THE AGL ENGINEERING CENTRE by Precision AGL Academy · Electrical Protection

Lightning & Surge Protection for AGL Circuits

Counterpoise, bonding, grounding and surge protection for the complete AGL path from CCR to light and control system, and how to test, maintain and investigate it after a lightning event.

Overview

Lightning & Surge Protection for AGL Circuits

Airfield Ground Lighting works over large outdoor areas, often with long underground series circuits, exposed fittings, metallic structures, transformers, connectors and control equipment. That makes the network vulnerable to direct and nearby strikes, induced voltage, earth-potential differences, switching transients, surge propagation along cables and transients on communication and control lines. A fitting can be damaged even when lightning does not hit it directly.

A proper strategy covers the complete AGL electrical path: power supply → CCR → primary circuit → cable → transformer → connector → light, together with grounding and bonding, counterpoise, surge protection and control-system protection.

The aim is not to claim that lightning can be eliminated. It is to control the consequences of lightning and surge energy and keep the required system integrity.

CCR power electronics and control boardsPrimary cable insulationIsolating transformersConnectorsInset and elevated lightsSignsPAPI electronicsALCMS and field controllersCommunication interfaces
FAA guidance treats lightning protection as part of visual-aid installation. In India, base the design on DGCA, AAI and project requirements together with the relevant Indian lightning and surge-protection standards.
Concepts

Lightning Protection vs Surge Protection

Lightning protection

Addresses the effects of lightning current and electromagnetic energy.

  • Air terminals where required
  • Down conductors
  • Grounding / earth termination
  • Bonding
  • Counterpoise
  • Equipotentialization
  • Physical separation where applicable

Surge protection

Limits transient overvoltage reaching electrical and electronic equipment.

  • Surge protective devices (SPDs)
  • Surge arresters
  • Transient protection
  • Protected power supplies
  • Signal-line protection

A strong design uses lightning protection + grounding / bonding + surge protection, not only a plug-in SPD. Under FAA AC 150/5340-30J the airfield-lighting lightning-protection system is meant to protect elevated and in-pavement fixtures, NAVAIDs, signs and underground power, communication and control circuits. It is an airfield-wide infrastructure system, not a device in the electrical room.

Interactive

Where Does the Surge Come From?

Pick an entry path to see what it affects and how it is usually addressed.

A nearby strike induces a surge on the primary cable, which an arrester passes to the earthing bus at the CCR.

SINGLE-LINE SCHEMATIC · WHERE A SURGE IS DIVERTED TO EARTHCCRequipmentLIGHTS ON THE LOOPSTRIKESURGETO EARTH123451SURGE SOURCElightning strike or switching2CIRCUIT CABLEcarries the surge to the CCR3SURGE ARRESTERdiverts the surge to earth4EARTHING NETWORKbonded bus, rods, counterpoise5PROTECTED EQUIPMENTheld within its voltage ratingTHE INTERFACE DIVERTS SURGE ENERGY TO EARTH BEFORE IT REACHES EQUIPMENT
Figure 1. Lightning surge interface: induced surge on the primary cable, a surge arrester at the CCR and a short lead to the earthing bus.
AGL Visual Encyclopedia: Lightning surge interface Lightning detector

Protection to consider

    Watch points

      A planning aid. Selection and ratings come from the protection study, the applicable standards and the manufacturers’ requirements.
      Counterpoise

      What Is an AGL Counterpoise?

      A bare copper conductor above the primary cable, bonded to ground rods along the route.

      BARE COPPER EARTH CONDUCTOR · SECTION AND PLAN uninsulated copper in the trench, bonded to rods and equipment SECTION THROUGH TRENCH WARNING TAPE PRIMARY CABLE BARE COPPER PLAN VIEW ALONG THE ROUTE ← FROM CCR EARTH BAR ROUTE CONTINUES → BASE CAN GROUND ROD GROUND ROD 1 2 3 4 5 1 BARE COPPER CONDUCTOR uninsulated, laid in the cable trench 2 SOIL CONTACT backfill touches the copper along its length 3 EARTH ELECTRODE ground rods bonded to it at intervals 4 BONDED JOINT exothermic weld or approved compression joint 5 EQUIPMENT CONNECTION branch to base can, fixture or CCR earth bar SOUND EARTH CONDUCTOR CONTINUOUS, BONDED, IN SOIL Low-resistance earth path along the whole route POOR EARTH CONDUCTOR BROKEN, CORRODED OR LOOSE Lost earth path, unsafe fault current, lightning damage SCHEMATIC · NOT TO SCALE · SIZE AND DEPTH PER THE DESIGN
      Figure 2. Counterpoise: trench section and plan of a bare copper earth conductor bonded to ground rods.
      AGL Visual Encyclopedia: Bare copper earth conductor Earthing network Earth pit arrangement

      A counterpoise is a conductor installed along the airfield lighting system as part of the lightning-protection arrangement. It matters most for long underground circuits. Its location, depth, conductor size and bonding must follow the selected design method and the applicable standard.

      Equipotential method

      The counterpoise is arranged and bonded so protected field components and the counterpoise rise toward a similar potential during a strike, reducing harmful potential differences and arcing. FAA guidance identifies it for locations with high lightning incidence, subject to engineering selection.

      Isolation method

      The counterpoise is not bonded to the protected elevated fitting in the same way. FAA guidance limits it to particular elevated-fixture installations on turfed or stabilized shoulders, with specific installation conditions.

      FAA AC 150/5340-30J says the two methods should not be mixed on the same circuit. This is also why a counterpoise layout should not simply be copied from another project. Base the method on airfield construction, lightning exposure, pavement, fixture type, soil, cable arrangement and standards.

      FAA AC 150/5340-30J (12 February 2018) is FAA / U.S.-specific guidance. Use it as an engineering reference, not as an Indian or ICAO requirement.
      Zoning

      Protection Zones and the Complete Path

      Representative zoning. Each zone has a coordinated protection strategy, and the counterpoise follows the field circuit.

      ZONE 1: INCOMING SUPPLY Main power + SPD ZONE 2: AGL POWER DISTRIBUTION UPS / DG / SPD CCR + protection ZONE 3: AGL FIELD NETWORK Primary AGL series cable Transformer + light Transformer + light Transformer + light Counterpoise bonded per the selected method ZONE 4: CONTROL AND MONITORING ALCMS + signal SPD Field controllers A-SMGCS interface

      Coordinated SPDs

      Protection is usually more effective when coordinated at several interfaces: substation → AGL power room → CCR panel → CCR control → field and control equipment. Coordination depends on the distance between SPDs, response characteristics, protection level, energy capability, conductor impedance and upstream and downstream devices. Use higher-energy protection upstream and finer protection downstream, not identical devices everywhere.

      Domains differ

      AC power (mains, UPS, DG, CCR input), the series-circuit output (CCR output, field cable, transformers), DC control (CCR controls, field controllers, relays) and communications (Ethernet, fibre, copper, monitoring) can each need a different approach.

      Bonding and Earthing

      Bonding, Grounding and Equipotentialization

      With bonding, almost no voltage appears between a fixture body and its base can.

      TWO METAL PARTS · WITH AND WITHOUT A BONDING JUMPERWITHOUT BONDINGWITH BONDINGFIXTURE BODYmetal partBASE CANmetal partINSULATION FAULTV ≠ 0TOUCH BOTH PARTS AND A VOLTAGE IS ACROSS YOUFIXTURE BODYmetal partBASE CANmetal partFAULTBONDING JUMPERV ≈ 0BOTH PARTS RISE AND FALL TOGETHERBONDED PARTS SHARE ONE POTENTIAL, SO NO VOLTAGE APPEARS BETWEEN THEM
      Figure 3. Bonding: a fault voltage between fixture body and base can without bonding, and almost none with a bonding jumper.
      AGL Visual Encyclopedia: Bonding Earthing principle

      Bonding leads from a CCR cabinet, a sign housing and a base can to a buried earthing conductor.

      ONE CIRCUIT · EVERY METAL CASE BONDED TO EARTHGROUND LEVELCCRmetal cabinetSIGNmetal housingINSULATION FAULTFIXTUREBASE CANPRIMARY CABLEFAULT CURRENT12341EXPOSED METAL PARTcase, housing, frame, cover2BONDING LEADties each part to earth3EARTHING CONDUCTORcommon buried earth path4GROUND RODconnection to the soilFAULT CURRENTflows to earth via the leadA BONDED CASE GIVES FAULT CURRENT A LOW-RESISTANCE PATH TO EARTH
      Figure 4. Equipment earthing: each item bonded to the buried conductor, with the primary cable kept insulated from earth.
      AGL Visual Encyclopedia: Equipment earthing Earthing network Earthing installation

      Why bonding matters

      Lightning can create very large temporary voltage differences. If two metallic parts are not bonded, part A can sit at high potential while part B stays lower, and the result can be arcing, flashover and equipment damage. FAA construction specifications require metallic field components on the CCR output side to be bonded to the lighting counterpoise under the applicable method.

      Grounding vs bonding

      Grounding / earthing is connection to the earth electrode system. Bonding connects conductive parts to each other to control potential difference. A design may need both, for example light base ↔ bonding conductor ↔ counterpoise, and counterpoise ↔ earth system where the method requires it.

      Earth resistance is not the goal

      The useful aim is a controlled, coordinated current path and minimal dangerous potential differences, not simply the lowest earth resistance. A low reading alone does not guarantee good lightning performance. Conductor inductance, geometry, current path, parallel paths and connection quality also matter.

      Parts to include

      Light bases, mounting hardware, fixture bodies, transformer housings, supports, equipment cabinets, cable armour where applicable, the counterpoise and lightning-protection conductors. Design the network so lightning current does not travel through sensitive equipment.

      A common field mistake is to treat the light fixture as a standalone object rather than part of the complete protection system.
      CCR

      CCR Protection and the Series-Circuit Difference

      Protection layers along the CCR power path, from the surge device to the earth monitor.

      TRIP SIGNAL AC SUPPLY INPUT BREAKERoverload / shortCONTACTORCLOSEDTHYRISTOR STAGEpower controlTRANSFORMERisolationOUTPUT SENSINGcurrent (CT)SERIES CIRCUITfloating loop SURGE PROTECTIONdiverts surges to earthSUPPLY MONITORover / under-voltageTEMPERATURE SENSORwarn, then tripCONTROL BOARDopens contactor on tripINSULATION / EARTH MONITORwarning only
      Figure 5. CCR protection layers: surge protection, breaker, supply monitor, contactor, thyristor stage, transformer and monitoring.
      AGL Visual Encyclopedia: CCR protection Surge protection devices

      The CCR is the source of the airfield series circuit and a key item to protect. A strike can affect its input components, power electronics, control boards, communication interfaces, monitoring circuits and output-side insulation. Consider two directions: incoming surge from the supply and field-circuit surge from the cable.

      FAA maintenance guidance describes a CCR-fed series circuit as an ungrounded circuit, where earth faults behave differently from an ordinary building circuit. So an SPD suited to a conventional LV board cannot be assumed suitable for the CCR output. Coordinate with CCR topology, output voltage, insulation coordination, series-circuit design, transformer insulation, the surge-current path and the manufacturer’s requirements.

      Before selecting an SPD for a CCR, check

      • Input voltage and phase configuration
      • Earthing system
      • Expected transient environment
      • Short-circuit capability and upstream protection
      • CCR manufacturer requirements
      • Control-system interface
      • Required protection level
      Older material cites AC 150/5340-26B. FAA’s current list shows AC 150/5340-26C, so confirm the wording against the current edition.
      SPD Selection

      Choosing and Coordinating SPDs

      Do not choose by “highest kA available”. Consider

      • System voltage and earthing arrangement
      • Expected surge environment
      • Impulse and nominal discharge current
      • Voltage protection level
      • Short-circuit capability and follow current
      • Coordination with upstream protection
      • Equipment withstand level
      • Conductor length and installation geometry

      Indian standards

      BIS lists IS 16463 (Part 11):2016 / IEC 61643-11:2011 for LV SPDs connected to LV power systems, with a 2026 review, and IS 16463 (Part 12):2026 / IEC 61643-12:2020 for selection and application principles. These cover LV power SPDs and do not by themselves settle suitability for the CCR output series circuit.

      BIS standard numbers and dates were not re-checked individually. Confirm on the BIS site before citing.
      Field Equipment

      Lightning Protection by Equipment Type

      Surge devices on the mains and control lines of a CCR, each tied to the earthing network.

      SCHEMATIC · WHERE SURGE PROTECTION DEVICES SIT ON A CCR AND ITS SERIES CIRCUIT EARTHING NETWORK · ONE BONDED SYSTEM EARTHING NETWORK MAINSSUPPLY CONTROLAND COMMS CCRconstant current regulator SPD 1 · MAINS INPUT SPD 3 · CONTROL LINE SPD 2 · OUTPUT TO EARTH SERIES CIRCUIT · TRANSFORMERS AND LAMPS NEARBY STRIKE SURGE INDUCED IN THE CABLE SURGE ENERGY TO EARTH Each device is idle in normal service, conducts when a surge arrives, and passes the energy to the earthing network through short, direct leads.
      Figure 6. Surge protection devices for a CCR: mains input and control line, each connected to the earthing network.
      AGL Visual Encyclopedia: Surge protection devices CCR protection Shielded cable screen connection

      Elevated fixtures

      More exposed than recessed ones: runway and taxiway edge lights, approach structures, obstruction aids, beacons. Treat fixture → support → base → bonding → counterpoise → earth as one path.

      In-pavement fixtures

      Exposed to direct or nearby effects, transient current through field conductors, water ingress, insulation stress and surge transfer through transformer and connector. Below pavement is not immunity.

      Approach lighting

      Can extend beyond the runway environment with elevated and inset fixtures, supports, cables, transformers and control circuits. Review the whole arrangement against project and authority requirements.

      PAPI

      Optical assemblies, electronics, metal housings, supports, cable connections and transformers. Protect PAPI unit, mounting, circuit, transformer, cable and control interface together. Do not use an arbitrary consumer SPD.

      Stop bars

      Many inset fittings, transformers, cables and switching interfaces, and a widespread outage affects holding-point protection. Cover power, field circuit, control and monitoring.

      Signs

      LED modules, drivers, power supplies, control interfaces and metal housings. Bonding, grounding, surge protection and protected communication lines. FAA includes airfield signs in the system scope.

      Runway and taxiway circuits

      Both can span long distances and affect many visual aids at once, so design the complete circuit rather than each fixture. On a precision runway a strike-related outage can affect many aids simultaneously.

      Vaults and electrical rooms

      Protect against direct or nearby effects and against transients entering through power and communication networks: building lightning protection, main SPD, bonding, equipment SPDs and signal protection. FAA guidance refers to NFPA 780 for certain structures and vaults in the U.S. context. For India the governing Indian and project requirements apply.

      Components

      Transformers, Connectors, Cables and LED Fixtures

      A cable screen is led out at the gland and bonded to earth, not left floating.

      SHIELDED CABLE · SCREEN CONNECTION AT THE CABLE END a metallic screen under the jacket, led out at the gland and joined to the earth bar EQUIPMENT ENCLOSURE e.g. CCR cubicle, control panel or junction box GLAND TERMINAL EARTH BAR 4 1 2 3 5 1 CONDUCTOR carries the circuit or signal current 2 INSULATION separates conductor from screen 3 SCREEN braid, tape or foil, earthed 4 OUTER JACKET cut back at the gland to expose the screen 5 SCREEN CONNECTION drain lead or clamp to the earth bar SOUND SCREEN CONNECTION CONTINUOUS, EARTHED, INSULATED Low-resistance path to earth, safe, quiet signal POOR SCREEN CONNECTION FLOATING, BROKEN OR SHORTED Induced voltage, noise, false alarms, shock hazard SCHEMATIC · NOT TO SCALE · FOLLOW THE CABLE AND EQUIPMENT MANUAL
      Figure 7. Shielded cable screen connection: jacket cut back at the gland, screen led out as a drain lead to the earth point.
      AGL Visual Encyclopedia: Shielded cable screen connection Plug-in isolation transformers Isolation transformer principle

      Isolating transformers

      The transformer isolates primary from secondary, but that does not make the equipment immune. Transients can couple through capacitance, insulation stress, primary surge, secondary wiring and common bonding structures, so insulation coordination is part of the protection system. FAA keeps a dedicated specification for series-to-series isolation transformers (AC 150/5345-47C).

      Connectors

      Exposed to moisture, contamination, mechanical stress, transients and ageing. FAA keeps a dedicated connector specification. A poor connection raises local voltage stress and can contribute to insulation failure in a transient.

      Underground cables

      Burial reduces physical exposure but not transient effects. A long cable is a distributed electrical system: induced voltage → cable → equipment → surge propagation. Consider length, routing, parallel metallic paths, bonding, counterpoise, transformer insulation and equipment withstand. Watch routes beside metallic structures, communication and power cables, fences, pipelines and other grounding conductors, and check induced voltage, coupling, separation and shield termination.

      LED AGL

      LED fixtures hold arrays, drivers, current control, monitoring and communication electronics. Surges can damage these without visible damage, causing complete failure, reduced output, intermittent operation, driver damage, communication failure or abnormal monitoring status. Coordinated surge protection is particularly valuable.

      Control Systems

      ALCMS, A-SMGCS, Follow the Greens and Communications

      ALCMS

      Sensitive electronics with surge-entry paths through AC power, control cables, copper communication, field I/O, remote interfaces and external sensors. Use power SPDs, signal protection, proper earthing and bonding and shield management so an airfield transient does not propagate into the control system.

      A-SMGCS and Follow the Greens

      Chain: field controller ↔ network ↔ ALCMS ↔ A-SMGCS → green centreline lighting and stop bars. A surge can disturb controller communication, switching, stop-bar control and status monitoring. Include protection in the system-level design, with protected control power, field-controller and network protection, degraded-mode operation and alarms, so the airport never shows an ambiguous or misleading route after a failure.

      Copper and fibre

      Fibre gives electrical isolation over long optical paths, but equipment on copper interfaces is still exposed. Where copper leaves a protected building, consider surge protection and bonding. Fibre itself carries no lightning current, but metallic armour, messenger wires, shielded cables and termination hardware can, so check the cable construction.

      Emergency power

      A surge can damage both normal and emergency power equipment. Coordinate protection with UPS, DG, ATS, switchgear and AGL distribution.

      India

      Lightning Protection Design in India

      Do not copy a foreign airport’s layout. Consider local lightning activity, soil resistivity, airfield geometry, runway and taxiway construction, AGL circuit topology, equipment ratings, authority requirements, electrical standards and project specifications.

      BIS lightning standards

      BIS identifies the IS/IEC 62305 family covering general principles, risk management, physical damage and life hazard, and protection of electrical and electronic systems within structures. It also lists IS 18925 for lightning-protection components, such as Part 2:2024 for conductors and earth electrodes and Part 6:2025 for lightning-strike counters.

      Low-visibility operations

      AAI low-visibility procedures monitor AGL serviceability and secondary power availability at airports. That makes lightning resilience part of operational resilience, because a strike-related outage costs more during CAT II/III or other low-visibility operations.

      Incorporate each standard only to the extent it applies to the actual installation. Standard listings were not re-checked individually.
      Risk

      Risk Assessment and Protection Design Workflow

      Geographic risk

      Lightning density and local climate.

      Physical exposure

      Elevated structures, open airfield and long exposed infrastructure.

      Criticality

      Importance of the affected AGL circuit.

      Equipment vulnerability

      CCR electronics, LED drivers, controllers, communications and ALCMS.

      Consequence

      Effect on runway operations, low-visibility operations, taxiway movement, ATC and airport availability.

      Design workflow

      01

      Airport survey

      02

      Lightning-risk assessment

      03

      System mapping and AGL circuit mapping

      04

      Counterpoise and bonding design

      05

      Grounding design

      06

      SPD coordination and equipment protection

      07

      Construction

      08

      Inspection

      09

      Testing

      10

      Commissioning

      11

      Periodic maintenance

      The workflow gives traceability from the risk assessment to the installed protection. A missing counterpoise or bond is far harder to fix after pavement and cable infrastructure are complete, so build it in during construction.
      Failure Modes

      Typical Lightning and Surge Failure Modes

      Click a failure to see the likely path and what to check.

      Shorted secondary, open secondary and a surge on the loop, each with its own waveform.

      SAME SERIES CURRENT · THREE EVENTS 1 · SECONDARY SHORTED AMPS VOLTS LAMP OUT LOOP CURRENT UNCHANGED NO VOLTS · HEAT AT THE FAULT 2 · SECONDARY OPEN AMPS VOLTS LAMP OUT CORE SATURATES PEAKY VOLTAGE · TREAT AS LIVE 3 · SURGE ON THE LOOP AMPS VOLTS OVERVOLTAGE SPIKE STRESSES THE INSULATION WINDINGS · CORE · EARTH CCR HOLDS THE CURRENT FIXED CURRENT EVENT SHORT, OPEN OR SURGE FROM OUTSIDE DUTY TRANSFORMER INSULATION AND CORE TAKES THE STRESS PROTECTION SPDs · EARTHING · CCR TRIP LIMITS THE DAMAGE RESPONSE ISOLATE AND PROVE DEAD THEN TEST A SHORT CANNOT OVERLOAD A CONSTANT-CURRENT LOOP · THE RISKS ARE LOCAL HEAT AND INSULATION STRESS
      Figure 8. Secondary shorting and overvoltage: the same series current with a shorted secondary, an open secondary and a surge.
      AGL Visual Encyclopedia: Secondary shorting and overvoltage Open secondary core saturation

      Where each transformer fault sits, and the symptom it produces.

      LIGHT FITTING SECONDARY ISOLATION TRANSFORMER PRIMARY SERIES CIRCUIT CONSTANT CURRENT FROM THE CCR EARTH / CASE OPEN PRIMARY OPEN SECONDARY LEAKAGE TO EARTH SHORTED TURNS DAMAGED / WET LEAD SHOWS UP AS WHOLE LOOP OUT ILLUSTRATIVE · SYMPTOMS VARY WITH THE FITTING AND THE CCR
      Figure 9. Transformer failure modes: open windings, insulation breakdown to earth, shorted turns and damaged leads or connectors.
      AGL Visual Encyclopedia: Transformer failure modes CCR failure modes

      CCR electronics damaged

      Likely path: incoming surge.

      • Check input SPD and its status
      • Check upstream protection
      • Review earthing and bonding
      • Compare against manufacturer limits

      Multiple lights fail after a storm

      Likely path: field-circuit transient.

      • Map the failed lights
      • Look for clustering on a circuit section
      • Check counterpoise continuity
      • Check transformers and connectors

      Repeated LED driver failure

      Likely: inadequate surge protection or bonding.

      • Do not just replace the fitting
      • Check transformer and secondary leads
      • Check bonding at the base
      • Review the surge path

      Transformer or connector failure

      Likely: excessive transient stress, moisture or insulation condition.

      • Insulation tests
      • Inspect connectors for flashover
      • Check for water ingress
      • Check coordination

      Light-base damage

      Likely: lightning current or equipotential issue.

      • Inspect bonding and counterpoise
      • Check for arcing marks
      • Review the chosen method

      Control system resets or comms failure

      Likely: transient on control power or communication interface.

      • Check power SPD
      • Check signal-line protection
      • Check shield and earthing
      • Review cable routing

      Stop-bar or PAPI electronics damaged

      Likely: power or control-line surge.

      • Check power and control protection
      • Check the PAPI/stop-bar circuit
      • Verify function and photometry after repair

      SPD repeatedly fails

      Likely: incorrect rating or very high surge exposure.

      • Check the rating against the study
      • Check installation geometry and earthing
      • Review the exposure
      Investigation

      After a Lightning Event

      Do not only replace what visibly failed. Investigate the pattern: which lights, transformers, controllers or CCRs failed, whether failures cluster in one circuit section, whether SPDs operated, whether counterpoise, bonding and grounding connections are intact, whether several equipment types failed together, and how the transient could have entered. Repeated failure at one location is an important clue.

      Troubleshooting a failed LED light

      Failed light

      Check transformer

      Check secondary cable and connector

      Check primary circuit

      Check nearby surge event

      Inspect protection and bonding

      Verify replacement and retest

      Photometry is not a lightning test, but after a major event it confirms that the lights have returned to the expected optical performance, not only that they turn on. Sequence: electrical testing → equipment inspection → functional testing → photometry.

      Testing

      Testing, Commissioning and Maintenance

      Fall-of-potential test of an earth electrode, with the potential probe near sixty-two percent of the distance.

      EARTH ELECTRODE · FALL-OF-POTENTIAL TEST BEFORE ENERGIZATION 1 · DISCONNECT 2 · SET PROBES 3 · MEASURE 4 · RECORD EARTH TESTER · AC TEST CURRENT Ω GROUND SURFACE LINK OPEN E · ELECTRODE P · POTENTIAL PROBE C · CURRENT PROBE 62% OF E-TO-C DISTANCE REMAINING DISTANCE AC CURRENT, E TO CP reads the voltage drop STRAIGHT LINE, CLEAR SOILaway from buried metalwork DISCONNECT THE ELECTRODEso only E is measured SCHEMATIC · NOT TO SCALE · PROBE SPACING AND LIMITS COME FROM THE TESTER INSTRUCTIONS AND THE SPECIFICATION
      Figure 10. Earth-resistance testing by the fall-of-potential method.
      AGL Visual Encyclopedia: Earth resistance testing Earthing inspection

      Check the bond lead, the conductor, the clamp and test link, and the rod, in order.

      EARTHING SYSTEM · SECTION bond, conductor, earth pit and ground rod EARTH-RESISTANCE TEST · PLAN rod isolated, tester probes in line (schematic) AIR GROUND EQUIPMENT EARTHING CONDUCTOR BOND LEAD PIT COVER CLAMP + TEST LINK GROUND ROD 1 2 3 4 CHECK POINTS 1 TO 4 ROD UNDER TEST test link open POTENTIAL PROBE CURRENT PROBE EARTH TESTER PROBE SPACING AND READING AS THE TESTER’S METHOD COMPARE WITH THE COMMISSIONING RECORD SIX MAINTENANCE STEPS · IN ORDER 1 ISOLATE circuit off, locked out, proved dead before any link opens 2 LOOK bonds, lugs, clamps, pit covers: corrosion, looseness, damage 3 CONTINUITY low-resistance test of bonds and the earthing conductor 4 MEASURE rod resistance with the earth tester by site procedure 5 REPAIR clean to bright metal, remake and protect, then retest 6 RESTORE, LOG link closed, circuit restored, results logged and trended
      Figure 11. Earthing maintenance: four check points and six steps.
      AGL Visual Encyclopedia: Earthing maintenance Earthing inspection Insulation-resistance testing

      Test layers

      • Visual: counterpoise, bonds, grounding conductors, base connections, SPD condition
      • Continuity: intended bonding paths
      • Earth / grounding: measured by the approved method
      • SPD verification: device, status, connection, coordination
      • AGL circuit: insulation, continuity, series-circuit condition, transformer performance

      Maintenance

      SPDs are not fit-and-forget. Follow manufacturer instructions and the approved maintenance programme.

      • Physical inspection and status indicators
      • Connection and terminal torque where specified
      • Thermal inspection where appropriate
      • Replacement after significant surge events when required
      • Review SPD alarm contacts
      • Counterpoise, bonding and grounding inspection

      Commissioning

      01

      Design review

      Lightning and surge-protection philosophy.

      02

      Material inspection

      Counterpoise conductor, bonding components, earth electrodes, SPDs, accessories.

      03

      Installation inspection

      Verify physical installation.

      04

      Bonding test

      Verify intended connections.

      05

      Earthing test

      Verify the grounding system.

      06

      SPD inspection

      Correct type, location and status.

      07

      AGL electrical test

      Field-circuit insulation and continuity.

      08

      Functional test

      Operate the lighting system.

      09

      Control-system test

      ALCMS and field-controller behaviour.

      10

      Documentation

      Record results as the initial protection baseline.

      Counterpoise inspection

      Verify continuity where testable, bonding connections, mechanical damage, corrosion, accidental disconnection and construction damage. Take particular care after runway rehabilitation, taxiway construction, trenching, utility installation, drainage work and foundation changes. Civil works can silently disconnect the network.

      SPD inspection

      Check the status indicator, alarm contact, enclosure, wiring, upstream protective device, signs of thermal damage and replacement status. A failed SPD can stay installed while giving little or no protection.

      FAA guidance treats counterpoise, light-base grounding, fixture bonding, testing and maintenance as integral parts of installation. Use the manufacturer’s methods and the approved test procedure for each measurement.
      Projects

      New Airports, Existing Airports and Gap Assessment

      New airports

      Build lightning protection into the initial AGL design to avoid expensive retrofit.

      • AGL and primary-cable layout
      • Counterpoise layout and light-base bonding
      • Transformer, CCR and control-system protection
      • Earthing network
      • Approach, PAPI, sign and communication protection

      Existing airports

      Start with inspection and a gap assessment, then a prioritized rehabilitation plan.

      • Existing counterpoise, earthing and bonds
      • Existing CCR, SPD and control protection
      • Lightning failure history
      • Repeated equipment failures
      AreaConditionRiskRecommended action
      CounterpoiseDamaged or unknownHighSurvey and repair
      Light bondingInconsistentHighStandardize
      CCR input SPDMissing or failedHighReview and install
      ALCMS powerProtectedLowMaintain
      CommunicationUnprotectedMediumEvaluate SPD
      Earth connectionPoor documentationMediumTest and document
      TransformerRepeated failuresHighInvestigate the surge path
      Example findings only.

      Service scope

      AGL lightning risk assessmentCounterpoise engineeringEarthing and bondingSurge protectionRunway and taxiway protectionPAPI protectionLED AGL surge reviewTesting and commissioningExisting-airport upgrades
      Mistakes

      Common Mistakes in AGL Lightning Protection

      1

      Installing only an SPD

      An SPD does not replace counterpoise, bonding, grounding or proper cable design.

      2

      Using building practice without AGL analysis

      An AGL series circuit behaves differently from building distribution.

      3

      Ignoring the CCR output circuit

      The series circuit needs protection that suits its actual architecture.

      4

      Mixing counterpoise methods

      FAA guidance says not to mix equipotential and isolation methods on one circuit.

      5

      Poor bonding

      No SPD compensates for missing or high-impedance bonds.

      6

      Forgetting communication interfaces

      ALCMS and A-SMGCS interfaces are exposed to transients too.

      7

      No post-lightning inspection

      Replacing failed fittings without finding the surge path leads to repeat failures.

      Standards

      Standards and References

      FAA (U.S.-specific)

      AC 150/5340-30J, Design and Installation Details for Airport Visual Aids, gives detailed guidance on counterpoise, bonding, grounding and lightning protection. FAA’s current list shows it alongside AC 150/5340-26C for maintenance. Neither is an Indian or ICAO requirement.

      Indian baseline (project by project)

      Build the compliance matrix around the contract and authority requirements.

      • IS/IEC 62305 series
      • IS 16463 (Part 11) and (Part 12), corresponding to IEC 61643
      • IS 18925 series for LPS components
      • DGCA, AAI, contract and manufacturer requirements
      FAA listings were checked. BIS standard numbers and the other references should be confirmed before citing.
      Checklists

      AGL Lightning Protection Design Checklist

      Click an item to mark it complete.

      Risk, counterpoise and earthing

      Local lightning environment assessed
      Criticality of each AGL circuit ranked
      Counterpoise method selected and not mixed
      Routing, geometry and bonding arrangement defined
      Earth electrodes, connections and test points defined
      0 / 5 complete

      Bonding and surge protection

      Light bases and elevated structures bonded
      Metal and transformer housings and cabinets bonded
      CCR input SPD selected for the system
      CCR output protection confirmed with manufacturer
      ALCMS, control power and communication protected
      0 / 5 complete

      Field equipment and documents

      Runway, taxiway, stop-bar, PAPI, approach and sign protection reviewed
      Lightning-protection drawings and counterpoise layout issued
      Bonding and SPD schedules issued
      Grounding details and test reports filed
      Maintenance records started
      0 / 5 complete
      Final Engineering Perspective

      Lightning protection for airport lighting is a system-design problem, not a surge-arrester purchase. Control the whole current and voltage path, then prove it and keep it maintained.

      Assess. Bond. Protect. Verify.

      Test Yourself

      Quick Knowledge Check

      Q1. What does a counterpoise do in an AGL installation?

      A. Supplies the CCR
      B. Helps control lightning-related potential differences and gives a designed bonding and current path
      C. Replaces isolating transformers
      D. Measures light intensity

      Q2. Can the equipotential and isolation methods be mixed on one circuit?

      A. Yes, for redundancy
      B. FAA guidance says they should not be mixed on the same circuit
      C. Only at night
      D. Only on taxiways

      Q3. Can any standard LV SPD be fitted on a CCR output?

      A. Yes
      B. No, a CCR series circuit is ungrounded and needs a compatible protection design
      C. Only if it has a high kA rating
      D. Only on LED circuits

      Q4. The same runway lights fail after every storm. What should you do?

      A. Keep replacing them
      B. Investigate the surge path: bonding, counterpoise, transformers, connectors and SPD coordination
      C. Raise the brightness step
      D. Remove the transformers

      Q5. After runway rehabilitation, what should be checked?

      A. Only the paint
      B. Whether civil works disconnected counterpoise or bonds
      C. Nothing
      D. Only the ATC display
      Explore More

      Explore More AGL Engineering

      PROTECTION

      AGL Surge Protection & Lightning Mitigation

      Existing guide on surge and lightning mitigation.

      Open AGL Surge Protection & Lightning Mitigation →
      POWER

      Emergency Power & Lighting Systems

      UPS, DG and switch-over performance.

      Open Emergency Power & Lighting Systems →
      ELECTRICAL

      CCR Working Principle

      Constant current regulators and series circuits.

      Open CCR Working Principle →
      COMPONENTS

      Airport Isolating Transformer

      The transformer between circuit and light.

      Open Airport Isolating Transformer →
      CONTROL

      ALCMS

      Airfield lighting control and monitoring.

      Open ALCMS →
      GUIDANCE

      Follow the Greens Concept

      Green centreline route guidance.

      Open Follow the Greens Concept →
      SAFETY

      A-SMGCS India

      Surface movement guidance and control.

      Open A-SMGCS India →
      VISUAL GUIDANCE

      PAPI Engineering Guide

      Precision approach path indicators.

      Open PAPI Engineering Guide →
      TESTING

      Testing & Commissioning Guide

      Test and commission AGL systems.

      Open Testing & Commissioning Guide →
      MAINTENANCE

      AGL Preventive Maintenance Guide

      Maintenance cycles and checks.

      Open AGL Preventive Maintenance Guide →
      FUNDAMENTALS

      How Airfield Lighting Works

      The full AGL system explained.

      Open How Airfield Lighting Works →
      STANDARDS

      ICAO Aerodrome Lighting Requirements

      Framework and requirements.

      Open ICAO Aerodrome Lighting Requirements →
      INDIA

      AGL Photometry India

      In-field photometric testing for Indian airports.

      Open AGL Photometry India →
      INDIA

      PAPI India

      PAPI installation, aiming, testing and maintenance.

      Open PAPI India →
      INDIA

      AGL Consultant India

      AGL design, specification and technical review.

      Open AGL Consultant India →
      INDIA

      AGL Contractor India

      AGL installation, testing and commissioning.

      Open AGL Contractor India →
      INDIA

      Airport Lighting Companies India

      Company types across the Indian AGL market.

      Open Airport Lighting Companies India →

      Protect the Whole Path.

      From counterpoise and bonding to SPD coordination, testing and maintenance, explore the complete AGL knowledge base.

      AGL Engineering Hub

      Explore the AGL Engineering Knowledge Hub

      Fundamentals

      Standards & Compliance

      Runway, Taxiway & Approach Lighting

      Surface Movement & Safety

      PAPI

      Electrical Engineering & Power

      Photometry & Testing

      Maintenance, Inspection & Safety

      Resources, Documentation & Careers

      FAQ

      Lightning & Surge Protection FAQ

      Q1Why does an AGL circuit need lightning protection?

      AGL circuits cover large outdoor areas and include long cables, transformers, connectors, light fittings and electronic controls. Lightning can create direct or induced transients that damage these components.

      Q2What is a counterpoise in airport lighting?

      A conductor installed as part of an AGL lightning-protection arrangement to help control lightning-related potential differences and provide a designed bonding and current path.

      Q3Is a counterpoise the same as an earth wire?

      No. A counterpoise, a grounding network and bonding conductors can perform different functions depending on the protection design.

      Q4Does every AGL circuit use the same counterpoise arrangement?

      No. It depends on the selected method, installation type, airfield construction, local conditions and governing requirements. FAA guidance, for example, distinguishes equipotential and isolation methods.

      Q5Can a standard electrical SPD be installed on an AGL CCR output?

      Not automatically. A CCR-fed series circuit differs from a conventional LV distribution circuit, so the device and installation must suit the actual circuit and equipment. FAA maintenance guidance describes the CCR-fed field circuit as ungrounded.

      Q6Where should SPDs be installed?

      It depends on the system design and protection study. Typical points include incoming power, distribution boards, control power, sensitive electronic equipment and communication interfaces.

      Q7Can lightning damage LED runway lights?

      Yes. LED fittings contain drivers and control electronics that transient overvoltage can damage even when the fitting looks normal.

      Q8Why do the same runway lights keep failing after storms?

      Repeated failure in one place can point to an unresolved surge path, inadequate bonding, a damaged counterpoise, transformer stress, connector problems or poorly coordinated surge protection.

      Q9Does lightning protection eliminate lightning damage?

      No. The aim is to reduce risk, control current paths and limit transient stress to acceptable levels.

      Q10Does PAPI need lightning protection?

      Include PAPI in the airport’s lightning and surge-protection assessment, considering its electrical circuit, transformer, mounting and control arrangements.

      Q11Does ALCMS need surge protection?

      Yes, where its power and external interfaces are exposed to transients, the protection strategy should include the control and communication architecture.

      Q12How often should AGL lightning protection be inspected?

      The interval comes from the airport’s approved maintenance programme, applicable standards and equipment requirements. Inspect especially after major lightning events and after civil works that may have disturbed counterpoise or bonding.

      Q13Can lightning protection be added to an existing airport?

      Yes. Do a gap assessment, then upgrade counterpoise, bonding, grounding, SPDs and control-system protection as required.

      Field Insight

      Engineering & Expert Notes

      Surge Protection and Lightning Protection Are Different Jobs
      Concepts

      Be clear which one you are designing or inspecting. Each addresses different threats.

      Keep Bonding Leads Short
      Bonding

      Long or looped leads reduce effectiveness. Check routing during installation and inspection.

      Coordinate Devices Across the System
      Coordination

      Verify ratings and sequence for devices at the CCR, along the circuit and at control equipment.

      Inspect After Storms
      Inspection

      Check device status and look for damage after lightning events.

      Do Not Forget Communication and Control Lines
      Control

      Data and signal cables can carry surges into sensitive equipment.

      Record Earthing Measurements
      Records

      Keep test results to track changes in earth resistance.

      Precision AGL Academy

      Understand AGL. Build Your Engineering Skills.

      You now understand how counterpoise, bonding and surge protection defend airfield ground lighting from lightning.

      Take the next step with Precision AGL Academy.

      Learn AGL Step by Step

      Build your knowledge through structured technical learning covering:

      AGL Fundamentals Components Electrical Systems Design Photometry Testing Troubleshooting Maintenance

      Move from understanding how AGL works to developing the practical knowledge needed to analyse, operate and maintain complete AGL systems.

      Understand the system. Build the knowledge. Apply the engineering.