Due to ongoing research into the phenomena of lightning and lightning
protection technology and product improvement, ERICO reserves the right to
alter any information and specifications contained herein at any time without
notice. Users should check with ERICO to ensure they have the latest edition.
Warning:
1. ERICO products shall be installed and used only as indicated in ERCIO product instruction
sheets and training materials. Instruction sheets are available at www.erico.com and from
your ERICO customer service representative.
2. ERICO products must never be used for a purpose other than the purpose for which they
were designed or in a manner that exceeds specified load ratings.
3. All instructions must be completely followed to ensure proper and safe installation and
performance.
4. Improper installation, misuse, misapplication or other failure to completely follow ERICO’s
instructions and warnings may cause product malfunction, property damage, serious bodily
injury and death.
SAFETY INSTRUCTIONS: All governing codes and regulations and those required by the job site
must be observed. Always use appropriate safety equipment such as eye protection, hard hat,
and gloves as appropriate to the application.
®
The ERITECH
International patents on the ERITECH SYSTEM 3000 are existing.
Local Distributors should be the user’s first point of contact with supply, delivery, installation,
limited warranty, and checking of the system for compliance with Manufacturer’s instructions.
www.erico.com
SYSTEM 3000 is manufactured by ERICO.
3
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Pre-Installation Requirements
This manual is a guide to the Installation,
Operation and Maintenance of the ERITECH
SYSTEM 3000 Lightning Protection System.
It assumes that the system to be installed
has been designed by an authorized ERICO
representative. The system design will
include:
t
Grounding system design - a
configuration should be designed as
a result of soil resistivity analysis.
®
t Downconductor routes - chosen to
avoid other services, maintain
minimum bending radii and minimize
downconductor run length.
t Downconductor securing requirements.
t Terminal types - operating environment.
t CAD analysis design software which
determines terminal placement, mast &
height requirements as well as protection
level calculation.
All of the above are recommended for a
successful installation. If there is any doubt
about any of the points mentioned, please
contact ERICO or your nearest Distributor
for clarification.
Only attempt to install the
ERITECH SYSTEM 3000
during storm-free periods.
Figure 1.
4
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
The recommended order of installation is as follows:
1. Full installation of the grounding system.
2. Full installation of the downconductor.
3. Termination of the downconductor to the grounding system.
4. Upper termination of the downconductor (may already have been completed
by ERICO) and connection to the ERITECH
5. Termination of bonding cable from upper termination to structure
(if required).
6. Raise mast into position and secure.
®
DYNASPHERE air terminal.
Grounding Systems
The grounding system is critical to the
integrity of any lightning protection
installation and should include
consideration of:
t Local Standards compliance
(IEC 61024-1, BS 6551, AS1768-1991,
®
780, C22.1-98, NEC® etc.)
NFPA
t Available space / location.
t Natural soil conditions - resistivity of
soil, soil moisture content, soil
temperature range, etc.
t Location of underground services -
Power, Communications, Fuel, Gas,
Water, etc.
t Corrosive environments, ie: salt
water, acid / alkaline contaminated
ground mass.
t Use of suitable grounding rods such
as ERITECH
®
rods.
t Minimization of risk to personnel.
Contact an ERICO office or Distributor if you
require further advice on grounding systems.
Downconductors
The ERITECH® ERICORE downconductor
or other recommended downconductor
should have been selected during the design
stage, as should the route, length and any
preterminations of the downconductor.
Re-check intended route of
downconductor immediately
prior to installation to ensure
that:
t There are no structural changes or
additions that may effect the initial
design.
t Most direct route possible to the
grounding system with minimal
number of bends and as flush with
the structure as possible.
t Minimum bending radii maintained
(500 mm, 20 in.).
t Parallel routing with other services -
minimum separation = 2 m (80 in.).
t Attachment to the structure is at a
maximum of every 1 m (40 in.) for the top
10% of the downconductor route and
2 m (80 in.) from then on.
t Pipe installations follow the instructions
given on page 17.
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5
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Re-check:
t Securing of downconductor - saddles,
cable ties, beam clamps, cable hangers,
etc, are appropriate.
t Method of cable installation, ie. cable
upper terminated on the outside of the
drum - to be rolled off from the base of
the structure, or cable upper terminated
on the inside of the drum - to be rolled
off from the top of the structure,
(refer Figure 6 on page 15).
t The outer sheath of the downconductor
must be electrically bonded to a
conductive structural point within 5 m
(17 ft) of the upper termination kit.
When installing the upper end of
the downconductor on a masonry
structure (concrete panels, brick,
etc), the downconductor should be secured
directly to the structural steel work. In
addition, the bonding cable (supplied in the
termination kit) must be connected via
2
(8 AWG) insulated copper cable to
6 mm
the nearest conductive structural point. This
point should be where the downconductor
first comes into contact with the structure
and may be either structural steel work or
the reinforcing within concrete panels or
slabs.
See Pages 18 to 24, figures 10-17 for more
details and diagrams.
Lightning Event Counters
The Lightning Event Counter (LEC IV) is
a device for registering and recording
the number of strikes that the ERITECH
SYSTEM 3000 has intercepted. The design
of this counter allows many installation
alternatives on the downconductor
as discussed in later text. Also, see
Specifications on page 60.
The following should be considered prior to
installation of the Lightning Event Counter:
®
t It is advisable to locate the LEC IV in
a secure area that is not prone to
contact with moving objects, theft,
or vandalism.
t If the LEC IV is to be encased in an
additional enclosure, ensure that it is
mounted to enable easy access to the
display, (see figure 32 on page 48).
ERITECH® DYNASPHERE
Terminals
The ERITECH® DYNASPHERE is the air
terminal of the ERITECH SYSTEM 3000.
Ensure that the appropriate air terminal has
been provided.
It is recommended that this point be
determined prior to the installation to allow
for any site work or equipment that may be
required prior to the installation.
2
The 6 mm
and the length of the cable will need
to be determined and obtained before
commencing the installation.
(8 AWG) cable is not supplied
Suitable for use in:
t General purpose applications
t High temperature environments
t Corrosive environments (salt or acid
atmosphere)
6
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Ensure the air terminal is supplied with the
finial tip secured in place. The air terminal
is supplied with three different finial tip
configurations (two separate, and one
secured in place), similar to that shown
in photo 1. It is important that the
correct finial tip is installed, specific
to the application. Photo 2 shows the
three different finial tip
sharp to blunt in dimension.
(middle), medium tip (left) and rounded tip
(right). The application of each of these tips
is detailed below:
sizes, ranging from
The sharp tip
Masts
There are three main types of mast
configurations:
t Guyed - generally required for mast
t Sharp Tip – Terminal heights less than
20 m (65 ft)
t Medium Tip – Terminal heights less
50 m (165 ft), greater than 20 m
than
(65 ft)
t Cantilevered - the lower third of the
t Rounded Tip – Terminal heights greater
than 50 m (165 ft)
Note: heights listed refer to the actual terminal height above ground
level
If required, replace the finial tip supplied
with the appropriate tip for the application,
and tighten firmly.
Warning – Do not install the ERITECH®
DYNASPHERE
correct finial tip.
without installing the
t Free-standing - base support only.
Ensure that the configurations and
heights for your specific installation
conform to the design and consultation
directives.
Specific advice for each mast configuration is provided on pages 40 to 47.
When all of the components for the
ERITECH
received, they should be checked against
the design “Bill of Materials” and for any
possible shipping loss or damage.
heights of over 3 m (10 ft) or for
climatic conditions where wind gusts
may exceed 160 km/h (100 mph).
Always consult with a local civil
engineer if in doubt. The mast is
anchored at the base and then guyed
using one or two guy sets, depending
on the mast height and configuration,
each with 3 lengths of non conductive
guying material.
mast is secured to a vertical surface
to provide support. These may also
require guying depending on mast
height.
®
SYSTEM 3000 have been
1 – ERITECH DYNASPHERE with two spare finial tips.
2 – Three (3) ERITECH DYNASPHERE finial tip sizes.
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7
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Checking Lightning Protection Components
on Receipt
Before installation, in particular, check the
following:
Terminal(s)
t ERITECH
not been dented in any way.
®
DYNASPHERE terminals have
t The correct finial tip has been installed,
based on the overall height of the air
terminal above ground.
®
ERITECH
ERICORE Downconductor(s)
t The cable drum (if supplied) is in a
serviceable condition.
t Correct length(s)
t That there is no obvious damage to the
cable.
t Is terminated as required. If the
downconductor has been preterminated before shipment, check that
the termination is still intact and in
good order. See note on Page 14 on
removing protective covers.
t If the Upper Termination Kit has been
supplied separately, check that the
Cold-Shrink tube in the kit is in good
order, has no tears or cuts and has
not collapsed.
This information along with downconductor lengths and quantities (if
more than one length on the one
drum), will be printed on a label on the
side of the Cable Drum(s).
8
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
ERITECH® SYSTEM 3000 Installation
During the installation of the ERITECH® SYSTEM 3000, all site restrictions
and safety requirements must be followed.
It is important to follow the recommended order of installation:
1. Full installation of the grounding system.
2. Full installation of the downconductor.
3. Termination of the downconductor to the grounding system.
4. Upper termination of the downconductor (may already have been completed
by ERICO®) and connection to the ERITECH® DYNASPHERE air terminal with
correctly sized finial tip.
5. Termination of bonding cable from upper termination to structure.
6. Raise mast into position and secure.
Only attempt to install the
ERITECH SYSTEM 3000
storm-free periods.
If the terminal must be raised before
being connected to the ground system, or
cannot be immediately connected, then
attempt to connect the lower end of the
down-conductor to either the structure
steel reinforcing or some other reasonable
ground point.
during
Grounding Systems
Installation
Prior to the installation of the
lightning protection grounding
systems, it is important to refer
to site drawings of all underground
www.erico.com
services to ensure that these are
avoided and not interrupted during
trenching, excavation, boring or
driving ground rods, (see figure 4 on
page 11).
Care must be taken to follow the
ground survey design. Ensure the
correct materials have been provided
and are used to achieve an acceptable
Ground DC resistance (typically <10Ω).
Examples of typical grounding systems
that may be used (Note: these may or may
not be relevant to the specific ERITECH
SYSTEM 3000 design) are shown in figures
2 and 3 on page 10.
9
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Lightning Event
Counter - LEC IV
Ground rods
clamped or
welded to
copper ground
tape using
CADWELD
Each trench is treated
with GEM or ERITECH
Enhancing Compounds
®
Conductive Saddles
ERITECH
®
ERICORE
Ground Pit
Lower Termination
(Bound in Waterproofing
Mastic)
Copper Ground Tape
Typical lengths, minimum of 5 m (17 ft). (Lengths are dependantupon soil resistivity reading) @ 600 mm (24 in.) depth or greater if
required, to ensure that it is below the frost line.
Figure 2: Radial Ground.
Copper ground tape grid
5000 x 5000 mm (17 x 17 ft.)
@ 600 mm (24 in.) depth or
greater if required to ensure
that it is below the frost line.
Figure 3: Grid Ground.
ERITECH ground rods
clamped or welded to
copper ground tape,
using CADWELD.
10
Conductive
Saddles
Lightning Event
Counter - LEC IV
ERITECH ERICORE
Ground Pit
Lower Termination
(Bound in
Waterproofing
Tape)
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
POWER
GAS
WATER
IRRIGATION
COMMUNICATIONS
SEWERAGE/STORMWATER
Figure 4: Precautions required for ground pit excavation and lower termination corrosion protection.
It is advised that a ground pit is installed
where the end of the downconductor
This provides a convenient access point for
disconnection and future testing.
terminates to the ground system.
www.erico.com
11
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
When using ground rods it is advisable to:
t Use driving heads to prevent
mushrooming on top of the rod.
t Use driving heads when using
coupled rods.
tUse a post or picket driver.
When bonding the grounding system
components, try to use the recommended
methods suggested below:
t CADWELD
used to provide permanent electrical
bonding, corrosion resistance and
mechanical strength between
conductors, including most types
of copper cable, bar, rod, tape,
structural steel work, reinforcing
steel and pipe.
t Supplied ground rod clamps should
be used for termination of ERITECH
ERICORE downconductors directly
to ground rods. This allows later
disconnection for maintenance
requirements.
®
connections must be
®
t Use of aluminum lugs or couplings is
prohibited.
t Waterproofing mastic tape should be
used for waterproofing corrosion
vulnerable connections.
Ground Resistance Lowering
Compounds
Ground enhancing compounds, (such as
GEM) are recommended and supplied when
the existing soil mass has a high resistivity.
These compounds can be used to increase
the total surface area of grounding
conductors,
resistance / impedance.
Compounds may require water and a
mixing container.
thereby reducing the ground
When applying these compounds, be sure
to take necessary handling precautions
as advised by the product instructions,
and ensure that the directions for use are
followed correctly.
Insulation of Grounding
Systems
In some installations, it may be necessary
to insulate part of the ground system from
an area of the surface, for the purposes of
safety or isolation, (pedestrian walkways,
proximity to other services, etc.). In this
situation, it is recommended that a
minimum of 70 mm
copper cable is run in PVC conduit to the
connection point (start) of the intended
ground system. This conduit should be at
a depth of at least 600 mm (24 in.), or
greater if required, to ensure that it is below
the frost line to the start of the intended
ground system.
Another possible design method for
reducing surface step-potentials may be to
insulate the ground system for the first few
meters of depth from the surface. This is
done by isolating the initial injection point
of the downconductor from the surface
of the ground mass by running it through
PVC conduit to the required depth before
exposing it to the ground mass.
2
(2/0 AWG), insulated
Bonding the Lightning
Protection Ground to Other
Service Grounds
Where separate grounds exist eg: Structure,
Power, Communications and Lightning
Protection, they should be bonded
to form an equipotential ground plane.
This will eliminate the possibility of
loops and potential differences arising
under transient conditions.
together
ground
12
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Surface Area of Isolation
Downconductor
Lower Termination
Ground Pit
600 mm (24 in.) or greater to ensure
it is below the frost line.
2 m (80 in.)
2
2/0 (AWG)
Insulated
Conduit
70 mm
Insulated Copper
Cable
Start of
Grounding
System
ERITECH
Ground Rod
Figure 5: Various methods of isolating the ground system.
Authorization may be required by the
particular service providers before bonding
of these grounds takes place.
2
Bonding cable must be 70 mm
(2/0 AWG)
minimum depending on local standards. In
some circumstances, it may be necessary
to use a Transient Earth Clamp (ERICO
Part No. TEC100C) which effectively bonds
all grounds to the same potential under
transient conditions, to satisfy service
providers.
For further information, it is advised that
local applicable standards are consulted, ie
IEC 61024-1, BS 6551, AS1768, NFPA
C22.1-98 and NEC
www.erico.com
®
.
®
780,
13
®
Labelling
The labelling of ground pits or grounding
systems to local requirements is the
responsibility of the customer / installer.
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Downconductors
Depending on site requirements, the downconductor(s) may have their
upper terminations completed at a pre-specified end of the cable by
ERICO before shipment. These terminations will be protected by a short
length of flexible PVC tube.
It is VERY IMPORTANT that when removing these tubes, they are not
removed with a knife or cut in any way as this will damage the outer
layer of the termination. It is suggested that the tape and cover are best
removed by hand. (See figure 6)
All ERITECH® purpose-designed downconductors have a semi-conductive outer
sheath which is approximately 2 mm (0.08 in.) thick. Rough or careless handling
of the downconductor can damage this sheath and compromise its performance.
Downconductor Hauling
Locate the downconductor cable drum at
the appropriate location, (refer to figure 6).
When hauling the downconductor, use the
following guide points:
t Ensure that the cable drum, if supplied, is
in a serviceable condition.
t If the downconductor has been upper
terminated on the outside of the drum,
then the downconductor must be hauled
off the drum from the ground.
t If the downconductor has been upper
terminated on the inside of the drum,
then the drum must be at or near the
of the structure, so that the down-
top
conductor
drum towards the base, (see figure 6).
can be unwound from the
t When using slings or ropes to haul
downconductors, use MULTIPLE hitches
around the cable.
t DO NOT sling from the termination
coupling or cold-shrink section of the
terminated downconductor.
t DO NOT use cable stockings over
TERMINATED downconductor ends.
t Protect the downconductor from
abrasion and tearing when hauling over
rough surfaces, at all times, especially
around corners or through penetrations.
14
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Downconductor pre-terminated
on the OUTSIDE end when
wound on the cable drum
Figure 6: Cable pre-termination and drum locations.
INCORRECT
Figure 7: Incorrect and correct cable hoisting methods.
www.erico.com
CORRECT
15
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Penetrations
Before routing the downconductor through
any penetrations, ensure that:
t If un-terminated, a minimum hole
diameter of 50 mm (2 in.) is provided.
t If terminated, a minimum hole diameter
of 60 mm (2
3
⁄8 in.) is provided.
t Enough physical protection (conduit
or similar) is provided to stop the
downconductor from being damaged
when being fed through the penetration.
t When feeding the upper termination
of the downconductor through any
penetrations, the termination sheds
(flanges) should be temporarily wrapped
in insulation tape to reduce their
diameter and protect them against
abrasion. This is very important as the
cold-shrink tubes are susceptible to
tearing if nicked or scuffed.
If either side of the penetration requires
environmental protection ie: waterproofing,
air-con pressure seal, etc., use a suitable
sealant or deck sealing gland.
Routing
The route taken by the downconductor is very important
and must follow these rules:
t Carefully survey the intended route
of the downconductor immediately
prior to the installation to check for
any alterations that may effect the
original design, ie: structural changes,
new antenna or mast installations, air
conditioning towers or ducting, etc.
t Use the most direct route practical to
minimize the downconductor length.
t To minimize the risk of side-flash,
DO NOT route the downconductor back
beside itself after change of direction,
ie: 180º.
t Minimize number of bends.
t Minimize strain on the downconductor
Minimum separation = 2 m (80 in.). Try
to isolate as much as possible from other
services.
t If the downconductor must cross other
services, ensure that it crosses at right
angles to minimize any inductive effect.
t The lower end of the downconductor
must terminate as close as possible to the
initial injection point of the grounding
system.
INCORRECT
t Allow 500 mm (20 in.) of slack
in the length of downconductor
at the upper end of the cable
to facilitate mast erection and correct
seating of the ERITECH
terminal in the top of the FRP mast.
t
Where isolation of the downconductor
required, (for physical or proximity safety
reasons) install the cable in a
insulating conduit with a min
thickness of 3 mm (
NOTE: This is the only time that the
downconductor should be isolated from the
structure and generally only for 2.4 m
(8 ft.) maximum. DO NOT route the entire
length of downconductor in insulated
conduit.
®
DYNASPHERE
1
imum wall
⁄8 in.).
is
suitable
CORRECT
Figure 9: Correct & incorrect cable routing.
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COMMUNICATIONS / POWER
17
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
t To seat the terminal correctly in the top
of the FRP mast, any cable slack will
have to be removed from the mast while
also minimizing any stress on the upper
termination sheds (flanges) by twisting the
FRP mast against the terminal for at least
one turn.
If the downconductor is damaged
during installation, it must be
checked by an ERICO
representative to see if the damage will
effect its safe operation.
Securing the Downconductor
Securing of the downconductor not only provides a
mechanical attachment to the
structure, but also an Electrostatic connection to the structure via
the semiconductive outer sheath of
the downconductor cable.
It is important that the downconductor is both physically and
electrically secured to the entire
length of the structure to relieve both
physical and electrical stresses along
the downconductors’ length.
The electrical bonding of the downconductor is especially important for
at least the first 10% of the downconductor route from the upper
termination, and for this reason the
downconductor must be secured at
least every 1 m (40 in.).
ERITECH® brand of saddles
and conductive clamps are
recommended for the purpose
of securing the downconductor. These
have been specifically designed and
manufactured to mechanically secure and
electrically bond the ERITECH
®
ERICORE
to the structure, while minimizing stress
points on the cable.
Use of a brand of saddles other than
ERITECH can compromise the outer sheath,
creating high stress points which can lead
to flashover, (see figure 10).
Use ERITECH clamps only
Figure 10: Detail shows the need to use ERITECH
Clamps.
18
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
t For brick and concrete walls or roofs,
use the ERITECH
saddles. These have two 6 mm (
®
brand of stainless steel
1
⁄4 in.)
diameter holes on either side and are
suitable for use with masonry anchors.
These saddles can also be used with other
suitable fastenings against wood, fiberglass
and metallic surfaces.
t When securing externally to round section
structures such as pipes, tower legs,
masts, etc, stainless steel cable ties are
recommended. Ensure that these are
firmly secured.
t For securing to other structures such as
angle iron, ie: radio towers, structural
beams etc., use CADDY
clamps and suitable cable clamps from
ERICO.
®
brand of beam
t If the downconductor is to be routed
above a false ceiling, ensure that it is
fixed to the underside of the concrete
floor slab.
t Use of exothermic fastening methods
on ERITECH brand of saddles is NOT
recommended.
t Use of CADDY
strut system) is recommended where
suitable, (see figure 11).
Use of Mast or Conventional
Cable as the Downconducto
In some installations, the mast may be used
as the downconductor or alternatively, in
short-run installations, conventional cable is
sometimes used. In these cases, a Terminal
Lug Coupling Adaptor will be supplied
to allow a lugged 50 mm
2
(2/0 AWG) (depending on local
70 mm
minimum standards) cable termination to
the base of the ERITECH
(see figure 12).
®
ERISTRUT (or other similar
r
2
(1/0 AWG) or
®
DYNASPHERE,
Use of CADDY® ERISTRUT
to anchor downconductor
with S/S cable ties
Figure 11: Downconductor anchored to strut.
Lock Screw
Lightning Protection
Lug Coupling
M10 Bolt
Figure 12: Lug Coupling for non-ERITECH
ERICORE
downconductors.
Terminal Base
2
50 mm
(1/0 AWG)/
2
70 mm
(2/0 AWG)
minimum
downconductor
(or as per local
standards)
®
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19
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