Lightning Protection International Guardian System 5 Installation Manual Download Page 10

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LPI GUARDIAN CAT TERMINAL

LPI UPPER TERMINATION KIT

LPI FRP SUPPORT MAST

LPI CABLE TIES

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LOWER MAST ASSEMBLY

WITH BASE

LPI LIGHTNING STRIKE RECORDER

LPI LOWER TERMINATION KIT

LPI INSPECTION PIT

LPI EARTHING SYSTEM

LPI GROUND RESISTANCE IMPROVEMENT POWDER

IMPORTANT:

Guardian CAT terminal to be a minimum of 2 metres

above the highest point of the building.

Recommended clearance height = 5 metres.

LPI GUY RING

LPI GUY KIT

DO NOT OVER TENSION GUY

WIRES (SLIGHTLY SAGGING)

GUY WHERE

NECESSARY

PREFERRED ANGLE 60-45

DEGREES

-45

ORDERING CODE: CAT I-G

CAT II-G

CAT III-G

ORDERING CODE: UTERMKIT-Mk2

ORDERING CODE:ILCOUPLING

ORDERING CODE: FRP-2M

FRP-3M

FRP-4M

FRP-4.6M

ORDERING CODE:S/S-CABTIES-STD

S/S-CABTIES-LONG

ORDERING CODE:HVSC-PM

ORDERING CODE: ALUMB-3M

ALUMB-4M

ALUMB-5M

ALUMB-6M

ORDERING CODE:GUYKIT-4M

ORDERING CODE:LSR1

ORDERING CODE: LTERMKIT

ORDERING CODE: EPIT-P

ORDERING CODE: GRIP-10

EPIT-C

TYPICAL PRODUCTS REQUIRED FOR RADIAL

LP EARTH

4 X CBER458
4 X RTC1625A

1 X EPIT-P
1 X GRIP-10

30 X CT253

ORDERING CODE:GUY RING

GUYKIT-7M

GUYKIT-4M-SS
GUYKIT-7M-SS

LPI INLINE COUPLING

Lightning Protection International Pty Ltd

Drawn

Date

Scale

Title

File

Version

CTA-04

Guardian CAT terminal assembly

component details

CAT Installation Type 4.dwg

NTS

9/4/2008

John Davey

V1.00

Figure 5.

Guardian Install Manual V12.indd 10

22/9/08 4:25:20 PM

Summary of Contents for Guardian System 5

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

Page 2: ...sible and cannot be provided due to the lightning discharge process being a natural atmospheric event Guardian System 5 Lightning Protection System System Owner _____________________________________________________ Date Installed _____________________________________________________ Installation Contractor ______________________________________________ Supplied by _________________________________...

Page 4: ...allation of Conventional Downconductors 20 Installation of Guardian CAT GI Terminal to threaded pipe 22 Termination of the HVSC Lower End 24 Lower Termination of Conventional Downconductor to the Lightning Earth 27 Termination of the HVSC Upper End 28 Connection of Factory Pre Terminated HVSC Upper End to Guardian CAT Terminal 34 Labelling 34 Masts 35 Types of Mast Configurations 35 Mast Bases 36 ...

Page 5: ...ovides authoritative guidance of a general nature only and it is not intended to become a mandatory set of regulations In general it is not economically possible to provide total protection against all the possible damaging effects for lightning but the recommendations in this standard will reduce the probability of damage to a calculated acceptable level and will minimise any lightning damage tha...

Page 6: ...andards and regulations Recommended Installation Method General Safety Guidelines To assist in the installation of the Guardian CAT terminal and accessories refer to drawings CTA 01 CTA 02 CTA 03 CTA 04 CTA 05 CTA 06 and HVC 1 as illustrated on pages 5 to 11 1 Installation of the lightning earth 2 Installation of the HVSC Downconductor 3 Lower termination of the HVSC Downconductor and connection t...

Page 7: ...ERING CODE CAT I G CAT II G CAT III G ORDERING CODE UTERMKIT Mk2 ORDERING CODE ILCOUPLING ORDERING CODE FRP 2M FRP 3M FRP 4M FRP 4 6M ORDERING CODE GUYKIT 4M GUYKIT 4M SS GUYKIT 7M GUYKIT 7M SS ORDERING CODE S S CABTIES STD S S CABTIES LONG ORDERING CODE HVSC PM ORDERING CODE ALUMB 3M ALUMB 4M ALUMB 5M ALUMB 6M ORDERING CODE SAD FIX ORDERING CODE LSR1 ORDERING CODE LTERMKIT ORDERING CODE EPIT P OR...

Page 8: ...eight 5 metres LPI SADDLES AND FIXINGS ORDERING CODE CAT I G CAT II G CAT III G ORDERING CODE UTERMKIT Mk2 ORDERING CODE ILCOUPLING ORDERING CODE FRP 2M FRP 3M FRP 4M FRP 4 6M ORDERING CODE S S CABTIES STD S S CABTIES LONG ORDERING CODE HVSC PM ORDERING CODE ALUM 3M ALUM 4M ALUM 5M ALUM 6M ORDERING CODE CANTSAD ORDERING CODE LSR1 ORDERING CODE LTERMKIT ORDERING CODE EPIT P ORDERING CODE GRIP 10 EP...

Page 9: ...PORT LPI U BOLT ORDERING CODE CAT I G CAT II G CAT III G ORDERING CODE UTERMKIT Mk2 ORDERING CODE ILCOUPLING ORDERING CODE FRP 2M FRP 3M FRP 4M FRP 4 6M ORDERING CODE S S CABTIES STD S S CABTIES LONG ORDERING CODE HVSC PM ORDERING CODE ALUM 3M ALUM 4M ALUM 5M ALUM 6M ORDERING CODE U BOLT ORDERING CODE LSR1 ORDERING CODE LTERMKIT ORDERING CODE EPIT P ORDERING CODE GRIP 10 EPIT C TYPICAL PRODUCTS RE...

Page 10: ... 5 ORDERING CODE CAT I G CAT II G CAT III G ORDERING CODE UTERMKIT Mk2 ORDERING CODE ILCOUPLING ORDERING CODE FRP 2M FRP 3M FRP 4M FRP 4 6M ORDERING CODE S S CABTIES STD S S CABTIES LONG ORDERING CODE HVSC PM ORDERING CODE ALUMB 3M ALUMB 4M ALUMB 5M ALUMB 6M ORDERING CODE GUYKIT 4M ORDERING CODE LSR1 ORDERING CODE LTERMKIT ORDERING CODE EPIT P ORDERING CODE GRIP 10 EPIT C TYPICAL PRODUCTS REQUIRED...

Page 11: ... the building Recommended clearance height 5 metres BASE OF MAST PIPE EXISTING STRUCTURE MOUNTING BOLTS STAINLESS STEEL WASHERS COMPRESSION LUG COPPER CABLE ORDERING CODE CAT IGI G CAT IIGI G CAT IIIGI G ORDERING CODE CATGI ADPT ORDERING CODE ALUM3M MGI ALUM4M MGI ALUM5M MGI ALUM6M MGI ORDERING CODE CANTSAD 3 PER SET Lightning Protection International Pty Ltd Drawn Date Scale Title File Version CT...

Page 12: ...g Recommended clearance height 5 metres BASE OF MAST PIPE EXISTING STRUCTURE MOUNTING BOLTS STAINLESS STEEL WASHERS COPPER TAPE ORDERING CODE CAT I GI ORDERING CODE CATGI ADPT ORDERING CODE ALUMB3M MGI ALUMB4M MGI CAT II GI CAT III GI ALUMB5M MGI ALUMB6M MGI COPPER TAPE OR COPPER CABLE DC TAPE CLIPS Lightning Protection International Pty Ltd Drawn Date Scale Title File Version CTA 06 Guardian CAT ...

Page 14: ...completed upper termination is supplied check to see that the termination is not damaged and confirm inside or outside termination s Order of lengths and quantities of HVSC if multiple lengths on one drum will be shown on the side of the Cable Drum s All site and safety requirements must be followed during the installation of the LPI Guardian System 5 The correct order of installation is as follow...

Page 15: ... or immediate connection is not possible then connect the lower end of the downconductor to structural steel reinforcing or other suitable earth point Installation of the Lightning Earth Before installation of the lightning protection earth consult site drawings of underground services so that these are not damaged during installation of the earthing system Figure 9 Guardian Install Manual V12 ind...

Page 16: ... recommended level of less than 10 ohms An earth pit should be installed where the end of the downconductor terminates to the lightning earth as shown in figure 9 This gives an access point for disconnection and future testing Do not lower terminate connect the downconductor to the earthing system at this point in time Note If due to space constraints it is not possible to install a radial earth a...

Page 17: ... gained Bonding cable must be 70mm2 2 0 AWG minimum depending on local standards It may be necessary to use a Transient Earth Clamp TEC 100 which bonds all earths to the same potential under transient conditions For further information it is advisable that local applicable standards are used ie IEC 61024 1 BS 6551 AS1768 2007 NFPA 780 C22 1 98 and NEC Labelling It is the responsibility of the cust...

Page 18: ...um is in a servicable condition Check that the correct length of HVSC downconductor has been supplied The length of HVSC will be marked on the drum If the HVSC downconductor has been upper terminated on the outside of the drum then the HVSC downconductor will need to be hauled up the structure with the drum staying on the ground Figure 10 Guardian Install Manual V12 indd 18 22 9 08 4 25 23 PM ...

Page 19: ...aken to the top or near the top of the structure then the HVSC downconductor can be hauled downwards from the drum to the ground Any lifting slings or ropes must be securely attached DO NOT haul the HVSC downconductor from the termination see Figure 11 Protect the HVSC downconductor at all times when it is being moved Guardian Install Manual V12 indd 19 22 9 08 4 25 23 PM ...

Page 20: ...ck 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 minimum bend radius maintained 500mm 20in Parallel routing wi...

Page 21: ...uctor cannot be run in insulated conduit HVSC Downconductor should be protected from damage at the lower end by installing a Top Hat surface mount cover 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 2m 2m Radius 500mm Radius 500mm 2m Max INCORRECT CORRECT Power a...

Page 22: ...nductor In such cases it may be necessary to install multiple downconductors in compliance with local standards and or international standards NFC 17 102 AS1768 2007 BS6651 IEC 62305 See the following dot points for further information The Guardian CAT Terminal provides a bolt for the lug connection to the lower finial connector of the mast butt adaptor All conventional downconductors should be lu...

Page 23: ...e structure should be bonded to the downconductor system at recommended intervals as per international standards MOUNTING BOLT WASHER CRIMP LUG INSULATED STRANDED COPPER CONDUCTOR MAST BUTT ADAPTER MAST BUTT ADAPTER 10mm HOLE DRILLED THROUGH COPPER TAPE 13mm FROM END 25mm X 3mm COPPER TAPE Lightning Protection International Pty Ltd Drawn Date Scale Title File Version BC 2 CONNECTION OF CONVENTIONA...

Page 24: ...ge 9 and figure 14 page 23 for further details The Guardian CAT GI terminal is supplied with a threaded coupler female thread fixed to the terminal and designed for connection to a 2 inch BSP pipe Male thread Following installation of the Guardian CAT GI terminal to the threaded pipe as per drawing CTA 05 and figure 14 it will be necessary to connect the metallic pipe to a conventional downconduct...

Page 25: ...O 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 1 2 3 4 Lightning Protection International Pty Ltd Drawn Date Scale Title File Version SA 2 GUARDIAN CAT GI TERMINAL ASSEMBLY SA 2 dwg NTS 15 7 2008 John Davey V1 00 ENSURE THAT BOTH THE MALE AND FEMALE THREA...

Page 26: ... 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 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 suppl...

Page 27: ...C remove the inner PVC Filler Core under the inner screen copper conductor leaving the inner screen copper conductor in place Figure 17 5 Bunch together both inner and outer screen conductors If connecting directly to the earth system as per figure 21 the bunched conductors should be connected to the earth rod clamp and the clamp tightened holding the conductors firmly in place To avoid oxidisatio...

Page 28: ...together both inner and outer screen conductors crimp them together in the 95mm2 crimp lug provided using a compression or mechanical crimping tool and connect the bus bar as per Figure 20 To Earthing System Compression Lug HVSC LSR1 Copper Bus Bar Figure 20 Figure 19 Guardian Install Manual V12 indd 28 22 9 08 4 25 25 PM ...

Page 29: ...mp and then wrapped with waterproofing tape to avoid oxidisation If installing 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 waterproofing tape to avoid oxidisation Earth Rod Earth Rod Waterproofing Tape Earth Rod Clamp HVSC Downconductor HVSC Downconductor Ground ...

Page 30: ...e measure cm Marker or pen Combination Pliers Cutters Terminal Base Assembly supplied with the Guardian CAT Terminal Upper Termination Kit consists of Instructions 1 x roll of Semi Conductive Tape 1 x 50mm2 Crimp Lug 1 5 x Heatshrink Tubes 1 x 1200 1 x 600mm lengths Insulation Friction Cutting Tool Insulation Tape 1 x roll Upper Termination Instructions For UTERMKIT Mk2 Heatshrink The diagram on t...

Page 31: ... cm above the end of the Black PVC Outer Sheath Figure 23 With the cutters carefully cut and remove the wires again without damaging the White XLPE Insulation below 3 Using the insulation friction cutting tool remove the White XLPE Insulation to expose the Inner Copper Conductors for a length of 5cm from the top end of the HVSC Figure 24 Also remove the clear plastic lining over the copper conduct...

Page 32: ...he Guardian CAT Terminal Base Assembly using the bolt and washers as supplied with the assembly Ensure the connection is aligned correctly and tightly secured using a 14mm spanner socket or shifting spanner Figure 26 7 Use a marker or pen to mark 30cm intervals on the White XLPE Insulation between the end of the Outer Copper Screen Wires and the Crimp this will act as a guide to wrapping the semic...

Page 33: ...k towards the Crimp end of the cable again stretching the tape and with 50 overlap leaving 5cm covering the Outer Copper Screen Wires and White XLPE Insulation and 3cm covering the Black PVC Outer Sheath This should use approx another 50cm of the tape Again do not cut the tape Figure 29 10 Using the 30cm markings as a guide continue to wrap the tape around the White XLPE Insulation in a coarse spi...

Page 34: ...the application of the Heatshrink tubes Do this first by covering the left half of the tape then using a second length to cover the right half of the tape for the full length of the spiral Figure 32 13 Remove the plastic Mast Butt Adaptor section of the Terminal Base Assembly by unscrewing the M6 Phillips head screw on the side Again straighten the cable as much as possible and carefully slip the ...

Page 35: ...sh Note If required feed the cable through the mast sections guying ring Replace the plastic Mast Butt Adaptor section of the Terminal Base Assembly back onto the brass connector and ensure that the M6 Phillips Head screw is tight and secure 15 The lugged HVSC is now ready to be connected to the base of the Guardian CAT terminal Screw the terminal onto the completed Terminal Base Assembly and secu...

Page 36: ...tallation 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 a Phillips Head screwdriver remove the M6 Phillips Head screw holding the mast butt adaptor if fitted to the...

Page 37: ...if required Types of Mast Configurations When mounting a Guardian CAT 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 CTA 02 CTA 03 CTA 05 and Figure 36 1 3 of the overall mast height must be fixed to the structure for adequate mec...

Page 38: ...connection of the guy wires Freestanding A freestanding mast configuration is typically used in situations where protection by isolation is required For example a Guardian CAT 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 ...

Page 39: ...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 U Bolts and Inline Couplings nuts must be tightened to no more than 55kg cm 45in lb Figure 39 Guardian Install Manual V12 indd 39 22 9 08 4 25 27 PM ...

Page 40: ...the FRP Mast as illustrated in Figure 40 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 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 guy...

Page 41: ...ompleted carefully so as to not damage the upper termination Fix the FRP support mast firmly into the inline coupling and tighten the coupling so that the FRP mast and the lower mast are secured firmly in position with no more than 55kg cm 45lb in 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 gra...

Page 42: ... ropes cannot damage the Guardian CAT terminal see Figure 41 When lifting the mast the HVSC downconductor must be tied off to the mast to remove any strain on the HVSC downconductor termination to the Guardian CAT terminal 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 Fig...

Page 43: ...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 When installing the LSR1 the following should be considered Guardian Install Manual V12 indd 43 22 9 08 4 25 27 PM ...

Page 44: ...ay 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 Lightning Strike Recorder installed on HVSC Downconductor Guardian Install Manual V12 indd 44 22 9 08 4 25 27 PM ...

Page 45: ...gs 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 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 becom...

Page 46: ...t 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 Guardian CAT Terminal Tools required to complete operational test of Guardian CAT terminal A Standard Insulation Tester such as a Megger will be required to complete testing of the Guardian CAT terminal The insulation t...

Page 47: ...ill 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 For advice on dealing with these specific environments contact your local LPI Distributor Testing the Li...

Page 48: ...mn 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 Reconnect the HVSC lower termination to the lightning earth and re seal the termination using waterproofing tape to ensure that it is waterproof 9 Report any problems arising from the above tests to your local LP...

Page 49: ... Version 1 02 Copyright 2008 LPI 47 Date of Inspected Earth Earth Earth LSR Comments Inspection by Resistance Resistance Resistance Reading Reading 1 Reading 2 Reading 3 Guardian Install Manual V12 indd 49 22 9 08 4 25 28 PM ...

Page 51: ...Guardian Install Manual V12 indd 51 22 9 08 4 25 28 PM ...

Page 52: ...n 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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