manual mastil

Tiltable Pole MastDKP206 and DKP210

USER'S GUIDEM210315en-B

March 2003

PUBLISHED BY

Vaisala Oyj Phone (int.): +358 9 8949 1P.O. Box 26 Fax: +358 9 8949 2227FIN-00421 HelsinkiFinland

Visit our Internet pages at http://www.vaisala.com/

© Vaisala 2003

No part of this manual may be reproduced in any form or by any means,electronic or mechanical (including photocopying), nor may its contents becommunicated to a third party without prior written permission of the copyrightholder.

The contents are subject to change without prior notice.

Please observe that this manual does not create any legally binding obligations forVaisala towards the customer or end user. All legally binding commitments andagreements are included exclusively in the applicable supply contract orConditions of Sale.

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Table of Contents

CHAPTER 1GENERAL INFORMATION............................................................................ 5

About This Manual ................................................................... 5Contents of This Manual ....................................................... 5Version Information ............................................................... 6Related Manuals ................................................................... 6Feedback............................................................................... 6

Safety......................................................................................... 6General Safety Considerations ............................................. 6Product Related Safety Precautions ..................................... 7ESD Protection...................................................................... 8

Warranty.................................................................................... 9Technical Support .................................................................... 9

CHAPTER 2PRODUCT OVERVIEW................................................................................ 11

Introduction to DKP206 and DKP210 ................................... 11Foundation Set .................................................................... 14Guy Wires............................................................................ 15Lightning Rod ...................................................................... 16Winch (Optional).................................................................. 16Product Nomenclature ........................................................ 17

CHAPTER 3INSTALLATION............................................................................................ 19

Siting Criteria.......................................................................... 19Ambient Measurements ...................................................... 19Tilting Direction.................................................................... 21Soil Evaluation..................................................................... 21

Site Preparation...................................................................... 21Power Supply and Communication Lines ........................... 21

Tools Required for Installation ............................................. 22Unpacking Instructions ......................................................... 22

Inspecting the Delivery........................................................ 22Contents of the Delivery...................................................... 22

Foundation.............................................................................. 25Soil and Frost Conditions .................................................... 25Orientation of the Mast........................................................ 25Concrete Foundations......................................................... 28

Making a New Concrete Block....................................... 29Using an Existing Concrete Block.................................. 32

Assembling the Mast ............................................................. 33Work Order.......................................................................... 33

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Installing the Pedestal Tube ................................................34Connecting the Lowest Mast Tube to thePedestal Tube .....................................................................36Connecting the Lifting Rod to the Mast ...............................37Connecting the Guy Wire Set to the Mast ...........................38Assembling the Mast Tubes ................................................39Assembling the Lightning Rod.............................................39Connecting the Grounding Cable to the InsulatedGuy Wire..............................................................................41Routing the Device Cables..................................................42

Erecting the Mast....................................................................43Installing and Using the Winch ............................................43Securing the Hinge ..............................................................46Connecting the Guy Wires to the Concrete Blocks .............46

Equipment Grounding and Lightning Protection................50Equipment Grounding..........................................................53Grounding of the Lightning Rod ..........................................55

CHAPTER 4MAINTENANCE............................................................................................57

Regular Maintenance..............................................................57Tilting the Mast .......................................................................57

Disconnecting and Securing the Guy Wire .........................57Using the Winch ..................................................................58Tilting the Mast Manually.....................................................58

Erecting the Mast....................................................................59

CHAPTER 5TECHNICAL DATA.......................................................................................61

Specifications .........................................................................61

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List of FiguresFigure 1 DKP210 Mast Dimensions (in mm) .......................................... 12Figure 2 DKP206 Mast Dimensions (in mm) .......................................... 13Figure 3 Foundation Set for DKP210 and DKP206 Masts ..................... 14Figure 4 Guy Wires Set .......................................................................... 15Figure 5 Passive Lightning Rod with the Cable and the Holders ........... 16Figure 6 Winch (Optional)....................................................................... 16Figure 7 Recommended Mast Location in Open Area ........................... 20Figure 8 Recommended Mast Length on Top of a Building................... 20Figure 9 Contents of the Mast Delivery (Part 1) ..................................... 23Figure 10 Contents of the Mast Delivery (Part 2) ..................................... 24Figure 11 DKP210 Mast Orientation......................................................... 26Figure 12 DKP206 Mast Orientation......................................................... 27Figure 13 Main Mast Block and Orientation Plate

(Dimensions in mm) ................................................................. 28Figure 14 Concrete Block for Guy Wire (Dimensions in mm) .................. 29Figure 15 Reinforcement for the Concrete Blocks ................................... 30Figure 16 Foundation Assembly for the Mast Base ................................. 31Figure 17 Foundation Assemblies for a New Concrete Block.................. 31Figure 18 Accessories for Existing Concrete Block Installation ............... 32Figure 19 Pedestal Tube Alignment to North-South Direction ................. 34Figure 20 Pedestal Tube Attachment ....................................................... 34Figure 21 Pedestal Tube Adjustment with Water Level ........................... 35Figure 22 Axle for Hinge........................................................................... 36Figure 23 Hinge Bolt Installation............................................................... 36Figure 24 Lifting Rod Installation Accessories ......................................... 37Figure 25 Lifting Rod Clamp Attachment ................................................. 38Figure 26 Guy Wire Attachment ............................................................... 38Figure 27 Alignment of the Mast Tubes.................................................... 39Figure 28 Lightning Rod Installation to the Mast ...................................... 40Figure 29 Dimensions (in mm) for Lightning Rod Assembly

on the Mast............................................................................... 40Figure 30 Alignment of the Insulated Guy Wire and the Lightning Rod

Holders ..................................................................................... 41Figure 31 Lightning Rod Cable Attachment ............................................. 42Figure 32 Winch Installation ..................................................................... 43Figure 33 Securing Clamp of the Winch................................................... 44Figure 34 Lower Cable Lead .................................................................... 44Figure 35 Attaching the Hook ................................................................... 45Figure 36 Bolts and Washers for Securing the Hinge .............................. 46Figure 37 Guy Wires................................................................................. 47Figure 38 Connecting the U-bolt to the Eye Bolt ...................................... 48Figure 39 Guy Wire 1 Attachment ............................................................ 48Figure 40 Securing the Guy Wires ........................................................... 49Figure 41 Installing Cable Shrouds .......................................................... 49Figure 42 Location of the Grounding Rods and an Optional Grid, the

Arrow Points to the Mast Tilt Direction ..................................... 51Figure 43 Ground Rod Installation............................................................ 52Figure 44 Installing the Grounding Bar..................................................... 53Figure 45 Connecting the Grounding Cables to the Bar .......................... 54Figure 46 Grounding Cable Protection ..................................................... 55Figure 47 Grounding of the Lightning Rod ............................................... 56Figure 48 Tilted Mast with Tilting Support ................................................ 58

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List of TablesTable 1 Manual Revisions .......................................................................6Table 2 Product Nomenclature for DKP206 Masts ...............................17Table 3 Product Nomenclature for DKP210 Masts ...............................17Table 4 Examples of Soil Resistivities, Ohm-Meters.............................52Table 5 DKP210 Specifications .............................................................61Table 6 DKP206 Specifications .............................................................62

Chapter 1 _________________________________________________________ General Information

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CHAPTER 1

GENERAL INFORMATION

This chapter provides general notes for the product.

About This ManualThe purpose of this manual is to describe and give guidelines how toconstruct the foundations for the DKP206 and DKP210 masts andhow to install the masts.

Contents of This ManualThis manual consists of the following chapters:

- Chapter 1, General Information, provides general notes for theproduct.

- Chapter 2, Product Overview, introduces the DKP206 and DKP210mast features, options, and the product nomenclature.

- Chapter 3, Installation, provides instructions for installing theDKP206 and DKP210 masts.

- Chapter 4, Maintenance, provides information that is needed for thebasic maintenance of the DKP206 and DKP210 masts.

- Chapter 5, Technical Data, provides the technical data of theDKP206 and DKP210 masts.

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Version InformationTable 1 Manual RevisionsManual Code DescriptionM210315en-A The first version of the DKP206 and DKP210

Tiltable Pole Mast User's Guide.M210315en-B This manual, the second version of the DKP206

and DKP210 Tiltable Pole Mast User's Guide.

Related ManualsFor sensor and other equipment specific foundation and installationinformation, refer to the separate instruction manuals that are suppliedwith the equipment.

FeedbackVaisala Customer Documentation Team welcomes your commentsand suggestions on the quality and usefulness of this publication. Ifyou find errors or have other suggestions for improvement, pleaseindicate the chapter, section, and page number. You can sendcomments to us by e-mail: [email protected]

Safety

General Safety ConsiderationsThroughout the manual, important safety considerations arehighlighted as follows:

WARNING Warning alerts you to a serious hazard. If you do not read and followinstructions very carefully at this point, there is a risk of injury oreven death.

CAUTION Caution warns you of a potential hazard. If you do not read andfollow instructions carefully at this point, the product could bedamaged or important data could be lost.

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NOTE Note highlights important information on using the product.

Product Related Safety PrecautionsThis section lists general precautions related to the mast installation.To ensure your safety, you must also read the device specific safetyprecautions that are listed in the corresponding field device manuals.

WARNING For safety reasons, do not install the mast alone.

WARNING For safety reasons, do not install the mast when the wind speed isover 7 m/s.

WARNING Always wear a safety helmet during mast installation.

WARNING Be careful when erecting the mast. See that there are no power linesor other obstacles above the mast.

WARNING Secure the mast properly to prevent it from falling. Tighten all theadjustment screws securely.

WARNING Be sure that there are no persons under the mast during erecting themast.

WARNING When erecting the mast with the winch, avoid touching the wire withbare hands. Do not try to guide the wire.

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WARNING To minimize shock hazard, the instrument chassis and cabinet mustbe connected to an electrical ground. The power cable must either beplugged into an approved electrical outlet or the instrument must becarefully grounded to a low-resistance safety ground.

WARNING Do not operate the equipment in an explosive environment, forexample, in the presence of flammable gases or fumes.

WARNING Do not attempt internal service or adjustment unless another person,capable of rendering first aid and resuscitation, is present.

WARNING Operating personnel must not remove instrument covers. Componentreplacement or internal adjustments must be made by qualifiedmaintenance personnel. Do not replace components with the powercable connected. Under certain conditions, dangerous voltages mayexist for some time even with the power cable disconnected. Toavoid injuries, disconnect power and discharge circuits beforetouching them.

CAUTION Do not install substitute parts or modify the unit. Impropermodification can damage the product or lead to malfunction. ContactVaisala for repairs to ensure that safety features are maintained.

ESD ProtectionElectrostatic Discharge (ESD) can cause immediate or latent damageto electronic circuits. Vaisala products are adequately protectedagainst ESD for their intended use. However, it is possible to damagethe product by delivering electrostatic discharges when touching,removing, or inserting any objects inside the equipment housing.


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To make sure you are not delivering high static voltages yourself:

- Handle ESD sensitive components on a properly grounded andprotected ESD workbench. When this is not possible, groundyourself to the equipment chassis before touching the boards.Ground yourself with a wrist strap and a resistive connection cord.When neither of the above is possible, touch a conductive part ofthe equipment chassis with your other hand before touching theboards.

- Always hold the boards by the edges and avoid touching thecomponent contacts.

WarrantyFor certain products Vaisala normally gives a limited one yearwarranty. Please observe that any such warranty may not be valid incase of damage due to normal wear and tear, exceptional operatingconditions, negligent handling or installation, or unauthorizedmodifications. Please see the applicable supply contract or conditionsof sale for details of the warranty for each product.

Technical SupportFor technical questions, contact the Vaisala technical support:

E-mail [email protected]

Telephone +358 9 8949 2789

Fax +358 9 8949 2790

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Chapter 2 ___________________________________________________________ Product Overview

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CHAPTER 2

PRODUCT OVERVIEW

This chapter introduces the DKP206 and DKP210 mast features,options, and the product nomenclature.

Introduction to DKP206 and DKP210DKP206 and DKP210 are designed for different kinds of weatherstation application areas, such as, airfields as well as synoptical andclimatological networks. The height of DKP206 is 6 m and that ofDKP210 is 10 m.

DKP206 and DKP210 are tiltable masts, that is, they can easily betilted up and down by one person when installing and maintaining thevarious devices on the mast. Also special attention has been paid toeasiness and quickness of the mast installation.

The mast is designed to withstand high wind conditions, up to 50 m/sof maximum wind speed with one standard set of guy wires. With anadditional set of guy wires, the maximum wind speed can be up to75 m/s.

The plate of the pedestal tube is made of stainless steel with a powdercoating resistant to corrosion. The material of the lifting rod and masttubes is anodized aluminum. Other mast constructions and mountingaccessories are made of stainless steel. The mast can be either paintedwhite or aviation-painted white/orange.

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0303-019

Figure 1 DKP210 Mast Dimensions (in mm)


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NOTE 50 mm ≈ 1.97 in.60 mm ≈ 2.36 in.75 mm ≈ 2.95 in.101.6 mm ≈ 4 in.1 890 mm ≈ 74.4 in2 353 mm ≈ 92.6 in.4 900 mm ≈ 192.9 in.5 475 mm ≈ 215.5 in.6 000 mm ≈ 236.2 in.7 000 mm ≈ 275.6 in.7 450 mm ≈ 293.3 in.9 000 mm ≈ 354.3 in.10 000 mm≈ 393.7 in.11 065 mm ≈ 435.6 in.

0303-020

Figure 2 DKP206 Mast Dimensions (in mm)

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Foundation SetThe foundation set includes all the necessary installation accessoriesboth for a new and an existing concrete block.

0303-021

Figure 3 Foundation Set for DKP210 and DKP206 Masts

The following numbers refer to Figure 3 above:

1 = Nuts and washers for the foundation bolts2 = Orientation plate for the mast base3 = Eye nuts for the guy wires4 = Wedge bolts for an existing concrete block5 = Plates with the nut for the guy wire blocks6 = Square plate for the mast base7 = Foundation bolts8 = Bar for installing the wedge bolts9 = Key piece for the wedge bolts


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Guy WiresOne set of guy wires is delivered in the basic set. The top fastener ofthe guy wires is mounted at the uppermost tube of the mast during theinstallation. The basic delivery contains one set of guy wires and theaccessories as shown in Figure 4 below.

0207-090

Figure 4 Guy Wires Set

The following numbers refer to Figure 4 above.

1 = Top fastener2 = Upper mast tube3 = Guy wires4 = Installation accessories5 = Cable shrouds

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Lightning RodThe mast is delivered with a passive lightning rod made from copper.The lightning rod holders are made of non-conductive material toprotect the mast devices from overvoltage when lightning occurs.Refer to Figure 5 below. An active type of lightning rod is available asan option for areas where heavy lightning activity occurs frequently.

0303-022

Figure 5 Passive Lightning Rod with the Cable and theHolders

Winch (Optional)The optional winch is equipped with the friction break, thus stoppingautomatically when the user releases the handle. The winch is easilyinstalled to the pedestal tube. After erecting the mast, the winchshould be removed from the pedestal tube and stored in a dry andwarm place.

0303-023

Figure 6 Winch (Optional)


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Product NomenclatureTable 2 Product Nomenclature for DKP206 MastsStandardNomenclature

Description Note

DKP206W 6 m high pole mast, colorwhite

DKP206AV 6 m high pole mast, colororange/white

The package containseither of these productalternatives.

DKF200 Foundation SetDKL200 Passive Lightning RodDKP206GW Guy Wire SetDKP200SW Support Guy Wire for

DKL200

The package containseither of these productalternatives.

DKP200LR Lifting Rod Optional with DKP206AVDKW200 Winch OptionalDKP200TS Tilting Support OptionalDKH200ACCESS Assembly Set for Active

Lightning RodOptional with ActiveLightning Rod

DKP200IS Installation/Tilting Set Optional with DKP206AV

Table 3 Product Nomenclature for DKP210 MastsStandardNomenclature

Description Note

DKP210W 10 m high pole mast, colorwhite

DKP210AV 10 m high pole mast, colororange/white

The package containseither of these productalternatives. Includesalways Guy Wire Set.

DKF200 Foundation SetDKL200 Passive Lightning RodDKP200LR Lifting Rod Optional with DKP210AVDKP210GW Additional Guy Wire Set OptionalDKW200 Winch OptionalDKP200TS Tilting Support OptionalDKH200ACCESS Assembly Set for Active

Lightning RodOptional with ActiveLightning Rod

DKP200IS Installation/Tilting Set Optional with DKP206AV

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Chapter 3 ________________________________________________________________ Installation

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CHAPTER 3

INSTALLATION

This chapter provides instructions for installing the DKP206 andDKP210 masts.

Siting Criteria

Ambient MeasurementsFinding a suitable site for the mast is important for gettingrepresentative ambient measurements with the mounted sensors. Forfurther information refer to the local and WMO recommendations.

Allow sufficient clearance especially for the wind sensors. The mastshould not be located next to a building or any other object that mightaffect the airflow. The following two figures provide generalguidelines for the mast location.

In general, there should be at least 150 m of open area to all directionsfrom the mast. The minimum distance between the mast and obstaclesis ten times the height of an obstacle. Refer to Figure 7 on page 20.

The recommended minimum length (h in Figure 8 on page 20) for themast installed on top of a building is 1.5 times the height of thebuilding (H). When the diagonal (W) is less than the height (H), theminimum length of the mast is 1.5 times W.

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0204-040

Figure 7 Recommended Mast Location in Open Area

NOTE 150 m ≈ 500 ft.

0204-041

Figure 8 Recommended Mast Length on Top of a Building


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Tilting DirectionAlso note the tilting direction of the mast. When installed in thenorthern hemisphere, the mast tilts to west. There should be a cleararea up to 9 m on the west side of the mast. The area should be free ofobstacles preventing the mast from being erected and tilted.

Soil EvaluationAlways, evaluate the soil to determine the appropriate type of thefoundation required. When designing the foundation, the localconstruction companies must be consulted to find out about the soiland frost conditions in your area. When the soil is frost-susceptible,make sure to always use the proper insulation.

CAUTION For the mast base installation, the soil bearing capacity has to exceed45 kPa (940 pounds-force/sq. foot).

Site Preparation

Power Supply and CommunicationLinesBefore assembling the mast the power supply and communicationlines must be available. The primary AC power service must complywith the National Electrical Code (NEC) or equivalent specificationsfor grounding the primary power service entrance. The mains must becontinuous and without spikes and blackouts. If the AC (mains)voltage is fluctuating more than the given tolerance allows, the AC(mains) voltage stabilizers are recommended.

The following applies to all field cabling:

- Use armored field cables.

- Cables must be suitable for underground use.

- Check the cable core diameter according to maximum allowabledrop.

- Route the cables through conduits to the equipment.

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- Check cable conduit diameters or use additional termination boxes.

- Ground the cable shield at both ends.

- Use spike and overvoltage protection devices at both ends of fieldcables.

Always make a detailed cabling and wiring plan. Data transmissionlines from the outdoor sites to indoor devices have to be preparedcarefully. Also the power supply for the equipment used needs to beplanned carefully.

It is recommended to use a conduit to protect the cables that connectthe indoor components to the outdoor components from damage andmoisture. Also traffic, standing water, and the twist and stress causedby the connectors will damage the cables.

Tools Required for InstallationYou need a set of Allen keys, two adjustable wrenches, a water level,a compass, and a big hammer.

Unpacking Instructions

Inspecting the DeliveryCheck the shipping boxes for possible damage. Check that there areno loose parts or connectors before installing the mechanics of theequipment and cabling them. If there has been any damage, contactVaisala without delay.

Contents of the DeliveryThe mast and the accessories are packed into cartons. The contents ofthe cartons may vary depending on the selected options. Check thedelivery contents against the packing list provided in a plastic folderon the carton. Refer to Figure 9 on page 23 and Figure 10 on page 24to identify the items.


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0303-024

Figure 9 Contents of the Mast Delivery (Part 1)


1 = Holders of the lightning rod (2 pcs)2 = Upper mast tube, ∅ 60 mm3 = Lightning rod with the cable4 = Guy wires5 = Cable shrouds for the guy wires (yel/blk, 3 sets)6 = Winch7 = Lifting rod, ∅ 60 mm

NOTE Figure 9 above and Figure 10 on page 24 provide only examples ofthe contents. The contents may vary depending on the model of themast and on the selected options.

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0303-025

Figure 10 Contents of the Mast Delivery (Part 2)


1 = Tilting support2 = Pedestal tube, ∅ 100 mm3 = Lower mast tube, ∅ 75 mm4 = Assembly set:

Guy wire fasteners (3 pcs)Guy assembly set (1 set)Hinge set (1 set)Lifting rod assembly set (1 set)Lightning rod assembly set (1 set)

5 = Foundation set:Foundation bolts, M20 (7pcs)Wedge bolts, M20 (7 pcs)Tool for wedge bolts (1 pc)Eye nuts for guy wires (3 pcs)Spring washers, M20 (10 pcs)Washers, M20 (10 pcs)Nuts, M20 (14 pcs)Nuts with plate, M20 (3 pcsc)Square plate with 4 nuts (1 pc)Orientation plate (1 pc)


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Foundation

Soil and Frost ConditionsWhen designing the foundation, the local construction companiesmust be consulted to find out about the soil and frost conditions inyour area. When the soil is frost-susceptible, make sure to always usethe proper insulation.

Orientation of the MastRefer to Figure 11 on page 26 for the orientation of the mast. Theconcrete blocks for guy wires have to be placed so that the pole mastcan be tilted west (east in the southern hemisphere) by releasing onlythe guy wire 1, see Figure 11 on page 26.

To ease the orientation of the mast, the two-headed arrow is cut on theorientation plate. "N" should face north and "S" should face south toensure the aiming of the weather station devices to the correctposition.

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0207-064

Figure 11 DKP210 Mast Orientation

NOTE 5 - 6 m ≈ 16.4 - 19.7 ft.


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0207-065

Figure 12 DKP206 Mast Orientation

NOTE 4 m ≈ 13.1 ft.

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Concrete FoundationsThe DKP206 and DKP210 pole masts can be mounted on a new or anexisting concrete block. The pole mast is fixed to the concrete blockwith foundation bolts.

NOTE The minimum weight of the main mast block is 400 kg (882 lb.).

When constructing a new concrete block, fasten the foundation boltassembly simultaneously with the concrete pour. If there is an existingconcrete foundation, you have to drill the holes for the foundationbolts. In both cases, use the delivered orientation plate for correctplacing of the foundation bolts. For the protection of the cables, it isrecommended to install a cable conduit, which has a minimumdiameter of 70 mm (2.76 in.). See Figure 13 below.

0303-026

Figure 13 Main Mast Block and Orientation Plate(Dimensions in mm)

NOTE 70 mm ≈ 2.76 in.80 mm ≈ 3.15 in.200 mm ≈ 7.87 in.250 mm ≈ 9.84 in.600 mm ≈ 23.62 in.800 mm ≈ 31.50 in.


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Concrete block dimensions for the guy wires are presented in Figure14 below.

0303-027

Figure 14 Concrete Block for Guy Wire (Dimensions in mm)

NOTE 40 mm ≈ 1.57 in.50 mm ≈ 1.97 in.240 mm ≈ 9.45 in.400 mm ≈ 15.75 in.600 mm ≈ 23.62 in.800 mm ≈ 31.50 in.

Making a New Concrete Block

1. Make a cast mould with steel reinforcements according to thedesign shown in Figure 15 on page 30. Use the 12-mmdeformed steel. In addition to the reinforcement presented inFigure 15 on page 30, you need to add two additional horizontalbar layers. The distance between the layers should beapproximately 200 mm. Note that you can make the guy wireblocks similarly, but the reinforcement horizontal bar lengthshould be 300 mm instead of 400 mm presented in Figure 15 onpage 30.

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NOTE 10 mm ≈ 0.39 in.12 mm ≈ 0.47 in.40 mm ≈ 1.57 in.50 mm ≈ 1.97 in.70 mm ≈ 2.76 in.150 mm ≈ 5.91 in.300 mm ≈ 11.81 in.400 mm ≈ 15.75 in.600 mm ≈ 23.62 in.

40060

0

0207-068

Figure 15 Reinforcement for the Concrete Blocks

2. If necessary, place the cable duct tubes into the casting mouldprior to casting. The recommended inner diameter of the ducttube is 70 mm (2.76 inches).

3. Place the steel reinforcement into the casting mould.

4. Screw the foundation bolts (number 1 in Figure 16 on page 31)to the nuts (6) which are fixed to the square metal plate (3).


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0207-069

Figure 16 Foundation Assembly for the Mast Base

5. Fix the orientation plate (2) to the upper ends of the foundationbolts (1) with eight nuts (4 and 5), see Figure 16 above. The topof the bolt should be approximately 80 mm above theorientation plate, refer to Figure 13 on page 28.

0207-062

Figure 17 Foundation Assemblies for a New ConcreteBlock

6. Install the foundation assembly into the mould so that thefoundation bolt threads stand above the surface, see Figure 13on page 28. The orientation plate (number 4 in Figure 17 above)should be at the same height as the top of the finalized concreteblock. Protect the threads of the bolts above the orientationplate, for example, by taping them. Also check the correctalignment of the foundation assembly with the orientation plate

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(number 4 in Figure 17 on page 31). "N" should face north and"S" should face south.

7. For the guy wires, fix the foundation bolt (number 2 in Figure17 on page 31) to the plate with a nut (3). Fix the eye nut (1) tothe other end of the foundation bolt. Level the assembly so thatthe top of the bolt will be 40 mm above the concrete in thefinalized block. The eye nut will then be one centimeter abovethe finalized concrete block.

8. Pour in the concrete. Finish the concrete block.

Using an Existing Concrete Block

1. Drill holes with a diameter of 25 mm into the concrete blockusing the orientation plate as a guide. Make sure that the depthof the holes is 240 mm (±5 mm).

NOTE 5 mm ≈ 0.20 in.25 mm ≈ 0.98 in.240 mm ≈ 9.45 in.

0207-070

Figure 18 Accessories for Existing Concrete BlockInstallation

2. First, install the key piece (number 3 in Figure 18 above)correctly inside the wedge bolt (4). The narrow end should pointto the direction of the lower arrow in Figure 18 above. Assemblethe wedge bolts into the holes. There are four bolts for the mastbase and one bolt for each of the guy wire blocks.


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3. Hammer the wedge bolts (4) down using the provided bar (2).

4. Screw the foundation bolts (1) to the wedge bolts and tighten thescrews properly.

5. Fill the remaining space of the holes with a suitable compound.

6. Start erecting the mast after the compound is dry.

Assembling the Mast

Work OrderTo assemble the mast, follow the work order below:

1. Attach the 2-meter-high pedestal tube to the concretefoundation.

2. Lift the lower base of the mast to the upper end of the pedestaltube and assemble the hinge axle.

3. Attach the lifting rod to the clamp that is preinstalled to thelowest mast tube.

4. Attach the guy wires to the uppermost mast tube.

5. Connect the mast tubes together.

6. Lift the upper end of the mast on the tilting support.

7. Assemble the holders to the lightning rod and attach theassembly to the mast.

8. Attach the winch and route the winch wire to the appropriateguides.

9. Install any other devices that will be installed to the tiltable partof the mast and attach the cables to the mast with cable ties.

10. Attach the jacketed copper grounding wire to the insulated guywire with the cable ties.

11. Erect the mast with the winch and secure the hinge with thebolts.

12. Connect the guy wires with fasteners to their foundations andmark them with the cable shrouds.

13. Remove the winch and assemble the devices to the pedestaltube.

For detailed instructions, refer to the following sections.

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Installing the Pedestal Tube1. Turn the pedestal tube so that the plate lug faces south in the

northern hemisphere and north in the southern hemisphere, seeFigure 19 below. The plate lug is for attaching the guide for thewinch wire.

0303-028

Figure 19 Pedestal Tube Alignment to North-SouthDirection

2. First place the washers and then the spring washers onto thepreviously installed nuts and lift the pedestal tube through thebolts onto the washers.

3. Install the nuts with the washers and spring washers to thefoundation bolts. Refer to Figure 20 below.

0303-029

Figure 20 Pedestal Tube Attachment


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The following numbers refer to Figure 20 on page 34:

1 = Foundation bolt2 = Spring washers, under and above the plate3 = Washers, under and above the plate4 = Nuts, under and above the plate

4. Level the pedestal tube to vertical with the nuts that are underthe plate. For adjusting the level, use the appropriate wrench andthe water level to check that the pedestal tube is vertical. Referto Figure 21 below.

5. Finally, tighten the bolts with the appropriate wrenches.

0303-030

Figure 21 Pedestal Tube Adjustment with Water Level

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Connecting the Lowest Mast Tubeto the Pedestal TubeTo connect the lowest mast tube to the pedestal tube, install the axlefor the hinge. For installing the axle, follow the procedure below:

1. Take the axle (number 1 in Figure 22 below) for the hinge fromthe plastic bag labeled Hinge Set.

0303-031

Figure 22 Axle for Hinge

2. Thread the Allen bolt (4) with the washers (2 and 3) to eitherend of the axle.

3. Lift the mast end (3) on the hinge (1) and install the axle (2), seeFigure 23 below.

0303-032

Figure 23 Hinge Bolt Installation


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4. Thread the other Allen bolt to the axle and tighten both endswith the Allen key.

Connecting the Lifting Rod to theMastThe delivery may contain the lifting rod that is used with the winch toerect and tilt the upper mast assembly. The clamps are preinstalled atthe factory to the pedestal tube and to the lowest mast tube. The clampon the lifting rod has hooks (number 1 in Figure 24 below) and taps(2) to ease the installation. The stainless steel bolts (3) are included inthe Lifting Rod Assembly Set (4).

0303-033

Figure 24 Lifting Rod Installation Accessories

To attach the lifting rod to the previously installed lower mast tube,follow the procedure below:

1. Place the lifting rod (number 1 in Figure 25 on page 38) on themast assembly as shown in Figure 25 on page 38.

2. Make sure that both taps on the clamp go into the railing and thehooks (number 3 in Figure 25 on page 38) at the end of theclamp go firmly around the opposite clamp.

3. Install the bolts (number 2 in Figure 25 on page 38) with thewashers and tighten them with an Allen key.

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0303-034

Figure 25 Lifting Rod Clamp Attachment

Connecting the Guy Wire Set to theMast1. Install the clamps (1) around the mast with the bolts (2) to

assemble the top fastener. The top fastener should be assemblednext to the tapered edge (3). See Figure 26 below.

2. After installing the lightning rod, you should aim the insulatedguy wire so that it points northwest when the mast is erected.The lightning rod holders are aligned to the same direction asthe insulated guy wire, refer to Figure 30 on page 41.

0303-035

Figure 26 Guy Wire Attachment


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Assembling the Mast TubesThe upper mast tube(s) has the O-ring (number 1 in Figure 27 below)installed on the tube.

For connecting the mast tubes, just slide the mast tubes together. Youneed to rotate either of the tubes to align the groove (2) on the uppertube and the ridge (3) inside the lower mast tube, see Figure 27 below.

0303-036

Figure 27 Alignment of the Mast Tubes

Assembling the Lightning RodLightning protection is provided with a well-grounded lightning rodplaced to the highest point of the mast. The lightning rod iscompletely insulated from other mast construction and separatelyconnected to its own lightning ground rod(s) several meters awayfrom other equipment ground rod(s). A 25 mm² grounding cable isrouted down from the top of the mast via an insulated guy wire. SeeFigure 31 on page 42.

To install the lightning rod, follow the procedure below:

1. Slide the lightning rod to the holes in the holders. The arrow inFigure 28 on page 40 shows the recommended direction.

2. Attach the lightning rod to the holders with the bolts (number 1in Figure 28 on page 40).

3. Slide the optional obstruction light holder (2) to the mastbetween the lightning rod holders and tighten the nuts (3).

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0303-037

Figure 28 Lightning Rod Installation to the Mast

4. Secure the holders to the mast with the bolts in the clamps (4).

5. Check that the dimensions for the installed lightning rod are asillustrated in Figure 29 below.

0303-038

Figure 29 Dimensions (in mm) for Lightning RodAssembly on the Mast

NOTE 20 mm ≈ 0.79 in.150 mm ≈ 5.91 in.350 mm ≈ 13.8 in.440 mm ≈ 17.3 in.1065 mm ≈ 41.9 in


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Connecting the Grounding Cable tothe Insulated Guy WireBefore erecting the mast, connect the grounding cable to the insulatedguy wire as follows:

1. Aim the insulated guy wire so that it points northwest (in thenorthern hemisphere) when the mast is erected. The lightningrod holders are aligned to the same direction as the insulated guywire, see Figure 30 below.

0303-039

Figure 30 Alignment of the Insulated Guy Wire and theLightning Rod Holders

2. Attach the grounding cable (number 3 in Figure 31 on page 42)with a wire rope clip (5) below the insulator (4).

NOTE Leave some extra cable between the lightning rod and the wire ropeclip on the guy wire to ensure that the guy wire does not pull thelightning rod downwards.

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0303-040

Figure 31 Lightning Rod Cable Attachment


1 = Lightning rod2 = Lightning rod holders3 = Grounding cable4 = Insulator5 = Wire rope clip

Routing the Device CablesRoute the device cables from the top of the mast down the hinge sideto avoid possible damage to the cables when tilting the mast. It is alsoimportant to attach the cables to the mast with the cable ties. Therecommended distance between the cable ties is from 30 to 40 cm(11 ... 16 in.).


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Erecting the Mast

NOTE Before erecting the mast, refer to the installation instructions of theadditional sensors and devices. It is important to aim the sensorscorrectly before erecting the mast.

Before erecting the mast, check that the bolts of the top fastener aretight. The top fastener (number 1 in Figure 26 on page 38) is mountedon the upper mast tube.

Installing and Using the WinchIt is recommended to use the winch for erecting the mast. The winchis easy to install and should be removed after use.

1. Attach the handle (number 5 in Figure 32 below) to the shaft ofthe winch.

0303-041

Figure 32 Winch Installation

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2. Install the winch towards the pedestal tube so that the tap (3) onthe tube goes to the hole (2) on the winch. Make sure that theplastic cover on the winch faces up.

3. Wrap the clamps (1) around the tube to the clamp assemblies (4)and attach them.

4. Finally, secure the clamps with the provided pin clips as shownin Figure 33 below.

0303-042

Figure 33 Securing Clamp of the Winch

5. Attach the cable bearer (number 2 in Figure 34 below) with thequick link (3) to the plate lug (4) of the pedestal plate. Makesure that the wire (1) with the hook points east (when installingin the northern hemisphere).

0303-043

Figure 34 Lower Cable Lead

6. Clip the hook (number 2 in Figure 35 on page 45) to the platelug (1) of the lifting rod.


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0303-044

Figure 35 Attaching the Hook

7. Take a good grasp on the handle and turn it clockwise to erectthe mast. The winch is equipped with a friction break and thus,it stops automatically when you release the handle.

WARNING Make sure that there are no people under the mast when the mast isbeing erected.

WARNING When erecting the mast with the winch, avoid touching the wire withbare hands. Do not try to guide the wire.

WARNING Always wear gloves when using the winch. Do not touch the gears ofthe winch.

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Securing the HingeAfter erecting the mast, secure the hinge with the provided accessoriesas illustrated in Figure 36 below.

NOTE Always assemble the washers (number 3 in Figure 36 below) underthe spring washers (2) to prevent the paint from being damaged.

0303-045

Figure 36 Bolts and Washers for Securing the Hinge


1 = Allen bolt2 = Spring washer3 = Washer

Connecting the Guy Wires to theConcrete Blocks

WARNING Always wear gloves when handling the guy wires.


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Follow the procedure below to connect the guy wires to the concreteblocks:

1. Connect the guy wires 2 and 3 as instructed in step a. below andconnect the guy wire 1 as instructed in step b. below. The guywire 1 is installed differently from the others, because it isreleased when the mast is tilted. For the location of the guywires, refer to Figure 37 below.

0303-046

Figure 37 Guy Wires

a. For the guy wires 2 and 3, connect the U-bolt (number 2 inFigure 38 on page 48) to the eye bolt (1) installed on theconcrete block. Slide the strap (3) onto the U-bolt andthread the nuts.

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0207-091

Figure 38 Connecting the U-bolt to the Eye Bolt

b. For the guy wire 1, connect the U-bolt (number 3 in Figure39 below) to the eye nut (1) with an additional bowshackle (2) to enable easy releasing of the wire. The strap(4) is used as with the guy wires 2 and 3.

0303-047

Figure 39 Guy Wire 1 Attachment

NOTE The additional bow shackle (number 2 in Figure 39 above) may differfrom the one shown in the figure.

2. Secure the guy wires with the provided wire rope clips (number3 in Figure 40 on page 49). Place the wire rope clips on the wireso that the forged, grooved part clamps the wire coming fromthe mast (the tension side) and the U-bolt clamps down on theend-most section of the wire. Check also that the wire isproperly in the key groove (1).

3. After assembling the wire rope clips properly, tension the guywire by tightening the nuts (number 2 in Figure 40 on page 49)to slide the strap, until the initial tension of the guy wires is


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sufficient. When tensioning the guy wires, make sure that themast remains straight and that all the guy wires are equallytensioned.

0207-092

Figure 40 Securing the Guy Wires

4. Cut the extra guy wire.

5. Finally, place the black and yellow cable shrouds around the guywires, see Figure 41 below. There is one package of shrouds foreach wire.

0207-093

Figure 41 Installing Cable Shrouds


1 = Guy wire2 = Cable shrouds

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Equipment Grounding and Lightning ProtectionWith mast installations equipment grounding and lightning protectionmust be done separately. The main principles are described below:

- Proper equipment grounding is required for personnel safety andfor equipment protection. A piece of equipment is grounded byconnecting its metal structures and electrical equipment to anexternal buried ground rod. Individual site requirements maydictate changes in the procedures described in this manual.Changes are permissible as long as protection equivalent to theoriginal requirements is provided for the system.

WARNING Failure to provide proper grounding may result in personnel injury ordeath from electrical shock and may severely damage equipment.

WARNING Lightning protection is required to prevent personnel injury andequipment damage due to direct lightning strikes and lightning-induced current surges.

- The materials used in the manufacture of the grounding systemsmust be chosen to prevent them from forming an electrolyticcouple. It is recommended to use copper (Cu).

- The equipment grounding system and lightning protectiongrounding system should be located as far as possible from eachother. The minimum recommended distance is 5 m (16 ft.). Due tothis the lightning rod grounding cable is routed down from the topof the mast via the guy wire which is insulated from the mastconstruction, refer to number 2 in Figure 42 on page 51. Theequipment grounding should be done near the mast block asillustrated in Figure 42 on page 51.


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0303-048

Figure 42 Location of the Grounding Rods and an OptionalGrid, the Arrow Points to the Mast Tilt Direction


1 = The grounding rod2 = The guy wire block of the insulated guy wire3 = The mast block4 = An optional grounding rod5 = An optional connecting cable6 = The 5-meter minimum distance between the rods

- The recommended grounding resistance is 10 Ω or less for both thegrounding of lighting protection rod and for the equipmentgrounding. Soil conditions (sand, rocks, etc.) and the groundresistance measurement determines the design and construction ofthe grounding system. Buried ground rods and / or buried wire canbe used for the ground network. The type and combination useddepend on soil conditions (ease of installation) and on the value ofmeasured ground resistance (the most effective way of reducing

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resistance to the required value of 10 Ω or less). Measurements ofthe earth resistance must be made at least 48 hours after rainfall.

- The connection between ground rods and the equipment frames andcopper cables should be made with appropriate compression lugs,bolts, nuts, and lock washers.

- Optionally, the top of the earth electrode can be housed insidecovered pit as illustrated in Figure 43 below.

Table 4 Examples of Soil Resistivities, Ohm-MetersSoil Type Median VariationTopsoil, loam 26 1 ... 50Inorganic clays of high plasticity 33 10 ... 55Silty or clayey fine sands with slight plasticity 55 30 ... 80Fine sandy or silty clays, silty clays, clean clays 190 80 ... 300Silty sands, poorly graded sand-silt mixtures 300 100 ... 500Well graded gravel, gravel sand mixtures 800 600 ... 1 000

Due to the above reasons and soil variations, the groundingaccessories presented in this manual (rods, connectors, etc.) are onlyexamples of the proper ones, thus recommended to be suppliedlocally.

0303-049

Figure 43 Ground Rod Installation


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The following numbers refer to Figure 43 on page 52:

1 = Access well2 = Grounding rod3 = Compression lug4 = Grounding cable

Equipment GroundingThe equipment grounding cable is connected to the equipment groundsystem (rod or other) from the one main grounding point, which isnormally a grounding bar located underneath the main systemenclosure.

CAUTION Always use clamps for connecting a cable to the grounding rod ortwo cables together, do not solder.

Consult the local authority for local grounding requirements. A coppergrounding cable and conductive grounding rod(s) are recommended.Usually, the customer is responsible for supplying grounding cables,rods, clamps, power cables, long distance signal cables, and conduitsfor cables.

0207-094

Figure 44 Installing the Grounding Bar

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The following numbers refer to Figure 44 on page 53.

1 = Hammer2 = Protective cap3 = Grounding bar

NOTE The grounding accessories shown in Figure 44 on page 53 areexamples of the grounding accessories. It is recommended to supplythem locally.

Silver epoxy material or equivalent should be used to bond theinterconnecting wire to the ground rods. The cross section of theinterconnection copper wire is recommended to be 25 mm2. Thelength should be about 2 meters. The 2-meter cable can be obtained byfirst cutting the connection cable of the lightning rod to the correctlength. The rest of the cable can be used for grounding the equipment.The original length of the cable is 15 m.

0207-095

Figure 45 Connecting the Grounding Cables to the Bar


1 = Grounding cable2 = Clamp3 = Grounding bar

Always protect the grounding cable on the surface of the concreteblock as illustrated in Figure 46 on page 55. This applies only when


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the mast is installed on an existing concrete block. It is recommendedto use a conduit when you cast the block for the mast.

0303-050

Figure 46 Grounding Cable Protection


1 = Clamp2 = Grounding cables, for the lightning detector and power

supply unit3 = Plate to protect the grounding cables and the AC power cable4 = Mast base

Grounding of the Lightning RodDo this in a similar way to the equipment grounding. The lightningrod is grounded near the guy wire block, see Figure 47 on page 56.

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0303-051

Figure 47 Grounding of the Lightning Rod


1 = Clamp2 = Rod3 = Cable from the lightning rod4 = Guy wire attachment

Chapter 4 _______________________________________________________________Maintenance

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CHAPTER 4

MAINTENANCE

This chapter provides information that is needed for the basicmaintenance of the DKP206 and DKP210 masts.

Regular MaintenanceThe mast tubes are anodized and painted for durability in demandingharsh environments. Normally there is no need for maintenance. Onlythe mast should be checked yearly for any damage to the coating.

Check also yearly the guy wires for correct tightness. Inspect the guywires for damage as well.

Tilting the MastYou need to tilt the mast, for example, when devices installed on theupper assembly need maintenance. The following sections provideinstructions on tilting the mast.

Disconnecting and Securing theGuy Wire1. Disconnect the guy wire 1 that is on the opposite side of the

mast to the hinge. For the location, see Figure 37 on page 47.

2. Connect the spring clip that is mounted to the released guy wireto the hole in the hinge.

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Using the Winch1. Install the winch to the mast as instructed in section Installing

and Using the Winch on page 43.

2. Open the securing Allen bolts in the hinge.

CAUTION Do not open the Allen bolts in the horizontal hinge axle.

3. Lower the mast slowly with the winch by turning the handle.

CAUTION Make sure to have a good control of the handle.

4. Install the tilting support to the end of the mast, see Figure 48below.

5. Lower the mast slowly with the winch so that finally the mastrests on the tilting support.

0303-052

Figure 48 Tilted Mast with Tilting Support

Tilting the Mast ManuallyManual tilting is recommended only if the maximum height of themast is 6 meters.

Chapter 4 _______________________________________________________________Maintenance

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Erecting the MastTo erect the mast after maintenance operations, refer to the sectionInstalling and Using the Winch on page 43.

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Chapter 5 _____________________________________________________________ Technical Data

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CHAPTER 5

TECHNICAL DATA

This chapter provides the technical data of the DKP206 and DKP210masts.

SpecificationsTable 5 DKP210 SpecificationsProperty Description/ValueHeight 10 m (32.8 feet)DiameterLowest sectionHighest section

100 mm (3.94 in)60 mm (2.36 in)

Maximum wind speedWith one set of guy wiresWith two sets of guy wires

50 m/s (100 knots)75 m/s (145 knots)

Weight (DKP210W with winch) 125 kgPedestal tube and hinge Stainless steelMast tubes and lifting rod Aluminum alloyGuy wiresMaterialBreaking strengthMarking

Stainless steel28 kN (6 295 lbf)Black and yellow colored cable shroudsto the height of 2 meters from the ground

Threaded anchor bolts Galvanized steel, thread M20, length300 mm (11.8 in), with M20 wedge bolts(cast or drilled into concrete using theprovided orientation plate)

Other parts, e.g., bolts Stainless steelCoating/PaintingPedestal tubeAluminum partsSteel partsStainless steel parts

Corrosion-resistant powder coatingAnodized and paintedGalvanizedUncoated

Temperature -40 … +60 °C (-40 ... 140 °F)

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Table 6 DKP206 SpecificationsProperty Description/ValueHeight 6 m (19.7 feet)DiameterLowest sectionHighest section

100 mm (3.94 in)60 mm (2.36 in)

Maximum wind speedWith one set of guy wires 50 m/s (100 knots)Weight (DKP206W with winch) 105 kgPedestal tube and hinge Stainless steelMast tubes and lifting rod Aluminum alloyGuy wiresMaterialBreaking strengthMarking

Stainless steel28 kN (6 295 lbf)Black and yellow colored warning piecesto the height of 2 meters from the ground

Threaded anchor bolts Galvanized steel, thread M20, length 300mm (11.8 in), with M20 wedge bolts (castor drilled into concrete using the providedorientation plate)

Other parts, e.g., bolts Stainless steelCoating/PaintingPedestal tubeAluminum partsSteel partsStainless steel parts

Corrosion-resistant powder coatingAnodized and paintedGalvanizedUncoated

Temperature -40 … +60 °C (-40 ... 140 °F)

manual mastil

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