Professional Documents
Culture Documents
EDITION 14
ERITECH® SYSTEM 3000 INSTALLATION,
OPERATION AND MAINTENANCE MANUAL
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. Installers of ERITECH®
SYSTEM 3000 should check that they have the latest edition.
This manual replaces HB-HBCR-134 (Issue 1) edition number 6-2000.
The ERITECH SYSTEM 3000 is manufactured by ERICO.
International patents on the ERITECH SYSTEM 3000 are existing and pending.
ERITECH SYSTEM 3000 (or any other lightning protection system) does NOT offer 100%
protection against all lightning events. However, correct installation is essential for the
maximum level of safety.
System Owner:
Location:
Date Installed:
Installation Contractor:
Purchased From:
Installation, Operation
and Maintenance Manual
HB-HBCR-169
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Table of Contents
Pre-Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
Grounding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Downconductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Structural Bonding Braid & Conductive Structural Points . . . . . . . . . . . . . . . . . . . Page 6
Lightning Event Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
ERITECH® DYNASPHERE Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Checking Lightning Protection Components on Receipt . . . . . . . . . . . . . . . . . Page 8
ERITECH® SYSTEM 3000 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
Grounding Systems Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
Ground Resistance Lowering Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
Insulation of Grounding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
Bonding the Lightning Protection Ground to other Service Grounds . . . . . . . . . Page 12
Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
Downconductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
Downconductor Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
Penetrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16
Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16
Securing the Downconductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 18
Use of Mast or Conventional Cable as the Downconductor . . . . . . . . . . . . . . . . Page 19
Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 20
Structure Bonding Braid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20
Terminating the ERITECH® ERICORE Lower End . . . . . . . . . . . . . . . . . . . Page 24
Terminating the ERITECH ERICORE Upper End . . . . . . . . . . . . . . . . . . . Page 28
Terminals and Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40
Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40
Mast Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 41
Mast Couplings & Guying Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 42
Guying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 44
Raising of Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 45
Lightning Event Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 48
Long Lengths of ERITECH ERICORE Downconductor . . . . . . . . . . . . . . . . . . . .Page 49
Parallel ERITECH® ERICORE cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 51
Series connected ERITECH ERICORE cable sections . . . . . . . . . . . . . . . . . . . . . . . Page 52
Practical Examples for long lengths of ERITECH ERICORE . . . . . . . . . . . . . . . Page 54
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 55
Operation & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 55
Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 58
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 59
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 62
Certificate of Compliance and Warranty Registration . . . . . . . . . . Inside Back Cover
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Installation, Operation
and Maintenance Manual
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.
The customer is responsible for:
a. Conformance to all governing codes.
b. The integrity of structures to which the products are attached, including their
capability of safely accepting the loads imposed, as evaluated by a qualified
engineer.
c. Using appropriate industry standard hardware as noted above.
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.
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.
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Pre-Installation Requirements
Figure 1.
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If required, replace the finial tip supplied Ensure that the configurations and
with the appropriate tip for the application, heights for your specific installation
and tighten firmly. conform to the design and consultation
directives.
Warning – Do not install the ERITECH® Specific advice for each mast configur-
DYNASPHERE without installing the ation is provided on pages 40 to 47.
correct finial tip.
When all of the components for the
ERITECH® SYSTEM 3000 have been
received, they should be checked against
the design “Bill of Materials” and for any
possible shipping loss or damage.
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• The correct finial tip has been installed, • If the Upper Termination Kit has been
based on the overall height of the air supplied separately, check that the
terminal above ground. Cold-Shrink tube in the kit is in good
order, has no tears or cuts and has not
ERITECH® ERICORE Downconductor(s) collapsed.
• The cable drum (if supplied) is in a This information along with down-
serviceable condition. conductor lengths and quantities
• Correct length(s) (if more than one length on the one
drum), will be printed on a label on the
• That there is no obvious damage to side of the Cable Drum(s).
the cable.
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During the installation of the ERITECH® SYSTEM 3000, all site restrictions
and safety requirements must be followed.
If the terminal must be raised before being Care must be taken to follow the
connected to the ground system, or cannot ground survey design. Ensure the
be immediately connected, then attempt to correct materials have been provided
connect the lower end of the down- and are used to achieve an acceptable
conductor to either the structure steel Ground DC resistance (typically <10Ω).
reinforcing or some other reasonable
Examples of typical grounding systems that
ground point.
may be used (Note: these may or may not
be relevant to the specific ERITECH SYSTEM
Grounding Systems 3000 design) are shown in figures 2 and 3
Installation on page 10.
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Conductive Saddles
Lightning Event
Counter - LEC IV
ERITECH® ERICORE
Ground Pit
ERITECH ERICORE
Ground Pit
Lower Termination
(Bound in
Waterproofing
Tape)
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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 This provides a convenient access point for
where the end of the downconductor disconnection and future testing.
terminates to the ground system.
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When using ground rods it is advisable to: When applying these compounds, be sure
to take necessary handling precautions as
• Use driving heads to prevent
advised by the product instructions, and
mushrooming on top of rod.
ensure that the directions for use are
• Use driving heads when using followed correctly.
coupled rods.
• Use a post or picket driver. Insulation of Grounding
Systems
When bonding the grounding system
components, try to use the recommended In some installations, it may be necessary to
methods suggested below: insulate part of the ground system from an
area of the surface, for the purposes of
• CADWELD® connections must be
safety or isolation, (pedestrian walkways,
used to provide permanent electrical
proximity to other services, etc.). In this
bonding, corrosion resistance and
situation, it is recommended that a
mechanical strength between
minimum of 70 mm2 (2/0 AWG), insulated
conductors, including most types
copper cable is run in PVC conduit to the
of copper cable, bar, rod, tape,
connection point (start) of the intended
structural steel work, reinforcing
ground system. This conduit should be at a
steel and pipe.
depth of at least 600 mm (24 in.), or
• Supplied ground rod clamps should greater if required, to ensure that it is below
be used for termination of ERITECH® the frost line to the start of the intended
ERICORE downconductors directly to ground system.
ground rods. This allows later
disconnection for maintenance Another possible design method for
requirements. reducing surface step-potentials may be to
insulate the ground system for the first few
• Use of aluminum lugs or couplings is meters of depth from the surface. This is
prohibited. done by isolating the initial injection point
• Waterproofing mastic tape should be of the downconductor from the surface of
used for waterproofing corrosion the ground mass by running it through PVC
vulnerable connections. conduit to the required depth before
exposing it to the ground mass.
Ground Resistance Lowering
Compounds Bonding the Lightning
Protection Ground to Other
Ground enhancing compounds, (such as
GEM) are recommended and supplied when
Service Grounds
the existing soil mass has a high resistivity. Where separate grounds exist eg: Structure,
Power, Communications and Lightning
These compounds can be used to increase
Protection, they should be bonded together
the total surface area of grounding
to form an equipotential ground plane.
conductors, thereby reducing the ground
This will eliminate the possibility of ground
resistance / impedance.
loops and potential differences arising
Compounds may require water and a under transient conditions.
mixing container.
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Downconductor
Lower Termination
Ground Pit
2 m (80 in.)
ERITECH®
Ground Rod
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Downconductors
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)
• Ensure that the cable drum, if supplied, • DO NOT use cable stockings over
is in a serviceable condition. TERMINATED downconductor ends.
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Downconductor pre-terminated
on the OUTSIDE end when
wound on the cable drum
INCORRECT CORRECT
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Penetrations Routing
Before routing the downconductor through
any penetrations, ensure that: The route taken by the down-
conductor is very important
• If un-terminated, a minimum hole and must follow these rules:
diameter of 50 mm (2 in.) is provided.
• If terminated, a minimum hole diameter • Carefully survey the intended route of
of 60 mm (2 3⁄8 in.) is provided. the downconductor immediately prior to
• Enough physical protection (conduit the installation to check for any
or similar) is provided to stop the alterations that may effect the original
downconductor from being damaged design, ie: structural changes, new
when being fed through the penetration. antenna or mast installations, air
conditioning towers or ducting, etc.
• When feeding the upper termination of
the downconductor through any • Use the most direct route practical to
penetrations, the termination sheds minimize the downconductor length.
(flanges) should be temporarily wrapped • To minimize the risk of side-flash,
in insulation tape to reduce their DO NOT route the downconductor back
diameter and protect them against beside itself after change of direction,
abrasion. This is very important as the ie: 180º.
cold-shrink tubes are susceptible to
tearing if nicked or scuffed. • Minimize number of bends.
If either side of the penetration requires • Minimize strain on the downconductor
environmental protection ie: waterproofing, during installation.
air-con pressure seal, etc., use a suitable
sealant or deck sealing gland.
Radius
< 500 mm
(20 in.)
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• Ensure bend radius maintained >500 mm • Allow 500 mm (20 in.) of slack
(20 in.). in the length of downconductor
at the upper end of the cable to
• Parallel routing with other services -
facilitate mast erection and correct
Minimum separation = 2 m (80 in.).
seating of the ERITECH® DYNASPHERE
Try to isolate as much as possible from
terminal in the top of the FRP mast.
other services.
• If the downconductor must cross other
• Where isolation of the downconductor
is required, (for physical or proximity
services, ensure that it crosses at right
safety reasons) install the cable in a
angles to minimize any inductive effect.
suitable insulating conduit with a
• The lower end of the downconductor minimum wall thickness of 3 mm (1⁄8 in.).
must terminate as close as possible to
NOTE: This is the only time that the
the initial injection point of the
downconductor should be isolated from the
grounding system.
structure and generally only for 2.4 m (8 ft.)
maximum. DO NOT route the entire length
of downconductor in insulated conduit.
INCORRECT
COMMUNICATIONS / POWER
CORRECT
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• To seat the terminal correctly in the top ERITECH® brand of saddles and
of the FRP mast, any cable slack will have conductive clamps are
to be removed from the mast while also recommended for the purpose
minimizing any stress on the upper of securing the downconductor. These
termination sheds (flanges) by twisting have been specifically designed and
the FRP mast against the terminal for at manufactured to mechanically secure and
least one turn. electrically bond the ERITECH® ERICORE
to the structure, while minimizing stress
If the downconductor is damaged points on the cable.
during installation, it must be
checked by an ERICO®
representative to see if the damage will Use of a brand of saddles other than
effect its safe operation. ERITECH can compromise the outer sheath,
creating high stress points which can lead
to flashover, (see figure 10).
Securing the Downconductor
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If more labels are required, contact your The use of the Structure
nearest ERICO® Distributor. Bonding Braid is NOT optional,
and MUST always be used.
Structure bonding
cable connected
to structural steel
Figure 13(a): Cantilevered FRP section on building. Figure 13(b): Cantilevered FRP section on Radio Tower.
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ERITECH®
Aluminum Mast ERICORE
ERITECH
Saddles at
1 m (40 in.)
intervals
(max.)
To nearest conductive
structural point (steel
work, concrete
re-inforcing, etc)
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CADWELD®, bolted, or
other suitable electrically
bonded method
Concrete Panel
Structure bonding cable
CADWELD, bolted, or
other suitable electrically
bonding method
Reinforcing Steel
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The 6 mm2 (8 AWG) copper cable used to metallic mast using 6 mm2 (8 AWG)
connect the Structure Bonding Braid to the insulated copper cable, (see figure 17).
structure must be one continuous length.
To bond the downconductor inside a
Joins in this cable would represent a
conductive mast pipe or conduit, secure
potential maintenance issue.
two stainless steel cable ties around the
Any metallic surfaces that the down- downconductor at every 1 m (40 in.) or at
conductor may be secured to, if possible, 2 m (80 in.) intervals with their tails left on,
should be electrically connected to the alligned at 180° to each other so that
structural steel work. when fed into the pipe, they maintain
contact with the inside wall of the pipe,
Also, when using a metallic mast (ie: free (see figure 17).
standing light pole), the Structure Bonding
Braid must be connected to the top of the
2 x stainless steel
cable ties at 180°
with tails left on
Structure bonding
cable attached to
top of freestanding
mast 1 to 2 m (40-80 in.)
intervals as appropriate
Freestanding metallic
mast where Downconductor
downconductor
cannot be secured
to inside of mast
Figure 17: Electrical bonding of downconductor within metallic mast section or pipe.
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1. Sharp Knife
2. Tape Measure
3. Flat Blade Screwdriver
4. Hacksaw
5. 150 mm (6 in.) Adjustable Spanner / Wrench
6. Roll Spring - (supplied with Upper Termination Kit)
7. Insulation Cutting Tool - (supplied with Upper Termination Kit)
8. Crimper (90 mm2) (only required if the cable lug is to be used)
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Refer to Figure 18 for the following 4. Carefully clean up the insulation friction
instructions (1 to 10). cut, removing any burrs for a neat finish.
1. With the hacksaw (or appropriate 5. Fit the roll spring 15 mm ( 5⁄8 in.) from the
cutters), cut the downconductor cable to end of the outer insulation over the
length, leaving enough cable to be able to exposed copper tape (roll spring supplied
easily and directly route it to the ground with upper termination kit).
termination. 6. Remove the copper tape up to the roll
2. At a distance of 100 mm (4 in.) from spring (exposing black triple extrusion
the end of the cable, carefully cut a shallow layers) by unrolling, then tearing the tape
notch into the black outer insulation, no up and back over the edge of the roll spring
deeper than 1 mm, ( 3⁄64 in.). Using the at about a 45º angle. If necessary, cut about
insulation cutting tool, cut around the 6 mm ( 1⁄4 in.) of the copper tape up against
circumference of the black outer insulation the roll spring with a knife and then tear
until the copper screen underneath is over the spring.
exposed. 7. Wrap one end of the 2.5 mm2 x 105 mm
Important! The insulation (12 AWG x 4 1⁄8 in.) bare copper wire
cutting tool uses friction to cut (supplied with the kit) around the hose
into the sheath and is less likely clamp, then fix the hose clamp over the
to damage the layers under- exposed copper screen of the down-
neath than using a knife. conductor and tighten with a screwdriver.
3. Use a knife to carefully cut along the 100 8. At 85 mm (3 3⁄8 in.) from the end of
mm (4 in.) length of black outer insulation the cable, carefully cut around the
to a depth of no more than 1 mm. ( 3⁄64 in.). circumference of the black triple extrusion
Be careful not to cut too deeply so that the layers with a knife, then, from the first cut,
copper layer underneath is not exposed or along the length of the insulation to the
damaged. Starting from the end of the end of the cable. Remove the layers and
cable, carefully remove the outer insulation discard.
and discard.
Copper Strands Copper Tape Black Copper Strands and Copper Tape Black
and Double Tape Layer Outer Sheath Double Tape Layer Outer Sheath
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9. Lay back all of the copper strands and wire from the hose clamp is bonded with
tape cut off the filler core with a hacksaw the final grounding connection and all of
or knife as close to the strands and tape as the other downconductor copper strands
possible without damaging them. Lay the and tape. Then securely tighten the whole
copper strands and tape neatly and connection.
uniformly back in place.
Note: The ground rod clamp supplied in this
10. If using the compression lug, combine kit must be tightened to 44Nm (32 lbf.ft.).
the end of the 2.5 mm2 (12 AWG) bare
copper wire from the hose clamp with the 13. Make sure the lower termination is free
downconductors’ copper strands and then of moisture. Using rubber gloves, shape the
fit ALL conductors into the 90 mm2 lug waterproofing mastic (supplied) around all
supplied with the kit. Make sure that it is of the exposed areas of the lower
fitted correctly before crimping with an termination.
appropriate crimper.
Note: Depending on the environment of the
11. Securely connect the lugged down- lower termination, it may be necessary to
conductor to the grounding system. wrap a sealing tape or mastic around the
waterproofing mastic to stop it from drying
12. If the ‘U’ bolt ground rod clamp (or
out over time.
other method) is to be used, then ensure
that the 2.5 mm2 (12 AWG) bare copper
ERITECH ERICORE
ERITECH®
ERICORE
System 3000
LEC IV
Hose Clamp
Copper Tape
2.5 mm
(12 AWG) Entire lower
Copper Wire termination
to be bound
Compression in waterproofing Rod Clamp
Lug mastic
Copper
Bus Bar
Ground Rod
To Grounding System
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Ground Pit
Downconductor
lower termination
bound in
waterproofing
mastic
Sy
ste
m
30
LEC IV 00
ERITECH®
Ground Rod
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Photo 2: Contents of upper termination kit and the tools required to complete the termination procedure.
1. Sharp Knife
2. Tape Measure
3. 2 x 375 mm (15 in.) Shifting Spanner / Wrench
4. PVC Electrical Tape
5. Roll Spring - supplied with termination kit
6. Insulation Cutting Tool - supplied with termination kit
The Upper Termination Kit consists of:
1 x Coldshrink Tube (red) 1 x Vital Warning Label 1 x Mastic Tape
1 x ERITECH ERICORE Coupling 1 x Structure Bonding Braid 1 x Instructions
(4 pieces when dismantled) 1 x Insulation Cutting Tool 1 x Crimp Lug
1 x Silicone Tape - 1.3 m (93 in.) 1 x Semi Conductive Tape 1 x Roll Clip
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The Insulation Cutting Tool uses 2. Using a knife, carefully cut the outer
friction to cut into the sheath and is insulation of the cable to a depth of no
less likely to damage the layers more than 1 mm (3⁄64 in.), for the full
underneath than using a knife. When 600 mm (23 5⁄8 in.), in the direction of the
the instructions call for the knife to be end of the cable. Be sure not to cut so deep
used, be sure not to cut any deeper as to expose or damage the copper layer
than instructed. underneath. Starting from the end of the
cable, carefully remove the outer insulation
If the instructions are not followed correctly, and discard.
or if any of the insulation layers or the
copper foil are incorrectly cut, then the 3. Carefully clean up the friction cut,
integrity of the lightning protection is removing any burrs for a neat finish.
affected.
4. Fit the roll spring 20 mm (6⁄8 in.) from the
Refer to Figure 21 on page 36 for the end of the outer insulation over the exposed
following instructions (1 to 11). copper tape.
1. At a distance of 600 mm (23 5⁄8 in.) from 5. From the end of the cable, remove the
the end of the cable, carefully cut a shallow copper tape up to the roll spring, exposing
notch into the black outer insulation no the black semi-conductive material by
deeper than 1 mm, (3⁄64 in.). Then, using the unrolling, then tearing the tape up and back
insulation cutting tool, cut around the over the edge of the roll spring at about a
circumference of the black outer insulation 45˚ angle. (If necessary, carefully cut about
until the copper screen underneath is 6 mm of the copper tape up against the roll
exposed. spring with a knife and then tear over the
spring).
Photo 3: Use of the insulation cutting tool to cut the insulation without damaging the layers beneath.
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6. Carefully remove the roll spring, then end of the cable, carefully cut a notch in
tape up the last 6 mm (1⁄4 in.) of the copper triple layered insulation no deeper than
tape with a piece of PVC tape, to stop 1 mm (3⁄64 in.). Then using the insulation-
further unravelling. cutting tool, cut around the circumference
of the triple layered insulation until the
7. Clean and degrease the outer sheath for copper underneath is exposed.
a distance of 100 mm (4 in.) from the cut
position. Using slight tension, wrap one 10. With a knife, carefully cut along the
layer of sealant tape (red) around the black 70 mm (2 3⁄4 in.) length triple layered
outer insulation with a small overlap of insulation of the cable to a depth of no more
5 mm (1⁄5 in.) over the copper tape screen, than 1 mm (3⁄64 in.). Be sure not to cut too
(see photo 5). deep, as to expose or damage the copper
layer underneath. Starting from the end of
8. Place the structure bond braid over the the cable, carefully remove the triple layered
cable so that it sits over the copper screen insulation and discard.
and up against the sealant tape (red).
Ensure that the braid loops are tight around 11. Remove one release foil from the stress
the copper screen. Tape the bond braid into control patch (green) and apply it level with
place with PVC tape, (see photo 6). the outer insulation cut, against the red
(Ultimately, this braid may require electrical sealant tape, (see photo 7). Wrap the entire
bonding to the structure.) patch around the cable as shown and
remove the release foil during installation.
9. At a distance 70 mm (2 3⁄4 in.) from the Avoid air pockets, wrinkles or creases.
Photo 4: Using the roll clip to cut and remove the copper screen.
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• A Compression Nut
• A Compression Ring
• A Compression Cone
• A Main Coupling Piece
15. Unwrap the material double tape layer Photo 5: Red sealant tape applied over overlap.
back to the compression ring. Place the
compression cone between the filler core
and the copper strands as shown in Figure
22. The cone should be “pushed on” until
it is flush with the end of the filler core.
Neatly form the copper strands back over
the cone in their original order.
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19. Loosening Termination Slide the termination off the holdout with a
twisting motion, holding the termination
This operation is vital to the simple that is on the holdout in one hand and
installation of the product. pulling the holdout with the other.
There are two terminations in this kit, Note: Do NOT stretch the termination.
(one with three sheds, the other with five).
Loosen both in the manner shown opposite. Do NOT hold the termination that is
Install the five shed termination first. partially installed and attempt to pull the
remaining termination off the holdout, as
Hold the termination in one hand and the this will stretch the termination and
holdout in the other. Gripping firmly, twist generate an improperly installed termination
the termination and holdout in opposite if not repositioned.
directions. Repeat twisting the termination
and holdout, moving the hand in short Using the pull tabs, pull the flip-back
increments up the termination until the portion away from the main termination, at
entire termination is felt to move on the the same time working the first two fingers
holdout. Slide the termination until it lines of each hand between the flip-back and
up with the end of the holdout tube as main termination. Pull the stretched out flip-
shown. Note: Take care not to slide the back over the cable jacket and sealant.
termination off the end of the holdout.
Stop the termination about 1⁄4” (6 mm) from Make sure the termination length is in
the end of the holdout. accordance with the dimensions shown.
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Slide the three-shedded termination over the cable until it meets the leading edge of the
sealant strip as shown. Twist the termination and slowly push it to the end of the holdout.
Slide the termination completely off the holdout using a twisting and pulling motion as shown.
Using the pull tabs, pull the flip-back portion away from the main termination, at the same
time working the first two fingers of each hand between the flip-back and main termination.
Pull the stretched out flip-back over the sealant.
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20 mm
70 mm (2 3/4 in.) 380 mm (15 in.) (6/8 in.)
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22. Using the roll of silicone tape (grey), Connecting the ERITECH® DYNASPHERE
overwrap half layers from 20 mm (3⁄4 in.)
over the end of the coldshrink to 30 mm 24. Feed the downconductor (and structure
(1 1⁄8 in.) over the coupling so that it covers bonding cable) through the FRP mast so
the joint between the main coupling and that the entire termination is protruding
compression nut, (refer to figure 24 on from the top of the mast. Remove the lock
page 39). screw in the base of the ERITECH®
DYNASPHERE terminal, then screw the
Wrap with moderate tension (10 to 100% terminal all the way onto the termination
stretch). Apply one final layer with no coupling thread. Replace the lock screw
stretch. Press down, to avoid the end lifting back into position so that it locks the thread
before fusion of the tape takes place. into place and will stop the terminal from
unscrewing.
The finished termination must be
protected against any abrasion 25. Carefully pull the downconductor (and
and sharp edges during transport structure bonding cable) back down
or installation, as the coldshrink through the FRP mast so that the terminal
tubes are susceptible to ripping or base sits correctly in the top of the mast.
tearing if nicked or scuffed. Twist the FRP mast at least one complete
turn at the base of the terminal to remove
23. The structure bonding braid MUST be any stress on the termination sheds (flanges)
electrically connected via a 6 mm2 (8 AWG) and to seat the terminal correctly.
length of insulated copper cable to the
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Note: It may be necessary to pull 27. Place the Vital Warning Label in a
back any slack of ERITECH® ERICORE prominent position at the base of the mast,
downconductor through the FRP or beside the downconductor at eye level, if
support mast to achieve a properly the installation is in an area where it is
seated fit for the ERITECH® possible for persons to gain access.
DYNASPHERE.
These termination procedures
The ERITECH DYNASPHERE must not should be strictly adhered to
be skewed and the base of the since an incorrect termination
terminal must be fully inserted into will result in failure of the
the top of the mast. system.
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30 mm 40 mm 20 mm
(1 1/4 in.) (1 1/2 in.) (3/4 in.)
Figure 24.
Photo 14.
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Terminals
If the lower section of the
Once the terminal has been checked and mast is conductive, ie.
found to be in an acceptable condition for aluminum or galvanized
installation, it can be attached to the iron; then:
terminated downconductor as shown in the • It must be electrically bonded to
Upper Termination instructions on page 37. the nearest conductive structural
point. This may be either
Please note, the serial number of each unit structural steel work or concrete
will have been recorded in the Certificate Of reinforcing. Refer to page 20 for
Compliance (inside back cover) in this details.
manual. • The downconductor must be
secured to the mast at 1 m (40
Masts in.) intervals (max.).
The selected mast configuration chosen must: Three basic types of mast configuration
include:
• Elevate the terminal to the required
height as determined by the design Guyed
process (minimum height of 3 m • Single length guyed - one section of
(10 ft.) above the highest point of the FRP (Fiberglass Reinforced Plastic)
structure). mast material guyed at the top.
• Include a minimum of 2 m (81 in.) of • Double length guyed - two sections of
insulated mast material (FRP) immediately mast material, usually aluminum lower
below the air terminal. and FRP upper, guyed between the two
sections and at the top.
• Be suitably rated for local weather
conditions. It is advisable that guidance Cantilevered
from a local civil engineer be sought. Used in situations where it is more practical
to mount without a base, eg: radio towers.
• Be securely attached to the selected
mounting point(s). • At least one third of the lower mast
should be secured against the structure.
• Be guyed if applicable.
• Cantilevered masts can either be free
standing or guyed for extra stability.
Freestanding
Often used where the terminal, down-
conductor and grounding system are
isolated from volatile areas by installing the
ERITECH® SYSTEM 3000 at least 5 m (17 ft.)
away from those areas.
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ERITECH
DYNASPHERE
ERITECH® ERITECH 2.0 m (81 in.) FRP
DYNASPHERE DYNASPHERE
Storage
2.0 m (81 in.) FRP Tank
Free Standing
4.6 m (15 ft.) Mast
FRP (1/3 of
Inline Coupling Mast Mounted
to Structure)
1.5 m (5 ft.)
Aluminum
Mast
5 m (17 ft.)
Comms Tower
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ERITECH®
DYNASPHERE
Insulated Guying
FRP
Mast
ERITEECH®
DYNASPHERE
U Bolts
U Bolts
5 m (17 ft.)
Aluminum Mast
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Minimum spacing
between Saddles
Fiberglass "Dead" End
30 mm (1 1/4 in.) 30 mm (1 1/4 in.)
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• Everyone involved in the lift knows what • The mast can be easily and safely
has been planned and how the lift is to secured at the base and guying points
be performed. immediately after it has been lifted
into position.
• The mast is securely footed and cannot
move out of control during the lift. • Any extra rigging that is required for
the lift only, can be removed after the
• Any guying has been properly secured at mast is in place.
the mast anchor points.
It may be necessary to use a gin pole
• The downconductor has been correctly arrangement to assist when lifting the mast,
terminated and the structure bonding especially if the mast is over 6 m (20 ft.) in
cable has been attached to the height or it is being lifted from a sloping
termination. surface (typical arrangement shown below).
• The downconductor can not be damaged When using a crane to lift the mast into
at the base of the mast while lifting, ie: if position, ensure that:
the cable exits from the mast base it
must be protected and not used as the • The crane has enough weight and
pivot point for the mast. Maintain a height capacity to safely do the job.
minimum bending radius of 500 mm
(20 in.). • There is nothing overhead that will
obstruct the lift.
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• Any guying has been properly secured at • The downconductor can not be
the mast anchor points. damaged at the base of the mast while
lifting (maintain a minimum bending
• The downconductor has been correctly radius of 500 mm (20 in.)) or can not be
terminated and the structure bonding damaged as a result of dragging over
cable has been attached correctly. rough or sharp surfaces during the lift.
• The ERITECH® DYNASPHERE terminal is • Any extra rigging that is required for
NOT used as a slinging point. the lift only, can be removed after the
mast is in place.
• When slinging the mast, ensure that
the slings or ropes can not foul the • The mast can be easily and safely
ERITECH DYNASPHERE terminal. secured at its base and guying points
when it is lifted into position.
• When lifting the mast, the down-
conductor is tied off to the mast as well
to remove any strain on the down-
conductors termination to the ERITECH
DYNASPHERE terminal.
Do not sling
at base of
terminal
Slung at
multiple points
INCORRECT CORRECT
Do not lift
with more than Stress removed from upper
5 m (17 ft.) of termination by securing
Max 5 m downconductor downconductor to lower mast
(17 ft.) hanging from with flat webbing or other
mast without appropriate sling.
tying off to
mast.
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Protective enclosure
Sy
ste
m
Counter 3
Clear window
Figure 32: LEC IV in protective enclosure with clear viewing window, for
easy counter reading.
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Up to 2.7 20
2.8 to 3.9 30
4.0 to 5.2 40
5.3 to 6.6 50
6.7 to 9.5 60
9.6 to 12.5 80
12.6 or more 100
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LOCKING SCREW
COMPRESSION COUPLINGS
E2 ERITECH® ERICORE
FRP MASTS
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GUY RING
ERITECH®
DYNASPHERE
1 x TERMDUALCOUP
2 x FRP MAST
(2 m or 4.6 m)
GUY KIT
2 x ERITECH® U Bolts
ERICORE
CABLE
ALUMINUM MAST
Figure 35: Typical mast arrangement using the twin ERITECH® ERICORE arrangement.
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The lower end of the upper cable section In some installations, both lugs can be
is fitted with a Lower Termination, and directly connected to a suitable
the upper end of the lower cable section conductive structural point, but in some
is fitted with an Upper Termination. The installations it will be more convenient to
Lower Termination inherently has a lug connect both lugs to a small busbar, and
termination, but the Upper Termination have this busbar connected to a suitable
needs to be fitted with a bonding nearby conductive structural point. Note
termination (ERICORE/UTSP) and lug that the conductor used in this case must
(termlugcoup) to allow it to be lugged. be a minimum of 16 mm2 (4 AWG) and
Each of these two lugged terminations should not exceed 5 m in length. A
must be electrically bolted together and suitable conductive structural point may
to a suitable Conductive Structural Point. be either structural steel work or the rein-
forcing within concrete panels or slabs.
ERITECH®
ERICORE
Lower
Termination
Busbar connected
to conductive
structural point
Upper Termination
ERITECH® Lug Coupling
ERICORE Upper
Termination
Figure 36: The twin ERITECH ERICORE conductors Figure 37: The method of joining ERITECH
are run parallel down to the ground. ERICORE sections.
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Certification
The certification of the ERITECH® SYSTEM • The integrity of the mast and any
3000 installation must be performed by an associated brackets and fastenings.
authorized ERICO® representative.
• Guying, anchor points and fastenings.
This is done in conjunction with issuing of a
Certificate of Compliance, which is supplied • Downconductor routing, securing and
in the back of this manual. seals.
When this certificate has been completed • Ground termination of downconductor.
and signed, a copy must be either taken by
the ERICO representative or sent to the • Grounding System.
nearest ERICO office.
• Labelling.
During the process of certification, the
following will be checked: • Completion of Maintenance Records
in this manual.
• Installation matches the originally
approved design. • Certificate of Compliance and
web site registration completed.
• Installation needs to be registered at
www.erico.com. • General mechanical check of all
fastenings.
• The system does not require any external • If any changes have been made to the
power requirements or replacement structure, whether they be structural,
components for normal operation. antennae or building maintenance
unit additions, etc.
• It is essential that the ERITECH
SYSTEM 3000 Lightning Protection Use the maintenance record table on page
System be regularly maintained. 58 to record the relevant details. These
records and manual should be kept in a safe
place near the installation.
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NOTICE
Users are advised that the ERITECH® SYSTEM 3000 Lightning Protection System
may not function to its full efficiency under ice or snow conditions or on
chimneys or stacks emitting gasses or pollutants. For advice on temperature or
corrosion concerns, please contact your local ERICO® Distributor.
MAINTENANCE RECORD
Lightning Ground Check of
Date of Event Resistance Maintenance Comments Inspected
Inspection Counter Readings Points 1 to 11 by
Reading 1 2 3
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Specifications
Diameter: 36 mm (1 7/16”)
Weight: 1.2 kg / m
13 oz / ft.
FRP Mast
Purpose designed Fiberglass Reinforced Plastic, manufactured from non-
hydroscopic epoxy and glass laminate, provides an insulated mast for
mounting the ERITECH® DYNASPHERE.
Lengths: 2 m (81 1/2 in.) & 4.6 m (187 3/4 in.)
Inside Diameter: 60 mm (2 3/8 in.)
Outside Diameter: 68 mm (2 11/16 in.)
Weight: 2 m = 3.3 kg (7 1/4 lbs.)
4.6 m = 7.6 kg (16 3/4 lbs.)
Color/Finish: Black
Aluminum Mast
Light weight lower mast material.
Lengths: 3, 4, 5 & 6 m
(122 1/2, 163 1/4, 204 & 245 in.)
Inside diameter: 61.9 mm (2 7/16 in)
Outside diameter: 69.9 mm (2 3/4 in.)
Weight: 2.4 kg / meter
Available with or without mast base plate.
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Inline Coupling
Guy Ring
Purpose designed guy ring, providing 3 guy anchoring points from the
neck of the ERITECH DYNASPHERE.
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Guy Kit
Purpose designed guying kits for anchoring from a guy ring or
inline coupling. Each kit comes complete with six stainless steel
thimbles, plus 18 guying grips per kit. Refer to pages 44 and 45 for
more detail.
4 m Guy Kit 7 m Guy Kit
Guy Diameter: 4 mm (5/32 in.) 5 mm (3/16 in.)
Actual Guy Length: 6 m (20 1/2 ft.) 10 m (34 ft.)
Guy Tensile Strength: 430 kg (946 lb.) 560 kg (1232 lb.)
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Securing Fastenings
Saddles, cable hangers or clamps used to Bolts, screws, masonry anchors or other
mechanically and electrostatically secure the hardware used to secure anchors to the
downconductor to the structure. structure.
Bond FRP
Electrical connection between the outer Fiberglass Reinforced Plastic. Insulated mast
semi-conductive sheath of the down- for mounting ERITECH® DYNASPHERE.
conductor and other electrically conductive
materials. Metallic Mast Section
Any type of electrically conductive mast
Clamp section, ie: aluminum masts, galvanized free
Electrically conductive, mechanical standing mast, etc.
anchoring of the downconductor to the
structure. Structure Bonding Braid
Conductive lead at the base of the upper
Conductive Structural Point termination used to electrostatically bond
Any point of the structure that is electrically the downconductors’ outer sheath to a
conductive and is either connected to the conductive structural point if the down-
structure earth or has a substantial metallic conductor cannot be clamped to a
mass. conductive structural point within 5 m
(17 ft.) of the upper termination.
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CERTIFICATE OF COMPLIANCE & WARRANTY REGISTRATION
E1498IS06EN:Manual
For warranty purposes, please ensure that you are registered for warranty service, by completing and mailing this card to ERICO®, preferably within seven (7) days of installation.
Installation Contractor:
Address:
Type of Structure :
11:00 AM
Installed by:
Terminal Type(s):
63
Serial Number(s): IMPORTANT NOTICE:
Page 65
This certificate is to certify that the installation and equipment is in accordance with the requirements of ERICO
Tests witnessed by accredited representative of the owner The accredited representative of ERICO
www.erico.com
www.erico.com Standards. The Manufacturer and the Purchaser mutually acknowledge that the product by its nature
may be subject to degradation as a consequence of the number and severity of surges and transients
that it experiences in normal use and this warranty excludes such gradual or sudden degradation. This
warranty does not indemnify the Purchaser of the product for any consequential claim for damages or
loss of operations or service or profits. Customers should contact their nearest ERICO agent to obtain a
Product Repair Authorization Number prior to making any claim under this warranty. This is only a
summary of the warranty given by the Manufacturer. The full text of the warranty is set out in the
Manufacturer’s Conditions of Quotation and Sale.
www.erico.com Standards. The Manufacturer and the Purchaser mutually acknowledge that the product by its nature
may be subject to degradation as a consequence of the number and severity of surges and transients
that it experiences in normal use and this warranty excludes such gradual or sudden degradation. This
warranty does not indemnify the Purchaser of the product for any consequential claim for damages or
loss of operations or service or profits. Customers should contact their nearest ERICO agent to obtain a
Product Repair Authorization Number prior to making any claim under this warranty. This is only a
summary of the warranty given by the Manufacturer. The full text of the warranty is set out in the
Manufacturer’s Conditions of Quotation and Sale.
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WARNING
ERICO products shall be installed and used only as indicated in ERICO’s product instruction sheets and training materials. Instruction sheets are available at www.erico.com and from your ERICO
customer service representative. 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.