DKE110F - User Guide

M211788EN-C
User Guide
Vaisala Guyed Frangible Mast
DKE110F
PUBLISHED BY
Vaisala Oyj
Street address: Vanha Nurmijärventie 21, FI-01670 Vantaa, Finland
Mailing address: P.O. Box 26, FI-00421 Helsinki, Finland
Phone: +358 9 8949 1
Fax: +358 9 8949 2227
Visit our Internet pages at www.vaisala.com.
© Vaisala 2017
No part of this manual may be reproduced, information contained in this manual.

published or publicly displayed in any form Vaisala makes no representations on this
or by any means, electronic or mechanical manual’s compliance with the local rules
(including photocopying), nor may its and regulations applicable at any given
contents be modified, translated, adapted, time, and hereby disclaims any and all
sold or disclosed to a third party without responsibilities related thereto.
prior written permission of the copyright
This manual does not create any legally
holder. Translated manuals and translated
binding obligations for Vaisala towards
portions of multilingual documents are
customers or end users. All legally binding
based on the original English versions. In
obligations and agreements are included
ambiguous cases, the English versions are
exclusively in the applicable supply
applicable, not the translations.
contract or the General Conditions of Sale
The contents of this manual are subject to and General Conditions of Service of
change without prior notice. Vaisala.
Local rules and regulations may vary and
they shall take precedence over the
Table of Contents
Table of Contents
1. About This Document........................................................................................ 5
1.1 Version Information............................................................................................... 5
1.2 Related Manuals..................................................................................................... 5
1.3 Documentation Conventions................................................................................ 5
2. Product Overview................................................................................................ 7
2.1 Vaisala Guyed Frangible Mast DKE110F...............................................................7
2.2 Frangible Pole Mast............................................................................................... 9
2.3 Foundation Set....................................................................................................... 9
2.4 Guying Set...............................................................................................................9
2.5 Additional Middle Guying Set (Optional)............................................................9
2.6 Lightning Protection Kit (Optional).....................................................................9
2.7 Winch (Optional)..................................................................................................10
2.8 Product Nomenclature........................................................................................ 10
2.9 Parts Lists.............................................................................................................. 10
2.10 Safety..................................................................................................................... 12
2.10.1 Pre-installation Safety................................................................................... 13
2.10.2 Installation Safety.......................................................................................... 14
2.10.3 Grounding and Lightning Protection........................................................... 17
2.10.4 Safety when Lowering Mast..........................................................................18
2.10.5 Maintenance Safety........................................................................................19
2.10.6 ESD Protection.............................................................................................. 20
2.11 Regulatory Compliances.................................................................................... 20
3. Installation Preparation...................................................................................23
3.1 Selecting Site........................................................................................................23
3.2 Preparing Site ......................................................................................................24
3.2.1 Power Supply and Communication Lines.................................................. 24
3.3 Unpacking.............................................................................................................25
3.4 Required Tools and Materials............................................................................. 25
4. Foundation........................................................................................................... 27
4.1 Foundation Works Overview..............................................................................27
4.2 Reference Calculations for Foundations........................................................... 27
4.2.1 Reference Calculation with Wind Speed of 75 m/s.................................. 28
4.2.2 Reference Calculation with Wind Speed of 50 m/s..................................30
4.3 Planning Site Layout............................................................................................32
4.4 Making Concrete Foundations........................................................................... 35
4.4.1 Preparing Foundations for Concrete Pour................................................. 36
4.4.2 Casting Concrete Foundations....................................................................44
4.5 Using Existing Foundation................................................................................. 46
4.5.1 Drilling Holes for Foundation Bolts............................................................ 46
4.5.2 Installing Foundation Bolts..........................................................................48
4.6 Finalizing Concrete Foundations.......................................................................50
5. Mast Installation.................................................................................................. 51
5.1 Installation overview........................................................................................... 52
5.2 Assembling Mast Base on Mast Foundation.................................................... 54
5.3 Assembling Mast..................................................................................................58
5.4 Installing Air Terminal...........................................................................................61
5.5 Installing Sensors and Other Devices................................................................62
5.6 Routing Cables.....................................................................................................62
1
DKE110F User Guide M211788EN-C
6. Guying Installation............................................................................................65
6.1 Assembling Frangible Guy Rods....................................................................... 66
6.2 Assembling Guy Wires........................................................................................68
6.3 Attaching Guy Rods to Guy Wires..................................................................... 72
7. Erecting Mast.......................................................................................................75
7.1 Installation Safety................................................................................................ 75
7.2 Installing Winch to Lowered Mast......................................................................77
7.3 Erecting Mast....................................................................................................... 83
7.4 Removing Winch and Adjusting Guyings.........................................................88
8. Equipment Grounding...................................................................................... 91
8.1 Installing Grounding Connector.........................................................................92
8.2 Connecting Down Conductor to Grounding Connector.................................94
8.3 Ground Electrodes...............................................................................................96
9. Lowering Mast for Maintenance and Upgrades.................................... 97

9.1 Installing Winch to Erected Mast.......................................................................98
9.2 Lowering Mast.................................................................................................... 103
10. Maintenance......................................................................................................... 111

10.1 Regular Maintenance.......................................................................................... 112
10.2 Repair Painting.................................................................................................... 112
10.3 Glass Fiber Tube Repair......................................................................................113
10.3.1 Pre-Treatment of Glass Fiber Tubes........................................................... 115
10.3.2 Mixing Components......................................................................................115
10.3.3 Repairing Glass Fiber Tubes........................................................................ 115
10.4 Erecting Mast....................................................................................................... 115
11. DKE110F Specifications.................................................................................. 117
Appendix A: Foundation Design Drawings................................................... 119
Warranty.......................................................................................................................125
Technical Support.....................................................................................................125
Recycling......................................................................................................................125
2
List of Figures
List of Figures
Figure 1 DKE110 Dimensions..............................................................................................8
Figure 2 Safety Precautions............................................................................................. 13
Figure 3 Recommended Mast Location in Open Area............................................. 23
Figure 4 Recommended Mast Height on Top of Building....................................... 24
Figure 5 Example 1: Mast Assembly in Reference Wind Load Calculation......... 29
Figure 6 Example 2: Mast Assembly in Reference Wind Load Calculation......... 31
Figure 7 DKE110F Foundation......................................................................................... 35
Figure 8 DKE110F Parts..................................................................................................... 53
Figure 9 Mast Tube 1.......................................................................................................... 54
Figure 10 Down Conductor Position on Mast............................................................... 63
3
List of Tables
Table 1 Document Versions................................................................................................5
Table 2 Related Manuals..................................................................................................... 5
Table 3 Product Nomenclature for Vaisala Guyed Frangible Mast........................ 10
Table 4 Parts List for Mast DKE110F............................................................................... 10
Table 5 Parts Lists for Foundation Set DKF100-EXEL................................................11
Table 6 Parts List for Top Guying Set DKE110-GW1.....................................................11
Table 7 Parts List for Additional Middle Guying Set DKE110-GW2......................... 11
Table 8 Parts List for Vaisala Lightning Protection Kit DKL201.............................. 12
Table 9 Parts List for Winch DKW100............................................................................ 12
Table 10 Example 1: Wind Load Calculation for Mast Concrete Foundation........29
Table 11 Example 1: Wind Load Calculation for Guy Wire Concrete
Foundation............................................................................................................ 30
Table 12 Example 1: Mast Calculation Weights.............................................................30
Table 13 Example 1: Mast Calculation Concrete Values..............................................30
Table 14 Example 2: Wind Load Calculation for Mast Concrete Foundation........ 31
Table 15 Example 2: Wind Load Calculation for Guy Wire Concrete
Foundation.............................................................................................................32
Table 16 Example 2: Mast Calculation Weights............................................................ 32
Table 17 Example 2: Mast Calculation Concrete Values............................................. 32
Table 18 DKE110F Specifications......................................................................................117
4
Chapter 1 – About This Document
1. About This Document

1.1 Version Information
Table 1 Document Versions
Document Code Date Description
M211788EN-C June 2017 • New wind load reference calculation with wind speed of 50 m/s and
one set of guy wires.
• Foundation instructions updated.
M211788EN-B October 2016 • Foundation specifications and instructions updated.

• Lightning protection and grounding instructions updated.
• New base plate design for the mast.
• Winching instructions added.
M211788EN-A July 2015 First, draft version of this manual.
1.2 Related Manuals

Table 2 Related Manuals
Document Code Name
M211943EN Vaisala Composite Pole Mast DKE110W and DKE110AV User Guide
M211785EN Vaisala Lightning Protection Kits DKL201, DKL202, and DKL203 Technical Reference
M211786EN Grounding and Lightning Protection in Vaisala Outdoor Installations Technical Reference
1.3 Documentation Conventions

WARNING! Warning alerts you to a serious hazard. If you do not read and follow
instructions carefully at this point, there is a risk of injury or even death.
CAUTION! Caution warns you of a potential hazard. If you do not read and follow
instructions carefully at this point, the product could be damaged or important data
could be lost.
5
Note highlights important information on using the product.
Tip gives information for using the product more efficiently.
Lists tools needed to perform the task.
Indicates that you need to take some notes during the task.
6
Chapter 2 – Product Overview
2. Product Overview
2.1 Vaisala Guyed Frangible Mast DKE110F
DKE110F is suitable for a wide range of surface weather and climatological applications,
including locations at the airports. The DKE110F mast is 10 meters (33 feet) high.
The mast tubes are made of glass-fiber reinforced plastic (GRP) which has very good
weathering properties. The same material is also used for the guying set.
The mast is very lightweight, but rigid enough to withstand wind speeds of up to 60 m/s
(134 mph) with one guying set. To achieve excellent weather resistance, the metal parts of
the mast are made of anodized aluminum alloy and maritime grade stainless steel.
7
Figure 1 DKE110 Dimensions
8
2.2 Frangible Pole Mast

The frangible pole mast is assembled from 3 mast tubes and a top section, which are joined
together with joining elements. The mast set also contains a grounding connector.
2.3 Foundation Set

The foundation set contains the accessories that are needed to install the mast foundation
and 3 guy wire foundations.
2.4 Guying Set

The guying set consists of guy wires and frangible guy rods. The upper ends of the guy rods
are attached to the guy rod flange on the highest mast tube. The lower ends of the guy
wires are attached to the guying foundations.
The basic delivery contains 1 guying set and the accessories.
2.5 Additional Middle Guying Set

(Optional)
Optionally, the mast is delivered with an additional guying set. The upper ends of the guy
rods are attached to a guy rod flange on the mast. The lower ends of the guy rods are
attached to the guying foundations.
The delivery contains the guy rods and 1 set of the accessories.
2.6 Lightning Protection Kit (Optional)

The optional Lightning Protection Kit DKL201 includes an air terminal, brackets, a groove
connector, and a down conductor. The air terminal and the down conductor are made of
aluminum.
The air terminal helps to protect the equipment installed on the mast from overvoltage
when lightning occurs.
CAUTION! Vaisala recommends an air terminal for all mast structures that reach 10 m
(32 ft 10 in). For mast structures that reach 6 m (19 ft 8 in) or lower, an air terminal is
recommended in regions with high lightning density. Especially in tropical or sub-tropical
regions, a lightning protection system is a necessity.
9
2.7 Winch (Optional)

The optional winch is used to erect the mast during installation, and to erect and lower the
mast during maintenance tasks.
2.8 Product Nomenclature

Table 3 Product Nomenclature for Vaisala Guyed Frangible Mast
Item Common/Full Name
DKE110F Vaisala Guyed Frangible Mast (10 m, 33 ft)
DKF100-EXEL Foundation set
DKE110-GW1 Top guying set
DKE110-GW2 Additional middle guying set
DKL201 Vaisala Lightning Protection Kit
DKE100TS Support stand
DKW100 Winch
2.9 Parts Lists

Table 4 Parts List for Mast DKE110F
Item Quantity
Mast tube 1 1
Joining element 2
Mast tube 2 1
Mast tube 3 1
Aluminum top section 1
Hex socket head screw ISO4762 M8 × 20 15
Set screw DIN913 M8 × 20 2
Washer DIN125 B 8.4 15
Washer DIN125 A21 9
Thin hex nut ISO4035 M20 6
Grounding connector 1
Attachment plate for grounding connector 1
10
Item Quantity
Allen screw M6 × 30 DIN912 A4 2
Washer M8 DIN125 A4 2
Table 5 Parts Lists for Foundation Set DKF100-EXEL
Item Quantity
Foundation bolt 6
Hex nut ISO4032 M20 18
Lifting eye nut DIN582 M20 3
Template for positioning foundation bolts 1
Table 6 Parts List for Top Guying Set DKE110-GW1
Item Quantity
Wedge clamp for guy wire (SH49) 3
D-Shackle 10 mm A4 6
Guy rod, white 1500 mm (59.06 in) 9
Guy rod, red 1500 mm (59.06 in) 9
Chain link connector 15
Guy wire with thimble 3
Guy rod flange 1
Table 7 Parts List for Additional Middle Guying Set DKE110-GW2
Item Quantity
Wedge clamp for guy wire (SH49) 3
D-Shackle 10 mm A4 6
Guy rod, white 1500 mm (59.06 in) 6
Guy rod, red 1500 mm (59.06 in) 6
Chain link connector 9
Steel wire with thimble 3
Guy rod flange 1
11
Table 8 Parts List for Vaisala Lightning Protection Kit DKL201
Item Quantity
Air terminal, aluminum bar D15 mm 1
Air terminal bracket 2
Hex screw M6 × 45 DIN933 A4 9
Spring lock washer B6 DIN127 A4 9
Hex nut M6 DIN934 A4 9
Flat washer A6.4 DIN125 A4 18
Parallel groove connector 1
Split pin M4 × 28 DIN94 A4 1
Down conductor, aluminum wire 50 mm2 20kV L11 m BLK 1
Cable ties 5 × 400 mm, black 30
Table 9 Parts List for Winch DKW100
Item Quantity
Lifting rod 1
Hoisting belt 1) 1
Wire rope winch with steel wire 1
1) The hoisting belt is not needed if you install the winch as instructed in this document.
2.10 Safety
This section lists general precautions related to the mast installation, operation, and
maintenance. To ensure your safety, read also the device-specific safety precautions. See the
corresponding product documentation.
This product has been tested for safety and approved as shipped from the factory. Note the
following precautions:
12
Figure 2 Safety Precautions
2.10.1 Pre-installation Safety
WARNING! Assess the risks from the installation work. Take into account also the
effects of local weather conditions.
WARNING! Do not install the mast when the wind speed is over 7 m/s (16 mph).
WARNING! Do not perform installation or maintenance procedures when there is a

risk of thunderstorm or lightning activity in the area.
WARNING! Incorrectly installed foundation presents a safety hazard. To ensure safety,

follow these instructions, as well as local and state legislation and regulations during
installation.
13
WARNING! Follow the risk assessments you have carried out for the installation work.
To ensure safety, make sure that all work is organized and planned, and carried out by
competent persons.
WARNING! For safety reasons, do not install the mast alone. At least 4 persons, one
of whom must be a designated supervisor for the work, are needed for installing the
mast safely. If you use the winch when installing and servicing the mast, at least 2
persons are needed.
WARNING! Follow local and state legislation and regulations on occupational safety.
CAUTION! For the mast base installation, the soil bearing capacity must be at least
45 kPa (940 pounds-force/ft2).
CAUTION! All design values mentioned in this manual are purely indicative. Vaisala
does not take responsibility for their applicability to the area in question.
CAUTION! Always consult a local civil engineer about the foundation design and to find
out about the soil and frost conditions in the area. When the soil is frost-susceptible,
always use proper insulation.
CAUTION! Unpack the mast carefully on the assembly site. Handle the glass fiber
structures with care.
2.10.2 Installation Safety
persons are needed.
14

WARNING! Always wear a safety helmet during installation.
WARNING! To protect your hands, always wear gloves when handling the guy wires.
WARNING! Make sure your clothing and equipment do not get tangled in the wires or
equipment during installation.
WARNING! Do not stand under the mast when it is being erected or lowered.
WARNING! To prevent the mast from falling, secure it by tightening all the
adjustment screws properly.
WARNING! Check the winch before each use. Do not use the winch if it is damaged or
not working properly. Damaged or severely worn parts in the winch can cause incorrect
operation or accidents.
15
WARNING! Before erecting the mast, verify that it has not been damaged during the
handling.
WARNING! Before erecting the mast, see the installation and aiming instructions of
the additional sensors and devices. It is important to aim the sensors correctly before
erecting the mast.
WARNING! Before erecting the mast, see that guy wires 2 and 3 are attached also by
their lower ends, so that the mast does not fall down.
WARNING! Be careful when erecting or lowering the mast. Check that there are no
power lines or other obstacles above the mast or close to the guy wires.
CAUTION! Do not modify the mast. Use only Vaisala parts, mounting brackets, and
spare parts that are designed for frangible structures.
CAUTION! Do not step on the fragile glass fiber structures during assembly and
installation.
CAUTION! Use a spirit level to check the horizontal position of the mast base plate.
Check the correct tilting direction of the mast.
CAUTION! To avoid damaging the cables when lowering the mast, leave enough slack
next to the hinge when routing the cables to the mast base.
CAUTION! Install the down conductor on the opposite side of the mast from the other
cables.
16
CAUTION! To make sure that the mast is standing straight, tighten all the guy wires
equally.
2.10.3 Grounding and Lightning Protection
WARNING! Always consult local authorities on decisions that relate to aviation safety,
grounding, lightning protection, safe installation, and power supply. It is the
responsibility of the customer to see that local and state legislation and regulations
have been properly observed. Subcontractors must also comply with any and all
applicable local regulations, if any.
WARNING! Ground the product and verify outdoor installation grounding

periodically. Failure to provide proper grounding can result in injury or death from
electrical shock and can severely damage the equipment.
WARNING! Lightning protection is required to prevent injury and damage to

equipment due to direct lightning strikes and lightning-induced current surges.
WARNING! To minimize shock hazard, the instrument chassis and cabinet must be
connected to an electrical ground. The instrument is equipped with a three-conductor
AC power connector. The power cable must either be plugged into an approved three-
contact electrical outlet or the instrument must be carefully grounded to a low-
resistance safety ground.
CAUTION! To prevent equipment damage, install an air terminal so that the tip is as
high above the instruments and sensors as possible.
CAUTION! Keep the curve of the down conductor smooth with a minimum radius of the
bent cable 20 cm (8 in) and never over 90 degree angles.
17
2.10.4 Safety when Lowering Mast
grounding, lightning protection, safe installation, and power supply. Follow local and
state legislation and regulations.

WARNING! Before disconnecting the guy wire, check that the winch is installed
securely and that the winch wire is tight.
WARNING! When lowering the mast, do not remove the hinge bolt and nut.
WARNING! After disconnecting the power cable, dangerous voltages can exist for
some time. To avoid injury, disconnect the power and discharge circuits before touching
them.
18
2.10.5 Maintenance Safety

WARNING! Read and follow the mast manufacturer safety instructions.
WARNING! Wear safety glasses and rubber gloves all the time. Wear a dust respirator
filter when necessary.
WARNING! Acetone is flammable. Make sure that there is good ventilation and avoid
skin contact during repair and painting.
WARNING! Do not service the system alone. Do not reach into parts and assemblies
that are AC (mains) powered and live except in the presence of someone who can
provide first aid.
WARNING! Only licensed experts may install electrical components. They must
adhere to local and state legislation and regulations.
19
WARNING! Do not replace components when the system is powered up. Switch off
both AC (mains) and battery power before performing maintenance procedures.
them.
CAUTION! Improper modification can damage the product or lead to malfunction. Any
modification voids your warranty.
CAUTION! Contact Vaisala or its authorized representative for repairs.
2.10.6 ESD Protection

Electrostatic Discharge (ESD) can damage electronic circuits. Vaisala products are
adequately protected against ESD for their intended use. However, it is possible to damage
the product by delivering electrostatic discharges when touching, removing, or inserting any
objects in the equipment housing.
To avoid delivering high static voltages to the product:
• Handle ESD-sensitive components on a properly grounded and protected ESD
workbench or by grounding yourself to the equipment chassis with a wrist strap and a
resistive connection cord.
• If you are unable to take either precaution, touch a conductive part of the equipment
chassis with your other hand before touching ESD-sensitive components.
• Hold component boards by the edges and avoid touching component contacts.
2.11 Regulatory Compliances

This product complies with the following performance and environmental test standards:
• ICAO: Annex 14, para 5.3.14
• Aerodrome Design Manual Part 6 (Doc 9157)
20
21
22
Chapter 3 – Installation Preparation
3. Installation Preparation
3.1 Selecting Site
To obtain representative ambient measurements, it is important to find a suitable location
for the mast. Normally, the suitable location should be a steady and dry place that
represents the general area of interest. For further information, see local recommendations
and the World Meteorological Organization (WMO) recommendations.
Always make a detailed siting plan according to local requirements. Vaisala recommends
that you always consult a local civil engineer for this purpose.
Allow sufficient clearance for the wind sensors. Do not locate the mast next to a building or
any other object that may affect the airflow. The following two figures provide general
guidelines for the mast location.
In general, there should be at least 150 m (500 ft) of open area to all directions from the
mast. The minimum distance between the mast and any obstacles is ten times the height of
an obstacle.
Figure 3 Recommended Mast Location in Open Area
23
The recommended minimum height (h in the following figure) for the mast installed on top
of a building is 1.5 times the height of the building (H). When the diagonal (W) is less than
the height (H), the minimum length of the mast is 1.5 times W.
Figure 4 Recommended Mast Height on Top of Building
The position of the wind mast should be representative of the touchdown zone and take-off
area. Surrounding obstacles and soil surface should be considered because they may affect
wind measurements. By using frangible masts, such as DKE110F, wind sensors can be
installed closer to the runway.
3.2 Preparing Site

3.2.1 Power Supply and Communication Lines
The primary AC (mains) power service must comply with the local specifications for
grounding the primary power service entrance. The AC power needs to be continuous,
without spikes and blackouts.
The following applies to all field cabling:
• To protect the cabling from wildlife or vandalism, use armored field cables. The cables
must be suitable for underground use.
• Check the cross-sectional area of the cable core according to maximum allowable
voltage drop.
• Route the cables through protective conduits to the equipment according to local
requirements.
24
Chapter 3 – Installation Preparation
• Check cable conduit diameters or use additional termination boxes.

• Ground the cable shield at both ends, if possible.
• Use spike and overvoltage protection devices at both ends of field cables.
Always make a detailed cabling and wiring plan. If you are going to use an external DC
power system, plan the power supply carefully according to the power needs.
CAUTION! Use a conduit to protect the cables from damage and moisture. Also traffic,
standing water, ice, and any twist or stress will damage the cables.
3.3 Unpacking
Check the cartons and boxes for possible damage. Check that there are no loose parts or
connectors before installing the mechanics of the equipment and cabling them. If there has
been any damage, contact Vaisala without delay.
CAUTION! Unpack the mast carefully on the assembly site. Handle the glass fiber
structures with care.
3.4 Required Tools and Materials

The following tools and materials are required and not supplied by Vaisala.
For all work phases, you need personal protective equipment (PPE), including:
• Protective eyewear
• Protective gloves
• Safety helmet
For the foundation work (new concrete foundations):
• Bucket for water (1 - 2 pcs)
• Cable conduit 525 mm (20.67 in) Ø 50 mm (1.97 in) R300 (2 pcs)
• Cover such as tarpaulin
• Hammer
• Pen or marker
• Saw
• Shovel (1 - 2 pcs)
• Spirit level
• Stands for reinforcement structure
• Steel wire
• Tape
• Steel reinforcement bar TW8 18.8 m (61.6 ft) / 7.4 kg (16.4 lb) to make:
a. Reinforcement TW8 C-shape, base rod length 1000 mm (39.37 in) Ø 8 mm (12 pcs)
b. Reinforcement TW8 straight, base rod length 850 mm (33.46 in) Ø 8 mm (8 pcs)
25
a. Lift part TW10, base rod length 1050 mm (41.34 in) Ø 10 mm (2 pcs)
• Water
• Wooden board for leveling, 1.2 ... 1.5 m (3 ft 11 in ... 4 ft 11 in)
• Wood for building the mold
For the foundation work (existing concrete foundations):
• Adhesive tape
• Brush and compressed air or air pump
• Chemical anchor such as injectable adhesive anchor
• Drill hammer
• Hammer
• Percussion drill
• Spirit level
For the planning and installation:
• Adjustable wrench or wrenches: 10-mm, 17-mm, 24-mm (2 pcs), and 30-mm
• Allen keys: 4-mm, 5-mm, 6-mm, and 30-mm
• Cable stripper
• Cable ties
• Compass
• Crosshead and slothead screwdriver
• Hammer
• Measuring tape
• Spirit level
• Torque wrench with adapters for hex-head bolts M12, M16, and M20
• Wire cutters
26
Chapter 4 – Foundation
4. Foundation
4.1 Foundation Works Overview
To create foundations for the mast and the guy wires, follow this work order:
• Design the foundations. See 4.2 Reference Calculations for Foundations (page 27)
• 4.3 Planning Site Layout (page 32)
• Depending on the site, make new foundations or use existing foundations:
• 4.4 Making Concrete Foundations (page 35)
• 4.5 Using Existing Foundation (page 46)
• 4.6 Finalizing Concrete Foundations (page 50)
4.2 Reference Calculations for

Foundations
Always design the foundation based on the site conditions and requirements, and take into
account the height of the mast, the area and weight of the mast and the instruments on it,
soil quality, wind load, and other conditions on the site.
CAUTION! All design values mentioned in this manual are purely indicative. Vaisala
does not take responsibility for their applicability to the area in question.
CAUTION! Always consult a local civil engineer about the foundation design and to find
out about the soil and frost conditions in the area. When the soil is frost-susceptible,
always use proper insulation.
CAUTION! For the mast base installation, the soil bearing capacity must be at least
45 kPa (940 pounds-force/ft2).
In a groundwater area, the foundation must be deeper or wider.

In an area with frost-susceptible soil, the foundation must reach below the soil frost
penetration depth or sufficient foundation depth.
A slab foundation is recommended. If the site is unsuitable for a slab foundation, choose a
different site.
27
The mast foundation instructions in this manual apply to both reference calculations when
you use one or two sets of guy wires, like in the examples.
This document describes a typical example of a mast foundation.
4.2.1 Reference Calculation with Wind Speed of 75 m/s

The reference calculation in this example is based on the following criteria:
• Gust wind speed of 75 m/s at the top of the mast
• 10-m mast with two sets of guy wires
28
Figure 5 Example 1: Mast Assembly in Reference Wind Load Calculation
Table 10 Example 1: Wind Load Calculation for Mast Concrete Foundation
Parameters Description Example 1: Maximum Example 2: Maximum

Vertical Load Overturning Moment
Nd Normal force -14.3 kN (down) -5.0 kN (down)
Qd Shear force 0.9 kN 3.1 kN
Md Overturning moment 0.9 kNm 3.1 kNm
29
Table 11 Example 1: Wind Load Calculation for Guy Wire Concrete Foundation
Parameters Description Example 1: Maximum Guy Wire

Tension
Nk Normal force 6.4 kN (up)
Qk Shear force 4.7 kN
Mk Moment 0 kNm
Table 12 Example 1: Mast Calculation Weights
Part Weight
Mast 35 kg (77.2 lb)
BOX652 40 kg (88.2 lb)
Sensor support arm 5 kg (11.0 lb)
Solar panel 3.5 kg (7.7 lb)
Antenna 1 kg (2.2 lb)
Obstruction light 2 kg (4.4 lb)
Lightning protection (air terminal) 2 kg (4.4 lb)
Sensor 2 kg (4.4 lb)
Table 13 Example 1: Mast Calculation Concrete Values
Description Value
Concrete volume 0.45 m3
Concrete weight 11.3 kN
Net pressure of soil ≥70 kN/m2
Groundwater No
4.2.2 Reference Calculation with Wind Speed of 50 m/s

The reference calculation in this example is based on the following criteria:
• Gust wind speed of 50 m/s at the top of the mast
• 10-m mast with one set of guy wires
30
Figure 6 Example 2: Mast Assembly in Reference Wind Load Calculation
Table 14 Example 2: Wind Load Calculation for Mast Concrete Foundation
Parameters Description Example 1: Maximum Example 2: Maximum

Vertical Load Overturning Moment
Nd Normal force -6.5 kN (down) -4.4 kN (down)
Qd Shear force -0.5 kN 1.9 kN
Md Overturning moment -0.8 kNm 2.8 kNm
31
Table 15 Example 2: Wind Load Calculation for Guy Wire Concrete Foundation
Parameters Description Example 1: Maximum Guy Wire

Tension
Nk Normal force 3.5 kN (up)
Qk Shear force 2.1 kN
Mk Moment 0 kNm
Table 16 Example 2: Mast Calculation Weights
Part Weight
Mast 35 kg (77.2 lb)
BOX652 40 kg (88.2 lb)
Sensor support arm 5 kg (11.0 lb)
Solar panel 3.5 kg (7.7 lb)
Antenna 1 kg (2.2 lb)
Obstruction light 2 kg (4.4 lb)
Lightning protection (air terminal) 2 kg (4.4 lb)
Sensor 2 kg (4.4 lb)
Table 17 Example 2: Mast Calculation Concrete Values
Description Value
Concrete volume 0.41 m3
Concrete weight 10.1 kN
Net pressure of soil ≥70 kN/m2
Groundwater No
4.3 Planning Site Layout

• Compass
• Measuring tape
Before you start the concrete works, plan how to place the mast concrete foundation and
the 3 guy wire foundations on the site.
32
Plan the placing of the mast and guyings, as well as the orientation carefully. All of these
affect the placing of the equipment on the mast and the lowering of the mast for
maintenance.
1. Select a location with at least 10 m (33 ft) of clear area around the mast.
2. Mark the place for the mast concrete foundation at the center of the location.
33
3. Use a compass to check the orientation. Mark the place for guy wire 1 foundation. Place
the foundation 5 … 6 m (16 ft 5 in … 19 ft 8 in) from the mast:
• On the Northern Hemisphere, to the east from the mast concrete foundation
• On the Southern Hemisphere, to the west from the mast concrete foundation
1 Guying 1 foundation
2 Mast foundation
34
4. Mark the place for the two other guy wire foundations. The guy wire foundations must
be at 120‑degree angles to each other (<10‑degree deviation).
4.4 Making Concrete Foundations
Figure 7 DKE110F Foundation
1 Lift part (2 pcs)

2 Foundation bolt (3 pcs)
3 Cable conduit (2 pcs)
35
4.4.1 Preparing Foundations for Concrete Pour
• Cable conduit 525 mm (20.67 in) Ø 50 mm (1.97 in) R300 (2 pcs)

• Hammer
• Measuring tape
• Pen or marker
• Saw
• Spirit level
• Stands for reinforcement structure
• Steel wire
• Tape
a. Reinforcement TW8 C-shape, base rod length 1000 mm (39.37 in) Ø 8 mm (12 pcs)
a. Lift part TW10, base rod length 1050 mm (41.34 in) Ø 10 mm (2 pcs)
• Wood for building the mold
Wear protective eyewear, gloves, and a safety helmet.
To prepare the foundations, use:

• Foundation bolt (6 pcs)
• Hex nut ISO4032 M20 (9 pcs)
• Template for positioning the foundation bolts (1 pc)
Prepare the installation location for 1 mast concrete foundation and 3 guy wire concrete
foundations.
1. The dimensions of the concrete foundations in the reference calculation must be: height
500 × width 950 × length 950 mm (19.69 × 37.40 × 37.10 in). Make 4 cast molds from
wooden boards for the concrete foundations.
36
2. For each foundation, dig a hole with sides approximately 2 m × 2 m (6 ft 7 in × 6 ft 7 in)

and depth 1 m (3 ft 3 in).
In a square foundation, the sides of the square must be in the North/South/East/

West direction.
3. Spread a layer of gravel and level the gravel with a wooden board. The distance from
the surface of the gravel to the ground level must be 500 mm (20 in).
1 Concrete foundation
2 Backfill
4 Drainage (if required)
5 Compacted gravel
4. Compact the gravel with a plane compactor or similar device.
37
5. Take into account individual site requirements and use drainage pipes if the ground on
the site is wet.
6. For each foundation, use:
• TW8 to create 8 straight pieces, base rod length 850 mm (33.46 in)
• TW10 to create 18 straight pieces, base rod length 850 mm (33.46 in)
• TW8 to create 12 pieces of C-shapes
• TW10 to create 2 lift parts
38
7. Build the reinforcement structure in the cast mold from TW8 and TW10 according to
the given measurements and layout instructions.
• Place stands under the reinforcement structure.
• To hold the structure, use steel wire.
1 TW10 straight (18 pcs); if no lift parts are used (20 pcs)
2 TW10 lift part (2 pcs), optional
3 TW8 straight (8 pcs)
4 TW10 straight
5 TW10 straight
6 TW8 C-shape (12 pcs)
7 TW10 straight
On the top layer of the reinforcements, place the lift parts under the straight parts.
39
8. For the guy wire foundations, place 1 foundation bolt to each foundation and tie the
bolt with wire to the steel reinforcement bars.
40
9. For the mast foundation:

a. Attach the mast foundation bolts to the template with nuts.

2 Template
3 Hex nut ISO4032 M20 (9 pcs)
b. Attach two 2-by-4-inch wood planks with screws to the cast mold so that they hold
the template in the middle of the cast mold.
c. In the cast mold, attach the template assembly with screws to the planks and with
wire to the steel reinforcement bars.
Check the correct orientation of the template.
41
d. Check the correct position of the foundation bolts. The bolts must be:
• At the correct height
• On the same level with each other
• Vertical
Make sure that 120 mm (4.72 in) of the foundation bolts is above the surface of
the concrete foundation.
42
10. For the mast foundation, place 2 cable conduits to the cast mold and tie the cable
conduits with wire to the steel reinforcement bars.
11. To protect the threads of the foundation bolts from concrete splashes, use electrical
tape or similar.
43
4.4.2 Casting Concrete Foundations
• Bucket for water (1 - 2 pcs)

• Cover such as tarpaulin
• Measuring tape
• Spirit level
• Water
• Wooden board for leveling, 1.2 ... 1.5 m (3 ft 11 in ... 4 ft 11 in)
1. Water the cast molds.

2. To make sure the concrete meets cubical strength requirements, use prefabricated
concrete that is delivered and pumped by a concrete delivery truck.
If you make the concrete on the site, pay special attention to the mixing ratio, mixing
and working times, and to the purity of the water (potable water).
3. Pour or shovel the concrete in the cast molds.
4. Proceed gradually layer by layer until the form is full. Vibrate the concrete on the mold
or use a hammer on the cast mold.
CAUTION! Do not over-vibrate the concrete in the mold. This causes the concrete
mixture to liquify, separates stone and cement material in the concrete mixture, and
may break the mold.
5. To level the surface of the concrete foundation, use a wooden board. Check with a spirit
level.
44
6. On the mast foundation, check the correct position of the foundation bolts. The bolts
must be:
• Vertical
7. Cover the concrete foundations.

8. Loosen the cast molds after 2 to 3 days, and remove the cast mold and the template
after a week. To achieve compressive cube strength, wait for 28 days for the concrete to
harden.
9. Compact the soil around the concrete foundations with the backfill.
The concrete foundations are ready.
45
4.5 Using Existing Foundation

4.5.1 Drilling Holes for Foundation Bolts
• Adhesive tape
• Drill hammer
• Hammer
• Spirit level
To drill the holes, use the template (1 pc) for positioning the foundation bolts.
46
You can use existing concrete blocks as foundations for the mast and the guy wires.
1. Start with the mast foundation. Mark the drilling depth on the drill bit with tape:
20 ... 23 cm (7.87 ... 9.06 in).
The size of the holes for the foundation bolts depends on the chemical anchor that you
are using. Read the instructions of the chemical anchor manufacturer.
2. Place the template on the concrete foundation. Check the correct position and
orientation of the template depending on your location.
47
3. To make sure the template does not move, hold the template in place with your feet.
4. Aim the drill bit through one of the holes in the template and drill a hole that is a couple
of centimeters deep.
5. To avoid getting the drill bit stuck in the hole, lift the drill bit every once in a while when
drilling to remove excess dust.
6. When the first hole is ready, place a foundation bolt in the hole through the template.
This bolt locks one corner of the template in place.
7. Drill a second hole, and place a foundation bolt in the hole through the template.
8. Drill the third hole, and remove the template.
9. Clean dust from the holes with a brush and compressed air or air pump.
10. Continue drilling the holes until you reach the tape mark in the drill bit. Clean dust from
the holes using a brush and compressed air or air pump.
11. To check that the holes are of the same depth, put the foundation bolts in the holes.
Use a spirit level to make sure the bolts are level.
12. For the guy wire foundations, drill 1 hole to each foundation. Make sure that
120 mm (4.72 in) of the foundation bolts is above the surface of the concrete
foundation. Clean dust from the holes with a brush and compressed air or air pump.
4.5.2 Installing Foundation Bolts
• Adhesive tape
• Drill hammer
• Hammer
• Measuring tape
• Spirit level
48
To install the bolts, use the foundation bolts (6 pcs) for the mast and guy wire foundations.
1. Check the correct position of the foundation bolt holes. On the mast foundation, make
sure that 120 mm (4.72 in) of the foundation bolts is above the surface of the concrete
foundation. Use a spirit level to check the vertical position of the foundation bolts.
2. Make sure that the holes are free of dust, and clean and dry.
3. Check the instructions of the chemical anchor manufacturer before use.
The chemical anchor may harden very fast. Work in a coordinated manner and follow
the instructions and given working times.
4. Fill the holes with chemical anchor.

5. Place the foundation bolts in the holes, and turn the bolts to make sure the chemical
anchor paste spreads evenly.
Extra paste flows out from the holes.
6. To push the foundation bolts all the way in, lightly tap the bolts with a hammer.
7. Use the template and check again that the mast foundation bolts are:
• Vertical
8. Check the instructions of the chemical anchor manufacturer for the time it takes for the
chemical anchor to set. Leave the chemical anchor to set.
49
4.6 Finalizing Concrete Foundations

30-mm wrench
1. To finalize the installation, attach the lifting eye nuts to the guy wire foundation bolts.
1 Lifting eye nut DIN582 M20 (3 pcs)

2 Hex nut ISO4032 M20 (3 pcs)
50
Chapter 5 – Mast Installation
5. Mast Installation
persons are needed.

installation.
51
cables.
5.1 Installation overview

To help the assembly, the mast tubes in the delivery package are numbered. The marking is
inside the mast tubes:
• Lowest mast tube is 1
• Middle mast tube is 2
• Highest mast tube is 3
To install the mast, follow this work order:
• 5.2 Assembling Mast Base on Mast Foundation (page 54)
• 5.3 Assembling Mast (page 58)
• 5.4 Installing Air Terminal (page 61)
• 5.5 Installing Sensors and Other Devices (page 62)
• 5.6 Routing Cables (page 62)
52
Figure 8 DKE110F Parts
1 Aluminum top section

2 Mast tube 3
3 Mast tube 2
4 Mast tube 1
5 Guy rod flanges
6 Joining element, inside the mast tubes
7 Mast base
53
5.2 Assembling Mast Base on Mast

Foundation
• 17-mm wrench
• 30-mm wrench
• Measuring tape
• Spirit level
To assemble the mast base, you need:

• Hex nut ISO4032 M20 (3 pcs)
• Thin hex nut ISO4035 M20 (6 pcs)
• Washer DIN125 A21 (6 pcs)
• Mast tube 1
Figure 9 Mast Tube 1
1. Attach hex nuts to foundation bolts.
54
2. Place mast tube 1 on the foundation bolts. The hinge of the mast base must be:
• in Northern Hemisphere, on the west side (W) of the mast foundation.
• in Southern Hemisphere, on the east side (E) of the mast foundation.
1 Mast tube 1
2 Hex nuts ISO4032 M20 (3 pcs), tightening torque 100 Nm
3 Foundation bolt
3. Position the lower part of the base approximately 30 mm (1.18 in) from the foundation.
55
4. Use a spirit level to check the horizontal position of the mast base plate.
5. If necessary, adjust the nuts to achieve the correct horizontal position.
6. Attach the nuts and washers.
1 Washer DIN125 A21 (6 pcs)

2 Thin hex nut ISO4035 M20 (6 pcs), tightening torque 100 Nm
56
7. Lift mast tube 1 to a vertical position.

The hinge must be able to move (open/close) when erecting the mast.
8. If the hinge does not close (the foundation bolts are too high up) or there is not enough
room to fit the topmost nuts and washers, adjust the height of the plate with the nuts
and washers.
9. Use a spirit level to check the horizontal position of the base hinge and the vertical
position of the mast tube. If necessary, adjust the bolts and nuts.
57
10. Lower the mast tube.
5.3 Assembling Mast

• 4-mm Allen key
• 6-mm Allen key
To assemble the mast, you need:

• Aluminum top section (1 pc)
• Guy rod flange (1 pc) (if you use additional middle guyings, 2 pcs)
• Hex socket head screw ISO4762 M8 × 20 (15 pcs)
• Joining element (2 pcs)
• Mast tube 2 (1 pc)
• Mast tube 3 (1 pc)
58
• Set screw DIN913 M8 × 20 (2 pcs)

• Washer DIN125 B 8.4 (15 pcs)
Connect the mast tubes on the ground or on an appropriate support, such as the support
stand. Place the support between mast tubes 2 and 3.
1. Attach a joining element to mast tube 1 and mast tube 2.
1 Joining element (yellow)

2 Hex socket head screw ISO4762 M8 × 20 (2 pcs), tightening torque 10 Nm
3 Washer DIN125 B 8.4 (2 pcs)
4 Mast tube 1
5 Mast tube 2
59
2. Attach the second joining element to mast tube 2 and mast tube 3. If you have 2 guy
rod flanges, install one of them before attaching mast tube 3.

4 Mast tube 2
5 Mast tube 3
9 Guy rod flange installation position (for additional middle guying set)
60
3. Attach a second guy rod flange and the aluminum top section to mast tube 3.
1 Aluminum top section

3 Washer DIN125 B8.4 (3 pcs)
4 Guy rod flange
5 Set screw DIN913 M8 × 20 (2 pcs), tightening torque 5 Nm
4. Align the bent part of the guy rod flange or flanges towards the guy wire foundations.
5.4 Installing Air Terminal

For air terminal installation instructions, see Vaisala Lightning Protection Kits DKL201,
DKL202, and DKL203 Technical Reference.
For grounding instructions, see Grounding and Lightning Protection in Vaisala Outdoor
Installations Technical Reference.
61


The installation of the air terminal as instructed by Vaisala is based on international IEC
standards. If local and state legislation and regulations differ from the Vaisala installation
instructions, it is the responsibility of the customer to make sure that grounding and
lightning protection comply with the local and state legislation and regulations.
5.5 Installing Sensors and Other Devices

Install sensors and other devices that are placed on the top part of the mast, for example
wind sensors.
Vaisala recommends that you align the wind sensor so that it points to true North, which
uses the earth’s geographic meridians.
For installation instructions, see the relevant product documentation.
5.6 Routing Cables

• Cable ties
62
Route all cables from the top of the mast down the side of the mast and attach the cables to
the mast with cable ties. The recommended distance between the cable ties is 30 … 40 cm
(1.18 … 1.57 in).
cables.
Figure 10 Down Conductor Position on Mast
1 Mast down conductor

2 Equipment/sensor cable
63
Install the grounding connector after you have installed the guy wires and erected the mast.
64
Chapter 6 – Guying Installation
6. Guying Installation

persons are needed.
installation.
To install the guyings, follow this work order:
65
• 6.1 Assembling Frangible Guy Rods (page 66)

• 6.2 Assembling Guy Wires (page 68)
• 6.3 Attaching Guy Rods to Guy Wires (page 72)
6.1 Assembling Frangible Guy Rods

• Safety helmet
1. Put the guy rods in a chain with chain link connectors. Alternate the red and white guy
rods. There are 3 white and 3 red guy rods for each guying.
66
2. Attach the guy rods to the guy rod flange on mast tube 3 with a shackle. Put a white
guy rod closest to the top of the mast.
1 D-Shackle 10 mm A4 (3 pcs)
2 Guy rod, white 1500 mm (59.06 in) (9 pcs)
3 Guy rod, red 1500 mm (59.06 in) (9 pcs)
4 Chain link connector (15 pcs)
67
6.2 Assembling Guy Wires

• 17-mm wrench
• 24-mm wrench
• Hammer
In assembling guy wires, you need:

• Guy wire with thimble (3 pcs)
• Wedge clamp for guy wire (SH49) (3 pcs) (if you use additional middle guy wires, 6
pcs)
Attach the guy wires with the wedge clamps to the guy wire foundations.
1. Connect the U-bolt to the lifting eye nut that is installed on the concrete foundation.
68
2. Slide the strap onto the U-bolt and thread the nuts.
1 U-bolt nuts
2 Strap
3 U-bolt
69
3. Push the guy wire through the strap and slide the wedge on the guy wire.
1 Guy wire
2 Wedge
70
4. Push the wedge to the strap and hammer it in tightly. Check that the wire is pre-
tensioned.
1 Strap
2 Wedge
71
5. To secure the wedge, tighten the wedge adjustment screw.
6.3 Attaching Guy Rods to Guy Wires

• 17-mm wrench
• 24-mm wrench
• Protective gloves
• Safety helmet
In attaching guy rods to guy wires, you need D-Shackle 10 mm A4 (3 pcs).

1. Locate guyings 2 and 3 which are on the same side as the hinge of the mast base:
• in Northern Hemisphere, on the west side (W) of the mast foundation.
• in Southern Hemisphere, on the east side (E) of the mast foundation.
72
2. Attach the guy rods of guyings 2 and 3 to the guy wires with the shackle.
1 D-Shackle 10 mm A4 (3 pcs)
2 Guy wire with thimble (3 pcs)
3. To eliminate excess slack, tighten guyings 2 and 3 to 60 … 200 N. This prevents the
mast from tilting over.
At this point, the mast is not erected. The guy wire length from the wedge on the
guying foundation to the shackle is approximately 1 ... 1.5 m (3 ft 4 in ... 4 ft 11 in),
depending on the distance from the guy wire foundation to the mast base
(5 ... 6 m / 16 ft 5 in … 19 ft 8 in). After you have erected the mast, adjust the guyings
to their proper length and tightness.
73
74
Chapter 7 – Erecting Mast
7. Erecting Mast
7.1 Installation Safety
persons are needed.

75
WARNING! To prevent the mast from falling, secure it by tightening all the
adjustment screws properly.
handling.
erecting the mast.
installation.
76
cables.
CAUTION! To make sure that the mast is standing straight, tighten all the guy wires
equally.
7.2 Installing Winch to Lowered Mast

• 10-mm wrench
• 24-mm wrench (2 pcs)

WARNING! Do not work on the mast when the wind speed is over 7 m/s (15.7 mph).
77
WARNING! Damaged or severely worn parts can cause incorrect operation or

accidents. Check the winch before each use. Do not use the winch if it is damaged or
not working properly.
WARNING! Do not touch the wire with bare hands. Use gloves. If the wire must be
adjusted, carefully guide the wire with your hand and make sure nothing gets caught
between the wire or the equipment.
WARNING! Make sure that the winch wire does not get tangled or cause someone to
trip and fall.
CAUTION! Make sure that the winch wire does not bend. Keep the winch wire straight
or in coil.
78
If the lifting rod and winch are already installed, start by 7.3 Erecting Mast (page 83).
1. Attach the lifting rod to the mast base plate.
1 Hex screw (2 pcs)

3 Hex nut (2 pcs)
79
2. To adjust the length of the middle rod, unscrew the wing nuts.
1 Hex screw (2 pcs)

2 Washer (2 pcs)
3 Wing nut (2 pcs)
4 Adjuster rod
80
3. Lift the lifting rod up and push it towards the mast.
4. Attach the end of the lifting rod with a shackle to the guy rod.
1 Lifting rod
2 Shackle
3 Guy rod
5. Check that the guy rods are straight.
81
6. Pull approximately 7 .... 8 meters (23 ... 26 ft) of the winch wire towards the end of the
lifting rod.
7. Attach the winch hook to the end of the lifting rod.
1 Winch hook
2 Lifting rod
82
8. Remove the locking pin from the winch and install the winch to the lifting eye bolts on
the guy wire foundation.
1 Winch
2 Locking pin
9. Secure the winch with the locking pin.
7.3 Erecting Mast

• 30-mm wrench
83

WARNING! For safety reasons, do not operate the winch alone.
handling.
erecting the mast.
84
When you have performed necessary installation or maintenance tasks, erect the mast.
1. Place the winch handle on the lower lever (see the following picture). To lock the handle
in place, turn it.
2. To check that the wire is tight and the winch is firmly in place, pull the wire.
3. Check that the grounding and sensor cables do not get caught between the lifting rod
or mast hinge.
85
4. Check that the guy rods are straight.
WARNING! Never go under the mast when the winch is operated or when the
mast is in a tilted position and supported only by the winch wire.
WARNING! Make sure nobody is in the danger zone when you use the winch.
5. Before erecting the mast, check that the screws and washers of the guy rod flange are
tight and that guy wires 2 and 3 are secure.
6. Start winching.
7. Keep an eye on the cables and the guy rods when erecting the mast. Make sure the guy
rods are straight.
86
8. If you need to organize and straighten the guy rods, stop winching and approach the
mast through the safe areas.
9. When the mast is almost upright, check that the mast bolts are aligned with the holes in
the mast base plate.
10. When the winch wire becomes loose, pull the mast to an upright position.
87
11. Lock the mast with two washers and nuts. Do not attach the washer and nut to the
foundation bolt where you install the down conductor.
1 Hex nut ISO4032 M20 (2 pcs), tightening torque 100 Nm

2 Washer DIN125 A21 (2 pcs)
7.4 Removing Winch and Adjusting

Guyings
• 17-mm wrench
• 24-mm wrench
• Hammer
• Spirit level
88
1. Remove the winch and connect guy wire 1 (opposite the tilting direction).
2. Tighten all guy wires. Tighten the U-bolt nuts in the guy wires to 20 Nm until the
tension is sufficient.
3. Check with a spirit level that the mast is vertical.
4. If the mast is not vertical, adjust the guy wires, and check the position of the mast
again. Make sure that each guy wire is tight.
CAUTION! Do not over-tighten the guy wires because this may bend and damage
the mast.
5. Remove the lifting rod.

6. If you loosened the grounding and sensor cables or removed the cables from their
connectors, reattach them.
More Information
‣ Assembling Guy Wires (page 68)
‣ Attaching Guy Rods to Guy Wires (page 72)
‣ Installing Grounding Connector (page 92)
‣ Connecting Down Conductor to Grounding Connector (page 94)
‣ Ground Electrodes (page 96)
89
90
Chapter 8 – Equipment Grounding
8. Equipment Grounding
Proper equipment grounding is required for personnel safety and for equipment protection.
A piece of equipment is grounded by connecting its metal structures and electrical
equipment to a ground electrode.
With mast installations, equipment grounding and lightning protection must be done
separately.
For lightning protection instructions, see Vaisala Lightning Protection Kits DKL201, DKL202,
and DKL203 Technical Reference.
For grounding instructions, see Grounding and Lightning Protection in Vaisala Outdoor
Installations Technical Reference.
For instructions about grounding the enclosure, see relevant product documentation.
grounding, lightning protection, safe installation, and power supply. It is the
responsibility of the customer to see that local and state legislation and regulations
have been properly observed. Subcontractors must also comply with any and all
applicable local regulations, if any.


WARNING! To minimize shock hazard, the instrument chassis and cabinet must be
connected to an electrical ground. The instrument is equipped with a three-conductor
AC power connector. The power cable must either be plugged into an approved three-
contact electrical outlet or the instrument must be carefully grounded to a low-
resistance safety ground.
CAUTION! To prevent equipment damage, install an air terminal so that the tip is as
high above the instruments and sensors as possible.
91
CAUTION! Keep the curve of the down conductor smooth with a minimum radius of the
bent cable 20 cm (8 in) and never over 90 degree angles.
The installation of the air terminal as instructed by Vaisala is based on international IEC
standards. This means routing the down conductor along the side of the mast and
connecting the lightning protection grounding and equipment grounding to a grounding
connector at the base of the mast. If local and state legislation and regulations are
different from the Vaisala installation instructions , it is the responsibility of the customer
to make sure that that grounding and lightning protection comply with local and state
legislation and regulations.
8.1 Installing Grounding Connector

• 5-mm Allen key
• 30-mm wrench
92
The grounding connector comes with 2 black plastic caps. Remove the caps before starting
the installation.
1. Attach the grounding connector on the attachment plate.
1 Hex nut ISO4032 M20 (1 pc), tightening torque 100 Nm

2 Washer DIN125 A21 (1 pc)
3 Attachment plate for grounding connector (1 pc)
4 Grounding connector (1 pc)
5 Allen screw M6 × 30 DIN912 A4 (2 pcs)
6 Washer M8 DIN125 A4 (2 pcs)
2. Install the attachment plate on the foundation bolt that is closest to the down
conductor.
93
8.2 Connecting Down Conductor to

Grounding Connector
• 5-mm Allen key
• Cable stripper
• Wire cutters
1. Turn the down conductor towards the grounding connector, avoiding sharp turns.
2. Cut the down conductor to the appropriate length.
3. Strip 40 mm (1.57 in) from the end of the down conductor.
4. Unscrew one of the fixing screws in the grounding connector and push the down
conductor through the grounding connector.
94
5. Secure the down conductor with the fixing screw.
CAUTION! Keep the curve of the down conductor smooth with a minimum radius
of the bent cable 20 cm (8 in) and never over 90 degree angles.
95
8.3 Ground Electrodes

For instructions about routing the cables from the grounding connector to the ground, see
Grounding and Lightning Protection in Vaisala Outdoor Installations Technical Reference.
CAUTION! The grounding connector is removed when the mast is lowered. To avoid
possible damage to the cables when lowering the mast, leave enough slack when routing
the cables to the ground.
Note the following:

• The materials used in the manufacture of the grounding systems must be chosen to
prevent them from forming an electrolytic couple.
• Recommended grounding resistance is 10 or less. Soil conditions (for example sand or
rocks) and the ground resistance measurement determines the design and construction
of the grounding system.
• Buried ground rods and buried wire can be used for the ground network. The type and
combination used depend on the soil conditions and on the value of measured ground
resistance. Consider the ease of installation and the most effective way of reducing
resistance to the required value of 10 or less.
• Measurements of the earth resistance must be made at least 48 hours after rainfall.
The customer is responsible for supplying the grounding accessories (grounding rods,
connectors, and similar).
WARNING! Consult local electricity professionals for the local and state legislation
and regulations about grounding.
96
Chapter 9 – Lowering Mast for Maintenance and Upgrades
9. Lowering Mast for

Maintenance and Upgrades

97
them.
9.1 Installing Winch to Erected Mast

• 10-mm wrench
• 24-mm wrench (2 pcs)

WARNING! Damaged or severely worn parts can cause incorrect operation or

accidents. Check the winch before each use. Do not use the winch if it is damaged or
not working properly.
WARNING! Do not touch the wire with bare hands. Use gloves. If the wire must be
adjusted, carefully guide the wire with your hand and make sure nothing gets caught
between the wire or the equipment.
98
WARNING! Make sure that the winch wire does not get tangled or cause someone to
trip and fall.
CAUTION! Make sure that the winch wire does not bend. Keep the winch wire straight
or in coil.
1. Attach the lifting rod to the mast base plate.
1 Hex screw (2 pcs)

3 Hex nut (2 pcs)
99
2. To adjust the length of the middle rod, unscrew the wing nuts.
1 Hex screw (2 pcs)

2 Washer (2 pcs)
3 Wing nut (2 pcs)
4 Adjuster rod
3. Disconnect the guy wire that is closest to the lifting rod from the guy rod.
100
4. Lift the lifting rod and attach it with a shackle to the guy rod.
1 Guy rod
2 Shackle
3 Lifting rod
101
5. Attach the winch hook to the end of the lifting rod.
1 Winch hook
2 Lifting rod
6. Disconnect the guy wire from the foundation.

If you use additional middle guy wires, disconnect also the additional guy wire from the
foundation.
102
7. Remove the locking pin from the winch and install the winch to the lifting eye bolt on
the guy wire foundation.
1 Winch
2 Locking pin
8. Secure the winch with the locking pin.
9.2 Lowering Mast

• Support stand
• 30-mm wrench
103

WARNING! For safety reasons, do not operate the winch alone.
104
1. Place the winch handle on the upper lever (see the following picture). To lock the
handle in place, turn it.
2. Make sure that the wire is tight and the winch is firmly in place.
3. Loosen some of the winch wire in the coil so that there is enough wire when you start
winching.
105
4. Remove the nuts from the mast base.
5. Check that the grounding and sensor cables do not get caught between the lifting rod
or mast hinge and that there is enough slack cable. If necessary, loosen the grounding
and sensor cables or remove the cables from their connectors.
WARNING! The weather station is powered. Take the necessary precautions, and
disconnect power from the station if needed.
CAUTION! Check that the grounding and sensor cables are not in the way or in
danger of being damaged. Check that there is enough slack cable to allow for the
lowering of the mast.
6. Place the support stand to where the mast will be lowered.
106
7. Start winching. If needed, push the mast lightly.
WARNING! Never go under the mast when the winch is operated or when the
mast is in a tilted position and supported only by the winch wire.
WARNING! Make sure nobody is in the danger zone when you use the winch.
CAUTION! Monitor the cables and guy rods when lowering the mast. If the guy
rods are stuck vertically, they break easily.
107
8. To organize and straighten the guy rods, stop winching and approach the mast through
the safe areas.
108
9. Lower the mast on the support stand.
CAUTION! To prevent equipment damage, make sure that the weight of the mast
is not on the sensors.
CAUTION! Do not leave the mast load on the winch longer than necessary.
10. Straighten the guy rods.
109
110
Chapter 10 – Maintenance
10. Maintenance
WARNING! Do not service the system alone. Do not reach into parts and assemblies
that are AC (mains) powered and live except in the presence of someone who can
provide first aid.
WARNING! Only licensed experts may install electrical components. They must
adhere to local and state legislation and regulations.
WARNING! Do not replace components when the system is powered up. Switch off
both AC (mains) and battery power before performing maintenance procedures.
111
them.
CAUTION! Improper modification can damage the product or lead to malfunction. Any
modification voids your warranty.
CAUTION! Contact Vaisala or its authorized representative for repairs.
10.1 Regular Maintenance

The mast tubes are made of glass-fiber reinforced plastic (GRP). The metal parts of the mast
are made of anodized aluminum alloy and maritime-grade stainless steel.
Once a year:
• Check the mast for any damage to the coating.
• Check the guyings for correct tightness and possible damage.
10.2 Repair Painting

The repair paint kit is available from the mast manufacturer Exel.
• Acetone
• Brush, width approximately 20 … 50
• Paper or cloth towel
• Sand paper: fine, 200 … 400
• Tape, polypropylene, PP
• Two-component polyurethane paint, signal red RAL 3001 and traffic white RAL 9016
(valid only for the coloring that complies with ICAO standards)
• Wooden or plastic mixing stick
112
Wear personal protective equipment (PPE).
Read the instructions of the paint manufacturer on painting conditions.
The recommended temperature during the painting work is at least +18 °C (+64 °F).
1. Clean all surfaces with sand paper.

2. Remove dust with acetone and paper or towel.
3. Mix the paint carefully. Follow the paint manufacturer instructions.
4. Brush the paint on the clean surface.
5. Let the paint dry.
10.3 Glass Fiber Tube Repair

The glass fiber tube repair kit is available from the mast manufacturer Exel.
The damage can be repaired as long as it is less than half of the circumference of the tube.
If the tube is fully broken, contact Vaisala.
113
• Acetone
• Brush, width approximately 20 … 50
• Glass fiber mat reel: reel B = 35 … 50 mm (1.38 ... 1.97 in). For example, weight
425g/m”, ward 70 x 320, weft 53 x 272, thickness 0,32 weave plain
• Hardener (Component B), Butanox 50
• Mixing pots: PE/PP-plastic, 1 liter (0.26 gal)
• Paper or cloth towel
• Pre-accelerated Epoxy Vinyl Ester Resin (Component A), Derakane 411 … 45
• Sand paper: fine, 200 … 400
• Syringe, 20 ml (0.053 gal)
• Tape, polypropylene, PP
• Two-component polyurethane paint, signal red RAL 3001 and traffic white RAL 9016
(valid only for the coloring that complies with ICAO standards)
• Wooden or plastic mixing stick
Wear personal protective equipment (PPE).
Due to the flammability of the components, special packaging is required. Be prepared for
higher air freight costs.
Arrange the repair conditions as instructed by the resin or hardener producer.
114
10.3.1 Pre-Treatment of Glass Fiber Tubes

1. Remove dirt and old paint with acetone and paper.
2. Abrade and clean the surfaces with sand paper.
3. Remove dust with acetone and paper or towel.
10.3.2 Mixing Components

1. Read the manufacturer instructions carefully and follow them.
2. Use a syringe or a scale to measure the quantities of the different components.
3. Do not mix more than 100 g (3.53 oz) at a time, because you have only about
25 minutes to work before the mix hardens.
Normal mixing ratio:
�� 100
=
�� 1,5
10.3.3 Repairing Glass Fiber Tubes

1. Spread the mixed resin on the damaged area.
2. Soak the damaged area with the resin.
3. Wrap the glass fiber mat tightly around the damaged area, and simultaneously spread
more resin over the mat. To obtain as much strength as possible, make sure that the
mat is fully soaked.
4. Wrap at least 2 full layers, from 3 to 4 layers where possible. Place the layers in 30 … 45°
angles to each other.
5. To remove air and penetrate the resin into the tube structure, wrap polypropylene tape
around the repaired area.
6. Let the resin cure in the instructed temperature for 24 hours.
7. Remove the polypropylene tape.
8. Abrade the surface with sand paper.
9. Continue to paint the repaired area.
More Information
‣ Repair Painting (page 112)
10.4 Erecting Mast

Erect the mast after maintenance operations.
115
More Information
‣ Installation Safety (page 14)
‣ Installing Winch to Lowered Mast (page 77)
‣ Erecting Mast (page 83)
‣ Removing Winch and Adjusting Guyings (page 88)
116
Chapter 11 – DKE110F Specifications
11. DKE110F Specifications

Table 18 DKE110F Specifications
Property Description/Value
Compliance with standards ICAO: Annex 14, para 5.3.14
Aerodrome Design Manual Part 6 (Doc 9157)
FAA: AC150/5345-45C
Environmental impact Low carbon footprint
Recycling according to EU directive 2008/98/EC
Height (assembled) 10 m (33 ft)
Height, mast tube 1 0 … 3.0 m (0 … 0.98 ft)
Height, mast tube 2 3.0 … 6.0 m (0.98 … 1.97 ft)
Height, mast tube 3 6.0 … 9.0 m (1.97 … 2.95 ft)
Height, top section 9.0 … 10.0 m (2.95 … 3.28 ft)
Length, mast tubes 1, 2, 3 3 m (9.84 ft) each
Length, top section 1 m (3.28 ft)
Diameter, mast tubes 1, 2, 3 106 mm (4.17 in)
Diameter, top section 60 mm (2.36 in)
Maximum wind speed with one guying set 60 m/s (134 mph)
Maximum wind speed with additional guying set 75 m/s (168 mph)
Weight (mast only) 35 kg (77 lb)
Material, 1st … 3rd mast tubes Glass-fiber reinforced plastic (GRP)
Material, top section Aluminum alloy
Material, base and hinge material Aluminum alloy
Other parts Aluminum alloy or marine grade stainless steel
Fastener parts Marine grade stainless steel
Guy rods
Material GRP
Fasteners Marine grade stainless steel
Number of guy rods 18 pcs
Breaking strength 15 kN
Foundation set
Material Galvanized steel
117
Property Description/Value
Thread of foundation bolts M20
Length of foundation bolts 350 mm (13.78 in), cast in or drilled to concrete
Coating
GRP Painting, red or white
Aluminum parts Anodizing and painting
Steel parts Galvanized
Stainless steel Painted
Packaging
Material Plywood
Mast package dimensions (L × W × H) 3100 × 500 × 390 mm (122.05 × 19.69 × 15.35 in)
Mast package weight 48 kg (106 lb)
Foundation set package dimensions (L × W × H) 385 × 275 × 110 mm (15.16 × 10.83 × 4.33 in)
Foundation set package weight 12 kg (26.5 lb)
118
Appendix A – Foundation Design Drawings
Appendix A. Foundation
Design Drawings
119
120
121
1 Concrete foundation
2 Backfill
4 Drainage (optional)
5 Compacted gravel
122
123
124
Warranty
For standard warranty terms and conditions, see www.vaisala.com/warranty.
Please observe that any such warranty may not be valid in case of damage due to normal
wear and tear, exceptional operating conditions, negligent handling or installation, or
unauthorized modifications. Please see the applicable supply contract or Conditions of Sale
for details of the warranty for each product.
Technical Support
Contact Vaisala technical support at helpdesk@vaisala.com. Provide at least the following
supporting information:
• Product name, model, and serial number
• Name and location of the installation site
• Name and contact information of a technical person who can provide further
information on the problem
For more information, see www.vaisala.com/support.
Recycling
Recycle all applicable material.
Follow the statutory regulations for disposing of the product and packaging.
125
126
www.vaisala.com

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9. Lowering Mast for Maintenance and Upgrades.................................... 97

10. Maintenance......................................................................................................... 111

11. DKE110F Specifications.................................................................................. 117

Appendix A: Foundation Design Drawings................................................... 119

1. About This Document

Document Code Date Description

M211788EN-B October 2016 • Foundation specifications and instructions updated.

M211788EN-A July 2015 First, draft version of this manual.

1.2 Related Manuals

Document Code Name

1.3 Documentation Conventions

Note highlights important information on using the product.

Tip gives information for using the product more efficiently.

Lists tools needed to perform the task.

Figure 1 DKE110 Dimensions

2.2 Frangible Pole Mast

2.3 Foundation Set

2.4 Guying Set

2.5 Additional Middle Guying Set

2.6 Lightning Protection Kit (Optional)

2.7 Winch (Optional)

2.8 Product Nomenclature

Item Common/Full Name

DKE110F Vaisala Guyed Frangible Mast (10 m, 33 ft)

DKF100-EXEL Foundation set

DKE110-GW1 Top guying set

DKE110-GW2 Additional middle guying set

DKL201 Vaisala Lightning Protection Kit

DKE100TS Support stand

2.9 Parts Lists

Aluminum top section 1

Hex socket head screw ISO4762 M8 × 20 15

Set screw DIN913 M8 × 20 2

Washer DIN125 B 8.4 15

Washer DIN125 A21 9

Thin hex nut ISO4035 M20 6

Attachment plate for grounding connector 1

Allen screw M6 × 30 DIN912 A4 2

Table 5 Parts Lists for Foundation Set DKF100-EXEL

Hex nut ISO4032 M20 18

Lifting eye nut DIN582 M20 3

Template for positioning foundation bolts 1

Table 6 Parts List for Top Guying Set DKE110-GW1

Wedge clamp for guy wire (SH49) 3

Guy rod, white 1500 mm (59.06 in) 9

Guy rod, red 1500 mm (59.06 in) 9

Chain link connector 15

Guy wire with thimble 3

Guy rod flange 1

Table 7 Parts List for Additional Middle Guying Set DKE110-GW2

Wedge clamp for guy wire (SH49) 3

Guy rod, white 1500 mm (59.06 in) 6

Guy rod, red 1500 mm (59.06 in) 6

Chain link connector 9

Steel wire with thimble 3

Guy rod flange 1

Table 8 Parts List for Vaisala Lightning Protection Kit DKL201

Air terminal, aluminum bar D15 mm 1

Air terminal bracket 2

Hex screw M6 × 45 DIN933 A4 9