A SIX POINT PROTECTION APPROACH FOR LIGHTNING PROTECTION, SURGE

PROTECTION AND SINGLE POINT GROUNDING FOR LOW VOLTAGE FACILITIES

D.W. Edwards and P.M. Wherrett

ERICO Lightning Technologies Pty Ltd

Abstract

High energy over-current and over-voltage transients induced by direct lightning strikes or
conducted into a site by power and telecommunication lines cause millions of dollars damage
each year. Whilst no single technology can prevent damage, a six point protection approach
provides a comprehensive check list covering all damage mechanisms. Commencing with
effective means to capture, conduct and then safely dissipate the energy in direct lightning
strikes to ground, the plan continues with clamping and diverting transients arriving at the
site via external cables.

The importance of capturing the direct lightning strike on a purpose designed air terminal
is explained. Lightning currents (up to 200 kA) can then be conducted directly to ground
via purpose designed down conductors, while minimising the dangers of “side flash”.
In addition to surge protection and transient product technologies, the need to provide a low
impedance ground plane throughout the site is emphasised. A single point ground
connection for all equipment within a facility is recommended. This reduces the likelihood
of earth loops or “sneak” potential gradients induced by the high frequency, high dI/dt and
dV/dt transients.

Transient protection technologies for equipment connected to mains power are discussed.
Communications equipment, data processing and signal equipment has additional protection
requirements.

1 - THE PROBLEM 2 - SIX POINT PROTECTION PLAN

Lightning and over-voltage transients cause millions There is no single technology that can eliminate the
of dollars damage to low voltage installations each risk of lightning and its transients. A holistic systems
year. Damage to equipment in the US alone was approach is required. From over 20 years experience
estimated to US$1.2 billion annually, before in examining the nature and extent of damage created
including the loss of productivity from industrial and by lightning transients, ERICO Lightning
business downtime. Technologies has developed a comprehensive Six
Point Plan to minimise exposure to damage.
High energy over-voltage transients may be derived
from direct lightning strikes to building structures or The Six Point Plan recommends
they may be conducted on power and telephone cables
entering buildings and facilities. Induced transient 1. Capture the direct lightning strike at a preferred
over-voltages may also originate from near strikes point on purpose-designed air terminals;
due to capacitive or inductive coupling. 2. Conduct the lightning current to ground safely via
a purpose-designed downconductor system to
• Peak currents can exceed 200 kA with 10/350 µs minimise the dangers of side-flashing;
waveshape (I.E.C. 1024-1). 3. Dissipate the energy into the ground with
• Current rise times vary between 0.1 - 100 µs. minimal rise in ground potential through a low
• Multipulse surges are experienced in over 70 per impedance grounding system;
cent of direct strike situations. This is a naturally 4. Eliminate earth loops and differentials by creating
occurring phenomenon where up to 20 restrikes an equipotential grounding plane under transient
may follow the path of the main discharge at conditions;
intervals of 10-200 milliseconds. 5. Protect equipment from surges and transients on
• Continuing currents of 200-500A lasting 1-2 power lines; and
seconds may also occur.
6. Protect equipment from surges and transients on away from antennae and cabling to minimise the risk
communications and signal lines to prevent of damage to equipment from the direct force and
equipment damage and costly operational energy of a lightning discharge.
downtime.
The patented Dynasphere is an effective air terminal
Figure 1 shows a schematic representation of which intercepts lightning discharges at a preferred
comprehensive lightning and surge protection for a point earlier than conventional lightning protection
typical low voltage facility. techniques. This air terminal was developed from
research into the formation of corona and space
2.1 - Point 1: Capture the lightning strike charge effects around grounded points during the
millisecond time-frame prior to the development of
The first point of the Six Point Plan involves lightning upward streamers.
capturing the lightning strike to a preferred point on
purpose-designed air terminals. The Dynasphere’s floating sphere construction is
passive on approach of a storm, and produces
In general, the most vulnerable point to direct strike minimal corona.
is located at the highest point or corner of a structure
where some electric field intensification will occur In the milliseconds prior to the approach of a
under storm conditions. Satellite or microwave lightning down leader it becomes active through
dishes and communications antenna systems and capacitive coupling, it absorbs energy and assists in
their control equipment are typically vulnerable to triggering an upward intercepting discharge to
direct strikes. capture and control the main downleader.

By correctly installing a purpose-designed air Lightning can then be drawn to the downconductor
terminal on the top of the structure, direct lightning system to enable the safe transfer of energy to ground.
strikes can be attracted to a preferred point which is

Figure 1 -Comprehensive lightning and surge protection for a typical low voltage facility.
 2.2 - Point 2: Conduct the lightning current to • There should be a “single” point connection to the
ground safely ground network from all equipment within a
facility. Figure 2 shows an example of a well-
Once the lightning has been captured at a preferred designed grounding system with a “single” point
point, it is necessary to convey the discharge current connection of mains power and communications
safely to ground, and to minimise the conduction of equipment ground wires to the ground ring. If a
lightning currents on ancillary conductors such as surge arrives at the facility via the mains power
coaxial feeder cables as these can carry dangerous supply, the surge protection equipment will divert
lightning energy directly to equipment racks. excessive energy to ground, and the
telecommunications and lightning protection
ERICO has developed a purpose-designed, screened, grounds will rise equipotentially with all other
downconductor cable to reduce the risk of “side- grounding / ground points as they are closely
flashing and to contain the discharge to a central core bonded together. There is therefore little
conductor during a strike. In a radio base situation, opportunity for potential differences between
this purpose-designed downconductor has the ability ground points creating earth loops, or causing
to reduce risks associated with conducted currents sparking or sideflashing.
entering equipment rooms via RF feeder cables.

2.3 - Points 3 and 4: Dissipate the energy into the

ground and eliminate ground loops and
differentials

Once the energy is conducted to ground level, a low

impedance ground is essential to dissipate the
lightning energy into the earth mass as effectively as
possible. The grounding systems for dedicated
lightning protection terminals, tower footings and
electronic equipment rooms or control centres are
critical design elements.

Attributes of an ideal grounding arrangement are

considered in Figures 2 and 3 and below: Figure 2 - Preferred grounding system.

• Each grounding system (lightning, electrical, Figure 3 case shows a “non-preferred” system
communications, and equipment room) must be with multiple connection points to the ground-
individually of high integrity, as well as being ring. Although adequate protection equipment
considered a component of an overall grounding on both the power and communications interfaces
network. Where separate grounds exist, they is provided, the separated electrical and
should be bonded together (especially under communications grounds are located some
transient conditions). Bonding of all grounding distance apart (as shown by the parameter ‘d’.)
systems is required by Code in the US. Regardless of the impedance of each individual
ground, for a very short time the potential of the
• Because lightning is a high frequency event, it is electrical ground will be higher than the
the high frequency “impedance” that is the critical communications’ ground. As a result the excess
design element, not the D.C. resistance. energy has two potential paths to follow to reach
the lower potential communications’ ground, thus
• A ground ring should surround sensitive creating a dangerous ‘earth loop’ that will damage
electronic equipment rooms, industrial plants and sensitive electronic equipment in the equipment
telecom facilities. This will reduce the risk of room.
potential gradients across the facility.

• The lightning protection ground should be directly

bonded to the facility ground ring.
 • CADWELD® - exothermic molecular bonding
processes (copper-to-copper or alloys and copper-
to-steel or alloys) for grounding, lightning
protection and cathodic protection systems provide
connections that are
• permanent, robust;
• low impedance;
• corrosion-free;
• and cannot loosen or weaken with age.

The CADWELD molecular bonding process

(including over 35,000 different applications)
means full current carrying (fusing) capacity for
Figure 3 - “Non-ideal” grounding system - connections at least equal to the capacity of
currents in an earth loop can damage sensitive conductors in a grounding network. These
electronics through magnetic induction. connection processes satisfy IEEE Standard 80 -
1986 (Grounding) and IEEE Standard 837 - 1989
• The use of “crows foot” radial grounding (Connectors).
techniques for the lightning protection ground
allows the lightning energy to diverge as each • The use of a pre-fabricated, low-impedance signal
conductor takes a share of the current. This can reference grid (SRG) grounding network inside a
lower impedance and means that voltage gradients specialised shelter is highly recommended to
leading away from the injection point will be create an equipotential plane for high frequency,
lower and there will be reduced danger from “step low voltage digital signal installations. Typical
potentials” affecting equipment or people. examples of such applications include intensive
computer, telemetry and telecommunications
• Electrolytically copper-plated steel, galvanised facilities. Because digital signal line voltages are
steel or stainless steel ground rod provide cost- typically low, their sensitivity to transient noise is
effective grounding anchor points and electrodes very high: typically 1 volt for some digital
for most standard applications. Solid ground systems.
plates, steel grates, safety mats, ground (mesh)
grids, custom-designed terminals, braids and The SRG should provide bonding between
bridges are used in grounding and bonding interconnected computer, switching, transmission
applications for high-voltage or heavy current and power supply equipment to provide an
environments such as near industrial furnaces or equipotential “ground” at frequencies from DC to
around electrical substations. over 30 MHz. All SRG connections should be
welded because even a momentary loosening or
• Special compounds can be used to reduce separation of a mechanical connection can create
grounding impedances at locations where the high noise voltages which may introduce false
ground resistivity is high such as in rocky, sandy data or destroy circuits. The SRG complies with
or mountainous areas with large particle soil sizes. IEEE Standard 1100-1992 for grounding practices
Ground impedances can be reduced by measures in sensitive electronic environments. (AT&T
in excess of 50 per cent when GEM (ground recently specified SRG when consolidating more
enhancement material) or EEC (earth enhancing than 400 computers and other equipment in their
compounds) are used to form conducting masses Denver “hub” to service Western USA customers,
or non-soluble gels around ground rods and tapes. and Goldman Sachs & Co., the New York City
Approved non-leaching compounds, which do not investment banking firm, similarly installed SRG
contaminate ground water or surrounding soils by when re-locating its data centre to new facilities in
releasing conductive ions (salts), are available in Brooklyn.)
order to meet environmental standards.
A number of indicative tests are available to diagnose
A number of technologies are available, to assist in grounding problems and to evaluate the true transient
the construction of effective “best practice” ground performance of a grounding system prior to a real
grids or grounding systems. lightning event.
 These very high dI/dt and dV/dt values can induce
The ERICO Earth Systems Analyser™ can provide destructive high voltages across components, leading
data in assessing the performance of a grounding to equipment damage and failure.
system by :
• providing a measure of soil resistivity; Suitably designed low pass filter technologies
• providing a measure of grounding system following the primary shunt diverter will reduce the
resistance (in low frequency DC test mode); peak residual voltage and dramatically reduce the rate
• providing a measure of impulse impedance which of current and voltage rise reaching the equipment.
will indicate the peak voltage rise expected for a Proline Surge Reduction Filters (SRFs) and DINLINE
given lightning (transient) current; and by filters (for sites with smaller current loads) provide
• providing diagnostic path tracing capability to multistage surge attenuation by clamping and then
determine the relative magnitude and direction of filtering transients on power lines.
lightning currents passing to ground. The aim
here is to ensure that the majority, if not all, of the Proline SRFs manufactured by ERICO Lightning
transient current travels to ground via a preferred Technologies feature Movtec™ primary transient
path, which will not cause damage to equipment protection. Movtecs incorporate arrays of Zinc Oxide
or be a risk to personnel. Varistors (MOVs) with individual end-of-life
disconnect fuses. Continuous monitoring on a 5-
These tests using the Earth Systems Analyser provide segment LED panel shows the life-time status of the
a comprehensive indication of the likely performance device. In the SRF, an efficient low-pass filter
of an integrated grounding system. follows the Movtec to modify the rates of current and
voltage rise reaching downstream equipment.

2.4 - Point 5: Protect equipment from surges and Table 1 shows typical residual voltages and rates of
transients on power lines change of voltage for various technologies.

Even if a structure is provided with an integrated This superior level of protection offered by Surge
direct strike protection system, there remains the risk Reduction Filters means enhanced operational
that overvoltage transients may arrive via external reliability for electronic and telecommunications
cables. High energy over-voltage transients can arise equipment connected to mains power supplies
from capacitive and inductive coupling from nearby downstream from the surge filter.
lightning strikes in addition to power switching and
from irregular power distribution. Efficient clamping 2.5 - Point 6: Protect equipment from surges and
and filtering of power transients at the point-of-entry transients on communications lines
of power lines to facilities is essential to minimise the
risk of physical equipment damage, loss of operations Coaxial surge protector (CSP) devices are important
and economic loss. to protect against transients tracking from towers
directly to transmission and telemetry equipment via
Simple surge diverters installed at the mains radio feeder cables. Although a purpose designed
switchboard may not provide adequate protection. In downconductor confines the vast majority of the
order to protect sensitive equipment, it is necessary to lightning current, some induction to coaxial feeder
limit residual voltages to within the immunity level of cables will occur with strikes to towers or as a result
the internal equipment. For equipment operating on of magnetic and capacitive coupling from the air
a 230 VRMS system, component damage may result channel component of a lightning strike.
from transients with peak values as low as 700 V.
Many manufacturers of battery chargers and rectifiers CSPs are based on gas arrester devices housed in a
state a peak tolerance under 800 V. chrome plated brass block. These devices are
precision machined for impedance matching with the
Whilst some shunt-only devices can clamp at below coaxial cable. They provide protection at typical
the recommended voltages, they do little to limit the power ratings of 50 W (continuous) and operate at
fast rising wavefront energy (dI/dt and dV/dt) prior to frequencies up to 3 GHz. Typically, CSPs should be
the onset of clamping. Rates of current rise can be as mounted directly into grounded bulkheads at the
high as 10 kA/µs (10 10 A/s) from the initial discharge point of entry of feeder cables into the facility to
of lightning and an order of magnitude higher for provide maximum protection. Other installation
subsequent restrikes in multiple strike lightning. arrangements are however possible.
Protection of land based telephone, signal and data analog equipment and for PCM digital circuits
lines into the facility may also be an issue for operating at up to 8 Mbits/s or 12 MHz.
comprehensive protection. Transients up to 20 kA
(8/20µs) injected onto telecommunications and signal 3 - SUMMARY
lines can damage and destroy sensitive terminal
equipment and lead to facility down time. Direct lightning strikes and over-voltage transients
create major equipment failures and cause downtime
Telecommunications line protectors (TLPs) are at telecommunications and radio sites where there is
designed to protect terminal and interface equipment little or no purpose-designed protection fitted.
from transients conducted on telecommunications
lines. Analysis of damage has shown that no one protection
device can provide lightning immunity.
• Single-stage, “gas arrester only” circuits provide Comprehensive protection is provided only by
cost-effective protection for less sensitive electro- employing an integrated Six Point Plan approach.
mechanical or discrete component-type terminals
and supplement circuits with “built-in” protection. ERICO Lightning Technologies has over 20 years
experience in examining the nature and extent of
• Multistage stage protectors employing primary gas lightning and transient damage to equipment and are
arrester and secondary decoupled semi-conductor pleased to offer more detailed advice on lightning and
protection stages can provide lower clamp (let- transient protection solutions. Prevention is better
through) voltages than single-stage protectors. than cure.
These devices are suitable for more sensitive

Residual Voltage (V) dV/dt applied to equipment

Technology Applied Impulse 20 kA Applied Impulse 70 at 20 kA 8/20µs
8/20µs kA 8/20µs (V/µs)
32 mm “25kA”
1,400 V Failure 1400
Block MOV
60mm “70kA”
1,050 V 1,500 V 1100
Block MOV
Critec “135 kA”
790 V 1,100 V 700
Shunt Movtec
SRF363F “135kA”
510 V 700 V 6 to 9
Proline Movtec Filter

Table 1 - Typical Residual Voltages and Rates of Change of Voltage.