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Lightning Protection International Guardian System 5 Installation Manual

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

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Summary of Contents for Lightning Protection International Guardian System 5

  • Page 1 LIGHTNING PROTECTION INTERNATIONAL PTY LTD www.lpi.com.au ABN 11 099 190 897 Guardian Install Manual V12.indd 1 22/9/08 4:25:18 PM...
  • Page 2 LPI reserves the right to alter any detail contained within at any time without notice. Prior to installation of the Guardian System 5, installers should check with LPI or an authorised distributor to confirm they have the most recent version of the Guardian System 5 Installation manual.
  • Page 3 Lightning Protection International Pty Ltd Document 36 II Guardian Version 1.02 © Copyright 2008 LPI Guardian Install Manual V12.indd 3 22/9/08 4:25:18 PM...

  • Page 4: Table Of Contents

    Termination of the HVSC Upper End Checking Lightning Protection Connection of Factory Pre-Terminated HVSC Components Supplied (Upper End) to Guardian CAT Terminal Labelling LPI Guardian System 5 Installation Masts Installation of the Lightning Earth Types of Mast Configurations Ground Resistance Lowering Compounds Mast Bases...

  • Page 5: Warranty

    Warranty LPI’s Guardian System 5 Lightning Protection System is guaranteed against defects in materials and workmanship for a period of 5 years from the original sales date when it was purchased from LPI or one of its authorised distributors. The warranty is limited to the ex factory cost of replacement of equipment providing it has been installed and or certified by LPI or its distributor.

  • Page 6: General Safety Guidelines

    The LPI Guardian CAT Terminal should only be installed during storm free periods. Figure 1. General Safety Guidelines • Ensure safe working environments and practices to local codes. • Use of personal protective equipment during installation. • Use mechanical methods of raising and installing masts over 6m. •...
  • Page 7 4 X RTC1625A RESISTANCE 1 X EPIT-P IMPROVEMENT 1 X GRIP-10 POWDER 30 X CT253 ORDERING CODE: GRIP-10 Drawn Version Lightning Protection International Pty Ltd John Davey V1.00 Date Title Guardian CAT terminal assembly 9/4/2008 CTA-01 component details Scale File Figure 2.
  • Page 8 4 X RTC1625A EPIT-C 1 X EPIT-P LPI EARTHING SYSTEM 1 X GRIP-10 30 X CT253 LPI GROUND RESISTANCE IMPROVEMENT POWDER ORDERING CODE: GRIP-10 Drawn Lightning Protection International Pty Ltd Version John Davey V1.00 Guardian CAT terminal assembly Date Title 9/4/2008 CTA-02...
  • Page 9 4 X RTC1625A EPIT-C 1 X EPIT-P LPI EARTHING SYSTEM 1 X GRIP-10 30 X CT253 LPI GROUND RESISTANCE IMPROVEMENT POWDER ORDERING CODE: GRIP-10 Drawn Lightning Protection International Pty Ltd Version John Davey V1.00 Date Title Guardian CAT terminal assembly 8/4/2008 CTA-03...
  • Page 10 4 X RTC1625A 1 X EPIT-P 1 X GRIP-10 30 X CT253 LPI GROUND RESISTANCE IMPROVEMENT POWDER ORDERING CODE: GRIP-10 Drawn Version Lightning Protection International Pty Ltd John Davey V1.00 Date Title Guardian CAT terminal assembly 9/4/2008 CTA-04 component details...
  • Page 11 ORDERING CODE: CANTSAD (3 PER SET) STRUCTURE MOUNTING BOLTS & STAINLESS STEEL WASHERS BASE OF MAST PIPE COMPRESSION LUG COPPER CABLE SUITABLE MOUNTING SADDLES Drawn Lightning Protection International Pty Ltd Version John Davey V1.01 Date Title Guardian CAT terminal assembly 28/7/2008 CTA-05...
  • Page 12 MOUNTING BOLTS & STAINLESS STEEL WASHERS COPPER TAPE COPPER TAPE (OR COPPER CABLE) EXISTING DC TAPE CLIPS STRUCTURE Drawn Version Lightning Protection International Pty Ltd John Davey V1.00 Date Title Guardian CAT terminal assembly 20/8/2008 CTA-06 component details File Scale Figure 7.
  • Page 13 Figure 8. Document 36 II Guardian Version 1.02 © Copyright 2008 LPI Guardian Install Manual V12.indd 13 22/9/08 4:25:22 PM...

  • Page 14: Checking Lightning Protection Components Supplied

    Checking Lightning Protection Components Supplied The Guardian System 5 components received should be checked against the “Bill of materials” for loss during shipping and for damage. Check the following: Terminal (s) • Terminals have not been dented or damaged in any way during transit.

  • Page 15: Installation Of The Lightning Earth

    LPI Guardian System 5 should only be installed during storm-free periods. If the Guardian CAT terminal needs to be raised prior to connection to the lightning earth or immediate connection is not possible then connect the lower end of the downconductor to structural steel reinforcing or other suitable earth point. Installation of the Lightning Earth Before installation of the lightning protection earth, consult site drawings of underground services so that these are not damaged during installation of the earthing system.
  • Page 16 Earth DC resistance (typically ‹10 ohms) and impedance (typically ‹30 ohms) is required for successful operation of LPI Guardian System 5. LPI recommends the installation of a radial lightning earth as shown in figure 9. • Recommended to install a 3 x 10 metre length radial trench.

  • Page 17: Ground Resistance Lowering Compounds

    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. •...

  • Page 18: Hauling The Hvsc Downconductor

    Hauling the HVSC Downconductor Place the HVSC downconductor cable drum close to where it is to be installed. Figure 10. • Make sure that the cable drum is in a servicable condition. • Check that the correct length of HVSC downconductor has been supplied. The length of HVSC will be marked on the drum.
  • Page 19 • 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. •...

  • Page 20: Hvsc Downconductor Clearance Holes

    HVSC Downconductor clearance holes Before running the HVSC downconductor through any clearance holes, ensure that: • A minimum hole diameter of 60mm (2 3/8”) is used. • Enough protection is provided so that the HVSC downconductor is not damaged during or after installation.
  • Page 21 • If it is necessary to isolate the HVSC downconductor from the structure, run the cable in an insulating conduit with a minimum wall thickness of 3mm (1/8in.). The maximum length isolated from the structure should be 2.5m (9ft). The entire length of the HVSC downconductor cannot be run in insulated conduit.

  • Page 22: Fixing Of The Hvsc Downconductor

    Fixing of 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 tapping screws.
  • Page 23 MOUNTING BOLT & WASHER 10mm HOLE DRILLED THROUGH COPPER TAPE 13mm FROM END CRIMP LUG INSULATED STRANDED COPPER CONDUCTOR 25mm X 3mm COPPER TAPE Lightning Protection International Pty Ltd Drawn Version Figure 13. John Davey V1.00 Title Date 15/7/2008 CONNECTION OF CONVENTIONAL DOWNCONDUCTORS...

  • Page 24: Installation Of Guardian Cat Gi Terminal To Threaded Pipe

    • The use of copper conductors are recommended and should have a cross sectional area of not less than 35mm . In addition, the use of PVC copper, bare aluminium and stainless steel as downconductors is permitted in compliance to most international standards. •...
  • Page 25 THE 2" BSP MALE THREAD OF THE PIPE. ENSURE THAT THE GI ADAPTOR IS FIRMLY SCREWED INTO PLACE ON THE PIPE, AND THAT THE CONNECTION BETWEEN THE GI ADAPTOR AND THE TERMINAL IS STILL SECURELY FIXED. Lightning Protection International Pty Ltd Drawn Version John Davey V1.00...

  • Page 26: Termination Of The Hvsc Lower End

    Termination of the HVSC Lower End Tools required for the completion of the HVSC Lower Termination include: • Compression or Mechanical Crimping Tool (for 95mm crimp lug). • Sharp Knife. • 2 x screwdrivers (used as friction cutting tool handles). •...
  • Page 27 2. Remove the clear binder tape (2 layer) for a length of 15cm from the end of the HVSC, this will expose the outer screen copper conductors as shown in Figure 17. Figure 17. 3. Bend outer screen conductors back without damaging them. For a length of 5cm from the end of the HVSC, remove XLPE insulation (4 layer) and inner binding tape (5 layer)
  • Page 28 Figure 19. 6. If terminating the lower end of the HVSC to a bus bar, bunch together both inner and outer screen conductors, crimp them together in the 95mm crimp lug provided using a compression or mechanical crimping tool and connect the bus bar as per Figure 20. HVSC LSR1 Compression...

  • Page 29: Lower Termination Of Conventional Downconductor To The Lightning Earth

    STEP 1. STEP 2. Ground Level HVSC Downconductor HVSC Downconductor Waterproofing Tape Earth Rod Clamp Earth Rod Earth Rod Figure 21. 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.

  • Page 30: Termination Of The Hvsc Upper End

    Termination of the HVSC Upper End Tools and parts required for the completion of the HVSC Upper Termination include: • Compression or mechanical crimping tool (for 50mm crimp lug). • Sharp knife. • Phillips Head Screwdriver. • Shifting spanner (or 14mm spanner/socket). •...
  • Page 31 Figure 22. 1. First, remove the Black PVC Outer Sheath for a length of 165cm by cutting radially round the HVSC cable with the supplied insulation friction cutting tool (this is less likely to damage individual copper conductors than by cutting with a knife). The lengthwise cut can be completed with a knife, but take great care not to score the White XLPE Insulation.
  • Page 32 5. Straighten the cable back to the Black PVC Outer Sheath as much as possible then crimp the Inner Copper Conductors into the supplied 50mm crimp lug using a suitable compression or mechanical crimping tool. (Figure 25) Figure 25. 6. Connect the crimp lug to the Guardian CAT Terminal Base Assembly using the bolt and washers as supplied with the assembly.
  • Page 33 8. Using the Semi-Conductive Tape provided, starting 2cm in front of the end of the Outer Copper Screen Wires (or 5cm in front of the Black PVC Outer Sheath), stretch and wrap the tape back over the wires and 3cm over the Black PVC with 50% overlap, securing the Outer Copper Screen Wires in place.
  • Page 34 11. Once the tape has reached the crimp, start to stretch the remaining tape and using 50% overlap, cover the last 3cm of the White XLPE Insulation, over the brass lower connector and up to the black plastic section of the Terminal Base Assembly in multiple layers, completely covering the crimp and achieving as smooth and level a surface as possible, removing all sharp edges.
  • Page 35 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 PVC Outer Sheath, Semi-Conductive Tape and White XLPE Insulation. Figure 33.

  • Page 36: Connection Of Factory Pre-Terminated Hvsc (Upper End) To Guardian Cat Terminal

    Connection of Factory Pre-Terminated HVSC (Upper End) to Guardian CAT 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.

  • Page 37: Masts

    Masts The mast chosen for the application must: • Raise the terminal to a height of at least 2 metres (81 in.) higher than the structure. (Minimum accepted). • Have an FRP mast section of at least 2 metres (81 in.) used below the air terminal if using LPI HVSC.

  • Page 38: Mast Bases

    Guyed When mounting a Guardian CAT terminal, a typical guyed configuration would involve the following. See drawing CTA-04 and Figure 37. • 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.

  • Page 39: Mast Couplings And Guying Points

    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 39) 2. The inline coupling fixes the upper and lower mast sections together and provides guying points and an exit point for the HVSC downconductor.

  • Page 40: Guying

    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 Guardian CAT terminal and the top of the mast. See Figure 40 Guying LPI offers a standard 4m (13 ft) and 7m (22.7 ft) guy kit made up of light weight plastic coated fibreglass, non-conductive cable.

  • Page 41: Preparation For Raising The Mast Into

    Preparation for 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.
  • Page 42 • It is very important to keep the mast straight during the lift to avoid damaging the mast. • The Guardian CAT terminal must NOT be used as a slinging point. • When lifting the mast, ensure that the slings or ropes cannot damage the Guardian CAT terminal, see Figure 41.

  • Page 43: Lightning Strike Recorder (Lsr1)

    Figure 42. 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 earth pit at the lower termination point of the HVSC.
  • Page 44 • The LSR1 should be mounted away from areas where damage may occur due to theft, vandalism or 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 43.

  • Page 45: Certification

    • Labelling. Operation and Maintenance The LPI Guardian System 5 Lightning Protection System is designed to react to the rise in electric field which is present in approaching thunder storms. The Guardian CAT Terminal becomes active only during storm activity.

  • Page 46: Testing The Guardian Cat Terminal

    • If changes have been made to the structure. Checks to be conducted in standard maintenance inspection: • Is there any damage to Guardian System 5? • Has the structure to be protected been modified since the last maintenance check? •...

  • Page 47: Testing The Lightning Earth And The Hvsc Downconductor

    8. If the terminal still fails the test, please contact LPI or an authorised LPI agent for further instructions. The LPI Guardian System 5 lightning Protection System may not operate at full efficiency in all environmental conditions ie. under ice or snow or on chimneys or exhaust stacks releasing gasses or pollutants.
  • Page 48 6. Reconnect the structure earth bonding cable to the lightning earth and measure and record in column 5 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.
  • Page 49 Date of Inspected Earth Earth Earth LSR Comments Inspection by: Resistance Resistance Resistance Reading Reading #1 Reading #2 Reading #3 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI Guardian Install Manual V12.indd 49 22/9/08 4:25:28 PM...
  • Page 50 Installation Notes Document 36 II Guardian Version 1.02 © Copyright 2008 LPI Guardian Install Manual V12.indd 50 22/9/08 4:25:28 PM...
  • Page 51 Guardian Install Manual V12.indd 51 22/9/08 4:25:28 PM...
  • Page 52 Lightning Protection International Pty Ltd ABN 11 099 190 897 PO Box 379 Kingston, Tasmania, Australia, 7051 Phone: +61 3 62271955 Email: info@lpi.com.au Fax: +61 3 62291900 Web: www.lpi.com.au Guardian Install Manual V12.indd 52 22/9/08 4:25:28 PM...

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