05 - #0019-2575 Vestas Earthing System V3

Document no.
:0019-2575 V03
2015-01-27
Vestas Earthing System

Foundation Earthing Work Description of Foundation Earthing on Anchor Cage Foundation
Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com
VESTAS PROPRIETARY NOTICE: This document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work. Vestas reserves all patent, copyright, trade secret, and
other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable conditions. Vestas
disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.
Document no.:0019-2575 V03 Date:2015-01-27
Document owner: Platform Management Vestas Earthing System Restricted
Type: T05 - Manual History of this document Page 2 of 20
History of this document
Version Date Description of changes

no.
03 2015-01-27 Created this version to get the pdf document version updated to correct
the errors for cross reference in ‘Drawings’ section.
Table of Contents
1 Preconditions ....................................................................................................................... 3
2 The Earthing System ........................................................................................................... 3
2.2 Installation of Foundation Earthing ......................................................................................... 3
3 Materials Lists ...................................................................................................................... 3
3.1 Materials Supplied by Vestas ................................................................................................. 3
3.2 Other Required Materials ....................................................................................................... 4
4 Work Instruction .................................................................................................................. 4
4.1 Installation of the Earthing Wire ............................................................................................. 4
4.2 Installation of Main Earth Bonding Bar ................................................................................. 12
4.3 Installation of Foundation Earth Wires to the Main Earth Bonding Bar ................................. 14
5 Drawings ............................................................................................................................ 16
6 Pile Anchors Foundation................................................................................................... 18
6.1 Materials Supplied by Vestas ............................................................................................... 18
6.2 Work Instruction ................................................................................................................... 18

Type: T05 - Manual Preconditions Page 3 of 20
1 Preconditions
Description and drawings apply to foundation earthing on anchor cage foundation
of a Vestas wind turbine.
The foundation earthing is only one part of the complete Vestas Earthing System.
Chapter 6Pile Anchors Foundation, p. 18 describes the additional installation to
be performed when pile anchors must be installed below the anchor
cagefoundation.
A description of the complete Vestas Earthing System for an anchor cage
foundation is given in document 0014-6511 ‘Vestas Earthing System Description
of Earthing System on Anchor Cage Foundation’.
The Vestas Earthing System design is based on and complies with the following
international standards and guidelines.
 IEC 61400-24. Wind turbines - Part 24: Lightning protection.
 IEC 60364-5-54. Second edition 2002-06. Electrical installations of buildings -
Part 5-54: Selection and erection of electrical equipment – Earthing
arrangements, protective conductors and protective bonding conductors.
 IEC 61936-1. First edition. 2002-10. Power installations exceeding 1 kV a.c.-
Part 1: Common rules.
2 The Earthing System

Vestas offers an approved earthing design for an anchor cage foundation for
tubular steel towers. The design documentation consists of an overviewdocument
where all requirements of a complete Vestas Earthing System are described, a
document describing the earthing between the individual wind turbine sites, a
document describing the equipotential connections of all cables entering a wind
turbine and this document describing the foundation earthing.
2.2 Installation of Foundation Earthing

The foundation earthing must be installed in accordance with the specifications
set out in this work description, including any drawings, and the related Quality
Control specification.
All parts on the foundation earthing must be installed before concreting the
foundation.
3 Materials Lists
3.1 Materials Supplied by Vestas

All materials listed below will be supplied by Vestas along with the steel
foundation section.
 90 m (100 yds.) of bare copper stranded conductor (50 mm2 (AWG 1/0)
earthing wire) supplied with cable lugs and protection shrink sleeve at each
end.
 M10 bolts, M10 washers and M10 nuts (stainless) for connecting the two
ends of the earth wire to the main earth bonding bar.

Type: T05 - Manual Work Instruction Page 4 of 20
 16 connection terminals (Dehn MAXI MV) for secure connections between

the copper earthing wire and the reinforcement steel bar crossings every 5 m
(5.5 yds) along the earthing wire.
3.2 Other Required Materials

 Steel tie wire; enough for approximately 600 ties between the copper earthing
wire and all reinforcement steel bar crossings.
 Tools.
4 Work Instruction
After installing the bottom layer of reinforcement steel and when the foundation
section is in place, begin work on the foundation earthing.
NOTE All parts on the foundation earthing must be installed before concreting the
foundation.
4.1 Installation of the Earthing Wire

– Dismount the roll of bare copper earthing wire from where it is fixed to the
main earth bonding bar inside the foundation section. The bag containing
the 16 connection terminals, to be used later, is also fixed here.
– Roll out the earthing wire beside the foundation section. See Figure 4-1,
p. 4.
Figure 4-1: Rolling out the earthing wire beside the foundation section

NOTE Make sure the earthing wire is not harmed by machinery or heavy items placed
on the earthing wire.
– Pull one end of the earthing wire in through the bottom of the foundation
section up to the position shown in Figure 4-2, p. 5.
Figure 4-2: Positioning of the earthing wire in the foundation on the backside of
the switchgear

Figure 4-3: Earthing wire fixated to wood bar for fixed position before concreting
– Place the earthing wire all the way along the inner side of the edge of the
reinforcement steel. See Figure 4-44, p. 6.
Figure 4-4: Earthing wire running along the edge

NOTE Routing of the earthing wire can be seen on the drawings enclosed in this
document.
NOTE If the foundation is very large and the prefabricated earthing wire is not long
enough for routing the earthing wire close along the inner side of the edge of the
foundation, simply route the earthing wire at a fixed distance from the edge. The
distance from the edge of the foundation to the earthing wire must be nearly the
same all the way around the edge.
– Once the earthing wire is in position along the edge of the foundation,
route the end of the wire down under the foundation section and up to the
second location shown in Figure 4-2, p. 5.
Figure 4-5: Foundation earth wire temporarily fixed to a wood bar
– Pull the two ends of the earthing wire through the bottom of the foundation
section up to the temporary wood bar. See Figure 4-6:, p. 8. The two ends
(with cable lugs) of the earthing wire must extend 60 cm above the
foundation.

Detail No.: 1
Earthing cable from

foundation fixated
to the wood bar
Wood bar to be placed on top of the tower for fixation

of the earthing cables, that comes from the foundation,
please see detail No.: 1. The fixation of the main
bonding bar must be carried in the period between
installation of the main bonding bar and the switch
gear.
Detail No.: 1
Anchor cage
(Top of foundation)
Tower ring
Concrete foundation
Figure 4-6: Foundation earth wire temporarily fixed to a wood bar
NOTE Do not cut off excess earthing wire. Instead, distribute the wire inside the
reinforced steel. Connect the excessearthing wire to the reinforced steel bar
crossings. See Figure 4-7: , p. 9.

Figure 4-7: Excess earthing wire distributed as slack
– Leave enough slack so that one end of the earthing wire can later be fixed
to the upper layer of reinforcement steel bars. See Figure 4-8:, p. 9.
Figure 4-8: Slack (left for later) for connection to the upper layer of reinforcement
steel bars
For the following instructions, refer to Figure 5-1:, p. 16.
– Install connection terminals every 5 m (5.5 yds) along the earthing wire.
Start at the end of the earthing wire that follows the lower layer of
reinforcement steel to the edge of the reinforcement steel. In Figure 5-1:,
p. 16, the connection terminals are marked 1 to 16. The connection
terminals must be installed so that the earthing wire is firmly connected to
the nearest crossing reinforcement steel bars. Install connection terminals
numbered 1 to 15 first. Connection terminal 16 must be installed along
with the upper layer of the reinforcement steel.

Figure 4-9: Earthing wire connected to the reinforcement steel bars by means of a
connection terminal
Figure 4-10: Earthing wire connected to the reinforcement steel bars by means
of a connection terminal
NOTE When connecting a connection terminal to the reinforcement steel place the
copper wire and the reinforcement steel bar on each side of the middle plate in
the connection terminal.
NOTE Before installing the connection terminal, make sure that there is no rust or dirt on
the reinforcement steel bar where the connection terminal is to be installed.
– Grind the reinforcement steel bar using a wire brush or emery cloth before
installing the connection terminal.
– Tighten the connection terminals firmly to a tightening torque of 25 Nm
(18lbf-ft).
– After installing the connection terminals numbered 1 to 15, the earthing
wire must be connected to all reinforcement steel bar crossings using wire
ties. No exceptions must be made. All cross points must be connected.

The maximum distance between the connections is 15 cm (0.5 ft). The

wire ties between the earthing wire and the crossing steel reinforcement
bars must be made with a wire tie between two reinforcement steel bars.
Figure 4-11: Earthing wire

Figure 4-12:: Earthing wires connected to
connected to
reinforcement bars by
reinforcement bar by
means of wire ties
means of a wire tie
– Leave a part of the earthing wire to be connected to the upper

reinforcement steel bars.
– Install the upper layer of reinforcement steel to the foundation.
– Install connection terminal number 16. See Figure 4-13:, p. 11.
– Connect the earthing wire to the upper reinforcement steel bars using
steel tie wire. See Figure 4-13:, p. 11 and Figure 4-14:, p. 11.
Figure 4-13: Earthing wire connected Figure 4-14: Earthing wire connected
to the upper to the upper
reinforcement steel reinforcement steel
– Make a final inspection of the installation according to 0019-2576 ‘Quality

Control of Foundation Earthing, Anchor Cage Foundation’.
– Concrete the anchor cage foundation.

4.2 Installation of Main Earth Bonding Bar

The main earth bonding bar must be temporarily installed during foundation work,
but must be dismounted during installation of the lower tower section, See Figure
4-15:, p. 12.
Detail No .: 1
Earthing cable from

foundation fixated
MBB must be fixated to to the wood bar
the wood bar until the
baseframe forthe switch
gear has been installed
Wood bar to be placed on top of the tower for fixation

of the earthing cables, that comes from the foundation ,
please see detail No.: 1. The fixation of the main
bonding bar must be carried in the period between
installation of the main bonding bar and the switch
gear.
Detail No.: 1
Anchor cage
(Top of foundation)
Tower ring
Concrete foundation
Figure 4-15: Temporarily installation of the MBB during foundation work.
After final installation of the lower tower section, the main earth bonding bar must
be installed on the back of the switchgear.

NOTE The switchgear is available in three versions: a twopanel, a three panel and a
four panel. For installation of the main earth bonding bar for each version, see
Figure 4-16:, p. 13, Figure 4-17:, p. 13 and Figure 4-18:, p. 14.
– Install both ends of the earthing wire (cable lugs) to the main earth
bonding bar. Connect the wires close to each end of the bonding bar. Use
the enclosed stainless M10 bolts, M10 washers and M10 nuts.
NOTE The main earth bonding bar must be fixed to the base frame of the switchgear by
two sets of stainless M10 bolts, M10 washers and M10 nuts.
Figure 4-16: Earthing wire (cable lugs) connected to the main earth bonding bar
on the base frame for four panel switchgear
on the base frame for three panel switchgear

on the base frame for two panel switchgear
– Fasten the main earth bonding bar to the switchgear.
– Tighten all nuts.
4.3 Installation of Foundation Earth Wires to the Main

Earth Bonding Bar
After installation of the foundation earth wires, the earth wires must be
temporarily fixed to a wood bar. When the switchgear is installed on the
foundation, the earth wires must be connected to the main earth bonding bar on
the switchgear.
The two foundation earth wires are prefabricated with cable lugs ready to be
connected to the main earth bonding bar.
– Connect the foundation earth wires (cable lugs) to the main earth bonding
bar using the stainless M10 bolts, M10 washers and M10 nuts. Tighten to
standard torque value.
– After installation of the switchgear, connect the earthing wire to the main
bonding bar on the switchgear.
– Route the two 50 mm2earthing wires from the main earth bonding bar to
the tower section. See Figure 4-19:, p. 15.

See detail No.: 1
Earthing cables
Ladder
Main Bonding Bar
HV-cable
See detail No.: 1
1. Routing of cables
One of the earthing cables must be fixated to the HV-cable, so they
follow the HV-cables route on the foundation from the MBB to tower
wall. When the earthing cables enter the ring of the tower, they are
placed on the, but in opposite direction in 1,5 m. The earthing
cables must be fixated to the Tower, please detail 1.
Detail No.: 1
Tower The fixation of the earthing cable
shall be done by a M10 bolt. The
earthing cable must be ended in
a cable lug for fixation to the
tower.
575 mm
Tower ring
Figure 4-19: Two 50 mm2earthing wires connected to the tower and routed in the
tower

Type: T05 - Manual Drawings Page 16 of 20
5 Drawings
Figure 5-1:, p. 16: Top view of foundation with earthing wire installed.
Figure 5-2, p. 17 Side view of foundation with earthing wire installed (detail 1).
Figure 5-3, p. 18 Side view of foundation with earthing wire installed (detail 2).
Earthing wire
12
13
11
14
Note 2
10
15 Main Bonding Bar
Note 2
Note 1
16 9
2 1
8
3
7
Connection terminals
4 6
5
Note 1. Note 2.
This part of the earthing wire is to be Slack of excessive earthing wire.
connected to the upper reinforcement,
when in place.
Figure 5-1: Top view of foundation with earthing wire installed

Note 1 This part of the earthing wire must be connected to the upper
reinforcement steel, when in place
Note 2 Slack of excessive earthing wire

Type: T05 - Manual Drawings Page 17 of 20
MAIN EARTH BONDING BAR
Detail 1
CONNECTION TERMINAL NO. 16
BINDING BETWEEN EARTHING WIRE

AND REINFORCEMENT STEEL BAR
CONNECTION TERMINAL NO. 1
EARTHING WIRE
DWG. NO. 934665
Figure 5-2: Side view of foundation with earthing wire installed (detail 1)
Detail 2
BINDING BETWEEN EARTH ING WIRE

AND REINFORCEMENT STEEL BAR
EARTHING WIRE
DWG. NO. 93466 6
Figure 5-3: Side view of foundation with earthing wire installed (detail 2)

Type: T05 - Manual Page 18 of 20
6 Pile Anchors Foundation

This chapter describes the additional installation that must be performed in cases
where pile anchors have to be installed below the Vestas Earthing System
anchor cage foundation.
Each pile anchor must be connected to the copper earthing wire.
When laying out the copper wire along the edge of the foundation, make sure
that all the pile anchors can be connected to the copper earthing wire.
6.1 Materials Supplied by Vestas

All materials listed below will be supplied by Vestas if pile anchors must be
installed below the anchor cage foundation. These materials are a supplement to
the materials described in section 3.1Materials Supplied by Vestas, p. 3
All materials listed below will be supplied by Vestas along with the steel
foundation section.
XX connection terminals (Dehn MAXI MV) for secure connections between the
copper earthing wire and the reinforcement steel bar crossings. (XX = the
number of pile anchors).
6.2 Work Instruction

– Connect the copper earthing wire to the reinforced steel bars by means of
connection terminals.
– Each pile anchor must be connected to the copper wire with one
connection terminal. See Figure 6-1, p. 20, Figure 6-2, p. 20 and Figure
6-3, p. 21
NOTE When connecting a connection terminal to the reinforcement steel, always place
the copper wire and the reinforcement steel bar on each side of the middle plate
in the connection terminal.
NOTE Before installing the connection terminal, make sure that there is no rust or dirt on
the reinforcement steel bar where the connection terminal is to be installed.
– Tighten the connection terminals firmly to a tightening torque of 25 Nm

(18lbf-ft).

Type: T05 - Manual Pile Anchors Foundation Page 19 of 20
Figure 6-1: Earthing wire connected to the reinforcement steel bar from the pile
anchors by means of a connection terminal
Figure 6-2: Earthing wires connected to the reinforcement steel bars from the pile
anchors by means of connection terminals

Type: T05 - Manual Pile Anchors Foundation Page 20 of 20
Figure 6-3: Vertical reinforced steel bars from the pile anchors connected to the
copper wire by means of a connection terminal

05 - #0019-2575 Vestas Earthing System V3

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Document no.

Vestas Earthing System

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

History of this document

Version Date Description of changes

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

2 The Earthing System

2.2 Installation of Foundation Earthing

3.1 Materials Supplied by Vestas

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

 16 connection terminals (Dehn MAXI MV) for secure connections between

3.2 Other Required Materials

4.1 Installation of the Earthing Wire

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Figure 4-4: Earthing wire running along the edge

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Figure 4-5: Foundation earth wire temporarily fixed to a wood bar

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Earthing cable from

Wood bar to be placed on top of the tower for fixation

Figure 4-6: Foundation earth wire temporarily fixed to a wood bar

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Figure 4-7: Excess earthing wire distributed as slack

For the following instructions, refer to Figure 5-1:, p. 16.

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

The maximum distance between the connections is 15 cm (0.5 ft). The

Figure 4-11: Earthing wire

– Leave a part of the earthing wire to be connected to the upper

– Make a final inspection of the installation according to 0019-2576 ‘Quality

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

4.2 Installation of Main Earth Bonding Bar

Earthing cable from

Wood bar to be placed on top of the tower for fixation

Figure 4-15: Temporarily installation of the MBB during foundation work.

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

4.3 Installation of Foundation Earth Wires to the Main

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

See detail No.: 1

Main Bonding Bar

See detail No.: 1

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

15 Main Bonding Bar

Figure 5-1: Top view of foundation with earthing wire installed

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

MAIN EARTH BONDING BAR

CONNECTION TERMINAL NO. 16

BINDING BETWEEN EARTHING WIRE

CONNECTION TERMINAL NO. 1

DWG. NO. 934665

BINDING BETWEEN EARTH ING WIRE

DWG. NO. 93466 6

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

6 Pile Anchors Foundation

6.1 Materials Supplied by Vestas

6.2 Work Instruction

– Tighten the connection terminals firmly to a tightening torque of 25 Nm

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com

Vestas Wind Systems A/S · Hedeager 44 8200 Aarhus N · Denmark · www.vestas.com