Installation Manual
Contents
1. gt Power Cables Figure 11 Turbine Mounting Step 2 Raise the tower about 1 meter 3 ft off the ground to provide room to assemble the XL 1 turbine We recommend fashioning a temporary support stand to hold the tower up during turbine assembly Step 3 Mount the wind turbine tower adapter to the top of the tower using the six M10 x 1 5 bolts and six lock washers We strongly recommend applying Loctite 242 Thread Locking Compound to the threads prior to installation to reduce the likelihood of loosening due to vibration We recommend using a torque wrench to achieve the proper fas tener torque on the tower mounting bolts The recommended toque is 47 N m 35 ft Ibs On the 19 32 m 64 104 ft towers the larger di ameter of the tower tubing means that spacers are added to the inside of the top section to pro vide the proper fit up for the wind turbine Step 4 Complete the wiring to the PowerCenter before adding the blades This is recommended so that you can test the DC polarity of the wiring by spin ning the alternator by hand It is very important that the polarity positive and negative is correct when the turbine is connected to the Pow erCenter The best way to ensure this is to com plete the wiring and then test the polarity with a Volt Ohm Meter Turning the alternator by hand will provide enough voltage to make this check Carefully mark the positive and negative electrical leads for later refer2. 3 HNBOO Dal 8 i jas NENNEN El l p E et o o Oooo AG a NENNEN p rs Base Base T Gin Pole Gin Pole Gin Pole HN8007 _ 1 2 Nylock Nut SS 2 Gin Pole 6621 GinPoleSafetyCable Tt Gin Pole HMS3002 3 16 MaleableClip HDG 48 HM300 _ 3 16 HD Thimble ie HMOO08 5 8 x 8 Grounding Rod 2 HM0042 ap D Ground Rod Clamp 2 11471 2 Ground Cable Assembly CZ HMO0018 6 Dia ExpandingAncho CS HMAO03 5 8 x7 AnchorRod 5 HOO000 j SnapLink Ji 6622 Nylon Guy Rope CT SF0081 Locite Compound Tt IG EE IK Packed By Latest Revision 5 4 06 Grounding Grounding Grounding Anchoring Anchoring Raising Raising Base 8 Gin Pole 2365 8 9 jt kal bal ojo o zz z 8 jos e oo go Gel 5 go UP ojolojolojo w lt cic g ci cicicicic 212 E Ei ele mor s 6 6 6 o6 6 e o 3 5 2 Ul U U ojo o ojo bai 21 BWC XL 1 Series Packing List HKGT4 100 Guyed Tilt up Tower 96 5 ft 29m Shipped to BWC No Part No Description Qty Packed 1 6613 TopTowerSecion 1 Section 2 6610 Standard Tower Section 8 Section 3 661 jBaseTowerSecion 1 Section 6611 GinPolelmerSecion 1 X GinPole 6610
3. 50 pounds Check the secu rity of the wire rope clips Maintaining tension on the lifting cables with the raising device use a carpenter s level on the base tube to adjust the guy wires until the base tube is vertical Insure that the tower is straight by sight ing up the tower while the final guy adjustments are being made For this initial lift it will not be necessary to trans fer the lifting guy wires from the gin pole to the forward anchor 8 Lowering the Tower The procedure is just the reverse of raising the tower although certain precautions must be taken Step 1 If the raising process has indicated that the ten sion of the side guy wires will vary as the tower is being lowered it is important that the side guy wires be tended to avoid excessive tightening or slackening WARNING Ar no time during the lowering operation should personnel vehicles or other equipment be located where they could be hit by the tower or the side guy wires Determine the boundaries of the potentially dangerous area and keep it clear Step 2 Tension must be applied to the back guy wires to pull the tower away from the raising device as it begins letting out cable In order to clear the dan ger area it will be necessary to apply the tension through ropes attached to the guy wires The ropes should be attached above the back anchor and should be long enough to insure that person nel are located well beyond the point where t
4. Adjust the angular alignment of the top tube so that the guy bracket ear of the spool with the free swedged thimble lifting eye is in line with the lower two brackets Now the top tower tube can be fully pressed on Step 4 A 24 m towers only On the 24 m 78 ft tower add one more standard section and then the top section as described in the previous paragraphs Step 4 B 29 m towers only On the 29 m 97 ft tower add two more 3 m 10 ft sections and slide on the 80 ft level guy ring and wires Make sure that the guy ring ears are facing towards the base plate Slide the guy ring all the way down the swedged part of the tube to the lip where the tubes join Do not unspool the guy wires at this stage Make sure that the guy wire spool with the free swedged thimble lifting eye is on the top Add one more standard section and then the top section as described in the previous paragraphs Step 5 Roll out the side guy wires to the side anchors Use a screwdriver or small diameter rod through the center of the wire spool as an axle Let the wire unwind as you walk out to the anchor point Note Theguy wires with the lifting eyes must be on the upper side of the horizontal tower sections This eye is clipped to the top of the gin pole These guy wires serve as the lifting wires until the tower is fully erected Note Guy wires must be rolled out to the an chors not let out from a coil held in the hand or fro
5. We recommend applying Loctite to the bolt threads prior to assembly Step 8 Place the tail boom on the rear of the turbine powerhead and insert the 12 mm 1 2 tail pivot pin from the top If the parts are aligned properly the pin should insert easily Do not use a hammer to pound the pin in place as this may cause scor ing of the bronze bushings Secure the tail pivot pin with two cotter pins as shown in Figure 14 Failure to properly install and secure both cotter pins will lead to loss of the tail boom Tail Pivot Pin gt Cotter Pin Cotter Pin Figure 14 Tail Boom Attachment Step 9 Check the XL 1 wind turbine carefully to make sure that the installation is complete We recom mend the following checklist L Blade fasteners are secure and prop erly torqued Blade tips are evenly spaced Spinner is secure Tail fin is secure Tail pivot pin is locked in place with both cotter pins Tower adapter bolts are secure Wiring polarity is tested and marked DD COOL 14 10 Final Tower Raising Tools Required 7 16 nut driver several Procedure Step 1 Short circuit the XL 1 alternator by twisting or bolt ing the output wires together This will keep the wind turbine from spinning during the raising of the tower If the PowerCenter connections have already been made this can be easily done by moving the positive lead over to the negative ter minal Step 2 Follow Steps 1 through 3 of the Initi
6. GinPoleStandardSecion 1 GinPole 6620 Gin Pole Outer Section 1 Gin Pole 6616 Tower Base Channel SZ 6617 RH TowerBaseBracket Right Hand 1 Base Base Gin Pole 6617 LH Tower Base Bracket Left Hand EM 6618 Gin Pole Cable Bracket 2 0 EET e 3 6619 8 Guy Bracket amp Guy Wire Assembly 55 1 6619 9 Guy Bracket amp Guy Wire Assembly 65 1 6619 10 Guy Bracket amp Guy Wire Assembly 77 1 6619 11 Guy Bracket Guy Wire Assembly 29 1 6619 12 Top Guy Bracket amp Guy Wire Assembly 109 1 HB4010 1 4 x1 HexHeadBot n 6 HW4001 1 4 FlatWashr LB H amp 6002 e eo HW6004 38 Washer SS 16 HN6008 3 8 NylockNu SS BT 3 4 x 6 1 2 Bolt Tower 8 Gin Pole Pivots 2 i HBB030 3 4 x6 1 2 Bolt Gin Pole Shackle 1 GinPole 3 4 Nut A536 3 i Sage i EEA E E NENNEN ar sii Base Base w ololololololo w i EIE i oO oo DO T o z Q go D 2 v o o o E go Q gt z o D HNB008 Du PalNut J8 1 2 x 2 1 4 Bolt Shackle to G P Anchor 1 2 Nylock Nut SS 2 Gin Pole Safety Cable 3 16 Maleable Clip HDG 60 HM3001 316 HDThimble 20 HMOO08 5 8 x8 GroundingRod CS 5 8 HD Ground Rod Clamp 2 11471 2 Gro
7. supplied in the guy set box onto each guy wire end Place the wire rope clips on the wire so that the forged grooved part cradles the wire coming from the tower the tension side and the U bolt part clamps down on the end most section of the wire Thread the guy wire end through the anchor rod eye and around a thimble double back and slide through the first wire rope malleable clip The guy wires are wrapped around the anchor eye thimbles as shown on the anchor detail in Fig ure 5 Leave a little slack in the guy wire Snug up the wire rope malleable clips using a 7 16 nut driver Tighten two of the clips Let the other clip remain loose until the tower has been erected and leveled i d Figure 5 Guy Wire Attachment Step 8 Referring to Figure 4 the gin pole will attach to the base plate with a 3 4 diameter x 6 1 2 long bolt The ginpole is assembled in the same direc tion as the tower itself with the ginpole resting on top of the tower sections Secure the 34 nut with a 34 pal nut The following procedure integrates the assembly of the gin pole safety wire see Figure 6 which will keep the gin pole from coming apart when the load direction changes during tower raising 1 Assemble gin pole align holes at each end 2 Slide safety wire inside gin pole 3 Assemble gin pole on top of tower 4 When bolting gin pole to base plate pass bolt through loop in safety wire 5 When assembling gin pole b
8. tilt down Move this A lt direction channel in when mounting on concrete Bolt hole for tower tube EH Bolt hole for N ginpole tube N Side View A 13 Figure 4 Base Plate Assembly 6 Tower Assembly Tools Required 1 1 4 box end wrench or 18 crescent wrench 34 box end wrench 7 16 box end wrench 18 crescent wrench 12 crescent wrench 7 16 nut driver or socket w ratchet Tape measure or rope Electrical tape Procedure Step 1 Bolt the base tower section to the base plate us ing a 3 4 diameter x 6 1 2 long bolt and nut through the hole drilled in the end of the base sec tion Use the lower hole in the center of the long base plate as shown in Figure 4 Secure the 34 nut with a 32 pal nut Note Ifthe power leads are to be carried in side the tower as is recommended they should be installed as the tower is being assembled See Section 9 for wire size recommendations Step 2 Add one 3 m 10 ft standard section to the base section for a total of 6 m 20 ft Slide on the first guy ring Labeled 20 ft Level over the top of the swedged reduced section of the tube while the spooled guy wire sets are attached Do not un spool the guy wires at this stage Slide the guy ring all the way down the swedged part of the tube to the lip where the tubes join The ring will rest against the lip of the tube and the next tower tube will press a
9. 617 RH Tower Base Bracket Right Hand 1 Base 6617 LH Tower Base Bracket Left Hand 1 Base 6618 GinPoleCableBracket 2 Gin Pole Guys Guys Top Guy Bracket amp Guy Wire Assembly 64 Guys HB4010 1 4 x1 HexHeadBot el Guys HW4001 1 4 FlaiWasher e Guys HB6002 j S e xi Bot 8 Base HN6008 3 8 NylockNu SS 8 3 4 x 6 1 2 Bolt Tower amp Gin Pole Pivots HBBOSO 3 4 x61 2 Bolt Gin Pole Shackle 1 HNBO11 3 4 Nu A536 3 3 4 Pal Nut 3 1 2 x 2 1 4 Bolt Shackle to G P Anchor HN8007 1 2 NylockNu SS 2 6621 GinPoleSafetyCable 1 3 16 Maleable Clip HDG 36 3 16 HD Thimble 12 HMOO08 5 8 x8 GroundingRod 1 2 HMO042 JS HD Ground Rod Clamp 2 11471 2 Ground Cable Assembly 2 HM0018 6 Dia ExpandingAnchor 5 5 8 x 7 Anchor Rod 5 Anchoring HOO0006 j SnapLink 4 Raising 34 6622 NyonGuyRoe 1 Raising 35 SF008 JjLoctte Compound 1 Gys 36 HM0040 AntisiezeCompound 1 Base amp Gin Pole i GIF KEES Packed By Latest Revision 5 4 06 CH Pye o Base Base Gin Pole w Gin Pole Gin Pole Gin Pole Gin Pole Guys Guys Grounding Grounding Grounding Anchoring ND IW ojo o SIS z SIS lola Qo Qo go oo o bf
10. Chance Expanding amp Tamping Bar or a heavy pipe Turn the Eye at the end of the rod so that it is oriented vertically so that the guy wires will at tach in a straight vertical line Make sure that the bell is fully expanded because its bite into virgin soil provides the primary strength of the anchor Refill the hole about 12 at a time then carefully compacting the soil using a tamping tool The fill must be compacted to develop proper strength and to keep water from seeping in and compro mising the anchor strength For weak or problematic soils it may be necessary to use concrete for the anchors or use an alter nate anchoring method These topics are covered in Section 11 under Anchoring Step 3 For most installations the base plate will sit di rectly on the ground This is actually the preferred configuration A concrete base is only needed when the soil strength is very low such as sand or marsh Assemble the four piece base plate with the 3 8 x 1 stainless bolts washers and locknuts supplied with the kit as shown in Figure 4 To prevent gall ing apply anti seize compound to the bolt threads before screwing on the nuts Install the base plate with its up turned flanges aligned with the tower lay down direction Sink the down turned edges into the soil Pound in the 8 ft 2 4 m copper clad ground rod through one of the two 7 8 holes in the base plate using a sledgehammer Leave 4 inches 10 cm of rod ab
11. Dense fine sand very Basal till boulder clay 2 hard silts and clays may caliche weathered be preloaded laminated rock Dense clays sands and Glacial till weathered 3 gravel hard silts and shales schist gneiss clays and sandstone Medium dense sandy Glacial till hardpan 4 gravel very stiff to hard marls silts and clays Medium dense course Saprolites residual 5 sand and sandy gravels silts stiff to very stiff silts and clays Loose to medium dense Dense hydraulic fill 6 fine to course sand firm compacted fill resid to stiff clays and silts ual soils Loose fine sand Alluvium Flood plain soils lake 7 loess soft firm clays clays adobe gumbo varied clays fill fill 8 Peat organic silts inun Miscellaneous fill dated silts fly ash swamp marsh Used by permission of A B Chance Co The presence of water reduces the holding strength of the anchors Anchor creep can be a problem in soils with large variations in moisture content If this condition can occur it is best to ensure that the bearing surface of the anchor be placed below the level of periodic surface satura tion If an anchor is located above the depth to which the ground freezes it may experience a phe nomenon known as freeze throw or jacking This is the tendency of buried objects to be pushed toward the surface by the freeze thaw cycles To avoid this problem the bearing surface of the anchors must be placed below the
12. Ee BWC XL 1 Tilt Tower Installation Manual 18 m 59 ft Tilt Tower 24 m 78 ft Tilt Tower 29 m 97 ft Tilt Tower Bergey Windpower Co Inc 2200 Industrial Blvd Norman OK 73069 USA Telephone 405 364 4212 Fax 405 364 2078 W BERGEY E mail sales bergey com INDPOWER Web www bergey com BWC Tilt up Tower 8 BWC XL 1 INSTALLATION MANUAL Table of Contents 1 Overview sese 1 2 Salely gdavis ak uocatis 2 3 Cautions and Warnings 2 4 Components 2 5 Anchors and Base 2 6 Tower Assembly 6 7 Initial Tower Raising 10 8 Tower Lowering 11 9 XL 1 Wind Turbine 11 10 Final Tower Raising 15 11 Miscellaneous Reference Ma 16 teral frr ET tts 12 Packing Lists 19 1 Overview The Tilt Tower is the factory recommended tower for the Bergey XL 1 turbine because it combines cost effectiveness and ease of installation Over the long term the Tilt Tower will also reduce total costs of ownership by making it easier for owners to inspect provide preventive maintenance par ticularly in corrosive environments and perform repairs to the XL 1 wind turbine The Tilt Tower kit includes all of the components and fasteners required to assemble and ground the tower The tower can be installed without con crete work in areas with good soil strength and no
13. al Tower Raising instructions in Section 7 Step 3 Transfer the lifting guy wires one at a time from the gin pole to the forward anchor as shown in Figure 15 Secure each wire with wire rope clips being sure to maintain tension on each cable as it is transferred Start with the top level and work down TEP2 WIRE TRANSFER SEQUENCE Figure 15 Guy Wire Transfer Sequence Step 4 Again use a carpenter s level on the base tube to check that the tower is vertical in all directions Make a final adjustment of all guys to insure that the tower is straight On the taller towers this may take some time due to the number of wires in volved Step 5 Pull all guy wires tight by hand with approximately 45 kg 100 lbs pounds tension Tighten the sec ond and third wire rope clips on each guy wire There will be a small amount of visible slack in all guy wires This is normal Step 6 Check the guy wires in 2 or 3 weeks and tighten as required Depending on the soil type it may require one or more checks and adjustments be fore the tower and anchors have fully settled Installation instructions for the PowerCenter con troller are provided in the XL 1 Owners Manual 11 Misc Reference Material Anchoring For most installation sites the 6 diameter expand ing anchors supplied with the Tilt Tower kits will be perfectly adequate In some cases the soil will either be too weak for proper strength or too hard fo
14. and that a spur gear type be avoided A worm gear winch is inher ently self locking and cannot free spool like a spur gear type winch Bergey Windpower offers manual winch kits that are rigged and ready to go The kitis shown in Figure 7 Contact your dealer or Bergey Wind power for information and pricing Figure 7 Bergey Tilt Tower Winch Kit Caution If using a tractor or truck extreme care must be exercised Use a pulley block at the lifting anchor Never attach a cable from a truck tractor directly to the gin pole end Proceed slowly and smoothly Step 12 Walk the gin pole toward the vertical position while taking in the slack with the lifting device When the gin pole is nearly vertical all the lifting wires should be tight If using a drum winch try to guide the cable onto the drum so that it is distrib uted evenly across the surface of the drum Step 13 Use some tape to secure the tower electrical wir ing at the top end of the tower so that it will not slide down the tower when the tower is raised Step 14 Lift the tower 1 2 m to 1 8 m 4 ft to 8 ft above the ground to check the operation of the lifting device and the security of the lifting and guy cables The side guy wires must be tended to prevent the tower from bowing or falling off to one side or the other In addition to checking the security and adjustment of the guy wires check the lifting an chor for movement If the gin pole anchor will not h
15. ate section of this manual 1 Read and follow the TOWER INSTALLA TION MANUAL 2 DO NOT climb the tower 3 DO NOT erect the tower within 1 1 2 times the tower height of electric power lines 4 DO NOT place guy anchors near roads driveways or normal paths for vehicles 5 DO NOT permit unauthorized persons on the tower site while the tower is being raised or lowered 6 DO NOT use a tractor or truck to erect the tower without exercising extreme caution 7 DO determine the soil type at your site and install the correct anchors 8 DO place tower anchors according to the anchor manufacturer s recommendations 9 DO properly ground the tower electrically 10 DO thoroughly understand the tower erec tion procedure before beginning the in stallation YOU MUST BECOME FAMILIAR with all compo nents of the tower including hardware and how they function before attempting to install the tower Tall guyed towers can be dangerous and you or members of your crew could be injured or killed 18 Tilt Tower Packing Lists 19 BWC XL 1 Series Packing List HKGT4 60 Guyed Tilt up Tower 58 5 ft 18m Shipped to BWC No Part No Description Qty Packed 1 6613 Top Tower Section IT Section 2 6610 Standard Tower Section 4 Section 6611 Base Tower Section 1 Section 6611 GinPolelmerSecion 1 GinPole Gin Pole Base 6
16. ause they can be used in a broader range of soli conditions The expanding anchors included with the tower are suitable for installation in Soil Classes 3 6 and in some Class 7 If there is any doubt about the quality of the soil consider other anchoring options or consult the factory Concrete Anchors A second option is to dig a hole about 0 75 m 2 5 ft square to a depth of at least 1 2 meter 4 ft You should move the centerline of the hole you will dig back 1 m 40 away from the center of the tower to account for angle of the anchor rod Place the anchor as shown in Figure 16 note previous screw anchors are shown and fill the bottom of the hole with concrete to a depth of at least 0 3 meters 1 ft covering the bell and part of the rod It is not necessary to expand the ex panding anchors but you need to shake the an chor during the concrete pour to free trapped air Reinforcing rods should be incorporated in the 16 concrete so as to provide adeguate strength and load distribution in the pad The backfilled earth should be tamped vigorously as itis returned to the hole lt Towards Center Pad L i 45 Degrees Ground level Screw in Anchor 1 14 m 45 for 19 25 amp 32 m Towers 300 mm 12 750 mm GO EM Top View 750 mm 307 Figure 16 Concrete Anchors Other anchor rod configurations may be used with a concrete pad but the size and depth of the pad must be at l
17. east as large and as deep as shown The anchor rod and its attachment to the foot that is to be imbedded in the pad must have at least the strength of the anchor supplied with the tower kit Rock Anchors Expanding rock anchors or bonded rock anchors are the best choice for Class 0 and Class 1 soil Rock drilling is hard and tedious work It requires special equipment including a compressor and air drill When needed rock anchors should be in stalled by or with the advice and assistance of a local contractor familiar with this type of anchor In all cases the recommendations of the anchor manufacturer should be followed Bergey Wind power can also provide advice on rock anchoring Customer Supplied Anchor Rods The oval eye anchors supplied by BWC allow guy wire thimbles to be installed preventing sharp bends in the guy wires Any alternative anchor rods should incorporate similar provisions Guy Wires Guy Wire Slack There must be visible slack in all guy wires during all phases of tower installation It is possible to have too much slack or too little slack The follow ing discussion is aimed at defining these condi tions Unless the anchors are placed precisely in their correct locations and the site is perfectly level some guy wires will tighten and some will loosen as the tower is raised or lowered For this reason all guy wires must be watched and adjusted as needed throughout the tower raising or lowering proc
18. ence Step 5 Turn the XL 1 powerhead upward so that the al ternator is facing up Attach the blades as shown in Figure 12 using the M10 hardware provided We recommend bolting one blade up solidly and leaving the other two somewhat loose while you check the tip to tip blade distance We recom mend checking and adjusting as necessary the blade tip spacing to ensure that the blade tips are equally spaced This step will help make the wind turbine as smooth running as possible which will maximize the operating life of the bearings and reduce vibration related noise The blade tip to tip distances should not differ by more than 12 mm 1 2 for smooth operation We recommend using a torque wrench to achieve the proper fastener torque on the blade nuts The recommended toque is 47 N m 35 ft lbs Loctite is not necessary on the blade fasteners because the nylon locking nuts provide adequate locking 13 Spinner Fasteners Blade Nuts 8 a Washers n e 9 e oan Pe Pid NL LU j Blade Bolts Longer bolt goes here Figure 12 Blade and Spinner Fasteners Step 6 Attach the spinner nose cone using the three M5 bolts and lock washers provided as shown in Fig ure 12 We recommend applying Loctite to the bolt threads prior to assembly Tail Fin Fasteners Figure 13 Tail Fin Attachment Step 7 Bolt the tail fin to the tail boom using the eight M5 bolts and lock washers provided as shown in Figure 13
19. ess When a guy wire loses its slack and becomes tight there is no easy or obvious way to tell how much tension there is in the wire A wire that be comes tight can quickly apply a very large force on both the anchor and the tower to which it is attached If the tower lifting or lowering process is continued the force may increase to the point at which the tower will buckle causing it to fall and endanger people vehicles or equipment nearby When the tower has been assembled and is first lifted slightly off the ground to test the winch an chor the lifting wires running from the top of the gin pole to the tower should be studied They will all have a certain amount of droop or slack Studying the tower s top lifting wire will give all members of the lifting crew a good idea of slack Make sure that the side guy wires have noticeably more slack than this reference wire They should not however appear sloppy A droop greater than three or four feet should not be allowed to develop during the raising lowering procedure The tower should have no more than a gentle bend from base to top If the bow becomes more than about one foot the side guy wires or the lift ing wires should be adjusted before proceeding further This sequence of observing communicating ob servations issuing commands to guy tenders adjusting guys and retightening wire rope clips must be well understood by all members of the team before lifting or lowering s
20. estruction of the equipment and or serious injury DO NOT cut corners or get into a hurry 3 Cautions and Warnings This manual contains important information on the installation of your Tilt Tower XL 1 wind turbine and PowerCenter controller We strongly recom mend that you read and follow the instructions contained in this manual At several points in the manual items of special interest or significant impact are highlighted by one of the following notices Warning Hazards or unsafe practices that could cause personal injury or death Caution Hazards or unsafe practices that could cause product damage Note Significant points of interest 4 Components The major components for the tower kits are shown in Figure 2 The tower sections are 114 mm 4 5 in diameter thin wall steel tubes that have been swaged down at one end except for end tubes so they fit into each other Every 6 m 20 ft in height which is two 3 m 10 ft tower sections there is a guy bracket with four 4 8 mm 8 16 diameter guy wires attached These guy wires go out to four earth anchors and are at tached with malleable clips The top guy bracket attaches to the top tower tube mid section The tower sections rest on a base plate assembly that often rests directly on the ground The base plate also provides the pivots for the tower and gin pole The gin pole is the lever arm used for raising and lowering the tower It does not reach all the wa
21. fl 2 TI U U ojo o o o O O1 O17 PO PO no JV V OI NININININININININ IN 1 11 N ail amp lo m o cd oo 1 D O BR OO o olol O0 H Oo oi Ry IO Co 20 BWC XL 1 Series Packing List HKGT4 80 Guyed Tilt up Tower 77 5 ft 24m Shipped to BWC No Part No Description Qty Packed 1 6613 TopTowerSecion 1 Section 2 6610 Standard Tower Section 6 Section 3 661 jBaseTowerSecion 1 Section 4 661 Gin Pole Inner Section 1 GinPole 6610 GinPoleStandardSecion 1 GinPole Gin Pole 6617 RH TowerBaseBracket Righ Hand 1 6617 LH Tower Base Bracket Let Hand 1 6618 GinPoleCableBracki 2 Base Gin Pole El NENNEN o i el a Oo 66195 Guy Bracket amp Guy Wire Assembly S 1 6619 6 Guy Bracket amp Guy Wire Assembly 73 1 66197 Top Guy Bracket amp Guy Wire Assembly 86 1 HB4010 _ 1 4 x 1 Hex Head Bot Jej HWw4001 1 4 FlatWasher 6 HBe002 38 xi Bot 1 8 Hwe 004 3 8 Washer SS_ o 16 HNeo08 3 8 NylockNu SS 1 18 HBB030 3 4 x6 1 2 Bolt Tower amp Gin Pole Pivots 2 HBBO30__ 3 4 x 6 1 2 Bolt GinPoleShacke 1 HNBOII S 4 NuL A536 O
22. gainst it Make sure that the guy ring ears are facing towards the base plate Make sure that the guy wire spool with the free swedged thimble lifting eye is on the top This thimble will attach to the gin pole so it needs to be oriented towards where the gin pole will be as sembled Step 3 Add two more 3 m 10 ft sections and slide on the 40 ft level guys Make sure that the guy ring ears are facing towards the base plate Slide the guy ring down the swedged end of the tube to the lip where the tubes join The ring will rest against the lip of the tube and the next tower tube will press against it Do not unspool the guy wires at this stage Make sure that the guy wire spool with the free swedged thimble lifting eye is on the top Step 4 On an 18 m 59 ft tower add one more 3 m 10 ft section Then loosely add the 3 m top section which has eight threaded hole at its mid section and six turbine mounting holes at its top The tur bine mounting holes must be at the top of the tower Add the Top Guy Bracket Collar ensuring that the bracket ears face towards the base Make sure that the guy wire spool with the free swedged thimble is on the top Do not unspool the guy wires Attach the Collar to the top tube using six 6 147 x 1 stainless hex head bolts after first applying Loctite to each bolt A small tube of Loctite is supplied in the tower kit DO NOT apply anti seize Torque these bolts to 6 5 ft lbs
23. guy wires are not twisted The free ends of the remaining guy wires will be at tached to the forward anchor after the tower is erected Keep the wires well organized so this will be easy to do Step 10 Attach the two yellow polypropylene ropes to the top of the gin pole Run one of the ropes to each of the side anchors The ropes prevent the gin pole from falling sideways when vertical and cen ter it as the tower is being raised Step 11 Attach the cable from the lifting device to the gin pole tie top bracket with a shackle from the hard ware kit Electric or hand winches may be used The pull up forces including the XL 1 turbine and the pull up cable lengths are given below Pull up Cable Travel meters ft 9 1 30 Pull up Force kgs Height Height meters feet 59 340 750 78 520 1 150 13 1 43 97 700 1 550 183 1 43 These loads are static loads Bouncing or shock loading can cause higher momentary loads We recommend using at least 3 16 steel wire rope for the lifting We also recommend a 2 1 pulley block arrangement to reduce the line tension for the 25 and 32 meter towers A 2 1 pulley block will cut the pull up force in half The pulley block is at tached to the ginpole shackle or snap link Please remember that using a 2 1 pulley will double the pull up cable travel to 27 m 86 ft on the taller towers Warning la winch is used we strongly recommend that a worm gear type be used
24. he top of the tower will touch the ground when low ered Pull as required to keep tension on the guy wires As the tower is lowered and reaches an angle be tween 60 and 45 it will no longer be necessary to maintain tension on the guy wires opposite the winch Step 3 Set the tower down on blocks placed about every 6 m 20 ft along the tower Step 4 Ground the tower base by installing the ground clamp to one of the ground rods and attaching one end of the bare copper grounding wire At tach the other end of the grounding wire using a small loop to one of the 3 8 tower base plate bolts 9 Installing the XL 1 Wind Tur bine XL 1 Wind Turbine Components The major components of the XL 1 wind turbine are shown in Figure 9 Installing the turbine re quires connecting it to electrical wiring to the PowerCenter controller and then assembling the turbine at the top end of the tower 11 Powerhead Tail Fin Alternator 4 Nacelle P 4 Blades Ce Spinner Tail Boom Tower Mount Figure 9 Major Components of the XL 1 Wiring The basic electrical schematic for the BWC XL 1 battery charging system is shown in Figure 10 Alternator DC Wire Run Rectifier on turbine PowerCenter Figure 10 XL 1 Wiring Schematic The wind turbine alternator produces a 3 phase AC which is rectified into DC up in the nacelle A two 2 conductor wire is needed between the wind turbine and the PowerCenter contro
25. hor Hemisphere If the site is not level try to position the tower so that it will be lowered in the uphill direction Check the diagonal distance between anchor points to ensure that they are square Warning The tower must not be erected near electric power lines Most over head power lines are not insulated so they pose a life threatening shock haz ard Note The side guy anchors and the base plate must be on a straight line to insure adequate cable tension during raising or lowering operations If exact placement XL 1 Wind Turbine Tower Tube Guy Set 60 ft Level Guy Set 40 ft Level 7 Guy Set 20ft Level x Lifting Guy Wires with swaged on lifting eyes MN Base Tube gt AN ki ki ES A Tower Tube Ginpole Top Tube with teeter brackets 24 m 79 ft Tower of an anchor point is not possible it should be moved outward from the Tower Uphill Guy Anchor Side Guy a Anchor Gin pole Anchor Distance Gin pole Anchor Downhill Guy Layout Dimensions in Feet Layout Dimensions in Meters Gin pole Gin pole Tower Guy Diagonal Anchor Tower Guy Diagonal Anchor Height Radius Distance Distance Height Radius Distance Distance 18m 9 2m 12 9 m 24m 12 2m 17 3m 29m 15 3m 21 6m Figure 3 Anchor Layout Step 2 Ve al a e E is Ge t Refer to the A B Chance instructions below At ld SS S ancang dien aga the four guy wire ancho
26. ing force on the turbine and tower Without the gin pole it would be virtually impossible to raise the tower i Figure 1 24 m 78 ft Tilt Tower 2 Safety and Quality Assurance The following recommendations should be care fully observed as part of any tower raising and lowering and during the tower siting process In particular the safety of the crewmembers must be placed ahead of all other considerations Some of the following warnings or cautions have been highlighted in the appropriate section of the man ual 1 DO read and follow the Tower Installation Manual 2 DO NOT climb the tower 3 DO NOT erect the tower near electric power lines 4 DO NOT place guy anchors near roads drive ways or normal paths for vehicles 5 DO NOT permit unnecessary persons on the tower site while the tower is being raised or lowered 6 DO NOT use a tractor or other vehicle to erect the tower without exercising extreme caution 7 DO determine the soil type at your site and install the correct anchoring 8 DO place tower anchors according to the an chor manufacturer s recommendations 9 DO properly ground the towers electrically 10 DO thoroughly understand the tower erection procedure before beginning the installation The Tilt Tower is cost effective safe and conven ient but the forces involved in raising and lower ing are very large Inadequate attention to proper rigging and procedures can lead to d
27. level to which the ground freezes In areas of permafrost the anchors should be below the permafrost line Provisions should be made to prevent solar en ergy from being transmitted down the rod If you must anchor within the permafrost zone we rec ommend using the services of a local contractor with expertise in artic cold climate anchoring Anchor Rods All the anchoring systems described in the follow ing sections use a galvanized steel rod to connect the guy wire to the bearing surface of the anchor The rod ends form an eye which provides an attachment point for the guy wires The anchor rods should be installed at an angle that will minimize the bending loads acting on them The angle for the BWC XL 1 towers should be approximately 45 degrees with the eye of the anchor rod toward the tower Anchor Types and Their Installation Three types of anchoring systems may be used to accommodate various soil types screw in ex panding anchors sub surface concrete pads and expanding or bonded rock anchors Screw Anchors Expanding Anchors In most areas of the country power installed screw anchors have become the standard anchor ing system used by the utilities Screw anchors were furnished as standard equipment with earlier versions the BWC XL 1 towers They were in tended to be installed manually with a stout bar through the eye or with a hand held electric drive We have switched to Chance 8 Way Expanding Anchors bec
28. ller The PowerCenter has a DC circuit breaker for the wind turbine input so no fused disconnect switch is required at the base of the tower as is recom mended for the other BWC wind turbines In some cases it will be possible to provide direct point to point wiring between the XL 1 wind tur bine and the PowerCenter For this purpose we recommend 2 conductor VNTC Vinyl Nylon Tray Cable which is suitable for outdoor and direct burial applications For rocky soils we recom mend that the underground wire run be installed in conduit If a wiring junction is made at the base of the tower then a watertight junction box should be installed for the connections The recommended wire sizes for the 24 VDC XL 1 wind turbine are shown in Table 2 The listed dis tances include the height of the tower Maximum Current 60 amps Caution Installing wire sizes larger than those recommended will increase the maximum current produced by the tur bine Table 2 Recommended Wire Sizes for the XL 1 Distance Size U S Size metric 23 m 75 ft 8 AWG 8 4 mm2 46 m 150 ft 6 AWG 13 3 mm2 69 m 225 ft 4 AWG 21 2 mm2 91 m 300 ft 4 AWG 21 2 mm2 114 m 375 ft 2 AWG 33 6 mm2 130 m 450 ft 2 AWG 33 6 mm2 Note These wire sizes have been engineered to provide op timum rotor loading for the BWC XL 1 24 wind turbine Devia tion from these recommendations can result in decreased pe
29. m the side of the spool These latter two methods will allow the wire to become severely twisted and stressed making it very difficult to han dle Step 6 When the guy wires are rolled out to all the an chors check to insure that the tower is 90 de grees with the line joining the side anchors and the base plate If the anchors were accurately placed the tower should lay close to the uphill anchor point see Figure 3 If not use a tape measure or a rope to check that the diagonal dis tances from the tower top to each side anchor are approximately the same Check also that the front and rear anchors and the lifting anchor are in line with the tower Caution Extra care must be taken while rais ing the tower if the anchor placement is not perpendicular 90 degrees to the tower or if the side anchors are not at the same elevation or if the side an chors and base plate are not in a straight line Any of these conditions will effect the guy wire tension as the tower is raised Tension must be ad justed periodically as the tower is raised Step 7 Assemble the 3 16 HD thimbles on the anchor rod eyes by twisting them open pressing them on and twisting them closed Two crescent wrenches work well for this task There will be 3 thimbles per anchor on the 18 m 59 ft tower 4 thimbles per anchor on the 24 m 78 ft tower and 5 thim bles per anchor on the 29 m 97 ft tower Slide three wire rope malleable clips
30. old the soil is too poor for this type of anchor or the depth of the anchor was insufficient The maximum lifting force is experienced when the tower is first lifted from the ground Warning Do not work under or near the tower while it is being lifted Do not work under or near the tower when it is off the ground unless it is resting on blocks or is fully guyed Step 15 Lower the tower and make any necessary adjust ments to the guy wires or anchors Roll out the guy wires that will be attached to the back anchor located under the tower pole Attach the set of back guy wires to the back anchor The back wires should be walked over to the side anchors to get an approximate length prior to attachment 7 Initial Tower Raising At this stage an initial tower raising without the wind turbine in place is recommended It will in sure that all the cables and anchors are secure that the lifting procedure is satisfactory and will allow the back guy wires to be attached and ad justed The sequence is shown in Figure 7 Tools Required 7 16 nut driver Procedure Step 1 Start lifting the tower 10 to 20 at a time Monitor the side guy wires and the yellow gin pole ropes carefully They may become either loose or tight if the site and the anchor points are not perfectly level Although there must be some tension in the wires at all times to provide side support for the tower there must always be visible slack in the guy wire
31. ove the Base Plate When using a concrete base for the tower we rec ommend a base that is roughly 60 cm x 60 cm x 30 cm deep 2 ft x 2 ft x 1 ft deep with several pieces of steel reinforcing bar placed horizontally Assemble the Base Plate with the Tilt Tower Base Plate must be secured to the concrete using two 5 8 hex head bolts not supplied or concrete an chor bolts not supplied installed through the 34 holes normally used for the ground rods You can either cast hex bolts into the concrete or pour the concrete pad and install anchor bolts af ter the pad has cured Drilling the pad for anchor bolts will generally require the use of a hammer drill For cast in bolts we recommend two 6 long galvanized 5 8 diameter bolts with 2 2 of the threaded end sticking up above the concrete The bolts should be centered on the pad and spaced 17 7 apart Note the tower tilt alignment direction required in Figure 4 For non concrete installations the channel plate that faces towards the gin pole anchor should be assembled in the extended position as shown in Figure 4 When being bolted to a concrete pad the channel plate should be assembled in the re tracted position Securely bolt the Base Plate to the concrete pad Install the ground rods adjacent to the concrete pad Galvanized Dol BE 7 8 holes for ground 4 rods or concrete anchors Top View o o Ginpole direction Tower
32. r augering the hole In these cases a subsurface concrete pad can usually be substi tuted In the case of hard rock however special rock anchors may be necessary This reference section is designed to provide you with considera tions and recommendations that will ensure that you install adequate anchors The installation of guy wire anchors is a critical element in the installation of the tower The an choring system must be able to withstand without appreciable creep the steady and vibratory loads of the guy wires through all weather conditions for the life of the installation Site conditions will dic tate the type of anchoring system used Soil type water level freeze depth and weather variations all have an effect the holding capacity of the an chors Soil Types amp Conditions Most anchoring systems are designed to work ina limited range of soil conditions To choose the proper anchoring system it must be possible to identify these various soils The accompanying Table 2 shows a system of soil classification de veloped by the A B Chance Company on the basis of the mechanical properties of the soil 15 Table 2 Soil Classifications Common Soil Type Geological Soil Class Description Classification 0 Sound hard rock un Granite Basalt Mas weathered sive Limestone Very dense and or ce Caliche Nitrate 1 mented sands coarse bearing gravel rock gravel and cobbles
33. r stakes and the gin pole PIANO Y S Same Pian anchor stake auger 6 diameter holes at a 45 degree angle oriented towards the tower base center The holes should be deep enough that APPLICATION INSTALLATION EXPANDING 8 WAY ANCHORS ANCHOR APPLICATIONS INSTALL IN THESE CLASS SOILS For distribution guying Use to depths of 12 feet Classes 3 4 5 6and7 100 600 inch pound with the soil test probe INSTALLING EQUIPMENT REQUIRED LIMITATIONS ON USE INSTALLATION GUIDE STEP 1 Hand or power auger Expand ing and tamping bar or mechani caltamper and shovel See page B 33 Depends on backfill effective ness Difficult to tamp in wet or plastic soil after rain Seeping ground water can cut holding capacity 50 percent The hole should be drilled at a 45 to 60 angle in line with the guy NOTE Hole size should be slightly larger than the unexpanded anchor See chart on page B 17 Attach rod to anchor and lower the assembly into the hole STEP 3 Expand the anchor with the expanding bai by striking the top plate NOTE The expanding bar should be rotated around the anchor during the busting process Backfill and tamp hole the anchor rod projects 4 6 inches above the surface when placed in the hole without the bell attached Attach the rod to the anchor bell and insert in hole Make sure it goes all the way to the bottom of the hole Expand the bell anchor using the
34. rackets at the outer end of the gin pole pass bolt through loop in safety wire The 18 m 59 ft tower uses a 20 ft gin pole made up of two 10 ft sections The 24 m 79 ft and 29 m 97 ft towers use a 29 ft gin pole made up of three 10 ft sections The safety wire has three thimbles attached one at each end and one 9 ft from the end Use the two thimbles at the ends for the 24 and 29 m tow ers Use one end thimble and the intermediate thimble for the 18 m tower Figure 6 Ginpole Safety Wire Assembly Make sure that the bracket bolt in the end section of the gin pole is aligned as shown in Figure 6 Bolt the gin pole brackets to the end section with the 34 bolt making sure to pass the bolt through the safety wire thimble Secure the bolt with a 34 nut and Pal Nut Attach the snap link to the gin pole bracket with a v2 bolt A snap link is a heavy galvanized steel or stainless steel loop with a spring loaded gate or opening side bar Be sure that the snap link opens down and away from the base plate This will allow the lifting guy wires to be clipped and unclipped in the correct order Step 9 Roll out each level of the lifting guy wires and at tach each of the swaged on lifting eyes to the snap links shackled to the bracket at the end of the gin pole The top guy wire attaches to the forward snap link The lower guy s are clipped to the second snap link the lowest guy wire first Make sure that the
35. rformance from your machine and or unnecessary addi tional wire run costs The use of a wire gage one size larger than the recommended size is acceptable and is recom mended if aluminum wire is used Turbine Installation The fasteners on the XL 1 are all metric Tools Required 17 mm box end wrench 17 mm socket and 12 ratchet drive 8 mm socket or wrench pliers crimpers for wiring terminals U shaped crimp preferred over straight crimp thread locking compound like Locktite 242 tape measure 12 ft Procedure 12 Step 1 Place the powerhead of the wind turbine near the top end ofthe tower The tower wiring is connected to the XL 1 wind turbine at the slip ring using the two small screws on the positive and negative slip ring terminals The best way to do this is with ring terminals cho sen for your tower wire type The polarity of the connections is marked If your conductors are color coded we recommend making note of the colors connected to positive and negative leads The slip ring assembly is not designed to support the weight of the down tower wire A strain reliev ing installation is required as shown in Figure 11 Use the two nylon cable ties provided to secure the tower wiring to the tower adapter casting Af ter completing the connections pull on the tower wire to make sure that it is secure before mount ing the wind turbine on the tower Nylon Cable Turbine Tes Mounting b d Bolts 7
36. rocks that would impede the auger for the guy wire anchors In weak or rocky soils the use of concrete to fix the anchors is required Proper grounding or earthing is an important element in protecting the system from lightning damage As shown in Figure 1 the tower is guyed in four directions The tower is guyed at vertical intervals of approximately 20 ft 6 meters The Tilt Tower is best installed on level ground but can be in stalled on slopes or uneven terrain provided that the base and the anchors on the tilt axis can be kept fairly level If this is not done the tension in the guy wires along the tilt axis will change appre ciably between the tilted up and tilted down posi tions If the anchors are lower than the base the tension in the cable s can become excessive If the anchors are higher than the base the cable s can become too loose to provide proper stability of the tower sections When installing in sloped terrain the Tilt Tower should always tilt down in the upslope direction After assembly of the tower wind turbine and tower wiring on the ground the tower and turbine are tilted up to the vertical position using a winch not supplied or a vehicle A winch is preferred because of the greater control they afford The towers are provided with a lever arm called a gin pole which runs from the base to one of the guy anchors The gin pole converts the pulling force on the pull up rope or cable into a lift
37. s If no slack is visible the tension is too great Over tension may cause failure of the wires the anchors or the tower For further in formation refer to the section on SLACK at the end of the instructions Failure to install the Ginpole Safety Wire can lead to ginpole separation Figure 8 Tower Tilt up Sequence Adjust the cable tension as required using the wire rope clips Work slowly Fast uneven movements tend to make the tower swing or wa ver Try to work smoothly and insure that those people tending the cables are able to follow along with the tower raising process Caution Be sure that communication be tween all members of the lifting team is clear and concise 10 Note The guy wires can be pulled in by one person when the winch is stopped Brute force is not reguired Step 2 As the tower approaches vertical it is important to maintain tension on the back guy wire set This should be done by standing to one side of the an chor not directly under the tower pulling on ropes attached to the guy wires All back guy wires should be held allowing the raising device to pull against the tension until the tower is vertical or the gin pole is on the ground Note The tower will lift easily at this point Very little force is required to lift the tower into its final position Step 3 Check the side guy wire tension for a moderate degree of slack corresponding to a wire pull of about 23 kilograms
38. tarts It is a con 17 tinuing process throughout the lifting lowering se guences Particular care should be taken at sites where guy wires might catch on tree limbs roots rocks or other obstructions A guy wire will have about 23 kilograms 50 pounds of tension when the tower is properly erected This amount of tension is a comfortable but hearty pull on the wire for an average crew member The uppermost guy wire will have one foot to two feet of droop with 23 kilograms 50 pounds of tension Letting out just six inches of the top guy wire will add approximately two feet of droop to the wire and will cause the tower to move over a few inches atthe attachment point Tower Lift Crew The following is a suggested guide to forming an efficient and safe crew to erect a BWC XL 1 tower Four members 1 One member to operate the winch and serve as the key person or leader 2 Two people to attend to and adjust each side guy anchor These individuals must be familiar with taking in and letting out guy wires 3 One person free to assist in holding or pulling guy wires as required This per son should also continuously observe the guy wires and the entire lifting operation for any unusual or dangerous situations Warnings The following warnings should be carefully ob served as part of any tower siting and raising or lowering operation Some of the following warn ings or cautions have been highlighted in the ap propri
39. und Cable Assembly CS HM0018 6 Dia ExpandingAnchor Z 5 5 8 x 7 Anchor Rod 51 HO0006 jSnapLink dt 6622 NylonGuyRope 4 ESI Packed By Latest Revision 5 4 06 Gin Pole Gin Pole Gin Pole Gin Pole Grounding Grounding Grounding Anchoring Anchoring Raising Raising Base amp Gin Pole E EE 9 EI o z D 0 OOD c cic go E SIS e 2 E o O 22
40. y out to the earth anchor in its direction so a transfer of guy wires is necessary during rais ing and lowering That is what the lifting eyes on the guy wires are for The gin pole has a teeter assembly at its end to accommodate the guy wires and the lifting line from the winch used for raising and lowering 5 Anchors 8 Base Plate Please review the Anchoring Reference section in Section 11 before proceeding further Different soil conditions may reguire different anchoring methods to ensure proper strength Tools Required 5 6 wood or metal stakes Hammer Sledge hammer 100 ft tape measure 6 Diameter x 5 ft power auger Chance Hubbell C302 0003 10 ft Expand ing amp Tamping Tool or 3 m 10 ft long x 75 mm 3 dia heavy wall steel pipe Shovel 9 16 box end wrench or 14 mm 9 16 socket and ratchet drive or 12 cres cent wrench Procedure Step 1 Mark the ground location for the tower base plate guy anchors and the lifting anchor for the gin pole The appropriate dimensions and ground lay out are shown in Figure 3 Make sure that you have sufficient room for the tower and turbine to tilt down If you plan to mount solar modules on the tower we recommend Guy Set 75 ft Level Guy Wires Base Plate Malleable Clips Figure 2 Major Tower Components that the ginpole be oriented towards South in the Northern Hemisphere and North in the Southern E e Base Tube Earth Anc
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