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The tower should have no more than a gentle bend from base to top. If the bow be-
comes more than about one foot, the side guy wires or the lifting wires should be ad-
justed before proceeding further.

This sequence of observing, communicating observations, 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 starts. It is a continuing process
throughout the lifting/lowering sequences. 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 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 50
pounds. 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
EXCEL1 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 person

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 observed as part of any
tower siting and raising or lowering operation. Some of the following
warnings or cautions have been highlighted in the appropriate sec-
tion of this manual.

1.  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, 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 cau-

tion.

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Summary of Contents for Tilt Tower

Page 1: ...llation Manual Bergey Windpower Co Inc 2200 Industrial Blvd Norman OK 73069 USA Telephone 405 364 4212 Fax 405 364 2078 E mail sales bergey com Web www bergey com 60 Tilt Tower 80 Tilt Tower 100 Tilt Tower Version 5 January 2012 ...

Page 2: ...bly 10 Figure 4 Anchor Installation 11 Figure 5 Guy Wire Attachment 15 Figure 6 Gin pole Safety Wire Assembly 16 Figure 7 Tower Tilt up Sequence 19 Figure 8 Major Components of the EXCEL 1 22 Figure 9 EXCEL 1 Wiring Schematics 23 Figure 10 Turbine Mounting 25 Figure 11 Blade and Spinner Fasteners 26 Figure 12 Nut Tightening Order 27 Figure 13 Tail Fin Attachment 27 Figure 14 Tail Boom Attachment 2...

Page 3: ...ANGER Hazard or unsafe practice that could cause personal injury or death WARNING Hazard or unsafe practice which could cause product damage NOTE Significant point of interest DANGER Installation of this tower and turbine system should only be conducted by qualified personnel Installation by unqualified personnel could result in damage to persons or property and may void the manufacturer s warrant...

Page 4: ...rcising extreme caution 7 Stay clear of the tower in the presence or possibility of severe weather of any kind 8 Thoroughly understand the tower erection procedure before beginning the installa tion TOP 10 REASONS FOR TOWER FAILURE 1 Improper torque on guy line grip clips no yearly inspection 2 Improper guy line tensioning no yearly inspection 3 Improper guy line radii 4 Improper anchor installati...

Page 5: ...r tube mid section The tower sections rest on a base plate assembly that often rests directly on the ground The base plate provides the pivot point 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 way out to the earth anchor in its direction so a transfer of guy wires is necessary dur ing raising and lowering The lifting eye...

Page 6: ...t 75 ft Level Guy Set 60 ft Level Guy Set 40 ft Level Guy Set 20 ft Level Tower Tube Base Tube Base Tube Tower Tube Gin pole Top Tube with teeter brackets Earth Anchor Base Plate Lifting Guy Wires with swaged on lifting eyes Malleable Clips Guy Wires 80 Tower ...

Page 7: ... recommend that the gin pole be oriented towards South in the Northern Hemisphere and North in the Southern Hemisphere If the site is not level try to position the tower so that it will be lowered in the uphill direc tion Check the diagonal distance between anchor points to ensure that they are spaced in a squared pattern DANGER The tower must not be erected near electric power lines Most over hea...

Page 8: ...7 Figure 2 Anchor Layout ...

Page 9: ... concrete for the anchors or use an alternate anchoring method These topics are covered in Chapter 8 under An choring Step 3 For most installations the base plate will sit directly 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 wash...

Page 10: ...d sticking up above the concrete The bolts should be centered on the pad and spaced 17 7 apart Note the tower tilt align ment direction required in Figure 3 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 3 When being bolted to a concrete pad the channel plate should be assembled in the retracte...

Page 11: ...Galvanized bolts 6 places Top View Side View 7 8 holes for ground rods or concrete anchors Move this channel in when mounting on concrete Bolt hole for tower tube Bolt hole for gin pole tube Tower tilt down direction Ginpole direction ...

Page 12: ...11 Figure 4 Anchor Installation ...

Page 13: ...ep 2 Add one 10 standard section to the base section for a total of 20 Slide on the first guy ring Labeled 20 ft Level over the top of the swedged reduced section of the tube with the spooled guy wire sets attached Do not unspool 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 tub...

Page 14: ...lbs 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 80 towers only On the 80 tower add two more standard sections and a guy level and then the top two section as described in the previous paragraphs Step 4 B 100 towers only O...

Page 15: ...to the tower or if the side an chors are not at the same elevation or if the side anchors and base plate are not in a straight line Any of these conditions will affect the guy wire tension as the tower is raised Tension must be adjusted pe riodically as the tower is raised Step 7 Assemble the 3 16 HD thimbles on the anchor rod eyes by twisting them open press ing them on and twisting them closed T...

Page 16: ...ges dur ing 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 brackets at the outer end of the gin pole pass bolt through loop in safety wire The 60 tower uses a 20 gin pole made up of two 10 sections The 80 and 100 t...

Page 17: ...n 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 attached to the forward anchor after the tower is erect ed Keep the wires well organized so t...

Page 18: ...nchor Never attach a cable from a truck or 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 de vice 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 distributed evenly across the surface ...

Page 19: ...locks or is fully guyed Step 15 Lower the tower and make any necessary adjustments 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 ...

Page 20: ...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 wires If no slack is visible the tension is too great WARNING Over tension may cause failure of the wir...

Page 21: ...ling 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 wi...

Page 22: ...e raising device as it begins letting out cable In order to clear the danger area it will be neces sary 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 ensure that personnel are located well beyond the point where the top of the tower will touch the ground when lowered Pull as required to keep tension on t...

Page 23: ...bine requires connecting it to electrical wiring to the PowerCenter controller and then assembling the turbine at the top end of the tower Blades Tail Boom Tail Fin Powerhead Alternator Tower Mount Spinner Nacelle Figure 8 Major Components of the EXCEL 1 Wiring The basic electrical schematic for the BWC EXCEL1 24 volt and 48 volt systems is shown in Figure 9 ...

Page 24: ... three 3 conductor whire is required between the wind turbine and PowerCenter for the 48V model The 24V model does not require a fused disconnect switch at the base of the tower while the 48V model does require the disconnect switch The recommended wire sizes for the 24 VDC EXCEL1 wind turbine are shown in Table 2 The listed distances include the height of the tower Maximum Current 60 amps WARNING...

Page 25: ...mmen dations can result in decreased performance from your machine and or unnecessary additional wire run costs It may also cause the incidence of nuisance breaker tripping The use of a wire gage two sizes larger than the recommended size is acceptable and is recommended if alumi num wire is used Turbine Installation The fasteners on the EXCEL1 are all metric Tools Required 17 mm box end wrench 17...

Page 26: ...able Ties Turbine Mounting Bolts Figure 10 Turbine Mounting Step 2 Raise the tower about 3 ft off the ground to provide room to assemble the EXCEL1 tur bine 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 six M10 1 5 x 20mm bolts and six flat washers We require applying Loctite ...

Page 27: ... tip to tip blade distance We recommend 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 1 2 for smooth operation Fina...

Page 28: ...l 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 We recommend applying Loctite to the bolt threads prior to as sembly Step 8 Place the tail boom on the rear of the turbine powerhead and insert the 1 2 tail pivot pin from the top If the parts are aligned properly the pin should insert eas...

Page 29: ...boom Cotter Pin Cotter Pin Tail Pivot Pin Figure 14 Tail Boom Attachment Step 9 Check the EXCEL1 wind turbine carefully to make sure that the installation is complete We recommend the following checklist Blade fasteners are secure and properly 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 se...

Page 30: ...om the gin pole to the forward anchor as shown in Figure 15 Secure each wire with wire rope clips being sure to maintain ten sion on each cable as it is transferred Start with the top level and work down 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 ensure that ...

Page 31: ...s and tighten as required Depending on the soil type it may require one or more checks and adjustments before the tower and anchors have fully settled Installation instructions for the PowerCenter controller are provided in the EXCEL1 Owner s Manual ...

Page 32: ... are designed to work in a limited range of soil conditions To choose the proper anchoring system it must be possible to identify these various soils The accompanying Table 3 shows a system of soil classification developed by the A B Chance Company on the basis of the mechanical properties of the soil The presence of water reduces the holding strength of the anchors Anchor creep can be a problem i...

Page 33: ...t firm clays varied clays fill Flood plain soils lake clays adobe gumbo fill 8 Peat organic silts inundated silts fly ash Miscellaneous fill swamp marsh Used by permission of A B Chance Co Anchor Rods All the anchoring systems described in the following 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 attach...

Page 34: ...e of the hole you will dig back 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 expanding anchors but you need to shake the anchor during ...

Page 35: ...he following discussion is aimed at defining these conditions Unless the anchors are placed precisely in their correct locations and the site is perfect ly level some guy wires will tighten and some will loosen as the tower is raised or low ered For this reason all guy wires must be watched and adjusted as needed through out the tower raising or lowering process When a guy wire loses its slack and...

Page 36: ...at the attachment point Tower Lift Crew The following is a suggested guide to forming an efficient and safe crew to erect a BWC EXCEL1 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 o...

Page 37: ... properly ground the tower electrically 10 DO thoroughly understand the tower erection procedure before beginning the in stallation YOU MUST BECOME FAMILIAR with all components 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 ...

Page 38: ... 3 8 x 1 Bolt 8 Base 16 HW6004 3 8 Washer SS 16 Base 17 HN6008 3 8 Nylock Nut SS 8 Base 18 HBB030 3 4 x 6 1 2 Bolt Tower Gin Pole Pivots 2 Tower Gin Pole 19 HBB030 3 4 x 6 1 2 Bolt Gin Pole Shackle 1 Gin Pole 20 HNB011 3 4 Nut A536 3 Tower Gin Pole 21 HNB008 3 4 Pal Nut 3 Tower Gin Pole 22 HB8021 1 2 x 2 1 4 Bolt Shackle to Snap Link 1 Gin Pole 23 HB8021 1 2 x 2 1 4 Bolt Shackle to G P Anchor 1 Gi...

Page 39: ...1 1 4 Flat Washer 6 Guys 17 HB6002 3 8 x 1 Bolt 8 Base 18 HW6004 3 8 Washer SS 16 Base 19 HN6008 3 8 Nylock Nut SS 8 Base 20 HBB030 3 4 x 6 1 2 Bolt Tower Gin Pole Pivots 2 Tower Gin Pole 21 HBB030 3 4 x 6 1 2 Bolt Gin Pole Shackle 1 Gin Pole 22 HNB011 3 4 Nut A536 3 Tower Gin Pole 23 HNB008 3 4 Pal Nut 3 Tower Gin Pole 24 HB8021 1 2 x 2 1 4 Bolt Shackle to Snap Link 1 Gin Pole 25 HB8021 1 2 x 2 1...

Page 40: ...x Head Bolt 6 Guys 17 HW4001 1 4 Flat Washer 6 Guys 18 HB6002 3 8 x 1 Bolt 8 Base 19 HW6004 3 8 Washer SS 16 Base 20 HN6008 3 8 Nylock Nut SS 8 Base 21 HBB030 3 4 x 6 1 2 Bolt Tower Gin Pole Pivots 2 Tower Gin Pole 22 HBB030 3 4 x 6 1 2 Bolt Gin Pole Shackle 1 Gin Pole 23 HNB011 3 4 Nut A536 3 Tower Gin Pole 24 HNB008 3 4 Pal Nut 3 Tower Gin Pole 25 HB8021 1 2 x 2 1 4 Bolt Shackle to Snap Link 1 G...

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