Installation Manual Installation Manual
Contents
1. 1O 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 controller 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 12 the tower then a watertight junction box should be Procedure installed for the connections oo xt Step 1 The recommended wire sizes for the 24 VDC XL 1 Place the powerhead of the wind turbine near the wind turbine are shown in Table 2 The listed dis top end of the tower tances include the height of the tower The tower wiring is connected to the XL 1 wind Maximum Current 60 amps turbine at the slip ring using the two small screws on the positive and negative slip ring terminals Caution Installing wire sizes larger than The best way to do this is with ring terminals cho2. 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 destruction 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 This figure shows a 25 meter 84 ft tower which like the 19 m 64 ft and 32 m 104 ft towers uses larger d
3. weathered sive Limestone Very dense and or ce Caliche Nitrate mented sands coarse bearing gravel rock gravel and cobbles Dense fine sand very hard silts and clays may be preloaded Basal till boulder clay caliche weathered laminated rock Dense clays sands and gravel hard silts and clays Glacial till weathered shales schist gneiss and sandstone Glacial till hardpan marls Medium dense course sand and sandy gravels silts stiff to very stiff silts and clays Saprolites residual Loose to medium dense fine to course sand firm to stiff clays and silts Dense hydraulic fill compacted fill resid ual soils Loose fine sand Alluvium Flood plain soils lake 7 loess soft firm clays clays adobe gumbo varied clays fill fill Peat organic silts inun Miscellaneous fill dated silts fly ash swamp marsh Used by permission of A B Chance Co Medium dense sandy gravel very stiff to hard silts and clays 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 obje
4. 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 rocks that would impede the screw in guy wire anchors In weak or rocky soils the use of con crete 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
5. U shaped to provide room to assemble the XL 1 turbine We crimp preferred over straight crimp recommend fashioning a temporary support stand thread locking compound like Locktite 242 to hold the tower up during turbine assembly tape measure 12 ft 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 13 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 lbs 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 referen
6. 15 14 apart Note the tower tilt alignment direction required in Figure 5 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 5 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 Bolte 6 places 3 4 holes for ground rods or concrete Top View anchors Ginpole direction Tower tilt down direction lt Move this channel in when mounting Not used on concrete Bolt hole for Bolt hole for tower tube ginpole tube Side View Figure 5 Base Plate Assembly 6 Tower Assembly Tools Required 3 4 box end wrench Yebox end wrench 12 crescent wrench 7 16 nut driver or box end wrench Tape measure Electric drill 7 32 drill bit 3 8 socket drive Electrical tape Procedures The procedures are somewhat different for the 9 and 13 meter towers and the taller 19 32 m tow ers 9 m 30 ft and 13 m 42 ft Towers These two heights use 89 mm 3 5 tubing that comes in nominal lengths of 2 m 6 5 ft The taller XL 1 towers 19 25 amp 32 m use tubing that is larger in diameter and longer Step 1 Bolt the base tower section to the base plate us ing a 1 2 diameter x 5 long bolt and nut through the hole dri
7. 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 A Pin F 4 2 Cotter T 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 LJ 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 OO OOOO 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 We recommend switching the turbine cir cuit breaker left side
8. highlighted in the ap propriate 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 18 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 19
9. tower and shown in Figure A Then slide on the 80 ft level guy ring On the a 32 m 104 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 to wards the base plate Slide the guy ring all the way down the tube to the flared connection where the tubes join The ring will rest against the flared diameter of the tube Do not unspool the guy wires at this stage Make sure that the guy wire labeled 80 ft level lifting is on the top There is a red tag on the lifter eye of this wire Step 6 On a 32 m 104 ft tower add one more 3 m 10 ft section Then add the shorter 1 4 m 4 5 ft tur bine mounting section Secure the top section with the three 14 self tapping fasteners as de scribed in Step 2 in previous section for the 9 m tower and shown in Figure A Then slide on the 100 ft level guy ring Make sure that the guy ring ears are facing to wards the base plate Slide the guy ring all the way down the tube to the flared connection where the tubes join The ring will rest against the flared diameter of the tube Do not unspool the guy wires at this stage Make sure that the guy wire labeled 100 ft level lifting is on the top There is a red tag on the lifter eye of this wire Step 7 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
10. an axle Let the wire unwind as you walk out to the anchor point Note On the 19 m and taller towers the guy wires marked for Lifting must be on the upper side of the horizontal tower sections The guy wires marked Lift ing have an eye swaged to the cable This eye is clipped to the top of the gin pole These guy wires serve as the lift ing 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 from 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 8 When the guy wires are rolled out to all the an chors check to insure that the tower forms a right angle with the line joining the side anchors and the base plate 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 to the tower or if the side anchors are not at the same eleva tion or if the side anchors 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 adjusted periodically as the tower is raised Step 9 Slide three wire rope malleable clips supplied in the guy set box onto each guy wire end Thread the guy wire end through the anchor rod
11. ar through the eye or with a hand held electric drive The screw an chors included with the tower are suitable for installation in Soil Classes 3 5 and in some Class 6 If there is any doubt about the quality of the soil consider other anchoring options or consult the factory Concrete Anchor A second option is to dig a hole about 0 7 m 2 5 ft square to a depth of at least 0 9 meter 3 ft Place the anchor as shown in Figure 16 and fill the bottom of the hole with concrete to a depth of at least 0 3 meters 1 ft covering the helix and part of the rod Since the anchor rods for the 19 25 and 32 m towers are longer the hole depth will need to be greater as shown Also 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 Reinforcing rods should be incorporated in the concrete so as to provide adequate strength and load distribution in the pad The backfilled earth should be tamped vigorously as it is returned to the hole lt Towards Center Pad 45 Degrees I 0 91 m 36 for 9 amp 13m Towers 1 14 m 45 for 19 25 amp 32 m Towers Ground level Screw in Anchor 750 mm 30 _ et 750 mm 30 Top View 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 least as large and as deep as shown The anchor ro
12. cal 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 4 Check the side guy wire tension for a moderate degree of slack corresponding to a wire pull of about 23 kilograms 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 11 WARNING At 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
13. ce 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 Spinner Fasteners Blade Nuts amp Washers TA I Longer bolt goes here LJ Blade Bolts 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 14 Figure 13 We recommend applying
14. choring 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 gal vanized bolts supplied with the kit as shown in Figure 5 Install the base plate with its upturned flanges aligned with the tower lay down direction Sink the down turned edges into the soil Pound in the 4 ft 1 2 m copper clad ground rod through one of the two holes in the base plate using a sledgehammer Leave 4 inches 10 cm of rod above 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 The Tilt Tower Base Plate must be secured to the concrete using two 5 8 hex head bolts not sup plied or concrete anchor bolts not supplied in stalled through the 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 Y2of the threaded end sticking up above the concrete The bolts should be centered on the pad and be spaced
15. cts 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 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 16 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 amp THEIR INSTALLATION Three types of anchoring systems may be used to accommodate various soil types screw in an chors sub surface concrete pads and expanding or bonded rock anchors Screw Anchors In most areas of the country power installed screw anchors have become the standard anchor ing system used by the utilities Screw anchors are furnished as standard equipment with the BWC XL 1 towers They are intended to be in stalled manually with a stout b
16. d 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 screw anchors provide a large radius for each of the guy wires as it is attached to the anchor eye This is an important part of the installation in order to avoid sharp bends in the cables Any alternative anchor rods should incorporate similar provisions 17 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 t
17. 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 Itis possible to raise the 30 ft 9 meter tower and turbine without a winch but it takes 3 4 crew members to do it safely 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 lifting force on the turbine and tower Without the gin pole it would be virtually impossible to raise the tower Figure 1 9 m 30 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 within 1 1 2 times the tower height of electric power lines 4 DO NOT place guy anchors near roads driw ways or normal paths for vehicles 5 DO NOT permit unnecessary persons on the tower site while the tower is being raised or lowered
18. e team before lifting or lowering starts It is a con tinuing process throughout the lifting lowering se quences 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 at the 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
19. e 9 and 13 m towers have a 4 helix and are 1 37 m 54 long The screw anchors for the taller tow ers have a 6 helix and are 1 68 m 66 long On the 19 25 and 32 m towers the Ginpole An chors are screwed in at a 45 degree angle also rover Uphill Guy aller ca Side Guy f Anchor Ginpole Anchor Distance Downhill Guy Anchor Layout Dimensions in Feet Layout Dimensions in Meters Ginpole Tower Guy Diagonal Anchor Tower Guy Diagonal Anchor Height Radius Distance Distance Height Radius Distance Distance 30 ft 19 ft 26 8 ft A 9m 5 8m 8 17 m 42 ft 19 ft 26 8 ft N A 13m 5 8m 8 17 m g 64 ft 35 ft 49 5 ft 20 ft 19 m 10 7 m 15 1 m 6 1m 84 ft 50 ft 70 7 ft 29 ft 25m 15 2 m 21 6 m 8 9m 104 ft 60 ft 84 6 ft 29 ft 32m 18 3 m 25 8 m 8 9m Figure 3 Anchor Layout Turn the screw anchor clockwise so that the auger bit bites into the ground One hint for getting the screw anchor started is to press the auger part into the ground with your foot while turning If the anchors cannot be screwed in due to rocks it may be necessary to dig holes insert the anchors and fill the hole with concrete lt Towards Center Pad 45 Degrees i 150 mm 6 Ground level Screw in Anchor Figure 4 Anchor Angle 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 An
20. e 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 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 12 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 13 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 Pull up Height Height Force kgs meters feet Ibs 160 350 250 550 340 750 13 1 520 1 150 13 1 104 700 1 550 13 1 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 pulle
21. e top of the fourth tube while the spooled guy wire set are attached Do not un spool the guy wires at this stage Top 1 4m Section 1 4 Self Tapping fe a O cD Screws 3 equally spaced around the tube 120 degree spacing Drill 7 32 5 6 mm pilot hole before inserting screw 1 25 mm Upper 2 m or 3 m Section Figure A Top Section Fasteners Step 3 Slide the guy ring all the way down the tube to the flared connection where the tubes join Make sure that the guy ring ears are facing towards the base plate The ring will rest against the flared diameter of the tube Make sure that the guy wire labeled 20 ft level lifting is on the top There is a red tag on the lifter eye of this wire Step 4 In the case of a 13 m 42 ft tower add two 2 m 6 5 ft sections Then add the shorter 1 4 m 4 5 ft turbine mounting section Secure the top sec tion with the three 4 self tapping fasteners as described in Step 2 and shown in Figure A Slide on the second guy ring Labeled 40 ft level over the top tube while the spooled guy wire set is attached Do not unspool the guy wires at this stage Slide the guy ring all the way down the tube to the flared connection where the tubes join Make sure that the guy ring ears are facing towards the base plate The ring will rest against the flared diameter of the tube Make sure that the guy wire labeled 40 ft level lifting is on the top The
22. er screw 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 for screwing the an chors in In these cases a subsurface concrete pad can usually be substituted In the case of hard rock however special rock anchors may be necessary This reference section is designed to provide you with considerations and recommen dations 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 Table 2 Soil Classifications Common Soil Type Geological Soil Class Description Classification Sound hard rock un Granite Basalt Mas
23. eye double back and slide through the first wire rope malleable clip The guy wires are wrapped around the anchor eye as shown on the anchor detail in Figure 6 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 Leave a little slack in the guy wire Snug up the wire rope clip nuts using a 7 16 nut driver but not too tight it may be necessary to adjust them dur ing the tilt up procedure Let the other two clips remain loose until the tower has been erected and leveled Malleable Clip Note 6 Tripleye anchor for 19 32m towers shown Figure 6 Guy Wire Attachment Step 10 Referring to Figure 5 the gin pole will attach to the base plate with a Yex 6 bolt The ginpole is assembled in the same direction as the tower it self with the ginpole resting on top of the tower sections The following procedure integrates the assembly of the gin pole safety wire see Figure 7 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 tie top brack ets at the outer end of the gin pole
24. 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 hold 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 17 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 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 10 allow the back guy wires to be attached and ad justed The sequence is shown in Figure 8 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 alway
25. guys Make sure that the guy ring ears are facing towards the base plate Slide the guy ring all the way down the tube to the flared connection where the tubes join The ring will rest against the flared diameter of the tube Do not unspool the guy wires at this stage Make sure that the guy wire labeled 40 ft level lifting is on the top There is a red tag on the lifter eye of this wire Step 4 On a 19 m 64 ft tower add one more 3 m 10 ft section Then add the shorter 1 4 m 4 5 ft tur bine mounting section Secure the top section with the three 14 selftapping fasteners as de scribed in Step 2 in previous section for the 9 m tower and shown in Figure A On the 25 m and 32 m towers add two more 3 m 10 ft sections and slide on the 60 ft level guy ring and wires Make sure that the guy ring ears are facing to wards the base plate Slide the guy ring all the way down the tube to the flared connection where the tubes join The ring will rest against the flared diameter of the tube Do not unspool the guy wires at this stage Make sure that the guy wire labeled 60 ft level lifting is on the top There is a red tag on the lifter eye of this wire Step 5 On a 25 m 84 ft tower add one more 3 m 10 ft section Then add the shorter 1 4 m 4 5 ft tur bine mounting section Secure the top section with the three 14 selftapping fasteners as de scribed in Step 2 in previous section for the 9 m
26. he tower raising or lowering process 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 th
27. iameter and longer tower tubes and has a ginpole that is shorter than the guy radius The 9 m 30 ft like the one shown on the cover of this manual and in Fig 1 and the 13 m 42 ft towers use smaller and shorter tubes and have a ginpole that extends out to the anchor point 5 Anchors amp Base Plate Please review the Anchoring Reference section in Section 11 before proceeding further Different soil conditions may require different anchoring methods to ensure proper strength Tools Required 5 6 wood or metal stakes Hammer Sledge hammer 100 ft tape measure 2 1 2 ft long x 1 1 1 2 diameter metal bar or pipe Shovel if ground is too hard for screw in an chors 9 16 box end wrench 12 crescent wrench Procedure Step 1 Mark the ground location for the tower base plate guy anchors and the lifting anchor for the gin pole not required for 30 and 42 towers The appro 4 ft Top Tube Guy Set 80 ft Level bh uy Wires la aay fea Base Tube Base Tube Malleable Clips vr Screw in Anchor Figure 2 Major Tower Components priate dimensions and ground layout 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 recom mend that the ginpole be oriented towards South in the Northern Hemisphere and North in the Southern Hemisphere If the site is not level try to positio
28. 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 the 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 brass acorn nut to one of the ground rods and attach ing one end of the 1 8 bare copper grounding wire Attach the other end of the grounding wire using a small loop to the Y2tower pivot bolt 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 Powerhead Tail Fin Alternator Nacelle Blades x amp SN Spinner Tail Boom Tower T 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
29. lled in the flared end of the base sec tion Use the lower hole in the center of the long base plate as shown in Figure 5 Note If the 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 On a 30 ft 9 m tower add three more 2 m 6 5 ft sections Add the shorter 1 4 m 4 5 ft turbine mounting section making sure that it is firmly seated This is a highly stressed joint and re quires reinforcement with three self tapping 1 4 screws as shown in Figure A below If these fas teners are not added the joint will loosen over time To install the 14 fasteners drill a 7 32 pilot hole 1 above the bottom of the top section Then use a 3 8 socket drive to screw in the 4 self tapping screw The other two screws are spaced 9 8 cm 3 7 8 in both directions around the outside of the tube from the first fastener This measure will place them equally spaced at 120 degrees Repeat the process of drilling and screwing in the 14 fasten ers Slide on the guy ring over the top of the tower while the spooled guy wire sets are attached Do not unspool the guy wires at this stage There is only one set of guy wires on the 9 m 80 ft tower On the 13 m 42 ft tower add three 2 m 6 ft sections to the base section for a total of 8 m 26 ft Slide on the first guy ring Labeled 20 ft level over th
30. n BWC XL 1 Tilt Tower Installation Manual 9 m 30 ft Tilt Tower 13 m 42 ft Tilt Tower 19 m 64 ft Tilt Tower 25 m 84 ft Tilt Tower 32 m 104 ft Tilt Tower Bergey Windpower Co Inc 2001 Priestley Ave Norman OK 73069 USA Telephone 405 364 4212 Fax 405 364 2078 Email sales bergey com Web www bergey com WINDPOWER Please Help Us Improve This Manual We would be very interested to hear any comments you might have on this new installation manual We are particularly interested in learning of mis takes or omissions and subjects that are unclear Please call fax or e mail and direct your comments to Steve Wilke in Customer Service Thank you very much for your assistance Tel 866 237 4397 toll free in U S Tel 405 364 4212 Fax 405 364 2078 e mail swilke bergey com BWC Tilt up Tower amp BWC XL 1 INSTALLATION MANUAL Table of Contents 1 OVErVIOW aaccess 2 2 SEY sra EENE 3 3 Cautions and Warnings 3 4 Components icseeeeeee 3 5 Anchors and Base 3 6 Tower Assembly 045 6 73 Initial Tower Raising 10 8 Tower Lowering 5 11 9 XL 1 Wind Turbine 12 10 Final Tower Raising 15 11 Miscellaneous Reference Ma 16 tenal essre cates nae 1 Overview The Tilt Tower is the factory recommended tower for the Bergey XL 1 tower because it combines cost effectiveness and ease of installation
31. n 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 Tower Tube Warning Note a XL 1 Wind Turbine ra T Tower Tube Guy Set 60 ft Level eto ft Level Lifting Wires with swaged on ing eyes Sf Ginpole Top Tube with teeter brackets 25 m 84 ft Tower The tower must not be erected within 1 1 2 times the tower height of electric power lines Most overhead power lines are not insulated so they pose a life threatening shock hazard 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 of an anchor point is not possible it should be moved outward from the base rather than inward Try to keep the side anchors and the base plate at approximately the same elevation Step 2 Screw in the four Guy Anchors at 45 degrees pointing towards the tower base stake leaving 4 inches to 8 inches 10 cm 20 cm above ground as shown in Figure 4 When finished the eye at the end of the anchor rod should have its eye ori ented vertically as in Fig 4 A 2 1 2 ft metal bar or heavy wall pipe 1 1 1 2 inch in diame ter will be necessary to develop the high torque required to screw the anchors in The 4 ground rods may be used but they are awkward because they are too long The screw anchors for th
32. of enclosure to the OFF position to avoid sparking during the reconnection procedure Step 2 Follow Steps 1 through 3 of the Initial 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 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 15 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 4 diameter 9 amp 13 m tower or 6 diamet
33. pass bolt through loop in safety wire The 9 and 13 m 80 and 42 towers use a6 m 20 ft gin pole made up of three 2 m sections The 19 m 64 tower uses a 20 ft gin pole made up of two 10 ft sections The 25 and 32 m 84 and 104 towers use a 30 ft gin pole made up of three 10 ft sections 7 4 DIA BRACKET BOLT SWAGED LOOP f GIN POLE TIE TOP BRACKETS SAFETY WIRE Sone SHACKLE amp SNAP LINKS ATTACHMENT Fl a A 1 Assembla gin pole 2 Side satety wire inside gin pole 3 Asseertite gin pole on top of tower 4 When betting gin pole to base plate pass bot through loop in safety wire 5 When assemdiying tietop to Imet of gin pole pass DOR through loop in satety wire 3 4 DIA BOLT A Figure 7 Ginpole Safety Wire Assembly Make sure that the bracket bolt in the end section of the gin pole is aligned as shown in Figure 7 Bolt the tie top brackets to the end section Attach the snap links to the tie top bracket with shackles A snap link is a heavy galvanized steel or stainless steel loop with a spring loaded gate or opening side bar A shackle is a heavy galva nized steel U shaped ring with a heavy pin that when assembled forms a D shaped connector 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 11 Roll out each level of the lifting guy wires and at tach each of th
34. re is a red tag on the lifter eye of this wire You can now proceed to Step 7 19 m 64 ft 25 m 84 ft and 32 m 104 ft Towers These three heights use 114 mm 4 5 tubing that comes in nominal lengths of 3 m 10 ft They also have a gin pole which is shorter than the guy radius requiring a fifth screw in anchor Step 1 Bolt the base tower section to the base plate us ing a 1 2 diameter X 6 long bolt and nut through the hole drilled in the flared end of the base sec tion Use the lower hole in the center of the long base plate as shown in Figure 5 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 two 3 m 10 ft sections to the base section for a total of 9 m 30 ft Slide on the first guy ring Labeled 20 ft level over the top of the third tube while the spooled guy wire set are attached Do not unspool the guy wires at this stage Slide the guy ring all the way down the tube to the flared connection where the tubes join The ring will rest against the flared diameter of the tube Make sure that the guy ring ears are facing to wards the base plate Make sure that the guy wire labeled 20 ft level lifting is on the top There is a red tag on the lifter eye of this wire Step 3 Add two more 3 m 10 ft sections and slide on the 40 ft level
35. s be visible slack in the guy wires 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 Note The guy wires can be pulled in by one person when the winch is stopped Brute force is not required Step 2 Continue lifting and adjusting until the tower is 45 to 60 toward the vertical 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 Step 3 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 verti
36. those recommended will increase the sen for your tower wire type The polarity of the maximum current produced by the tur connections is marked If your conductors are bine color coded we recommend making note of the colors connected to positive and negative leads Table 2 Recommended Wire Sizes for the XL 1 The slip ring assembly is not designed to support the weight of the down tower wire A strain reliev J F ing installation is required as shown in Figure 11 size US Use the two nylon c ties provided to Sia 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 Note These wire sizes have been engineered to provide op ere yJ Nylon Cable Turbine es he WS timum rotor loading for the BWC XL 1 24 wind turbine Devia tion from these recommendations can result in decreased performance 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 Cs 4 Turbine Installation The fasteners on the XL 1 are all metric Tools Required Figure 11 Turbine Mounting 17 mm box end wrench 17 mm socket and 12 ratchet drive Step 2 8 mm socket or wrench pliers Raise the tower about 1 meter 3 ft off the ground crimpers for wiring terminals
37. y 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 Warning If a winch is used we strongly recommend that a worm gear type be used 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 and electric winch kits that are rigged and ready to go Con tact your dealer or Bergey Windpower for informa tion and pricing 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 14 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 15 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 16 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
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