Beruflich Dokumente
Kultur Dokumente
InstallationManual&Specifications
34m_TallTower_Manual.docx 16 December 2015
2
34m_TallTower_Manual.docx 16 December 2015
TableofContents
WARNINGS..............................................................................................................................................
6
SAFETYBULLETINFORTOWERINSTALLATIONSINAGRICULTURALAREASORREMOTEAREASWHERE
LOWFLYINGAIRCRAFTOPERATE.............................................................................................................
8
Introduction..........................................................................................................................................10
TallTowerHistory..............................................................................................................................................10
ConstructionandAssembly.............................................................................................................................. 10
RequiredPartstoErectTowerSystem............................................................................................................. 10
ExperienceRequired.........................................................................................................................................10
TowerLiftCrew.................................................................................................................................................
10
ToolsRequiredforvarioustasks.......................................................................................................................
10
Unpackyourtower................................................................................................................................
13
Descriptionofthepackaging............................................................................................................................ 13
Toolsrequiredtounpackthe34mTallTower..................................................................................................
13
AccessandOrientation.....................................................................................................................................14
UnpackSequenceVeryImportant!................................................................................................................
14
SiteLayout ............................................................................................................................................16
PreinstallationPlanning...................................................................................................................................16
SoilTypeandAnchors....................................................................................................................................................16
Tip:CellularCoverage.....................................................................................................................................................16
SiteLayoutMap................................................................................................................................................16
TowerAssembly....................................................................................................................................18
AssembletheBaseplate....................................................................................................................................
18
InstalltheAnchors............................................................................................................................................21
TubeLayout......................................................................................................................................................22
SIUnits............................................................................................................................................................................22
ImperialUnits.................................................................................................................................................................22
InstalltheBaseTube.........................................................................................................................................
23
Attachsensorsandbooms................................................................................................................................
24
Spiralwrapyoursensorcables.......................................................................................................................................25
AttachtheGuyWires............................................................................................................................25
Organizeandlayouttheliftersandguywires.................................................................................................. 25
Shackleguywirestotheguyrings....................................................................................................................
25
Rollouteachguywirefromthetowertoitsanchorpoint.............................................................................. 26
Secureguywirestotheanchors.......................................................................................................................
27
Shacklelifterwirestotheguyrings.................................................................................................................. 28
AssembletheGinPole...........................................................................................................................
29
Layouttheginpoletubes..................................................................................................................................29
Attachtheginpolebasetubetothebaseplate................................................................................................ 29
Slidetogetherthe4tubesthatcomprisetheginpole...................................................................................... 29
Attachtheginpoletopmountinghardware..................................................................................................... 30
Attachthelifterwires.......................................................................................................................................33
Configurethehelperginpole............................................................................................................................ 33
GinpoleTiltUp......................................................................................................................................35
Confirmallliftersandshacklesaresecure....................................................................................................... 35
Lifttheginpole..................................................................................................................................................35
TowerTiltUp........................................................................................................................................36
UnderstandingGuyWireTensioningWhileRaisingTallTower(Donotraisethetoweryet)........................... 36
AdjustingGuyWires(theInchwormmethod)............................................................................................... 36
LooseningGuyWires......................................................................................................................................................36
TighteningGuyWires.....................................................................................................................................................38
LifttheTower....................................................................................................................................................
39
TransferLifters..................................................................................................................................................40
PlumbandStraighten.......................................................................................................................................42
FinalInspectionandMaintenance....................................................................................................................
43
TowerLowering.....................................................................................................................................
44
AppendixA:34mTallTowerDimensions..............................................................................................
46
TowerLayout....................................................................................................................................................46
SiteLayout.........................................................................................................................................................
47
BaseplateGeometry.........................................................................................................................................49
AppendixB:AnchoringGuidelines........................................................................................................
51
Determinesitesoilandanchortypebeforeyouorderyourtower................................................................. 51
AnchorChoicesandotherconsiderations........................................................................................................ 51
ScrewInAnchordescription..........................................................................................................................................51
ArrowheadAnchordescription......................................................................................................................................53
RockAnchordescription.................................................................................................................................................54
ConcreteAnchordescription..........................................................................................................................................54
InstallingScrewInAnchors...............................................................................................................................
55
InstallingArrowheadAnchors...........................................................................................................................
55
InstallingRockAnchors.....................................................................................................................................56
AppendixC:SiteVisitProcedures.........................................................................................................58
SiteChecklist.....................................................................................................................................................58
AppendixD:Glossary............................................................................................................................
59
AppendixE:AligningWindVanes.........................................................................................................67
Introduction......................................................................................................................................................67
MagneticDeclination........................................................................................................................................67
MountingandAligningWindVanes................................................................................................................. 67
UsingDataAnalysisSoftwaretoCorrectforMagneticDeclination...............................................................................70
AppendixF:HankmasterToolforUnrollingGuyWires.........................................................................71
Index.....................................................................................................................................................73
WARNINGS
SPECIALSAFETYINSTRUCTIONS
READALLINSTRUCTIONSANDWARNINGSBEFOREBEGINNINGANYTOWER
INSTALLATION.TOWERCOMPONENTSCONSISTOFHEAVYOBJECTSOFTEN
UNDERSIGNIFICANTTENSIONANDSERIOUSINJURYORDEATHCANOCCURIF
EXTREMECAUTIONISNOTUSEDDURINGEVERYASPECTOFTHEINSTALLATION.
EVERYINSTALLATIONCREWMEMBERSHOULDCAREFULLYREADAND
UNDERSTANDALLWARNINGS,INSTRUCTIONSANDOTHERINFORMATIONINTHIS
INSTALLATIONMANUAL,INCLUDINGTHEGLOSSARYOFTERMS.
ONLYEXPERIENCEDINSTALLERSSHOULDPERFORMTALLTOWERINSTALLATIONS.
DONOTATTEMPTTOINSTALLATALLTOWERIFYOUAREINEXPERIENCEDOR
UNTRAINED.TALL,GUYEDTOWERSANDTHEIRCOMPONENTSCANPOSE
DANGERSTHATCANLEADTOSERIOUSINJURYORDEATHTOYOUOROTHERS
AROUNDYOU.DONOTBEGINATALLTOWERINSTALLATIONUNLESSYOUHAVE
ASSEMBELDANEXPERIENCEDANDQUALIFIEDCREW.
USEONLYSUITABLETOWERANCHORSFORTHESOILTYPEATTHEINSTALLATION
SITE.STABILITYOFTHECOMPLETEDTOWERUNDERVARYINGCONDITIONS(E.G.,
HIGHWINDSANDICE),ANDSTABILITYDURINGINSTALLATION,DEPENDSONTHE
USEOFPROPERANCHORSFORTHESOILTYPEATTHEINSTALLATIONSITE.
FAILURETOUSEPROPERANCHORSCOULDCAUSETHETOWERTOFALL
RESULTINGINSERIOUSINJURYORDEATHORPROPERTYDAMAGE.CONSULT
WITHTHEAPPROPRIATEPROFESSIONALSTOFIRSTDETERMINESOILCONDITIONS
ANDTHENSELECTTHEPROPERANCHORSYSTEMBEINGSURETOFOLLOWALL
ANCHORMANUFACTURERSINSTRUCTIONS.
DONOTINSTALLATALLTOWERNEARELECTRICALPOWERLINES.METAL
TALLTOWERCOMPONENTSEFFICIENTLYCONDUCTELECTRICALCURRENTAND
CANRESULTINSERIOUSINJURYORDEATHIFTHEYCOMEINCONTACTWITHHIGH
VOLTAGEELECTRICALLINES.SURVEYTHEPROPOSEDINSTALLATIONSITEANDDO
NOTBEGINANYTALLTOWERINSTALLATIONIFANYELECTRICALLINESARE
PRESENT.
DONOTBEGINORCONTINUEATALLTOWERINSTALLATIONDURINGAN
ELECTRICALSTORM.IFLIGHTNINGSTRIKESATALLTOWERORITSMETAL
COMPONENTS,SERIOUSINJURYORDEATHCOULDOCCURTOTHOSEWORKING
WITHORAROUNDIT.DONOTBEGINANINSTALLATION,ORCONTINUEONE,
DURINGANELECTRICALSTORMORIFONEISIMMINENT.
WEARAPPROPRIATEPROTECTIVEGEARANDUSECAUTIONWHENUNPACKING
TALLTOWERCOMPONENTS.WEARGLOVESANDEYEPROTECTIONWHILE
UNPACKINGTHEENVIROCRATETOPREVENTCUTSANDOTHERINJURIESFROM
BANDSANDSHARPOBJECTS.HEAVYCOMPONENTSCANSHIFTIFNOTUNPACKED
CAREFULLYANDINTHEPROPERSEQUENCE.FOLLOWALLUNPACKING
INSTRUCTIONS.
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34m_TallTower_Manual.docx 16 December 2015
CARELESSNESSDURINGTOWERINSTALLATIONCANCAUSESERIOUSINJURYOR
DEATH.ANIMPROPERLYINSTALLEDTALLTOWERCANALSOCAUSESERIOUS
INJURYORDEATH.FORYOURSAFETYANDTHESAFETYOFOTHERSONTHE
INSTALLATIONCREW,ASWELLASTHOSEINTHEVICINITYOFACOMPLETED
TOWER:
ALWAYSDOTHEFOLLOWING:
OnlyinstallorremoveTallTowersusingexperiencedinstallationcrewmemberswhoarefamiliarwithall
TallTowercomponentsandsafeinstallationandremovalprocedures.
AlwaysfollowallinstructionsandwarningsintheTallTowerInstallationManual,aswellasallother
technicalinformationnecessaryforthesafeinstallationinaspecificlocation.
Alwaysconsultwithappropriateprofessionalstodeterminesoiltypeattheinstallationsiteandthenthe
mostappropriateanchorsystemforuseatthatsite.Followallanchormanufacturersinstructions.
Alwaysstandtothesideofanyguywireundertensionsothatyouarenotinthepathofaguywirethat
breaksorcomesloose.
Alwaysconsultwithappropriateauthorities(e.g.,theFederalAviationAdministration,localbuildingor
zoningdepartments,etc.)andsurroundinglandownersifaTallTowerisbeinginstalledinanagricultural
areatodetermineinstallationandtowermarkingrequirementssoastominimizerisktolowflying
agriculturalaircraft.
NEVERDOTHEFOLLOWING:
Neverbeginaninstallationwithaninexperiencedoruntrainedinstallationcrew.
Neverallowinstallationcrewmemberstocommenceworkunlessanduntileachcrewmemberhas
thoroughlyreadandunderstandstheinformationcontainedintheTallTowerInstallationManual.
Neverstandinadirectlinewithanyguywireundertensionasitcouldcauseseriousinjuryordeathifit
breaksorcomesloose.
NeverclimbaTallTower.
NevererectaTallTowerinanareawhereelectricalpowerlinesposeahazard.
NeverallowunauthorizedpersonsintheareawhereaTallTowerisbeinginstalled.
NeverbeginorcontinueaTallTowerinstallationduringhighwinds.
NeverbeginorcontinueaTallTowerinstallationduringanelectricalstormorwhenoneisimminent.
NeverusepartsforoneTallTowertocreateashorterTallTower;thiscannotbedonesafely.
RenewableNRGSystemsmanufacturesFAAcompliantpaintedtowersforuseinagriculturalareas.Inaddition,a
varietyofvisibilityenhancementaccessories,includingFAAcompliantaviationobstructionlightingkits,high
visibilitycableballkits,andguywireguards,areavailablefromRenewableNRGSystemsforusewithsuch
installations.
IftheinstallationofanMETisbeingproposedforanagriculturalareaorinremoteareaswherelowflyingaircraft
operate,RenewableNRGSystemsstronglyrecommendsthoseinvolvedintheprojectdoALLofthefollowing:
BecomefamiliarwithanyandallapplicableFederalAviationAdministration(FAA)towervisibilityandlighting
requirements,includingFAAAdvisoryCircularAC70/74601LObstructionMarkingandLightingdatedDecember
4,2015andasrevised,andensuretheinstallationcomplieswiththosestandardsandanyrecommendations
containedtherein,includingbutnotlimitedtothefollowing:
a.Voluntarymarkingofmeteorologicaltowerslessthan200feet(61m)AGLinaccordancewithmarkingguidance
containedintheFAAAdvisoryCircularAC70/74601L.
b.Paintingwithalternatebandsofaviationorangeandwhitepaintinaccordancewith Chapter3,paragraphs3.1
through3.4oftheFAAAdvisoryCircularAC70/74601L.
c.Utilizingseveralhighvisibilitysleeves(guyguards)onouterguywires.
d.Attachingsphericalmarker(cable)ballstotheguywires.Aviationorangemarkerballsshouldbeinstalled
accordingtoChapter3,paragraph3.5oftheFAAAdvisoryCircularAC70/74601L;
ContacttheFAAsObstructionEvaluation/AirportAirspaceAnalysis(OE/AAA)office(http://oeaaa.faa.gov)to
discusswhetheraNoticeofProposedConstructionorAlterationform(FAAForm74601)isrequired;
ContactthenearestFAARegionalorDistrictOfficeregardinginstallationreportingrequirements
(www.faa.gov/airports/news_information/contact_info/?s);
Becomefamiliarwithanyandallstateandlocalstatutes,ordinances,zoningorotherregulationsregardingtower
visibilityandlightingrequirements,assomestateshaveenactedstatutesorregulationsashavemanylocal
jurisdictionswhichmayaffecttowervisibilityandlightingandwhichmaydifferfromFAArequirements;
Contactlocalregulatoryagencies(e.g.,cityandcountybuildingdepartments)todetermineifthereareanylocal
zoningregulationsrelatingtotheinstallation;
Investigatewhetheragriculturalaviationispresentatoraroundtheinstallationsite(s)underconsideration,
includingcontactingstateandlocalfarmbureausand/orstateornationalagriculturalaviationorganizations(e.g.,
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34m_TallTower_Manual.docx 16 December 2015
NationalAgriculturalAviationAssociation[http://www.agaviation.org]),and;
Contactlocallandowners,farmingoperationsandagriculturaloperatorsandnotifythemofaproposedor
completedinstallation,includingspecificGPScoordinates.
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Introduction
TallTowerHistory
RNRGTallTowers,theoriginaltiltuptubulartowers,werefirstintroducedin1982andsoonbecametheindustry
standardtoquicklyandeasilygetsensorsupandintothewindtostartmeasurements.TallTowersaredeliveredin
completekits,assembledonthegroundandthentiltedupandsecuredwithguywires.
ConstructionandAssembly
TheRNRGTallTowerisofgalvanizedsteeltubeconstructionandisguyedatfourlevelsinfourdirections.
Sectionsslidetogetherwithouttheuseofboltsorclamps.Thetoweristiltedupfromthegroundwithaginpole
andwinch(winchisnotincluded).Liftingofthetowerisdonebyonesetofguywires(liftingwires)attachedtothe
ginpole.Thetowerisstabilizedsidewayswithtwosideguywiresets.Thebaseplateishingedsoboththetower
andginpolecanpivottotheerectedposition.
RequiredPartstoErectTowerSystem
RNRG34meterTallTowersaresuppliedcompletewithreadytoassembletubes,baseplate,guyrings,precutguy
wires,screwinanchors,groundingkit,andassociatedhardware.Screwinearthanchorsareincludedandare
suitableformanysoiltypes.Otheranchortypesareavailable.Itisyourresponsibilitytodeterminewhichtypeof
anchorisappropriateforyourspecificsite.
PleaserefertotheanchoringguidelinesinAppendixBofthismanualformoreinformation.
Awinchandginpole(ginpoleisincludedwiththepurchaseofthistower)arealsorequiredtoraisethetower.
Theginpoleforthe34mTallTowerisNOTcompatiblewithotherRNRGTallTowers.TheginpolesfromotherRNRG
TallTowersarenotcompatiblewiththe34mtower.
PleaseseetheGlossaryforpicturesanddescriptionsoftowerparts,hardware,andaccessories.
ExperienceRequired
IfyouhavenopriorexperiencewithTallTowerinstallation,seekassistancefromaqualifiedinstaller.
TowerLiftCrew
WesuggestthefollowingorganizationtoformanefficientandsafecrewtoerectRNRGTallTowers.Eachmember
oftheliftcrewshouldhaveagoodunderstandingofthetaskstheyarerequiredtoperformduringthelift.
FiveMemberCrew:
Crewleader:Thispersonwilloperatethewinchandcoordinatetheothermembers.Itisespeciallyimportantto
maintainclearcommunicationamongthemembersofthecrew.Thetowerfootprintislargeandwalkietalkie
radiosarehighlyrecommended.
Sideguywiretenders:Thesetwopeoplewillattendtoeachsideguyanchorandadjustsideguywires.Theymust
befamiliarwithtakinginandlettingoutguywires.Seethepicturesdescribingtheinchwormtechniqueforsafely
adjustingguywires.
Observers:Twopeopletoassistadjustingsideguys,tendingthebackguywiresattheendofthelift,andotherwise
observingguywires.
ToolsRequiredforvarioustasks
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inchnutdriver(forsensorinstallation)
5/16inchnutdriver(forhoseclamps)
7/16inch(11mm)socketwrenches(forwireropeclips)onepercrewmember
Largeadjustablewrench(forlargebolts)
1/2inchwrench,socketoropen(forbaseplateassemblyandunpacking
Pieceofrebarorsimilar(forturninganchors)
Handsledge(forgroundrods)
Smalladjustablewrench(foropening/closingacornclamps)
Smallpliers(forsensorcotterpins)
SmallPhillipshead(+)screwdriver(forsetscrews)
Flat()screwdriver(forantennamountingassembly)
Knives(tocutelectricaltape)onepercrewmember
Level,preferablywithamagneticbase(tostraightenthetower)
Compass(foraligningdirectionsensors)
Permanentmarker(forlabelinglowerendsofcables)
(2)12Vdeepcyclemarinebattery(forelectricwinch)
Hankmaster5000guywiretool(optional)
Gloves
2wayradiosorwalkietalkies
Electricdrillwith5/16inchbit(forunpackingandattachingtoptube)
Bandcutters(forunpacking)
2.5m(8feet)stepladder(forreachingendofginpoleonslopedsites)
Rebar,rockbolts,orsteelcabletosecuretowerbase
8woodposts(10cmx10cmx1m/4in.x4in.x3ft.)tosupporttower
Sawhorsetosupportginpole
Wirecutters
USEEXTREMECAUTIONWHENUNPACKINGHEAVYTALLTOWERCOMPONENTS.
LOOSETALLTOWERCOMPONENTSCANCAUSESERIOUSCRUSHINGINJURIES
DURINGUNPACKINGIFCAREISNOTTAKEN.ALWAYSFOLLOWUNPACKING
INSTRUCTIONSCAREFULLY,ANDUSESUFFICIENTINSTALLATIONCREWMEMBERS
TOREMOVETALLTOWERCOMPONENTSFROMTHEENVIROCRATEPACKAGINGIN
THEPROPERSEQUENCE.
WEARAPPROPRIATEPROTECTIVEGEARANDUSECAUTIONWHENUNPACKING
TALLTOWERCOMPONENTS.WEARGLOVESANDEYEPROTECTIONWHILE
UNPACKINGTHEENVIROCRATETOPREVENTCUTSANDOTHERINJURIESFROM
BANDSANDSHARPOBJECTS.HEAVYCOMPONENTSCANSHIFTIFNOTUNPACKED
CAREFULLYANDINTHEPROPERSEQUENCE.FOLLOWALLUNPACKING
INSTRUCTIONS.
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The34mTallTowerpackagingwasdesignedtoreducecardboardwaste,protectthetowercomponentsandallow
formoreeconomicalshipment.Allthetowercomponentsincludinganchorsandgroundkitarenowincludedin
onepackage.IfyoupurchasedthistoweraspartofanRNRGNOWSystem,theelectronics,sensorsandassociated
accessoriesarepackagedseparately.
Itisveryimportantthatyouunderstandhowtounpackthecontentsofthepackagingsafely.Therecommended
sequencetounpackthetowerisdescribedinthissectionofthemanual.
Thetubesmayshiftpositionsuddenlywhenbandsarecut,sopleasereadthissectioncarefullytoavoidserious
injury.
Toolsrequiredtounpackthe34mTallTower
5/16inchnutdriverorelectricdrillwith5/16inchbit
1/2inchwrenchforbolts
Bandcutters
Gloves
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AccessandOrientation
Ideally,youwillwantaccesstobothendsofthepackagingtounpackthecontents.Ifaforkliftisavailable,thatis
alsoideal.Removethe34mTallTowerpackagefromthetruckwiththeforkliftandsetitonanunobstructedflat
areabeforeunpacking.
Itisalsopossibletounpackthecontentswithaccesstoonlyoneendofthetowerpackaging.Forexample,the34
mTallTowermayhavebeenplacedintoatruckwithoneendagainstthefrontwallofthetruckscargoareaandno
forkliftavailabletoremoveitfromthetruck.Inthiscase,youwillbeabletofollowinstructionsinthissectionof
themanualtounpackthecontentsandunloadfromthetruckbyhand.
Note:YouwillNOTbeabletounpackthecontentsifthetowerpackagehasbeenloadedintoatrucksideways.Ifit
hasbeenloadedintoatrucksideways,youwillnothaverequiredaccesstotheendsandwillneedaforkliftto
removethetowerpackage.
UnpackSequenceVeryImportant!
Onceyouarereadytounpackthecontents,followthesesteps.Withthebandingcutters,cutthesinglehorizontal
band(#4)anddiscard.
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Figure1
Withthenutdriver(orpoweredscrewdriver),removethe4woodscrewsthatfasteneachendplateassembly
downtothewoodpallet.Setasidethe2endplateassemblies.Ifyoucanonlyremoveoneendplateassembly,that
isOK.Removetheendplateandsetaside.
Thetubecontentswillnowbeexposed.Beginningatthetop,removethecontentsofthetubes.Thesecontents
willinclude:screwinanchors,coilsofcable,groundrods,guyrings,rockerplates,andthehardwarekits.
Atthispoint,thereshouldonlybe152mm(6inch)diametertubesremainingonthepallet.Withthebandcutters,
cuttheouterbands(#2)andcenterband(#3)asshown.Removetubes.
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SiteLayout
PreinstallationPlanning
Itisagoodideatovisitthesitebeforeyouorderyourwindmeasurementsystem.Youwillneedtomake
arrangementsregardinghowtounloadyourtowersystem.Somesitepreparationmayalsobenecessary.
Duringthefirstliftofatower,themanyslipjointswillsettletothefullengagement.Duringthissettling,the
distancesfromthebasetoanygivenpointonthetowerwillshorten,andtheindividualtubesmayrotate.
Therefore,itisrecommendedthatthetowerbepreliftedbeforethesensorsarepermanentlyattached.The
preliftcanbeonlyafewfeet,buttheentiretowershouldleavetheground.Doingthisalsoisagoodwayto
avoidendangeringthebooms,sensors,andcablingshouldtherebeanunforeseenproblem.
SoilTypeandAnchors
Beforeorderingyourtower,researchthesitesoilandanchortyperequired.Itisyourresponsibilitytodetermine
whichtypeofanchorisappropriateforyourspecificsite.Dependingonthesoiltype,anchoringcantakevarying
levelsofplanning,effortandtime.Besuretoknowwhatsoiltypesyouaredealingwithaspartofyourpre
installationplanningprocess.
Note:(5)6inchdiameterscrewanchorsareincludedwiththetower.Otheranchortypesmustbeordered
separately.PleaserefertotheanchoringguidelinesinAppendixBofthismanualformoreinformation.
Tip:CellularCoverage
Thisisalsoagoodopportunitytoidentifywhattypeofcellularserviceisavailableatthesiteforthosewhowillbe
usinganRNRGiPacktotransmitdata.ContactusformoreinformationonRNRGiPacks.
SiteLayoutMap
Layoutlocationsforthetowerbaseplate,guyanchorsandthewinchanchor.Layoutthesitesothatthetoweris
laidoutdownwindofthebaseplatesothatthetowerwillbeliftedintothewind.Ifthesiteisonasteepslope,lay
outthesitesothatthetowerislaidoutuphillofthebaseplate.Unlesstheslopeissteep,itismoreimportantto
havethetowerliftedintothewind.
Measurecarefullytoplacetheanchorpoints,payingextraattentiontotheplacementofthewinchanchors.Verify
thattheanchorradiiandthediagonaldistancesbetweenanchorsarecorrect.
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USEONLYSUITABLETOWERANCHORSFORTHESOILTYPEATTHEINSTALLATION
SITE.STABILITYOFTHECOMPLETEDTOWERUNDERVARYINGCONDITIONS(E.G.,
HIGHWINDSANDICE),ANDSTABILITYDURINGINSTALLATION,DEPENDSONTHE
USEOFPROPERANCHORSFORTHESOILTYPEATTHEINSTALLATIONSITE.
FAILURETOUSEPROPERANCHORSCOULDCAUSETHETOWERTOFALLCAUSING
SERIOUSINJURYORDEATHORPROPERTYDAMAGE.CONSULTWITHTHE
APPROPRIATEPROFESSIONALSTOFIRSTDETERMINESOILCONDITIONSANDTHEN
SELECTTHEPROPERANCHORSYSTEMBEINGSURETOFOLLOWALLANCHOR
MANUFACTURERSINSTRUCTIONS.
Figure3:SiteLayoutMap(birdseyeview)
NOTE:TallTowerscanbeinstalledonslopesupto10.WhenlayingoutaTallTowerinstallationonaslope,measure
thecalculateddistancesalongthegroundtoplacetheanchors.Itisnotnecessarytocompensatefortheslope.
TallTowerguywiresarecutlongenoughtoallowforinstallationonslopesupto10whilemaintainingtheideal
anglebetweenthetowerandtheguys.
NOTE:Thesideguyanchorsandthebaseplateshouldbeonastraightline.Ifitisnotpossibletoplacetheminthe
locationsshown,itisbettertomovetheminoroutalongthelinetothebaseplatethantomovethemofftheline.
Donotmovethemmorethan1m(3feet)offtheline,althoughsomesitesmayrequireacompromisebecause
anchorsmaynotbeabletobelocatedatthepreferredspot.
NOTE:Extracarewillhavetobetakenwhileraisingthetowerif:
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34m_TallTower_Manual.docx 16 December 2015
Anchorplacementisnotperpendiculartothetowerasitlaysontheground.
Anchorsarenotatthesameelevation.
Sideanchorsandbaseplatearenotinastraightline.
NOTE:Anyoftheseconditionswillaffectthesideguywiretensionasthetowerisraised.Tensionwillhavetobe
adjustedperiodicallyasthetowerislifted.
Placementofthewinchanchoriscritical.Makesurethatyoumeasurecarefullyandsettheanchorheadscloseto
groundlevel.Anglealltheanchorstowardthetowerat45degrees.
Allthisisimportantforproperdistributionofforcesandforclearanceandproperoperationoftheginpole.SeeSite
LayoutMapandAnchortheWinchformoreinformation.
TowerAssembly
AssembletheBaseplate
Thebaseplatewillbelocatedaccordingtothesitelayoutmapdescribedintheprevioussection.Itisofteneasiest
toassemblethebaseplateinthislocation.Assemble4ofthe6largetriangularbaseplatesectionsasshownbelow,
inserting(8)5/16x3/4carriageboltsinholesclosesttothecenterofeachtriangularbaseplatesection.Leave
nutssomewhatloose;tightenbyhandonly.
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Flipoverthebaseplateassembly,andpropupononeedgewithablockofwoodtoallowaccesstoundersideof
baseplate.Attachverticalpiecestothecenterofthebaseplateasshownbelow,withbentedgesfacingoutward.
19
Installthegussets(4)asshownbelow.Besuretoinstallthegussetboltswiththecarriageboltheadawayfromthe
gussets.Tightenallboltsinthebaseplate.
Atthebeginningofalift,particularlyfortheginpole,thewinchforcesarelargelyhorizontal.Theseforcestendto
slidethebaseplatetowardthewinchand/ortipthebaseplateuponedge.Tocounteracttheseforces,itishighly
recommendedthatthebaseplatebeanchoredagainstslidingandtipping.Thereareseveralpossibletechniques
dependingontheterrain,soil,andsubsequentoperationsunderthetower.
RodsdriventhroughthebaseplateintothesoilWithfirm,deepsoil,driveseveralpiecesofrebarthroughthe
holesinbaseplateintothesoil.Anglethemawayfromthewinchandplaceasmanyaspracticalalongthe
baseplatefrontedge(farthestfromthewinch).
RockanchorstothebaseplateOnrock,orshallowsoils,attachrockanchorstothebaseplate,particularlyalong
thefrontedge.Theseshouldbepositionedandattachedtoholdtheedgeofthebaseplatedownaswellaskeepit
fromsliding.
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34m_TallTower_Manual.docx 16 December 2015
CabletotheGuyAnchorAcablemadeupasabridleconnectedtothetowerboltcanberuntotheinneranchor
oppositethewinchortoananchornearerthebaseplate.Seebelowfordetails.
Figure4
Drivegroundrodsthroughthebaseplateholessotheycanprovideadditionalanchoringforthebaseplate.
InstalltheAnchors
SeeAppendixB:AnchoringGuidelinesattheendofthismanualformoreinformationoninstallinganchors.
Dependingonthesoiltype,anchoringcantakevaryinglevelsofplanning,effortandtime.Besuretoknowwhat
soiltypesyouaredealingwithaspartofyourpreinstallationplanningprocess.
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34m_TallTower_Manual.docx 16 December 2015
Leavetheeyeofscrewinanchorsabout150mm(6inches)aboveground.
TubeLayout
Layoutthedisassembledtubesectionsonthegroundaccordingtosequencedescribed,beginningatthebaseplate.
Paycloseattentiontothelocationoftheguyrings.
SIUnits
Sequenceoftubesineachsection
Aguyringisplacedoverthelasttubelistedineachsection.
Section1 Section2 Section3 Section4
BaseTube+ (4)2.2m, (4)2.2m, (4)2.2m,
(4)2.2m, 152mmdia. 152mmdia. 152mmdia.
152mmdia. tubes tubes
tubes
Lifters Lifters Lifters Lifters
attachedto attachedto attachedto attachedto
thisguyring thisguyring thisguyring thisguyring
arecolor arecolor arecolor arecolor
coded: coded: coded: coded:
Red White Black Yellow
Table1
ImperialUnits
Sequenceoftubesineachsection
Aguyringisplacedoverthelasttubelistedineachsection.
Section1 Section2 Section3 Section4
BaseTube+(4) (4)87inch, (4)87inch, (4)87inch,
87inch, 6inchdia. 6inchdia. 6inchdia.
6inchdia. tubes tubes tubes
tubes
Lifters Lifters Lifters Lifters
attachedto attachedto attachedto attachedto
thisguyring thisguyring thisguyring thisguyring
arecolor arecolor arecolor arecolor
coded: coded: coded: coded:
Red White Black Yellow
Table2
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InstalltheBaseTube
Identifythebasetube.Thebasetubehasaholedrilledthroughtheflared(wider)end.Attachthebasetubetothe
baseplateusingthex8boltthroughthelowerholesinthecenterofthebaseplatesides.Securetheboltwith
theprovidednut.
Slidetubesectionstogetheruntiltheendoftheinteriortubeisinsertedallthewayintotheoutertubesflare.The
innertubewillbestopped.Aligningtheweldseams(visibleininterioroftube)ofeachtowersectionwillmakeit
easiertoslidethesectionstogether.Continuetoassemblethetubesandplaceguyringsoverthetubesaccording
tothesequenceabove.Makesuretheguyringisplacedsotheguyringcornersarebenttowardsthebaseplate,
andtheguyringcornersareinlinewitheachanchorpoint.Placewoodblocksevery5to6meters(1520feet)to
supportthetowerabovetheground,keepingthetowerasstraightaspossible.
Note:Donotuseoilontowerjoints.Thiscancausetowerfailureifthetubesselfflare.
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Attachsensorsandbooms
Assemblethesensors,sensorbootsandsensorsignalcablestothebooms.Wrapthesensorsignalcablestothe
boomasshownbelow.SecurewithweatherratedelectricaltapesuchasScotchSuper88.Securetheboomsto
thetowerwiththesuppliedhoseclamps.
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IfyoupurchasedthesensorsandboomsaspartofaNRGNOWSystem,cablingwassuppliedfor(1)34mlevel
directionvane,(2)34mlevelanemometers,and(1)20mlevelanemometer.Itisalwayseasiesttorunthecables
fromthesensorandboomsdownthetower.RefertoAppendixEforwindvanealignmenttips.
Spiralwrapyoursensorcables
Spiralwrapsensorcablesaroundthetower,onewrappertubejoint.Thespiralpromotesvortexsheddingand
reducesnaturalfrequencyoscillationsofthetower.Useelectricaltapetotapethesensorcablesandgroundcables
tothetowereveryfewmeters.Alsotapecablestothetoweraboveandbeloweachguyring.Wherethecables
crosseachguyring,protectthecablesbywrappingthemwithathicklayerofelectricaltapeasshownbelow.
AttachtheGuyWires
Organizeandlayouttheliftersandguywires
Sortoutandidentifytheguywiresandplacethreesetsateachguyringlevel.Theseguywiresareallthesame
lengthandareinterchangeable.Sortoutandidentifyeachlifterwire.ThelifterwiresareNOTinterchangeable.The
lifterwiresarecolorcodedandareassignedtotheguyringshowninthetablebelow.Youwillhave12guywires
and4lifterwires.AllwiresMUSTbeplacedcorrectly.
Highestlevel=4(yellow)
GuyRingLevel Length LifterColor
1 10.5m(34.56feet) Red
2 16.9m(55.45feet) White
3 24.3m(79.69feet) Black
4 31.98m(104.94feet) Yellow
Table3
Identifythelifterwireforeachlevel.Itisrecommendedthatbackguywires(theguywiresoppositethewinch)are
attachedtotheirguyrings,rolledout,andsecuredtotheiranchorsfirst,followedbythesideguywirestoeliminate
crossing.
Shackleguywirestotheguyrings
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Securethebackguywiresfirsttotheircorrespondingguyringsusingtheshackles.Attachtheguywirestotheguy
ringholesunderthetowertube.Rolloutthebackguywirestotheiranchorpointsandsecureasdescribedbelow.
Nextsecurethesideguywirestotheircorrespondingguyringsusingtheshackles.Theseguywireswillattachto
thesideguyringholes.Rollthesideguywiresouttotheiranchorpointsandsecureasdescribedbelow.
Rollouteachguywirefromthetowertoitsanchorpoint
Rolloutsideandbackguywiresfromtheirguyringstotheiranchorpoints.Donotallowtwistsorkinksintheguy
wires.Theguywireandliftercoilscanbeuncoiledinahandoverhandmethodwhilewalkingouttowardseach
anchororunrolledusingaHankmaster5000tool(seeAppendixF).
CORRECT
Donotunspoolcableoffthesideofthecoilasshownbelow.
NO!
TheHankmastercanbeusedtorolltheguywiresouttotheanchors.SeeAppendixFforinstructionsforbuilding
andusingaHankmaster.
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Passthesplitringsthroughtheeyeofeachshacklebolttokeeptheshacklepinsfromloosening.
Secureguywirestotheanchors
Secureguywirestothebackandsideanchorsbythreadingthecablethroughtheanchorloopandclampingthe
cableontoitselfusing3wireropeclips.Forthebackguywiresitisrecommendedthatthedistancetothesideguys
foreachcorrespondinglevelbeusedasareferencedistanceforattachingtothebackanchors.Placethewirerope
cliponthewiresothesaddle(theforged,groovedpart)cradlesthewirecomingfromthetowerandtheUbolt
partclampsdownonthedeadendoftheguywire(Neversaddleadeadhorsemayhelpyoutorememberhowto
securethewireropeclips).
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Leavealittleslackintheguywire,andtightenthewireropeclipnuts.Donttightenthewireropeclipnutstoo
tightly;youwillneedtoadjusttheguylengthnumeroustimesasthetoweriserected.
Shacklelifterwirestotheguyrings
Securethelifterwirestotheguyringholesonthetopofthetowertube.Carefullylayouttheliftersinanorderly
fashion.Theunattachedendscaneasilybecomeentangledaroundeachotherandtheotherguywireslyingonthe
ground.Makesurethatallbackandsideguywiresareunderneaththelifterguywires.Keepingthelifterwires
organizedwillavoidhavingtostopduringtheliftprocesstountanglethelifters.
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AssembletheGinPole
Layouttheginpoletubes
Identifytheginpoleandhelperginpoletubesandhardware.RefertotheGlossaryinAppendixDforpicturesand
descriptionsofginpoleparts.
Attachtheginpolebasetubetothebaseplate
Theginpolebasetubewilllieontopofthetowerbasetube.Placetheginpolebasetubewithholebetweenthe
baseplatesverticalchannels.Insertthesafetycableintotheginpolebasetube.Lineuptheholesintheginpole
basetubewiththeholesinthebaseplatesverticalchannelsandinsertthex8boltthroughthebaseplateholes
andtheeyeinthesafetycable.Securetheboltwiththeprovidednut.
Slidetogetherthe4tubesthatcomprisetheginpole
Slidesectionstogetheruntilahardstopisreached,andthreadthesafetycablethrougheachtubeasitis
assembled.Aligningtheweldseams(visibleoninterioroftubes)ofeachtowersectionwillmakeiteasiertoslide
thesectionstogether.Placealog,sawhorse,orothertypeofsupportunderneaththe3rdor4thsectiontoslightly
raisetheginpolefromthetower.
Slidethetopginpolesectiononsothattheholesintheginpoletopareparalleltotheground.
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Attachtheginpoletopmountinghardware
Bolttherockerplatestothetopsectionoftheginpolewiththelargebolt(3/4inchx8inches),makingsurethatthe
boltgoesthroughtheeyeoftheginpolesafetycable.
Ginpole
safetycable
Alsoplacethe(2)suppliedgraded5/16x3/4boltsattheendsoftherockerplates.Attachthe(2)quicklinksto
theholesonthebottom(sidetowardstower)oftherockerplate.
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Usingatwopartlinetoliftthetowerisoptional.Ifliftingthetowerwithasinglepartline,theturningblockand
oneoftheshacklesarenotneeded.Simplyattachthethimbleendofthewinchcabletotheshackleontherocker
plateasshownbelow.
Ifusingatwopartlinetoliftthetower,shacklethewinchcableturningblock(notsupplied)totherockerplates
usingthe(2)shackles(notsupplied)placedthroughtherockerplateholeshowninthepicturebelow.
Yourtowerwassuppliedwitha45.7mlengthof12mm(1/2inch)diameterbrownpolypropylenerope.Cutthe
ropeinhalftomaketwo22m(75ft.)pieces.Tieonepiecefromeachsideanchortothetopoftheginpoleto
stabilizetheginpolewhileitisbeingraised.
Warning:Failuretousetheginpoleropescouldcausetheginpoletofallovertoeithersideduringthelift.Besure
totiethesafetyropessecurelytothesideanchors;theginpoleisveryheavy,andthesafetyropescantbe
controlledbyhand.
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NOTE:Thegreatestloadseenbytheendoftheginpole(andthewinch)is907kg(2000lbs.).Thewinchcable
mustbe6mmdiameterandatleast24m(80ft.)longsothatitcanreachtheendoftheginpole.Sizeyourwinch
andriggingaccordingly.Anextraanchorhasbeensuppliedwiththe34mtowertoanchorthewinch.
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Attachthelifterwires
Attacheachofthefourlifterwirestotheginpoleusingthesuppliedquicklinks.Besuretoconnecttheminthe
properorderandmakesuretheyarenottangledwitheachotherorsideorbackguywires.
Configurethehelperginpole
Putthehelperginpolestandingvertically(pulleyspointingtowardsthesky)onthebaseplatebehindthemain
ginpole.Lineuptheholesinthehelperginpolewiththeholesinthebaseplatesverticalchannels.Slidethex8
boltsthroughholestosecureinaverticalposition.Securetheboltswiththeprovidednuts.Thehardwarekit
containstwo5diameterpulleysandanaxlebolttobeusedonthetopofhelperginpole.Ifyouareonlyusinga
onepartlinefromthewinch,thesecondpulleyisnotneeded.
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ALWAYSSECURETHEWINCHTOAWINCHANCHOR.FAILURETOUSEAWINCH
ANCHORCOULDCAUSEEXCESSIVELOADSONTHEVEHICLEUSEDTOSUPPORTTHE
WINCHANDWINCHPLATE.EXCESSIVELOADSCANRESULTINTHEVEHICLEBEING
HOISTEDINTHEAIRCAUSINGSERIOUSINJURYORDEATHORPROPERTYDAMAGE.
NEVERRELYONANUNSECUREDWINCHANDSUPPORTPLATEALWAYSUSEA
WINCHANCHOR.
ALWAYSMONITORTHEWINCHCABLETOENSUREITWINDSONTOTHEWINCH
DRUMEVENLY.UNEVENWINDINGCOULDRESULTINCABLECROSSOVERAND
CABLEDAMAGEORFILLTHEWINCHDRUMPREMATURELY.TOAVOIDDAMAGE
TOTHEWINCHCABLEANDPROVIDEFORSUFFICIENTCABLELENGTHDURINGTHE
TOWERRAISINGPROCESS,HAVETHEWINCHOPERATORENSUREEVENWINDING
ONTOTHEWINCHDRUM.
GinpoleTiltUp
Confirmallliftersandshacklesaresecure
Carefullydoublecheckallconnectionpointstomakesureeverythingissecurebeforestartingtolifttheginpole.
Lifttheginpole
Makesuretheginpoleremainscenteredsidetosideandthatthebrownropesarebothsnug.Iftheginpoleisoff
center,carefullyadjusttheropestorecenter.Astheginpolecomesup,removethehelperginpolewhenthewinch
cableisnolongerincontactwiththepulleysontheendofthehelperginpole.Payattentiontothelifterstomake
suretheyarenotcaughtonobjectsinthearea(stumps,debris,rocks,equipment,etc.).Alsocheckthattheyare
notcrossedovereachotherortheotherguywires.Asthelifterwirestighten,stop.
Donotliftthetoweryet.Checkthattheshacklesarenottwistedattheguyrings.
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TowerTiltUp
UnderstandingGuyWireTensioningWhileRaisingTallTower(Donotraisethetoweryet)
Asatowerisraised,unlesstheanchorsareplacedinpreciselytheircorrectpositions,andunlessthesiteis
perfectlylevel,someguywireswilltightenandsomewillloosenasthetowerisraised.Thesameistrueasatower
isloweredonthesamesite.Forthisreason,guywiretensionmustbecheckedandadjustedasneededtomaintain
uniformtensionuntilthetowerinstallationprocedureiscomplete.
Awirethatbecomestootightcanputveryhighforcesonboththeanchorandthetower.Thisforcecanrapidly
growifthetowerliftingorloweringprocedurecontinues.Thesehighforcescansuddenlybucklethetowerand
causeittofall,endangeringthetowerinstallationcrewandpossiblydamaginganyvehiclesorequipmentnearby.
Donotletthetowerbebowedtothesidemorethantwotubediametersawayfromastraightline.Ifthetoweris
bowedmorethanthis,thesideguysshouldbeadjustedtostraightenthetower.
Itiscriticallyimportantthatpropertensionbemaintainedonsideguywiresatalltimesduringtheliftingprocedure
toprovidesidesupportforthetower.Toolittletensioncanallowthetowertobuckletotheside.Toomuch
tensionmaycausefailureofthetower,anchors,orguywires.Theremustalwaysbevisibleslackintheguywires.
Ifnoslackisvisible,thetensionistoogreat.
Oncethetowerisvertical,twopeopleofaveragesize,pullingbyhand,canproperlytensiontheguywires.
MECHANICALTENSIONINGDEVICESSHOULDNEVERBEUSEDTOADJUSTGUYWIRESONTHE34MTOWER!!
Besurethatguywiresdonotgetcaughtontreebranches,roots,rocks,orotherobstructions.
Thissequenceofobserving,communicatingobservations,issuingcommandstoguywiretenders,adjustingtheside
guywiresandretighteningwireropeclipsmustbewellunderstoodbeforeliftingatower.Thesequencewillbe
repeatedmanytimesbeforeatowerinstallationiscompletedonallbutthemostflatandlevelsites.
AdjustingGuyWires(theInchwormmethod)
LooseningGuyWires
Asthetowerisraised,thesideguysmaybecometight.Toadjustthecable,startbymakingsurethe3wirerope
clipsaresecure.Tightenusingawrench.Then:
1)Loosentheupperclipandpullalengthofthetailthroughtheclip,creatingaloopasshownbelow.Tightenthe
uppercliptotraptheloopbetweentheupperclipandthelowerclips.
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2)Nowloosenthelowerclips,looseningthelowestclipslowly,allowingthelooptoslide,whichwillslackenthe
guywire.
3)Retightenthelowestwireropeclip.
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4) Repeatasnecessaryfromstep1tocreatethepropercabletension.
TighteningGuyWires
Aswithloosening,makesuretostartwithall3wireropeclipssecure.Tightenusingawrenchasshownbelow.
Then:
1. Loosenthelower2wireropeclipsasshownbelow.
2. Pull the 2 cables apart to form a loop (similar to the loop made while loosening), then tighten the
lowest rope clip to trap the loop between the upper and lower rope clips as shown below.
3. Loosentheupperropeclipandpullthetailtoremovetheloop.
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4. Finally,tightentheupperclip.
5. Repeatasnecessaryfromstep1totightenthecable.
LifttheTower
Whenallcrewmembersareready,thewinchoperatorwillbegintoliftthetower.Rememberthatmostelectric
winchesaredesignedforintermittentuse,andfrequentrestsmustbetakentopreventthewinchmotorfrom
overheating.Helpthecabletowindevenlybyusingthewinchcontrolhandletomovethewinchmotorfromside
toside.
CAREFULLYMONITORANYWINDDURINGTHELIFTASWINDBLOWINGINTHE
DIRECTIONOFTHELIFT(TOWARDTHEWINCH)CANCAUSEDANGEROUS
INSTABILITYANDALOSSOFCONTROLOFTHETOWER.IFTHETOWERBECOMES
UNSTABLEDURINGTHELIFT,SERIOUSINJURYORDEATHCANOCCUR.ALWAYS
MONITORBACKGUYWIRETENSIONDURINGTHELIFTTOENSUREPROPER
RESISTANCEISPROVIDEDTOPREVENTINSTABILITY.
Warning:Allowingthecabletowindunevenlywillresultincrossoversthatwilldamagethecableandfillthewinch
drumbeforethetowerisfullyraised.
Liftthetowerabout1m(3feet)offthegroundwhilecheckingsideguytensions.Theliftersaresetuptoproducea
slightbowinthetower,withthetop0.15mto0.3m(6to1foot)higherthanthemiddle(werefertothisasa
positivecurve).Thisisnormal,anditneedstobemaintainedthroughouttheentirelifttoavoidtowerbucklingor
collapse.Adjustthesideguywiretensionstopreventthetowerfromeitherfallingofftoonesideorbowingwhich
coulddamagethetower.
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Warning:Thetowermustremainstraightsidetosideandmaintainapositivecurveasdescribedabove.Failureto
maintainthepropershapecancausethetowertocollapse,endangeringthecrewandequipment.Thisisthe
higheststresspointofthelift.
Watchthewinchanchorsformovement.Themaximumliftingforcewillbeexperiencedwhenthetowerisfirst
liftedafewfeetofftheground.Ifthewinchanchorswillnothold,eithertheanchorwasnotinstalledcorrectlyor
anothertypeofanchorisneeded.SeeAppendixB:AnchoringGuidelinesformoreinformation.
Watchthetowerbaseplateformovementtowardthewinch.Ifeitherthewinchanchorswontholdorthe
baseplateslips,immediatelylowerthetower.
IfeverythinglooksOK,continuetoliftthetoweralittleatatime,checkingsideguytensionalongtheway.At
times,itmaybenecessarytoadjustthesideguywiretension.DothisONLYwhenthewinchisstopped.Readjust
withwireropeclips,lettingcableoutorpullingloosecablein(seeinchwormtechnique).Workslowlyand
smoothly.Fast,unevenmovementstendtomakethetowerbounce,shakeorswing.Be sure that
communicationbetween all members of the lifting team is clear and concise. Continueliftingandadjusting
untilthetowerisabout60degreesabovehorizontal(justabovehalfway).STOP.
Beyond60degreesabovehorizontal,itisabsolutelyessentialthattensionismaintainedonthebackguywires
duringthelastpartofthelift,particularlytheguywiresatlevels2and3.Excesstensiononlevel4willremovethe
positivecurveshapefromthetowerandpotentiallycauseacollapse.Sodontdoit.Thetowerwillliftveryeasily
atthispointbecausetheweightoftheginpoleandwinchwillbeenoughtotipthetowerwithoutpoweringthe
winch,causingtotallossoftowercontrol.Anywindblowinginthedirectionoftheliftwillalsohelpreducetheload
onthewinch.Therefore,thecrewmustcontroltheliftfromthispointonusingthebackguywires.
Beforecontinuingthelift,adjustthebackguywirestotakeouttheexcessslack.
Continuetheliftbyalternatelypoweringthewinchandsmoothlyandincrementally(afewfeetofguywireata
time)lettingoutonthebackguywires(inorderfromtoptobottom)usingtheinchwormtechnique.Donot
completelyremoveslackinbackguywiresbyrunningthewinchtoolong.Continuethisprocessuntilthetopofthe
towerisdirectlyoverthebase(sightwithacarpenterslevel).
Warning:Avoidwinchingintoomuchcable(tothepointwherethepulleycollideswiththewinch).Ifthepulley
andwincharewinchedtightlytogether,thewinchcablecanbreak,causingtotallossoftowercontrol.Pleasenote
thatthewinchsmotorhasaslightlydelayedresponseaftertheswitchisreleased,andwhilecoastingtoastopmay
produceenoughforcetobreakthewinchcable.
Recheckthatthetensioninthebackguywiresandinthesideguywiresissetupcorrectlytoabout23kg(50
pounds)oftension,allowingsomeslackineachguywire.Checkthatwireropeclipsaresecure.
TransferLifters
Next,youwilltransfertheliftingguywiresoneatatimefromtheginpoletotheirrespectiveanchors.Youwill
secureeachlifterguywirewithwireropeclips.Rememberthatwhilethelifterisdisconnected,youwillbeholding
thetower!Maintaintensionwhiletransferringtheguywires.
Asmentionedbefore,itisnormaltohavethetowerbowedslightlyawayfromthewinch.Asyoutransferthe
lifters,youmayhavetoaddalittleslacktothemiddlelevelbackguywirestoallowthetowertostraighten.
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Transfertheliftersoneatatimefromthequicklinksontheginpoletotheiranchor.Secureeachwithwirerope
clips.Rememberthatyouwillbeholdingthetower.Maintaintensionwhiletransferringthewires.Startwiththe
toplifterlevel(level4yellow).Adjusttheguytensiononthelifterandtheguyoppositetopullthetowerstraight
andvertical.Workingdownward,transferthelowerlevelliftersoneatatimetotheiranchorposition.Again,check
thetensiononthelifteranditsoppositeguywireaseachistransferred.Tokeepthetowerstraight,itmaybe
necessarytowinchoutslightlyandoradjusttheoppositeguywiresastheliftersaretransferred.Asyouremove
thelastlifter,lowertheginpoletotheground.
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PlumbandStraighten
Makefinaladjustmentstotheguywires.Usingacarpenterslevelonthebasetube,adjustthelowestlevelguy
wiresasneededsothebasetubeisvertical.Workingupward,adjustallfourguywiresateachlevelwhilesighting
upthetowerfromthebasetostraightenthetower(seepicturebelow).
Asyoufinalizethestraighteningofthetower,youwillneedtosetthefinaltensionontheguywires.
PROPERGUYWIRETENSIONISCRITICAL.FAILURETOENSUREPROPERGUYWIRE
TENSIONCANCAUSEAFAILUREOFTHETOWER,GUYWIRESORGUYANCHORS
RESULTINGINSERIOUSINJURY,DEATHORPROPERTYDAMAGE.ONCELIFTED,
ALWAYSREADANDFOLLOWINSTRUCTIONSFORMEASURINGANDREACHING
PROPERGUYWIRETENSION.
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FinalInspectionandMaintenance
Tighten all wire rope clips on each guy wire now, with about 100 mm to 200 mm (4 inches to 8 inches) between
clips. Recheck that all wire rope clips are tight. Final torque on wire rope clips should be 20 Nm (15 ftlb) for 1/4
inch wire rope clips. The ginpole may be left in place, or it may be removed and disassembled if desired. If using
guyguards,attachonetoeachguywireandonetothewinchanchorasshownbelow.
Checkthetowerin2or3weeks;tightenlooseguywiresandstraightenthetowerifneeded.Itisespecially
importanttodothisbeforeanyicingeventsoccur.Alsochecktheguywiresafteranysevereiceorwindstorm.
Somesettlingofthetoweroranchorsmayoccur,andguywirescanstretch.Looseguywirescanalsoresultwhen
thewireropeclipssecuringtheguysareforceddownbytheimpactofslidingice.
Oneofthemostimportantreasonsforgoodtowermaintenance,particularlyguytensionmaintenance,istoavoida
formoftowerfailureknownasSnapThrough.SnapThroughtypicallyoccurswhentheguysareallowedto
becomeloose,andahighwindisblowingonthetower.Eveninnormalconditions,theupperguysworkata
narrowerangletotheuppertowerthanthelowerguys,reducingtheireffectivenessatrestrainingsideways
bending(seefigurebelow).Iftheguysareallowedtobecomeloose,theworkingangleisfurtherdecreased.Ifthe
loadsarehighenough,ortheguysaretooloose,theanglebetweentheguyandthetowerwillreducetozero,and
theguycannolongerrestrainthesidewaysmotion.Theresultisthattheuppertowersnapsthroughandfalls
over.
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Figure8
TowerLowering
Loweringthetoweristhereverseofraisingthetower,thoughthereareafewadditionalprecautionstobetaken.
Justassideguywiretensionmayvaryduringtheliftingprocess,thesameistrueasthetowerislowered.Sideguy
wireswillhavetobetendedinordertomaintainproperguytension.
Iftheginpolewasremoved,setuptheginpoleasdescribedpreviously.Rememberthattheextensionsofthe
couplerplatewillnowbefacingtheground.Ifthetowerwillbeloweredontoblocking,placetheblockingnow
whileitisstillsafetoworkunderthetower.Lifttheginpoleandtransferthelowestlevelliftingguywirefromthe
anchortotheginpole.Rememberyouwillbeholdingthetower:maintaintensionwhiletransferringthewires.
Winchinoroutasneededtomaintainthecorrectamountoftensionintheguywirewhenitistransferred.The
winchcablemustalwaysspoolandunspoolfromthebottomofthecabledruminorderforthewinchbraketo
workproperly.
Transferthelifterguywiresfromtheanchortotheginpole,inorderfromlowesttohighest.Tensionmustbe
appliedtothebackguystopullthetowerawayfromthewinchasyoubeginlowering.Thiskeepswindloads
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and/ortheweightoftheginpolefromsuddenlypushingthetowerbackupright,whichcouldcauseguywireor
anchorfailure.Leavetheguywireattachedtotheanchorandpulloutwardontheguywiretotakeouttheslack.
Thesafestwaytodothisisbytyingaropearoundtheguywire.Thisallowsthecrewmemberstomaintaintension
byhandwithoutbeingunderthetower.
Maintaintensiononaminimumofonemidlevelandonetoplevelguywireduringlowering.Usetwocrew
memberstotendtwotoplevelandtwomidlevelguywires.Thesecrewmembersshouldmaintaintensioninthe
backguysandtakeuptheslackintheguywireasthetowerlowerstowardthem.
ALWAYSMAINTAINPROPERTENSIONONGUYWIRESDURINGTHELOWERING
PROCESS,ESPECIALLYWHENTHETOWERISBETWEEN90AND75.FAILURETO
MAINTAINPROPERGUYWIRETENSIONCANCAUSEDEFORMATIONOROTHER
DAMAGETOTHETOWER.ALWAYSREADANDFOLLOWLOWERINGINSTRUCTIONS
FORINCREMENTALLOWERINGANDCAREFULLYUTILIZETHEINCHWORMMETHOD
SETFORTHINTHEINSTALLATIONMANUAL.
Asthetowerisloweredandreachesanangleofbetween75and60degrees,itwillnolongerbenecessaryto
maintaintensiononthebackguywires.Stopthewinchatleastasoftenaseach20degreestorechecksideguy
wiretensionandtoallowthewinchtocoolforaminute.
Warning:
Theforceonthewinchisgreatestasthetowernearstheground.Besuretostandtoeithersideofthewinchcable
andbehindthewinch,batteries,andpowercablesratherthandirectlyinlinewithit.
Tolowertheginpole,putthehelperginpoleinplace.Astheginpolenearstheground,placethewinchcable(both
strandsifusingatwopartline)inthe2pulleysonthetopofthehelperginpole.Thepolecanthenbeloweredto
theground.
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AppendixA:34mTallTowerDimensions
TowerLayout
46
SiteLayout
47
BaseplateGeometry
49
Localutilitycompaniescanoftenprovideusefulinformationregardinganchoringusedinthesitearea.Donotuse
rebaranchors,especiallywhenthesurfacesoilsarelooseorwet.
Table6:SoilClasses
AnchorChoicesandotherconsiderations
Thechoiceofanchorsmusttakeintoconsiderationsoiltype,maximumwindsexpected,icingorotherweatherthat
mayaffectthetower,andasafetyfactorsuitableforthelocationandtomeetanylegalrequirements.
Considerationsincludebutarenotlimitedto:tornadoes,hurricanesortyphoons,locationswhereveryhighwinds
areexpected,potentialforfloodingorperiodicsoakingofthesoil,soilerosion,andicingevents.
ScrewInAnchordescription
Screwinanchorsarethemostcommonlyusedanchorsfornormalclaysoilswithoutrocks.Theyareinstalledby
hand,usingacrossbartoscrewthemintotheearthlikeacorkscrew.
Screwinanchorscanalsobeusedtoprovidetheanchoringrodandeyeforsitebuiltanchors,suchasconcrete.
Refertotheinformationonconcreteanchorsbelow.150mm(6.0inches)diameterscrewinanchorsarethe
standardanchorssuppliedwithRNRGTallTowers.203mm(8.0inches)diametersscrewinanchorsareavailable
uponrequest.
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Table7:Specificationsfor152mm(6inches)diameterScrewInAnchors
**Inclass7soils,itisadvisabletoplaceanchorsdeepenoughtopenetratetounderlyingclass5or6soil.
Table7A:Specificationsfor203mm(8inches)diameterScrewInAnchors
**Inclass7soils,itisadvisabletoplaceanchorsdeepenoughtopenetrateunderlyingclass5or6soil.
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ArrowheadAnchordescription
Arrowheadanchorscanpenetratestiffandrockysoilsbecausetheuniquetriangulardesignthreadsitsway
betweenobstaclessuchasrocks,whichcanpreventsuccessfulinstallationofscrewinanchors.Arrowheadanchors
aredrivenintothegroundwithahardenedsteeldriverod.Onceintheground,upwardforceontheattached
cablerotatestheanchorperpendiculartothecableformaximumholdingpower.
Table8:SpecificationsforArrowheadAnchors
**Inclass7soils,itisadvisabletoplaceanchorsdeepenoughtopenetrateunderlyingclass5or6soil.
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RockAnchordescription
Rockanchorsareplacedintosolidrock,whenanchoringtoeitherbarerock,orthinsoilswithsolidrocknearthe
surface.Theyareconstructedofathreadedrodwithintegraleye,andtwoopposingwedgehalves.Theanchoris
placedinaholepredrilledintherock.Twistingtheeyeoftheanchorforcesthewedgesagainstthesidesofthe
holeandlockstheanchorinplace.Loadactuallyincreasesthewedgingforce,developingholdingpowerequalto
thefulltensilestrengthoftherod.
Table9:SpecificationsforRockAnchors
ConcreteAnchordescription
Themostcommonalternativeanchoringsystemistoplacesitebuiltconcreteanchors.Aholeisexcavatedatthe
anchorposition.Reinforcingsteelisplacedinthehole.Ascrewinanchorisoftentiedintothereinforcingsteelto
providearodandeyeabovegroundtoattachtheguys.Concreteispouredinplacetoformtheanchoringmass,
andtheholeisthenbackfilled.
Theanchorsmustbeplacedcarefullytoprovideanchorpointsattheproperlocationsforthetower.Theholding
powerofconcreteanchorsisessentiallyduetotheirweight.Theweightofconcreteplacedmustexceedthe
requiredanchorholdingforce.Concreteanchorsstilldependonthesoiltopreventtheconcretemassfrom
shiftingtowardthetowerunderload.
Aswithallanchoringsystems,itisyourresponsibilitytoensurethattheanchorswillperformasrequired.Ifin
doubt,seekprofessionaladviceforanchordesign.
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InstallingScrewInAnchors
Note:Unlikeatentstake,screwinanchorsareinstalledinlinewiththepulloftheguywiresfromthetower.Itis
importanttoinstalltheanchoratanangle,sotheeyeoftheanchoristowardthetowerandthehelixscrewsin
awayfromthetower.Iftheanchorisincorrectlyinstalledstraightintotheground,theloadwillbendtherodand
pullitthroughtheground,allowingtheguystogoslack.RefertotheappropriatestampeddrawingintheAppendix
todeterminetheangleofthetowerguysfromtheground.
Figure9:InstallingScrewinAnchors
Screwtheanchorintothegroundbyplacingastoutbarthroughtheeyeoftheanchor,androtatingclockwise.Itis
sometimeshelpfultostarttheanchorintothegroundstraightdownforthefirstturn,thenpushitdowntothe
correctangleandcompletetheinstallation.Continuescrewingtheanchorintothegrounduntilabout150mm(6
inches)oftheanchorrodremainsabovetheground.
Iftheanchorcannotbeinstalledduetorocksinthesoil,orotherobstacles,tryplacingtheanchorasmuchas1m
(3feet)fromitsidealpositiontoavoidtheobstacle,orreplacethescrewinanchorwiththecorrectanchorforthe
soil.Arrowheadanchorsareoftensuitableforrockysoils.
Ifnecessary,aholecanbedugforthescrewinanchortotheproperinstalleddepth,theanchorplacedinthehole,
andtheholebackfilled.Theearthmustbetampedontotheanchorhardwhilebackfilling.Theholdingpowerof
ananchorplacedthiswaywillnotbeasgreatasananchorscrewedintoundisturbedsoil.Ifindoubt,get
professionaladviceonwhetherthisoptionwillworkforyoursite.
InstallingArrowheadAnchors
Arrowheadanchorsaredesignedforallsoilsbutareespeciallyeffectiveinrockysoils.Thearrowheadanchoris
drivenintothesoilwithadriverod.Therodisremovedandtheanchorisleftintheground.Thentheanchormust
bepretensionedwhichwillcausetheanchortorotateinthegroundanddevelopitsfullholdingpotential.
Likescrewinanchors,thearrowheadanchormustbeplacedsotheforcefromtheguywirespullsdirectlyonthe
anchor.Drivethearrowheadanchorawayfromthetoweratanangleintotheground.Refertotheappropriate
stampeddrawingintheAppendixtodeterminetheangleofthetowerguysfromtheground.
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Note:Itisimportanttodrivetheanchoratanangle.Iftheanchorisincorrectlyinstalledstraightintotheground,
theloadwillresultintheanchorcablecuttingthroughthegrounduntiltheangleiscorrect,resultinginsignificant
slackinthetowerguys,andpossibletowerfailure.
Figure10:InstallingArrowheadAnchors
Toinstalltheanchor,placethedriverodovertheanchorsshank.Drivetheanchorintothesoilusinga
sledgehammer,fencepostdriver,orpowerjackhammer,untilthecableeyeattachedtotheanchoris50mm(2
inches)to100mm(4inches)abovethesurfaceoftheground.
Aftertheanchorisdriven,removethedriverod,leavingtheanchorintheground.Theanchormustnowbepre
tensionedbyapplyingstraintothecable.Thiscanbedoneusingalever,comealong,jack,orwinch.Pre
tensioningcausestheanchortorotateinthegroundanddevelopitsfullholdingpower.Thepulldistancewillbe
approximatelythelengthoftheanchorhead,203mm(8inches).Thetensionshouldbecomesignificantlyhigheras
thepretensioningiscomplete.
Note:Theanchormustbeproperlypretensionedbeforeattachingthetowerguys.Ifitisnot,thetowerguywire
tensionwillturntheanchorlater,resultinginsignificantslackintheguywiresandpossibletowerfailure.
InstallingRockAnchors
Rockanchorsareusedwhenanchoringtoeitherbarerockorthinsoilswithsolidrocknearthesurface.Likeany
anchor,rockanchorsmustbeplacedsotheforcefromtheguywirespullsdirectlyontheanchor.Drilltheholefor
theanchorawayfromthetoweratanangleintotheground.
Note:Itisimportanttoinstalltheanchoratanangle,sotheeyeoftheanchoristowardthetowerandthe
expandingpartoftheanchorpointsawayfromthetower.Iftheanchorisincorrectlyinstalledstraightintothe
ground,theloadwillbendtherodandpullitthroughtheground,allowingtheguystogoslack.Refertothe
appropriatestampeddrawingintheAppendixtodeterminetheangleofthetowerguysfromtheground.
Toinstalltheanchor,aholemustbepredrilledintherockbyhandorpowertool.Theholemustbe50mm(2
inches)indiameter,andthewallsoftheholeshouldbesmoothintheareathattheanchorwillwedge.
Placetheanchorinthehole.Usingabarthroughtheeyeoftheanchor,turnclockwisetotighten.Theanchorwill
expandandwedgeintothehole.
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Afterplacingtheanchor,filltheholearoundtherodwithexpandingcementgrout.OnebrandisRockitemade
byHartlineProductsCo,Cleveland,OH,USA(telephone:+2162912303).Alwaysgroutrockanchorstoprevent
waterfromcollectingandfreezinginthedrilledhole.Groutingalsoincreasestheanchorsholdingstrength.
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AppendixC:SiteVisitProcedures
SiteChecklist
Whenmakingasitevisit,checkthefollowing:
Makesurethetowerisstraight.Standatthebaseofthetowerandlookuptoidentifyanybowedsections
orcurvesinthetowerthatmayhavedevelopedsincethetowerinstallation.Carefullyadjustguywiresas
necessarytostraightenthetower.
Checkguywiresforexcessiveslackandadjustasnecessary.Itisnormalforguywirestostretchovertime,
anditisespeciallyimportanttoadjustthembeforetheyaresubjectedtoicingorhighwinds.
Checkeachanchorformovementorloosening.Alooseanchorcanalsocauseexcessiveslackinguywires.
Checkthatmountingbooms,cellularantennas,temperaturesensors,etc.aresecurelyattached.
Confirmthatallgroundingconnectionsonthetowerandontheloggeraresecureandhaventcorroded.
Checkinstantaneoussensorreadingsoneachchannelofyourdatalogger.Anysensorprovidingerroneous
readingsshouldbedisconnectedfromtheloggerandtestedindependentlyand/orreplaced.Itisagood
ideatoalwayshavesparesensors,memorycards,batteries,andasparedatalogger!
Changethedataloggersbatteries.Rememberthatbatteriesarecheapitsbettertochangethem
prematurelyratherthanrisklosingdata!
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AppendixD:Glossary
Anchoreye
Arrowheadanchor
Basetube(SameasGinpole
BaseTube)
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Basetube,Ginpolebasetube,
andHelperGinpoleboltand
nut:x8bolt
Baseplategusset
Driverodforarrowhead
anchor
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Ginpolebasetube(Sameas
BaseTube)
Ginpoleguyropes:45.7mx
13mm(150ft.xin.)
Ginpolesafetycable
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Ginpoletoptube
HelperGinpole
Guyring
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Guywire
Hankmaster
Liftingwires
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QuickLink
Rockanchor
Rockerplate
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Screwinanchor
Shackle
Wireropeclip
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AppendixE:AligningWindVanes
Introduction
WindVanesmeasurewinddirectionrelativetotheorientationofthefixedbaseonthesensor.ThisApplication
Notegivesyoutheinformationyouneedtoorientyourwindvanescorrectlywhentheyaremountedtothetower.
ThisnotealsoincludesinformationonusingOffsetandMagneticDeclinationcorrectionswhenscalingyourdatato
obtainproperlyscaledandorienteddata.
MagneticDeclination
Sincetheearthsmagneticfieldisnotuniform,themagneticpolesdonotcoincidewiththetruegeographicpoles.
Moreover,acompassgenerallydoesntpointtoatruegeographicpole;itpointstoamagneticpole.This
differencebetweenatruegeographicbearingandamagneticbearingvariesfromlocationtolocationandiscalled
magneticdeclination.Magneticdeclinationorcompassvariationisthehorizontalanglebetweentruenorth(also
calledgeographicnorthormapnorth)andthedirectionthecompasspoints,magneticnorth.
Magneticdeclinationismeasuredasthenumberofdegreesoferroracompassshowsatasite.Thedeclinationfor
siteslocatedeastofthemagneticnorthpoleisexpressedasthenumberofdegreesthatmagneticnorthiswestof
truenorth.Thedeclinationforsiteslocatedwestofthemagneticnorthpoleisexpressedasthenumberofdegrees
thatmagneticnorthiseastoftruenorth.Forexample,Vermont(USA)hasamagneticdeclinationof15degrees
west.Inotherwords,magneticnorthinVermontis15degreestothewestoftruenorth.Magneticnorthin
Fairbanks,Alaska(USA)isabout27degreeseastoftruenorth;therefore,itsmagneticdeclinationis27degrees
east.
Theearthsmagneticfieldvariesslightlyinpositionovertime.Therefore,themagneticdeclinationatasitealso
variesovertime.Becauseofthisvariation,itisimportantthatyoureferenceanuptodatemapofdeclination
(isogonicmap)ifyouchoosetoorientyourwindvanestomagneticnorth.Lateryoucanenteracorrectionfor
magneticdeclinationintoyourwinddataanalysissoftwareifdesired.
MountingandAligningWindVanes
Sinceamagneticcompassisthesimplestdirectionreference,itissometimesconvenienttoorientwindvanesin
thefieldtomagneticnorth.MostRNRGcustomers,however,aligntheirwindvanestotruenorth.Beforeinstalling
yourRNRGlogger,decidewhetheryouwantwinddirectiondatatoreportnorthwhenthewindisfromthe
magneticnorthorwhenthewindisfromtruenorth.Besuretomakenoteofyourchoiceandmaintainconsistency
amongyoursitesandprojects.
Toalignawindvanetotruenorth:
1. Useatransparentorienteeringcompasswitharotatingbezelandmagneticdeclinationmarkings.Inthe
exampleinFigure1,15degreeswestmeansthatthedirectionofthecompassneedle(magneticnorth)lies
15degreeswestoftruenorth.
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Figure1
NOTE:Lininguptheridgesonthebodyofthewindvanewillcausethesensortoindicateanorthreading.Be
suretokeepthisinmindwhenorientingthewindvaneonthemountingboom.
2. Standsothatitispossibletosightalongthetowerfromthetoptothebase.Alignthebearingmarkonthe
compasssothatitpointsdirectlyinlinewiththetower,toptobase.ThebearingoftheTallTowerinthe
exampleinFigure2is270degrees.
Figure 2
3. Withoutmovingthebaseofthecompass,rotatethebezelsothenorthendoftheneedlepointstothe
declinationmarkthatcorrespondstolocaldeclination.
4. LooselyattachthemountingboomtotheTallTower.Liftthecompasstoaverticalpositionsothebearing
markpointsstraightup.Usealevelifnecessary.
5. Sightthroughthecompasssothecenterofthecompassisoverthepointwheretheboomcontactsthe
tower,withthebearingmarkstillstraightup.SeeFigure3.
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BOOM
UP
BEARING
MARK NORTH MARK
TOWER, VIEWED
FROM TOP
COMPASS
Figure3
6. Haveacrewmemberrotatetheboomuntilitalignswiththenorthmarkonthecompass,andtightenthe
boom.
7. Attachthewindvanewiththenortharrowindexmarkonthebasepointinginthesamedirectionasthe
northmarkonthecompass.The#200Pwinddirectionvaneisdesignedtomountwithacotterpinandset
screwtoaRNRGsensormountingboom.Thecotterpininstallshorizontallythroughdrillholesintheboom
andvane,allowingthebaseofthevanetopointinoneoftwodirections,towardthetowerorawayfrom
thetower.SeeFigure4.
Figure4
8. WhenyouraisetheTallTower,thenortharrowonthebaseofthewindvanewillpointtotruenorth.
9. Usethecompasstoverifyyoursettings.Ifnecessary,adjustthepositionofthemountingboombefore
raisingtheTallTower.
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Figure 5
UsingDataAnalysisSoftwaretoCorrectforMagneticDeclination
Ifyouorientyourwindvanestowardmagneticnorthbutwantthedirectiondatareportedrelativetotruenorth,
enterthemagneticdeclinationforthesiteintotheoffsetormagneticdeclinationfieldinyourwinddataanalysis
software.NRGsBaseStationSoftware,forexample,hasafieldcalledMagDeclin.BaseStaionappliesthe
declinationtoallwinddirectiondataforthesiteiftheMagDeclinfieldissettoanythingbutzero.Declinationis
notneededifyouorientyourwindvanestotruenorth.
Note:Winddirectionvaneshaveasmallrangecenteredaroundthesensorsnorthreadingthatiscalledthedead
bandandproducesazeroreading.AlthoughRNRGLoggershaveanalgorithmthatinterpretsnorthreadings
correctly,whentheprevailingwindisfromthenorth,itmaymakesensetoorientthevanetoadirectionother
thannorth.Ifyoudothis,compensatefortheorientationbyenteringavalueinthewindvaneoffsetfieldofyour
dataanalysissoftware.Forexample,ifyouorientyourwindvanetothesouth(180degrees),enteranoffsetof180
forthevane.
Note:Ifyouorientyourwindvanetoamagneticbearingotherthanmagneticnorth,youneedtoentervaluesfor
bothmagneticdeclinationandoffsetinyourdataanalysissoftware.Enterthesitesmagneticdeclinationsothat
yoursoftwarecancompensateforthedeclination;enteranoffsettocompensatefortheorientationofthevane.If
justoneoffsetfieldisavailableinyoursoftware,suchasRNRGsSymphonieDataRetrieversoftware,youwillneed
tocombinethemagneticdeclinationvaluewiththeoffsetvalue(ifwindvanesarenotorientedtotruenorth)and
enterthenetvalue.Forexample,ifyourwindvanesareorientedtothesouthinsteadofnorth,andyoursitehasa
magneticdeclinationof15degreeswest,youwouldenter165(or195)intheoffsetfield.Declinationstothewest
oftruenortharesubtractedfromthemagneticreading,anddeclinationstotheeastoftruenorthareaddedtothe
magneticreading.
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AppendixF:HankmasterToolforUnrollingGuyWires
TheguywireandliftercoilscanbeunrolledusingtheconvenientHankmastertool.AHankmastercanbebuiltfrom
materialsavailablefrommosthardwarestoresusingafewsimpletools.
Materials
1x41.5(105.4cm)of1.625(4.127cm)ODPVCPipe,cutinto:
1x17(43.18cm)section;
1x15(38.1cm)section;
1x5.5(13.97cm)section;
1x4(10.16cm)section.
2x90degreePVCElbowSocketFittings2(5.08cm)OD
1xPVCTSocketFitting2(5.08cm)OD
1xSquaredRetainerSnapSafetyPin,2.5(6.35cm)usablelength
2x28(71.12cm)diameterx0.5(1.27cm)thickplywood
8x0.37516x3.5HexHeadBolts(M10x90mm)
8x0.37516(M10)Nuts
8x0.625ODx1.5length(10mmODx90mmlength)Spacers
Tools
Saw
Drill
0.375(M10)drillbit
2x3/8(10mm)Wrenchesorequivalent
PVCAdhesive(UsedforallPVCpipeconnections)
Procedure
Connect(quantity1)ElbowSocketFitting(part#2)onto17(43.18cm)sectionof1.625(4.1cm)ODPVCPipe
(part#1a).
ConnectTSocketFitting(part#3)ontootherendof17(43.18cm)sectionofPVCpipe(part#1a).
Connect15(38.1cm)sectionofPVCpipe(part#1b)ontoTSocketFitting(part#3)inlinewiththe17(43.18cm)
section.
Connectother(quantity1)ElbowSocketFitting(part#2)ontootherendof15(38.1cm)PVCpipe(part#1b).
Drillaholethroughthe5.5(13.97cm)PVCPipe(part#1d)0.5(1.3cm)fromtheendofthepipesection.
Connect5.5(13.97cm)PVCPipe(part#1d)ontootherendofthesecondElbowSocketFitting(part#2).
Drilltwoholesthroughthe4(10.16cm)PVCpipe(part#1d),throughthesameplane,1.5(3.8cm)fromtheend
ofthepipe.
Cuta3/8slotfromtheendofthe4(10.16cm)PVCpipe(part#1d)throughtheholes(step#7).
Connect4(10.16cm)PVCPipe(#1c)intoremainingpointofTFitting(part#3).
Cut2(5cm)holesthroughthecenterofthe2plywooddiscs(part#5).
Drill(8)3/8holesevenlyaroundthe2plywooddiscs(part#5)witha10.5(26.7cm)radius.
Placethe(quantity8)bolts(part#6)throughthe8holesdrilledinoneoftheplywooddiscs(part#8).
Onthebolts(part#6)ontheothersideoftheplywooddisc(part#8),placethe(quantity8)spacers(part#8)
followedbythe(quantity8)nuts(part#7)tightenedsnugly.
Lineuptheholesontheotherplywooddisc(part#5),andputthetwodiscsonthe5.5(13.97cm)PVCPipe(part
#1c).
InserttheSafetyPin(part#4)intheholedrilledthroughthe5.5(13.97cm)PVCPipe(part#1c)tocomplete
assembly.
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TM
Figure1.CompletedHankmaster5000
Usage
UnclipSafetyPin,removefrompipe.
Removeouterplywooddisc.
LayHankmaster5000TMonitssidewiththehandlefacingdown.
Placecoiledguywireontoinnerdisc,aroundthe8bolts.
DONOTUNCLIPGUYWIRECOILUNTILYOUHAVEFINISHEDROLLINGITOUTTOTHEANCHOR.
RollHankmaster5000TMtoappropriateGuyRingoftower.
Unclipguywirecoil;attachcliptoguyring.
Unrollguywirecoiltotheappropriateanchor.
Torecoilaguywire,simplythreadguywirethroughtheangledholeintheouterplywooddisc,androll
Hankmaster5000TMoverguywire.
Whilerolling,guideguywirethroughthewireguideabovetheplywooddiscs.
Whencoilingiscomplete,usearubberbandtoholdthecoilandpreventunspooling.
LayHankmaster5000TMonitssidewiththehandlefacingdown.
Removecoiledguywire.
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Index
Inchwormmethod.................................................34
installingrockanchors..............................................
54
alternativeanchoring................................................52
lifterwires...........................................................
26,31
anchorplacement...............................................16,53
lifters.................................................
23,26,33,37,38
anchorradii...............................................................14
MagneticDeclination ...............................................65
anchorrequirements................................................49
oilontowerjoints.....................................................
21
anchoring........9,14,15,16,38,49,51,52,53,54,56
pivotpipe............................................................
21,27
AnchoringGuidelines................................................49
prelift.......................................................................14
anchoringinsolidrock..............................................52
pretensioningarrowheadanchors..........................54
anchoringthebaseplate.....................................18, 19
quickreleasepin.......................................................
21
anchors..........
10,14,15,16,19,41,49,50,51,52,53
rockanchors.............................................................52
Anchors.....................................................................14
rockanchors,installing.............................................
54
arrowheadanchors.............................................51,53
safety..........................................................................6
arrowheadanchors,installing...................................54
safetycable...................................................
27,28,59
arrowheadanchors,pretensioning.........................54
screwinanchors,installing......................................53
baseplate............................................
9,10,14,15,16
sensorcables............................................................23
basetube..................................................................21
settling......................................................................41
baseplate.........
9,14,15,16,17,18,20,21,27,31,38
shackles ..............................................................24,33
batteries....................................................................56
SiteLayout................................................................14
cementgrout............................................................55
sitevisitprocedures .................................................56
concreteanchors......................................................49
sitebuiltanchors......................................................
49
couplerplates.....................................................28,29
slackinguywires....................................38,53,54,56
driverod....................................................................51
soil ...........................................9,
49,50,51,52,53,54
electricaltape ...........................................................22
soiltype....................................................................49
ginpoleassembly......................................................27
straighteningthetower............................................
40
ginpoleropes............................................................29
stretch,guy wires.....................................................41
GinpoleTiltUp..........................................................33
TallTowerinstallationona slope..............................
15
glossary.....................................................................57
tension,guy wire....................................16,34,38,54
groundwire...............................................................23
tools..........................................................................10
gussets......................................................................18
TowerLowering........................................................42
guyguards.................................................................41
TowerTiltUp............................................................
34
guyringcorners........................................................21
transferringtheliftingguys......................................38
guyrings................................13,20,21,23,24,26,33
tubelayout ...............................................................20
guywiretensioning...................................................34
unpacking.................................................................11
guywires...................................................................23
WARNINGS .................................................................6
guys.......................................15,38,40,41,52,53,54
winch...............9, 10,14,16,29,37,38,42,43,54,60
Hankmaster.......................................
10,24,61,69,70
winchanchor............................................................14
helperginpole...............................................27,31,43
windvanealignment................................................65
icing...............................................................41,49,56
wirerope clips.............................10, 25,34,36,38,41
installingarrowheadanchors....................................53
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