ARE Short Towers Installation Manual Download

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SHORT TOWER INSTALLATION MANUAL

ARE

Tilt-up, Guyed, Pipe Towers for

ARE110

AWP-3.6

Wind Generators

Short Towers – 43, 64, and 85 feet tall

Summary of Contents for Short Towers

Page 1: ...SHORT TOWER INSTALLATION MANUAL ARE Tilt up Guyed Pipe Towers for ARE110 AWP 3 6 Wind Generators Short Towers 43 64 and 85 feet tall ...

Page 2: ...tion Installation Raising 13 Step 3 Prepare the Gin Pole 13 Step 4 Raising the Gin Pole 16 Step 5 Gin Pole Guy Wire Attachment 16 Step 6 Tower Assembly 16 Step 7 Top Guy Wire Attachment 17 Step 8 Hoist Guy Wire Attachment 18 Step 9 First Tower Raising 19 Step 10 Tower Adjustment 21 Step 11 Tower Lowering 21 Step 12 Re Raising the Tower 22 Step 13 The Final Raising of the Tower 22 Step 14 Final Che...

Page 3: ...signed to be climbed at any time 2 Site Selection and Preparation The ideal site for a tower is a flat level field However any area in which there is sufficient space for the foundations and which is reasonably level will work A hillside can also be made to work if there is a line available that allows the side guy anchors and the base to be level with each other For these towers the anchors are a...

Page 4: ...lamps Rebar bender Wire mesh or rebar see section 5 Tower Foundations subsection Center Foundation Wire ties Tower Installation Concrete min 5 yards Pliers channel locks Combination wrenches for saddle clamps 7 16 1 2 pivot and pin bolts 3 4 15 16 1 1 16 and turnbuckles 7 8 9 16 Round file Cable cutter Galvanizing spray Heavy hammer and block of wood Rope ...

Page 5: ...olts 2 2 2 5 8 Nylok Nuts 2 2 2 J E Turnbuckles 1 2 x 12 8 12 16 J J Turnbuckles 5 8 x 6 1 1 1 Thimbles 5 16 for Ø3 16 wire 6 11 16 Thimbles 1 2 for Ø 5 16 wire 5 5 5 Saddle Clamps 3 16 18 33 48 Saddle Clamps 5 16 15 15 15 Tower and Anchor Attachments Gin Pole Gusset 2 2 2 Pivot Bolt 3 4 x 8 1 1 1 Pivot Nuts and Washers 3 4 of each 2 2 2 Pin Bolts 1 2 x 6 5 5 5 Pin Nuts 1 2 Nylok 5 5 5 Pin Washers...

Page 6: ...ithout Crimped Eyes Tower Guy Wires with Crimped Eyes Tower Couplers with Guy Wires Attached Tower Height Wire Size Qty Length NA NA NA 43 foot Ø5 16 1 50 Ø3 16 1 52 64 foot Ø5 16 1 67 Ø3 16 1 52 Ø3 16 1 73 85 foot Ø5 16 1 88 Tower Height Wire Size Qty Length 43 foot Ø5 16 3 50 64 foot Ø5 16 3 67 85 foot Ø5 16 3 88 Tower Height Wire Size Qty of Wires per Coupler Length 43 foot Ø3 16 4 35 Ø3 16 4 3...

Page 7: ...racking Center Foundation The center foundation is reinforced using wire mesh or a rebar lattice Use No 2 or No 3 rebar 1 4 or 3 8 diameter for the lattice Wire mesh can be 4x4 W1 4xW1 4 to 6x6 W4 0xW4 0 The center foundation needs to have reinforcement on the sides and top faces of the block Locate the reinforcement 3 to 5 inches in from the surface of the cube faces See drawing D10 in the append...

Page 8: ...oist anchor A set of holes are provided in the gusset plates to adjust for higher or lower placement of the anchor Each hole is a 5 degree adjustment and moves the end of the gin pole 1 foot 9 inches at the hoist anchor If the locations shown in drawing D12 for the anchor are difficult to meet an extension kit consisting of 1 2 chain and a 7 16 shackle is offered to attach the retaining turnbuckle...

Page 9: ... it is suggested to pour directly over the anchor to avoid displacement The foundation should cure for 4 weeks 28 days before any loads are placed on them including tightening the nuts on the base plate anchor bolts Consult ARE if shorter curing times are necessary 6 Tower Section Preparation If you purchased a tower kit without pipe you will need to obtain 21 foot long sections of 4 inch schedule...

Page 10: ... recommend grounding the guy wires as well You will need five grounding rods and 4 to 8 AWG single strand bare copper wire Place a grounding rod near each of the foundations The grounding rods should be 8 feet long and embedded into the ground so the top of the rod is a minimum of 6 inches below the surface Connect a ground wire between each of the outer grounding rods making a circle around the c...

Page 11: ...the yaw head you can easily unwind any twists in the tower wire that may occur due to the generator rotating It can also serve as a location for an onsite brake switch We recommend using a lockable enclosure for safety Lightning arresters It is advised that lightning arrestors be installed in the wiring of the system We recommend that one be installed in a junction box at the base of the tower and...

Page 12: ...on The start of the tower assembly begins with the base plate Mount the base plate on the bolts in the center tower foundation and level it Use 5 8 nuts on the base bolts under the base plate and adjust them to level the base Next install the base plate with a 5 8 washer one on each side of the plate and a 5 8 nut on top Tighten the nuts and check for level If it is not level readjust until it is ...

Page 13: ... 12 Figure 2 Figure 3 Tower Base Section Gin Pole Non Shrinking Grout Pivot Bolt Adjustment Holes ...

Page 14: ...ection up by hand and attach the gin pole to the tower gussets Use 1 2 x 6 bolts washers and nuts as above Tighten until snug Caution do not over tighten as this will deform the pipe Step 3 Prepare the Gin Pole Insert the 4 Hole Gin Pole End Fitting in the Gin Pole Base Section and secure with a 1 2 x 6 bolt washers and nut Attach the pulleys using 3 8 shackles to the bottom side of the gin pole e...

Page 15: ... is farthest away from the center foundation Use a 1 2 open thimble After placing this and all other thimbles squeeze it closed before installing the wire and saddle clamps Secure with three 5 16 saddle clamps Refer to saddle clamp installation procedure in Figure 5 and make the dead end 30 inches long Attach the guy wire that is already attached to the first tower coupler to the turnbuckle closes...

Page 16: ...0 inches long Saddle Clamp Installation Procedure 1 Locate the first saddle clamp as close to the thimble as possible with the U bolt over dead end the live end rests in clip saddle See Figure 5 2 Install two more saddle clamps on 6 inch centers securing the guy wire with 3 clamps total 3 Do not over tighten and deform or damage the wires Recommended torque for both 3 16 5 16 saddle clamps 30 in l...

Page 17: ...degrees it will reach its balance point Maintain control by holding the hoist cable Go slow and play out the hoist cable and bring the Tower Base Section toward the ground When the Tower Base Section is level secure the hoist wire so the gin pole will be secure as the rest of the tower is assembled Step 5 Gin Pole Guy Wire Attachment Attach the gin pole guy wires to their anchors at the left and r...

Page 18: ...s or tangle the guy wires while you are measuring and marking Crossed wires could result in damage to the wires or prevent raising the tower Attach the down side guy wire in the same manner as the left and right sides except use the tape mark and do not add 6 inches The length of the guy wire may need to be adjusted to account for a difference in elevation between the down side guy anchor relative...

Page 19: ...r the tower has been adjusted Refer to the saddle clamp installation procedure in Figure 5 It will be easier to tighten the saddle clamps if the guy wire is led through the coupler from above and fed back on the side nearest the tower base see figure 7 Repeat the above procedure for the remaining guy wires attached to the gin pole Use a 1 2 thimble three 5 16 saddle clamps and a 1 2 shackle for th...

Page 20: ...rements All people are to remain clear of the tower during hoisting No one should walk under the tower or rigging during hoisting It is critical to raise and lower the tower very slowly This allows careful monitoring of all equipment and personnel Side guy wire tension must be continuously monitored The guy wires should always have some visible sag or slack in them throughout the entire raising If...

Page 21: ...be done from a safe location In that way the descent of the gin pole can be controlled and the guy wires prevented from slapping as the tower comes to the vertical position Figure 8 When the tower reaches the vertical position secure the gin pole by installing a jaw and jaw turn buckle between the equalizer plate and the gin pole end fitting If the turnbuckle cannot be adjusted to secure the gin p...

Page 22: ...justed to provide slack for this procedure Continue by adjusting the other sections so that the tower is visibly in line with the lower section Allow the amount of sag to increase in each higher guy wire The longer the guy wires the more sag for the same tension Tower adjustments may need to be made several times until all the sections are aligned vertically View tower upward along the pipe for be...

Page 23: ...er the tower in accordance with step 9 Block the tower up about three or four feet from the end and about three or four feet off of the ground This will put the tower at a good height for attaching your AWP3 6 Follow the instructions in the AWP3 6 Owner s Manual to assemble and attach your AWP3 6 to the tower When the machine is attached and ready to go raise the tower again per step 7 Use caution...

Page 24: ...nspected every 6 months at a minimum Ensure that all hardware is tight Ensure proper tension exists in the guy wires Inspect for corrosion If corrosion is found remove any scale clean and paint Guy wire dead end weaved through the turnbuckle eyes and bodies ...

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ARE Short Towers, Installation Manual

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