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Summary of Contents for Bergey Tilt Tower
- Page 1 Version 5 BWC EXCEL1 January Tilt Tower 2012 Installation Manual 60’ Tilt Tower 80’ Tilt Tower 100’ Tilt Tower 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...
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Page 2: Table Of Contents
6) Installing the EXCEL1 Wind Turbine ................ 22 7) Final Tower Raising ....................29 8) Misc. Reference Material ..................31 9) Tilt Tower Packing Lists ................... 37 Table of Figures Figure 1: Major Tower Components ................5 Figure 2: Anchor Layout ....................7 ... -
Page 3: Safety
Safety This manual contains important information concerning the installation of your Bergey Tilt Tower, EXCEL1 wind turbine, and PowerCenter controller. We strongly recommend that you read and familiarize yourself with its contents. At several points in this manual, items of special interest or significant impact are high- lighted by one of the following symbols: DANGER: Hazard or unsafe practice that could cause personal injury or death. - Page 4 TOWER SAFETY NOTES 1. Never climb the tower. 2. All persons not directly involved in the installation should stay clear of the area when the tower is being raised or lowered. 3. All persons near the tower should wear OSHA-approved hardhats. 4.
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Page 5: Components
1) Components The major components for the tower kits are shown in Figure 1. The tower sections are 4.5” diameter thin-wall steel tubes that have been swaged down at one end (except for end tubes) so they fit into each other. Every 20’ in height (two 10’... -
Page 6: Table Of Figures Figure 1: Major Tower Components
XL.1 Wind Turbine Guy Set, 75 ft. Level Tower Tube Guy Set, 60 ft. Level Guy Set, 40 ft. Level Guy Set, 20 ft. Level Lifting Guy-Wires Guy Wires (with swaged-on lifting eyes) Base Tube Base Plate Base Tube Tower Tube Gin-pole Top Tube (with teeter brackets) Malleable Clips... -
Page 7: Anchors & Base Plate
2) Anchors & Base Plate Tools Required: 5-6 wood or metal stakes Hammer Sledge-hammer 100’ tape measure 6” Diameter x 5’ power auger Chance/Hubbell #C302-0003 10’ Expanding & Tamping Tool or 10’ long x 3” diameter heavy wall steel pipe Shovel 9/16”... -
Page 8: Figure 2: Anchor Layout
Figure 2: Anchor Layout... - Page 9 26” x 12” deep, with several pieces of steel reinforcing bar placed horizontally. Assem- ble the Base Plate. The Tilt Tower Base Plate must be secured to the concrete using two 5/8” hex head bolts (not supplied) or concrete anchor bolts (not supplied) installed...
- Page 10 You can either cast hex bolts into the concrete or pour the concrete pad and install an- chor bolts after 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 about 2 ½”...
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Page 11: Figure 3: Base Plate Assembly
Galvanized bolts (6 places) 7/8“ holes for ground rods or concrete Top View anchors Ginpole direction Tower tilt- down Move this channel direction in when mounting on concrete Bolt hole for Bolt hole for tower tube gin-pole tube Side View Figure 3: Base Plate Assembly... -
Page 12: Figure 4: Anchor Installation
Figure 4: Anchor Installation... -
Page 13: Tower Assembly
3) Tower Assembly Tools Required: 1 1/4” box-end wrench or 18” crescent wrench ¾” 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 using a 3/4”... - Page 14 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.
- Page 15 Note: The guy wires with the lifting eyes must be on the upper side of the hori- zontal tower sections. This eye is clipped to the top of the gin pole. These guy wires will serve as the lifting wires until the tower is fully erected. Note: Guy wires must be rolled out to the anchors, not let out from a coil held in the hand or from the side of the spool.
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Page 16: Figure 5: Guy Wire Attachment
Figure 5: Guy Wire Attachment Step 8: Referring to Figure 3, the gin-pole will attach to the base plate with a 3/4” diameter x 6 1/2” long bolt. The gin-pole is assembled in the same direction as the tower itself, with the gin-pole resting on top of the tower sections. -
Page 17: Figure 6: Gin-Pole Safety Wire Assembly
BOLT Figure 6: Gin-pole 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 ¾” bolt, making sure to pass the bolt through the safety wire thimble. -
Page 18: Table 1: Pull-Up Force And Cable Travel
Table 1: Pull-up Force and Cable Travel Pull-up Pull-up Height Force Cable (ft) (lbs) Travel (ft) 1,150 1,550 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 rec- ommend a 2:1 pulley block arrangement to reduce the line tension for the 25 and 32 meter towers. - Page 19 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 adjustments to the guy wires or anchors.
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Page 20: Initial Tower Raising
4) Initial Tower Raising At this stage, an initial tower raising without the wind turbine in place is recommended. It will ensure that all the cables and anchors are secure, that the lifting procedure is sat- isfactory, and will allow the back guy wires to be attached and adjusted. The sequence is shown in Figure 7. - Page 21 Adjust the cable tension as required using the wire rope clips. Work slowly. Fast une- ven movements tend to make the tower swing or waver. Try to work smoothly and en- sure that those people tending the cables are able to follow along with the tower raising process.
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Page 22: Lowering The Tower
5) Lowering the Tower The procedure for lowering the tower is the reverse of raising the tower, although cer- tain precautions must be taken. Step 1: If the raising process has indicated that the tension 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 exces- sive tightening or slackening. -
Page 23: Installing The Excel1 Wind Turbine
6) Installing the EXCEL1 Wind Turbine EXCEL1 Wind Turbine Components The major components of the EXCEL1 wind turbine are shown in Figure 8. Installing the turbine requires connecting it to electrical wiring to the PowerCenter controller and then assembling the turbine at the top end of the tower. Powerhead Alternator Tail Fin... -
Page 24: Figure 9: Excel 1 Wiring Schematics
Figure 9: EXCEL 1 Wiring Schematics The wind turbine alternator produces a 3-phase AC, which is rectified into DC up in the nacelle of the 24V model, and rectified in the PowerCenter of the 48V model. A two (2)- conductor wire is needed between the wind turbine and the PowerCenter controller for the 24V model. -
Page 25: Table 2: Recommended Wire Sizes For The Excel1 24V
Table 2: Recommended Wire Sizes for the EXCEL1 24V DISTANCE FROM TURBINE WIRE SIZE TO POWERCENTER MM^2 METERS FEET 8 AWG 0 - 35 0 - 116 6 AWG 36 - 56 117 - 183 4 AWG 57 - 89 184 - 292 3 AWG 90 - 112... -
Page 26: Figure 10: Turbine Mounting
The tower wiring is connected to the EXCEL1 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 chosen for your tower wire type. The polarity of the connections is marked. -
Page 27: Figure 11: Blade And Spinner Fasteners
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 nega- tive electrical leads for later reference. Step 5: Turn the EXCEL1 powerhead so that the alternator is facing up. Attach the blades as shown in Figure 11 using the M10 hardware provided. -
Page 28: Figure 12: Nut Tightening Order
Figure 12: Nut Tightening Order Step 6: Attach the spinner (nose cone) using the three M5 bolts and lock washers provided, as shown in Figure 11. We recommend applying Loctite to the bolt threads prior to as- sembly. 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... -
Page 29: Figure 14: Tail Boom Attachment
hammer to pound the pin in place, as this may cause scoring 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 Cotter Cotter... -
Page 30: Final Tower Raising
7) Final Tower Raising Tools Required: 7/16” nut driver (several) Procedure: Step 1: Short-circuit the EXCEL1 alternator by twisting or bolting the output wires together. This will keep the wind turbine from spinning during the raising of the tower. If the Power- Center connections have already been made, this can be easily done by moving the positive lead over to the negative terminal. - Page 31 Step 6: Check the guy wires after 2 or 3 weeks 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.
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Page 32: Misc. Reference Material
8) Misc. Reference Material Anchoring For most installation sites the 6” diameter expanding 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 augering the hole. In these cases, a subsurface con- crete pad can usually be substituted. -
Page 33: Table 3: Soil Classifications
Table 3: Soil Classifications Class Common Soil-Type Description Geological Soil Classification Sound hard rock, unweathered Granite, Basalt, Massive Limestone Very dense and/or cemented sands; Caliche, (Nitrate-bearing gravel/rock) coarse gravel and cobbles Dense fine sand; very hard silts and Basal till; boulder clay; caliche; weath- clays (may be preloaded) ered laminated rock Dense clays, sands and gravel;... -
Page 34: Figure 16: Concrete Anchors
equipment with earlier versions the BWC EXCEL1 towers. They were intended 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 because they can be used in a broader range of soil conditions. - Page 35 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 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.
- Page 36 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.
- Page 37 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 recommenda- tions. 9. DO properly ground the tower electrically. 10. DO thoroughly understand the tower erection procedure before beginning the in- stallation.
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Page 38: Tilt Tower Packing Lists
9) Tilt Tower Packing Lists BWC XL.1 Series Packing List, HKGT4-60, Guyed Tilt-up Tower, 58.5 ft (18m) Shipped to: Item Part No. Description Packed USAGE 6613 Top Tower Section Section 6610 Standard Tower Section Section 6611 Base Tower Section Section... - Page 39 BWC XL.1 Series Packing List, HKGT4-80, Guyed Tilt-up Tower, 77.5 ft (24m) Shipped to: Item Part No. Description Packed USAGE 6613 Top Tower Section Section 6610 Standard Tower Section Section 6611 Base Tower Section Section 6611 Gin Pole Inner Section Gin Pole 6610 Gin Pole Standard Section...
- Page 40 BWC XL.1 Series Packing List, HKGT4-100, Guyed Tilt-up Tower, 96.5 ft (29m) Shipped to: Item Part No. Description Packed USAGE 6613 Top Tower Section Section 6610 Standard Tower Section Section 6611 Base Tower Section Section 6611 Gin Pole Inner Section Gin Pole 6610 Gin Pole Standard Section...