Lightning Protection International Guardian System 5 Installation Manual

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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

GUARDIAN SYSTEM 5 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 Guardian System 5, installers should check with LPI or an
authorised distributor to conrm they have the most recent version of the Guardian
System 5 Installation manual.

It should be noted that 100% (100 percent) protection level for direct lightning strikes
is not possible and cannot be provided due to the lightning discharge process being a
natural atmospheric event.

Guardian System 5 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: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.lpi.com.au

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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 1

Lightning Protection International Pty Ltd

Guardian Install Manual V12.indd 3 22/9/08 4:25:18 PM

2 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

Contents

Warranty 3

Lightning Protection 3

General Safety Guidelines 4

Recommended Installation Method 4

Checking Lightning Protection
Components Supplied 12

LPI Guardian System 5 Installation 12

Installation of the Lightning Earth 13

Ground Resistance Lowering Compounds 15

Bonding the Lightning Earth 15

Labelling 15

Installation of the HVSC Downconductor 15

Hauling the HVSC Downconductor 16

HVSC Downconductor Clearance Holes 18

Routing 18

Fixing of the HVSC Downconductor 20

Installation 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

Mast Couplings and Guying Points 37

Guying 38

Preparation for raising the Mast into
position 39

Raising of Mast 39

Lightning Strike Recorder (LSR1) 41

Certification 43

Operation and Maintenance 43

Testing the Guardian CAT Terminal 44

Testing the Lightning Earth and the
HVSC Downconductor 45

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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 3

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 certied by LPI or its distributor. All other costs such as freight, re-installation,
loss of prot, insurance premiums are not included.

Responsibility for other direct or indirect damages or death is also specically excluded from
the warranty.

The range of Guardian CAT terminals (or to our knowledge any other lightning protection
system) cannot provide 100% protection and therefore it is not inferred.

As conrmation of the above paragraph we refer to Australian Standard AS 1768 (2007).

Lightning Protection

Comments on the Australian Standard AS 1768 (2007).

We refer to the standard where it states that it provides 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
that does occur.

Thunderstorms are natural phenomena and there are no proven devices and methods capable
of preventing lightning ashes. Direct and nearby cloud-to-ground lightning discharges
can be hazardous to persons, structures, installations and many other things in or on them.
Consideration should always be given to the application of lightning protection measures.

Users are warned that direct strike lightning protection is only one aspect of the overall
protection strategy required for comprehensive structural, personnel and equipment safety.
Correctly designed and installed low impedance earthing, elimination of earth loops, systems
engineering, surge protection on power lines and transient protection of communications, data

and telephone lines are also essential.

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4 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

Figure 1.

• 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.

• 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.

• The installation must conform to all relevant local standards 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 to the lightning earth.

4. Upper termination of the HVSC Downconductor and connection to the Guardian CAT
terminal.

5. Preparation and raising of the mast into position.

The LPI Guardian CAT Terminal should only be installed during storm free periods.

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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 5

LPI GUARDIAN CAT TERMINAL

LPI UPPER TERMINATION KIT

LPI FRP SUPPORT MAST

LPI INLINE COUPLING

LPI GUY KIT

LPI CABLE TIES

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LOWER MAST ASSEMBLY WITH BASE

LPI SADDLES AND FIXINGS

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LIGHTNING STRIKE RECORDER

LPI LOWER TERMINATION KIT

LPI INSPECTION PIT

LPI EARTHING SYSTEM

LPI GROUND
RESISTANCE
IMPROVEMENT
POWDER

BUILDING

IMPORTANT:

Guardian CAT terminal to
be a minimum of 2
metres above the highest
point of the building.
Recommended clearance
height = 5 metres.

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: 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

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

Lightning Protection International Pty Ltd

Drawn

Date

Scale

Title

File

Version

CTA-01

Guardian CAT terminal assembly
component details

CAT Installation Type 1.dwg

NTS

9/4/2008

John Davey

V1.00

Figure 2.

Guardian Install Manual V12.indd 7 22/9/08 4:25:19 PM

6 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

LPI GUARDIAN CAT TERMINAL

LPI UPPER TERMINATION KIT

LPI FRP SUPPORT MAST

LPI CABLE TIES

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LOWER MAST ASSEMBLY

LPI SADDLES FOR CANTILEVERING MAST

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LIGHTNING STRIKE RECORDER

LPI LOWER
TERMINATION KIT

LPI INSPECTION PIT

LPI EARTHING SYSTEM

EXISTING STRUCTURE

LPI GROUND RESISTANCE IMPROVEMENT POWDER

IMPORTANT:

One third of the mast height
must be securely fixed to the
structure.
Guardian CAT terminal to be a
minimum of 2 metres above the
highest point of the building.
Recommended clearance
height = 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

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: SAD/FIX

LPI INLINE COUPLING

(3 PER SET)

Lightning Protection International Pty Ltd

Drawn

Date

Scale

Title

File

Version

CTA-02

Guardian CAT terminal assembly
component details

CAT Installation Type 2.dwg

NTS

9/4/2008

John Davey

V1.00

Figure 3.

Guardian Install Manual V12.indd 8 22/9/08 4:25:19 PM

Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 7

LPI GUARDIAN CAT TERMINAL

LPI UPPER TERMINATION KIT

LPI FRP SUPPORT MAST

LPI CABLE TIES

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LOWER MAST ASSEMBLY

LPI HIGH VOLTAGE SHIELDED CABLE

LPI LIGHTNING STRIKE RECORDER

LPI LOWER TERMINATION KIT

LPI INSPECTION PIT

LPI EARTHING SYSTEM

TYPICAL TOWER

LPI GROUND RESISTANCE IMPROVEMENT POWDER

IMPORTANT:

One third of the mast height
must be securely fixed to the
structure.
Guardian CAT terminal to be
a minimum of 2 metres
above the highest point of
the building.
Recommended clearance
height = 5 metres.

LPI BEAM AND CLAMP
SUPPORT

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 REQUIRED FOR
RADIAL LP EARTH

4 X CBER458
4 X RTC1625A
1 X EPIT-P

1 X GRIP-10
30 X CT253

ORDERING CODE: BEAM CLAMP/CABLE

SUPPORT-HSVC

LPI INLINE COUPLING

(2 PER SET)

Lightning Protection International Pty Ltd

Drawn

Date

Scale

Title

File

Version

CTA-03

Guardian CAT terminal assembly
component details

CAT Installation Type 3.dwg

NTS

8/4/2008

John Davey

V1.00

Figure 4.

Guardian Install Manual V12.indd 9 22/9/08 4:25:20 PM

8 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

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

6

0

-

4

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 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.

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Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 9

LPI GUARDIAN CAT TERMINAL

THREADED GI ADAPTOR (FEMALE
THREAD 2 INCH BSP)

LPI SADDLES FOR
CANTILEVERING MAST

MAST ASSEMBLY WITH GI ADAPTOR

SUITABLE MOUNTING SADDLES

IMPORTANT:

One third of the mast height must be
securely fixed to the structure.
Guardian CAT terminal to be a minimum
of 2 metres above the highest point of
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

CTA-05

Guardian CAT terminal assembly
component details

CAT Installation Type 5.dwg

NTS

28/7/2008

John Davey

V1.01

Figure 6.

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10 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

Figure 7.

LPI GUARDIAN CAT TERMINAL

THREADED GI ADAPTOR

(FEMALE THREAD 2 INCH BSP)

MAST ASSEMBLY AND BASE
WITH GI ADAPTOR

LPI GUY KIT ORDERING CODE:
GUYKIT-4M
GUYKIT-4M-SS
GUYKIT-7M
GUYKIT-7M-SS

IMPORTANT:

GUARDIAN CAT terminal to be a minimum of 2 metres above the highest
point of the building.
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 terminal assembly
component details

CAT Installation Type 6.dwg

NTS

20/8/2008

John Davey

V1.00

Guardian Install Manual V12.indd 12 22/9/08 4:25:22 PM

Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 11

Figure 8.

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12 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

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.

• Instructions, Warning Labels, Warranty, Test Certicate and relevant mast base components
supplied.

Downconductor(s)

• The HVSC cable drum (if supplied) is not damaged.

• The correct HVSC length(s) have been supplied.

• No obvious damage to the HVSC cable.

• If a factory completed upper termination is supplied, check to see that the termination is
not damaged and conrm 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 follows:

1. Installation of the lightning earth.

2. Installation of the HVSC downconductor.

3. Lower termination of the HVSC downconductor and connection to the lightning earth.

4. Upper termination the HVSC downconductor and connection to the Guardian CAT terminal.

5. Preparation and raising of the mast into position.

LPI Guardian System 5 Installation

Guardian Install Manual V12.indd 14 22/9/08 4:25:22 PM

Document 36 II Guardian Version 1.02 © Copyright 2008 LPI 13

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.

Figure 9.

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14 Document 36 II Guardian Version 1.02 © Copyright 2008 LPI

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 gure 9.

• Recommended to install a 3 x 10 metre length radial trench.

• Each radial should consist of a trench (Approx: 500mm Deep x 200mm wide x 10m length).

• An earth rod should be driven at the end of each trench.

• All rods should be interconnected through the use of 25mm x 3mm copper tape. The use of
earth rod clamps to x the tape to rods is recommended.

• Use waterproong mastic on all mechanical connections.

• The application of earth enhancing compounds such as LPI RESLO and GRIP assists to
reduce soil resistivity to the recommended level of less than 10 ohms.

• An earth pit should be installed where the end of the downconductor terminates to the
lightning earth as shown in gure 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 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.

Recommendations for bonding the earthing system components are listed below:

• The use of the EXOWELD exothermic welding process is a safe and efcient way of
providing a permanent connection between conductors. EXOWELD connections will not
corrode or rust with age.

• DO NOT use aluminium lugs or couplings.

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