Document is to be used in conjunction with the UTERMKIT-MK3 on HVSC
Plus cable only. Using the following guide, check the cable first prior to performing the
termination to ensure the use of the correct upper termination kit.
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HVSC Plus cable has an outer diameter of approximately 35 mm and has an aluminium
stranded centre conductor and copper tape screen (which can be easily seen from the
end of the cable).
This Termination Kit will not work with any other cable.
Tools and parts required for the completion of the HVSC Plus Upper Termination include:
∆
∆
∆
∆
∆
∆
∆
∆
∆
Compression or mechanical crimping tool (for 50 mm² crimp lug)
Sharp knife
Scissors
#2 Phillips head screwdriver
Shifting spanner (or 17 mm spanner/socket)
Heat gun or gas torch (LPG)
Tape measure (metric)
Combination pliers/cutters
Mast base assembly (supplied with the Stormaster Terminal)
Upper Termination Kit consists of:
∆
∆
∆
∆
Instructions
1 x Roll of semi-conductive tape
1 x 50 mm² crimp lug
2 Heatshrink tubes (1 x 1200 mm & 1 x 600 mm length)
Upper Termination Instructions for UTERMKIT-Mk3 (Heatshrink)
The diagram below (Figure 22) shows the different layers of the HVSC Plus cable and
indicates their names as referred to in the following instructions:
Black Inner
Filler
Figure 22.
Black Insulation
with Semiconductive Outer
Inner Aluminium
Conductors
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Black
Outer Sheath
Outer Copper
Screen Tape
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
31
1. First, remove the black outer sheath for a length of 160 cm by cutting radially round the
HVSC Plus cable with a sharp knife. The lengthwise cut is also performed with a knife, but
take great care not to score the black insulation under the copper tape as well as the 1st
3 cm of copper tape against the outer sheath. Cut and remove the material lining over the
copper tape (Figure 23).
2. With a knife, cut and remove the fabric tape material over the copper tape up to the outer
sheath. Measure and mark with a pen the outer copper screen tape at 3 cm along from
the end of the outer sheath (Figure 23). With a knife or scissors, carefully cut and remove
the copper tape, again without damaging the black insulation below. If using a knife,
carefully score the tape without cutting through it and use this score line to tear the tape
along the line.
160 cm
3 cm
Figure 23.
3. Using a sharp knife, remove the black insulation to expose the inner aluminium conductors for a length of 5 cm from the top end of the HVSC Plus (Figure 24). Also
remove the black fabric material lining over the aluminium conductors. Be careful not
to damage the conductor strands during this process. Note: There are many valid ways
of removing this layer, but it is very important that the aluminium conductor strands are
not scored or damaged in any way as this will decrease their strength and may lead to
breakage when bending them for insertion into the crimp lug.
4. Remove at least 3 cm of the black inner filler core under the inner aluminium conductors
by carefully bending back the conductors to expose the filler core then cut and remove the
core with a knife. Carefully bend the conductors back to allow them to be fed into the lug.
5 cm
Figure 24.
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5. Straighten the cable back to the black outer sheath as much as possible then crimp
the inner aluminium conductors into the supplied 50 mm² crimp lug using a suitable
compression or mechanical crimping tool (Figure 25).
Figure 25.
6. Connect the crimp lug to the Stormaster mast base assembly using the bolt and washers
as supplied with the assembly. Ensure the connection is aligned correctly and tightly
secured using a 17 mm spanner, socket or shifting spanner. Note orientation of lug
on lower finial connector (Figure 26).
Figure 26.
7. Using the semi-conductive tape provided, starting 2 cm in front of the end of the outer
copper screen tape (or 5 cm in front of the black outer sheath), stretch and wrap the tape
back over the tape and 3 cm over the black with 50 % overlap, securing the outer copper
screen tape in place. This should use approximately 50 cm of the tape (Figure 27).
Note: DO NOT cut the tape at this stage.
Start winding
Semi-conducting
tape here
2 cm
3 cm
3 cm
Figure 27.
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8. Over wrap back towards the crimp end of the cable, again stretching the tape and
with 50 % overlap, leaving 5 cm covering the outer copper screen tape and black insulation
and 3 cm covering the black outer sheath. This should use approximately another 50 cm of
the tape. Wrap another 2 layers, again stretched with 50 % overlap back up to where the
black outer sheath ends, to build up the cable diameter and to smooth out transitions in
diameter Figure 28. Cut the tape and press down firmly to ensure it amalgamates with the
tape below it.
5 cm
3 cm
Figure 28.
9. Again using the semi-conductive tape, start stretching and wrapping over the aluminium
conductor strands and connection to the lower finial connector to start building up in
multiple layers. Continue wrapping the tape over the area shown to cover the last 3 cm of
the black insulation, over the lower finial connector and up to the black plastic section of
the mast base assembly in multiple layers, completely covering the crimp and achieving as
smooth and level a surface as possible, removing all sharp edges (Figure 29).
3 cm
Figure 29.
10. Remove the plastic mast butt adaptor section of the mast base assembly (if fitted) by
unscrewing the M6 Phillips head screw on the side. Straighten the cable as much as
possible then carefully slip the first 1.2 m length of heatshrink over the cable until the end
of the heatshrink tube covers and overlaps the semi-conductive tape (over the black
outer sheath) by at least 3 cm (Figure 30). Ensure that the semi-conducting tape is not
damaged or lifted during this process. Using a gas torch or heat gun, carefully shrink the
lower end of the heatshrink into the correct position and gradually work up towards the top
of the heatshrink ensuring there are no pockets of air trapped under the heatshrink.
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Note: Ensure that the heat gun or gas torch is not pointed in the same area for too long as this
will burn the heatshrink. Also be careful around the ends of the tube as too much heat will
damage the black outer sheath, semi-conductive tape and black insulation.
3 cm
Figure 30.
1st Heatshrink length
11. Place the 2nd 600 mm heatshrink tube into place over the cable, again ensuring that the
semi-conductive tape is not damaged, overlapping the previous heatshrink tube by
approximately 6 cm. Shrink about 7 cm of the upper end of the heatshrink into place so
that it will sit flush with the base of the plastic mast butt adaptor when fitted back into
place. Note: That there is a mark on the lower finial connector indicating where the heatshrink needs to be fitted to. Shrink the rest of the heatshrink from the top down, ensuring
that it overlaps the previous piece of heatshrink by at least 6 cm Figure 31. Ensure the rest
of the heatshrink has a smooth overall finish. Note: Do not bend the cable while the heat
shrink is still hot.
Note: If required, feed the cable through the mast sections & guying ring prior to refitting the
mast butt adaptor. Replace the plastic mast butt adaptor section of the mast base assembly
back onto the lower finial connector and ensure that the M6 Phillips head screw is tight and
secure.
6 cm
2nd Heatshrink length
1st Heatshrink length
Figure 31.
12. The lugged HVSC Plus is now ready to be connected to the base of the Stormaster
terminal. Screw the terminal onto the completed terminal base assembly and secure with
the supplied M6 locking grub screw.
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35
Connection of Factory Pre-Terminated HVSC Plus (Upper End) to
Stormaster ESE Terminal
Tools required for the installation of the factory completed upper termination include:
∆ Sharp knife
∆ PH2 Phillips head screw driver
∆ 3 mm Hex/Allen Key
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 a Phillips Head screwdriver, remove the M6 Phillips Head screw holding the mast butt
adaptor (if fitted) to the lower connector and retain both screw and mast butt adaptor.
3. Feed the HVSC Plus cable through the FRP support mast.
4. Slide the black plastic mast butt adaptor back onto the lower finial connector, line up
holes and screw the Phillips Head screw into position tightly. Now screw the mast butt
adaptor into the Stormaster ESE terminal and tighten the M6 Grub screw at the base of the
terminal to lock the assembly.
Figure 32.
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 proximity to the HVSC Plus downconductor
Where the HVSC Plus downconductor connects to the earthing system
At the base of the support mast
There are 2 warning labels 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 higher than the structure
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∆
∆
∆
Have an FRP mast section of at least 2 metres below the air terminal if
using LPI HVSC Plus
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 on pages 9, 10 and 12 Figure 33.
∆
∆
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 Figure 33.
guying, the use of a guy ring and/or the eyelets provided on
Cantilevered Mast
the inline coupling can be utilized
Guyed
When mounting a Stormaster ESE terminal, a typical guyed configuration
would involve the following. See drawing on pages 8 and 11 Figure 34.
∆
∆
Two sections of mast (aluminium mast & FRP mast coupled together with an inline coupling. Securing of guy wires is completed at the eyelets as provided on the inline coupling
Alternatively or in addition, 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
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
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Figure 34. Guyed Mast
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
37
∆
The downconductor can exit through the base of the freestanding mast
if run internally
∆
Adequate information is provided for mast foundation requirements.
Contact LPI or an authorised dealer for further detail if required
Mast Bases
LPI supplies a mast base welded directly onto the required length of aluminium
mast.
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 Figure 36
2. The inline coupling fixes the upper and lower mast sections together and
provides guying points and an exit point for the HVSC Plus downconductor
U-Bolts and inline couplings nuts must be tightened to no more than
55 kg/cm (45 in/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 37.
Stormaster ESE Terminal
Figure 35.
Freestanding Mast
2.0 m (6.7 ft) FRP
U Bolts
3.0 m (10 ft)
Aluminium
Mast
Figure 36.
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Guying
LPI offers a standard 4 m and 7 m guy kit made up of light weight synthetic, non-conductive
cable. The LPI GUYKIT-4M and GUYKIT-7M are both non-conductive guying kits. They are
designed to be installed with the use of a guy ring at the top section of the FRP mast as
illustrated in figure 37. When guying from the LPI inline coupling, the use of stainless steel guy
wire kits (GUYKIT-4M-SS, GUYKIT-7M-SS) is recommended.
Important Recommendations:
∆
∆
The guying angle must be no greater than 60° from horizontal
∆
∆
∆
Minimum of 3 guying grips per guy end
∆
Tighten grips to no more than 60 cN.m
(5 Ibf.in) of torque
∆
Protect guying from
abrasion
∆
Customised guy kits
can be supplied
upon request
The inline coupling couples the upper and lower mast
sections and provides guying points and an exit
point for the HVSC Plus downconductor
Guying grips spaced at a minimum of 25 mm
Stormaster
ESE terminal
Grips are correctly orientated. Saddle on the
longer length side of the guy and U-bolt over
the tail side of the guy
Guy ring fitted
between Stormaster
ESE terminal
and FRP mast
Insulated
guying
FRP
mast
Figure 37.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
39
Preparation for Raising the Mast into Position
With the upper termination of the HVSC Plus 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 (on pages 8-11) fit the
inline coupling to the lower mast material
∆
If required, fit the HVSC Plus downconductor through the side entry of the inline coupling
and through the FRP mast. Refer to Figure 39 on page 42
∆
∆
∆
Feed the upper termination through the guying ring if required
∆
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 firmly into position with no more than
55 kg/cm (45 in/lb)
∆
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
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 Plus 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
Raising of the Mast
When raising the mast, ensure:
∆
∆
∆
Guys to inline coupling and/or guy ring are properly secured
Guys are not twisted, kinked or damaged
Guys are able to be easily secured at the lower guy anchoring points 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 in
height, or for hazardous areas or high areas.
∆
It is very important to keep the mast straight during the lift to avoid damaging the mast
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∆
∆
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 38
Do not sling at base
Sling in at
least two places
Stress removed from upper
termination by securing
downconductor to lower mast
with flat webbing or other
appropriate sling
Max 5 m
(17 ft)
Do not lift with more
than 5 m (17 ft) of
downconductor
hanging from mast
without tying off
to mast
Figure 38.
∆
When lifting the mast, the HVSC Plus downconductor must be tied off to the mast to
remove any strain on the HVSC Plus downconductor termination to the Stormaster ESE
terminal
∆
Protect the HVSC Plus downconductor at the base of the mast when lifting, maintain
a minimum bending radius of 430 mm and ensure it does not drag over rough or sharp
surfaces
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41
Secure
guying
Inline coupling
Removable gin pole
and associated
rigging
Protect the
HVSC Plus
from abrasion
during the lift
Figure 39.
Make sure the base will not slip during the lift
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 1.5 m from ground level or alternatively within the earth pit at the lower
termination point of the HVSC Plus.
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 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
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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Figure 40.
Lightning Strike Recorder
installed on HVSC Plus
Downconductor
Saddle
Lightning Strike
Recorder
(LSR1)
Counter
Downconductor
(HVSC Plus)
Earth Pit
(EPIT-P)
Downconductor
lower termination
bound in
waterproofing tape
Lightning Strike
Recorder (LSR1)
Figure 41.
Lightning Strike Recorder
installed on Rod.
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
43
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 Plus downconductor routing, fixing and weatherproofing
∆ Lower termination of HVSC Plus 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?
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LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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∆
∆
∆
Check finial tip for excessive pitting
∆
If conventional downconductors are used, check that all conductors are securely fixed
and not damaged
∆
Check for damage to the LPI HVSC Plus. The downconductor should not be able to be
accessed by non authorised people or machinery
∆
∆
All warning labels must still be in place
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
Check LSR1 for secure installation and record number of strikes
Testing the Stormaster Terminal
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.
Testing the HVSC Plus Downconductor
The HVSC Plus downconductor can be tested at various stages of its preparation for service.
These stages and the tests that can be performed are summarised below.
1. Before upper or lower terminations are made (raw cable):
∆
Use a digital multimeter or, preferably, a Megger to measure the continuity between the
inner and outer conductors of the HVSC Plus downconductor. The measurement should be
“open circuit” (exceeding 1 MΩ)
2. After the upper termination is made but before the lower termination is made:
∆
Use a digital multimeter or, preferably, a Megger to measure the continuity between the
inner conductor at the top (upper termination) and the shield (outer copper tape conductor)
at the bottom of the cable. The measurement should give a resistance greater than about 3
kΩ and no more than about 15 kΩ
3. After the upper termination and lower termination are first made:
∆
Use a digital multimeter or, preferably, a Megger to measure the continuity between the
inner conductor at the top (upper termination) and the shield (outer copper tape conductor)
at the bottom of the cable. The measurement should be a “short circuit” (less than 1 Ω,
excluding the resistance of the leads, the exact value depending on the length of HVSC Plus)
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45
4. After installation of the HVSC Plus downconductor:
∆
∆
∆
∆
Remove the waterproofing tape from the lower termination
Disconnect the HVSC Plus downconductor from the lightning earth
Use a digital multimeter or, preferably, a Megger to measure the continuity between the
inner conductor at the top (upper termination) and the shield (outer copper tape conductor)
at the bottom of the cable. The measurement should be a “short circuit” (less than 1 Ω,
excluding the resistance of the leads, the exact value depending on the length of HVSC Plus)
Reconnect the HVSC Plus lower termination to the lightning earth and re-seal the termination
using waterproofing tape to ensure that it is waterproof
5. Report any problems arising from the above tests to your local LPI distributor for further advice
Testing the Lightning Earth
The procedure for obtaining the resistance of the lightning earth is described below. The method
that is used is called the “fall-of-potential” (FOP) or “three-point” method. It relies on the use
of a suitable 3-point or 4-point earth tester. As testing is carried out, please record all values
per the table on page 48.
1. Disconnect the bonding cable from the structure to the lightning earth, as shown in Figure 42.
2. A “standard” LPI lightning earth will comprise radials of length 10 m. Assuming a 10 x 10 m
earthing system, the current injection point for the FOP test should be at least 50 m, but
preferably 100 m away from the lightning earth, with no intervening buried conductors.
For a larger earthing system, this distance should be increased. Install a remote current
injection electrode (RCIE) at a suitable location at about the above distance. This
electrode may be a simple driven rod of sufficient depth to get a low resistance. (Note:
if the resistance of this rod is too high, the instrument may be incapable of injecting a
current to make the test).
3. Now install a rod at about 62 % of the distance between the RCIE and the lightning earth. The
depth of this “potential rod” is not important (it can be less than 100 mm). Make a 3-point
resistance measurement and note the value.
4. Shift the potential rod 1 m closer to the lightning earth, measure and note the value.
5. Shift the potential rod 1 m further away from the original test point, measure and note
the value.
6. If the RCIE is sufficiently far away and there are no buried conductors affecting the results,
the three values recorded should all be within 5 % of each other. If this is the case, then
the resistance value measured is a true indication of the resistance of the lightning earth.
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Record the value in the table on page 48 (lightning earth resistance).
7. The same procedure can be used to measure the resistance of the structure earth, bearing
in mind that the RCIE distance needs to be 5-10 times the size of the earth grid. Record the
resistance in the table on page 48 (structure earth resistance).
8. Reconnect the structure earth bonding cable to the lightning earth and measure and record
resistance in the table on page 48 (overall earth resistance).
9. Record the lightning strike recorder (LSR) reading in the table on page 48.
10. Report any problems arising from the above tests to your local LPI distributor for further advice.
HVSC Plus Downconductor
(Disconnected from LP Earth)
Ground Resistance
Meter
LP Earthing System
Structure Earth Cable
(Disconnected from LP Earth)
Figure 42.
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47
Record of Earth Resistance Readings Table
Date
Inspected
by
Lightning earth
resistance (Ω)
Structure earth
resistance (Ω)
Overall earth
resistance (Ω)
LSR
reading
Note
(see below)
Notes:
48
LIGHTNING PROTECTION INTERNATIONAL PTY LTD
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