NRG Systems TallTower 34 m User manual

Global leader in wind measurement technology
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NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
NRG 34 m TallTower™
Installation Manual & Specifications

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Specifications are subject to change without notice.

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Installation of guyed towers is inherently dangerous. To minimize risks, read and follow the tower installation
instructions explicitly. Do not install during an electrical storm. Installation in agricultural areas may pose a threat to
low flying crop dusting aircraft. Notify appropriate parties and install warning devices as needed. We assume no
responsibility or liability in connection with any act, error, omission, or for any injury, loss, accident, delay,
inconvenience, irregularity or damage related to any TallTower installation.
DANGER: YOU CAN BE
KILLED
IF THIS TOWER COMES NEAR ELECTRIC POWER
LINES or IF YOU INSTALL THIS TOWER DURING AN
ELECTRICAL STORM.
FOR YOUR SAFETY, FOLLOW THESE
INSTALLATION INSTRUCTIONS.

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Table of Contents
WARNINGS ...................................................................................................................................6
Do these things:................................................................................................................................. 6
Do NOT do these things:.................................................................................................................... 7
Introduction ..................................................................................................................................8
TallTower History............................................................................................................................... 8
Construction and Assembly ............................................................................................................... 8
Required Parts to Erect Tower System.............................................................................................. 8
Experience Required.......................................................................................................................... 8
Tower Lift Crew.................................................................................................................................. 8
Tools Required for various tasks........................................................................................................ 8
Unpack your tower.....................................................................................................................11
Description of the packaging............................................................................................................ 11
Tools required to unpack the 34 m TallTower.................................................................................. 11
Access and Orientation.................................................................................................................... 12
Unpack Sequence –Very Important! ............................................................................................... 12
Site Layout..................................................................................................................................14
Pre-installation Planning .................................................................................................................. 14
Soil Type and Anchors ..................................................................................................................................14
Tip: Cellular Coverage...................................................................................................................................14
Site Layout Map............................................................................................................................... 14
Tower Assembly.........................................................................................................................16
Assemble the Baseplate .................................................................................................................. 16
Install the Anchors............................................................................................................................ 19
Tube Layout..................................................................................................................................... 19
SI Units..........................................................................................................................................................19
Imperial Units.................................................................................................................................................19
Install the Base Tube ....................................................................................................................... 20
Attach sensors and booms............................................................................................................... 21
Spiral wrap your sensor cables.....................................................................................................................21
Attach the Guy Wires.................................................................................................................22
Organize and layout the lifters and guy wires .................................................................................. 22
Shackle guy wires to the guy rings................................................................................................... 22
Roll out each guy wire from the tower to its anchor point ................................................................ 22
Secure guy wires to the anchors...................................................................................................... 24
Shackle lifter wires to the guy rings.................................................................................................. 24
Assemble the Gin Pole ..............................................................................................................25
Layout the ginpole tubes.................................................................................................................. 25
Attach the ginpole base tube to the baseplate................................................................................. 25
Slide together the 4 tubes that comprise the ginpole....................................................................... 25
Attach the ginpole top mounting hardware....................................................................................... 26
Attach the lifter wires........................................................................................................................ 28
Configure the helper ginpole............................................................................................................ 28

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Ginpole Tilt-Up ...........................................................................................................................30
Confirm all lifters and shackles are secure ...................................................................................... 30
Lift the ginpole.................................................................................................................................. 30
Tower Tilt-Up ..............................................................................................................................31
Understanding Guy Wire Tensioning While Raising TallTower (Do not raise the tower yet)........... 31
Adjusting Guy Wires (the “Inchworm” method) ................................................................................ 31
Loosening Guy Wires....................................................................................................................................31
Tightening Guy Wires....................................................................................................................................33
Lift the Tower ................................................................................................................................... 34
Transfer Lifters................................................................................................................................. 35
Plumb and Straighten....................................................................................................................... 36
Final Inspection and Maintenance ................................................................................................... 37
Tower Lowering..........................................................................................................................38
Appendix A: 34 m TallTower Dimensions...............................................................................40
Tower Layout ................................................................................................................................... 40
Site Layout....................................................................................................................................... 41
Baseplate Geometry ........................................................................................................................ 43
Appendix B: Anchoring Guidelines.........................................................................................45
Determine site soil and anchor type before you order your tower.................................................... 45
Anchor Choices and other considerations ....................................................................................... 45
Screw-In Anchor description .........................................................................................................................45
Arrowhead Anchor description......................................................................................................................47
Rock Anchor description................................................................................................................................48
Concrete Anchor description.........................................................................................................................48
Installing Screw-In Anchors.............................................................................................................. 49
Installing Arrowhead Anchors .......................................................................................................... 49
Installing Rock Anchors.................................................................................................................... 50
Appendix C: Site Visit Procedures ..........................................................................................51
Site Checklist ................................................................................................................................... 51
Appendix D: Glossary...............................................................................................................52
Appendix E: Aligning Wind Vanes...........................................................................................59
Introduction ...................................................................................................................................... 59
Magnetic Declination........................................................................................................................ 59
Mounting and Aligning Wind Vanes ................................................................................................. 59
Using Data Analysis Software to Correct for Magnetic Declination.............................................................. 62
Appendix F: Hankmaster Tool for Unrolling Guy Wires ........................................................63
Index............................................................................................................................................65

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WARNINGS
Do these things:
Read and follow the Tower Installation Manual!
Determine the soil type at your site and install the correct anchors.
Place tower anchors according to anchor manufacturer‟s recommendations.
Properly ground the tower electrically.
Stand to the side of any tensioned cables.
Thoroughly understand tower erection procedure before beginning installation. All crew members should read the
manual before arriving at the installation site!
Review glossary so that you are familiar with all tower parts and terminology.
If you are NOT familiar with erecting towers of this type, seek professional guidance. We will gladly help answer any
questions.
If you have never installed a TallTower before, seek the assistance of a qualified installer.
If you are not thoroughly familiar with all components of the tower, including all hardware and how all components
function, DO NOT attempt to install this tower yourself. Tall guyed towers are dangerous, and you or members of
your crew can be injured or killed.
If installing the TallTower in an agricultural area, notify appropriate parties and install warning devices as needed.
Towers can pose a threat to low-flying crop dusting aircraft.
If you are unsure of how to anchor your tower, seek professional guidance.

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Do NOT do these things:
DO NOT climb this tower.
DO NOT erect tower within 1 ½ times the tower height of electric power lines.
DO NOT install this tower during an electrical storm.
DO NOT erect tower within 1 ½ times the tower height of walkways, roads, or buildings.
DO NOT permit unauthorized personnel onto the site while the tower is being installed.
DO NOT raise or lower the tower on a day with high winds or gusty winds.
DO NOT use mechanical tensioning devices to adjust guy wires.
DO NOT use rebar anchors.
DO NOT stand in line with, directly in front of, or behind any tensioned cable.

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Introduction
TallTower History
NRG TallTowers™, the original tilt-up tubular towers, were first introduced in 1982 and soon became the industry
standard to quickly and easily get sensors up and into the wind to start measurements. TallTowers are delivered in
complete kits, assembled on the ground and then tilted up and secured with guy wires.
Construction and Assembly
The NRG TallTower™ is of galvanized steel tube construction and is guyed at four levels in four directions. Sections
slide together without the use of bolts or clamps. The tower is tilted up from the ground with a gin pole and winch
(winch is not included). Lifting of the tower is done by one set of guy wires (lifting wires) attached to the gin pole.
The tower is stabilized sideways with two side guy wire sets. The base plate is hinged so both the tower and gin pole
can pivot to the erected position.
Required Parts to Erect Tower System
NRG 34 meter TallTowers are supplied complete with ready to assemble tubes, baseplate, guy rings, precut guy
wires, screw-in anchors, grounding kit, and associated hardware. Screw-in earth anchors are included and are
suitable for many soil types. Other anchor types are available. It is your responsibility to determine which type of
anchor is appropriate for your specific site.
Please refer to the anchoring guidelines in Appendix B of this manual for more information.
A winch and ginpole (ginpole is included with the purchase of this tower) are also required to raise the tower.
The ginpole for the 34m TallTower is NOT compatible with other NRG TallTowers. The ginpoles from other NRG
TallTowers are not compatible with the 34 m tower.
Please see the Glossary for pictures and descriptions of tower parts, hardware, and accessories.
Experience Required
If you have no prior experience with TallTower installation, seek assistance from a qualified installer.
Tower Lift Crew
We suggest the following organization to form an efficient and safe crew to erect NRG TallTowers. Each member of
the lift crew should have a good understanding of the tasks they are required to perform during the lift.
Five Member Crew:
Crew leader: This person will operate the winch and coordinate the other members. It is especially important to
maintain clear communication among the members of the crew. The tower footprint is large and walkie-talkie radios
are highly recommended.
Side guy wire tenders: These two people will attend to each side guy anchor and adjust side guy wires. They must
be familiar with taking in and letting out guy wires. See the pictures describing the “inchworm” technique for safely
adjusting guy wires.
Observers: Two people to assist adjusting side guys, tending the back guy wires at the end of the lift, and otherwise
observing guy wires.
Tools Required for various tasks
¼ inch nut driver (for sensor installation)
5/16 inch nut driver (for hose clamps)
7/16 inch (11 mm) socket wrenches (for wire rope clips) –one per crew member
Large adjustable wrench (for large bolts)
1/2 inch wrench, socket or open (for base plate assembly and unpacking
Piece of rebar or similar (for turning anchors)

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Hand sledge (for ground rods)
Small adjustable wrench (for opening/closing acorn clamps)
Small pliers (for sensor cotter pins)
Small Phillips head (+) screwdriver (for set screws)
Flat (-) screwdriver (for antenna mounting assembly)
Knives (to cut electrical tape) –one per crew member
Level, preferably with a magnetic base (to straighten the tower)
Compass (for aligning direction sensors)
Permanent marker (for labeling lower ends of cables)
(2) 12 V deep cycle marine battery (for electric winch)
Hankmaster 5000™guy wire tool (optional)
Gloves
2-way radios or walkie talkies
Electric drill with 5/16 inch bit (for unpacking and attaching top tube)
Band cutters (for unpacking)
2.5 m (8 feet) stepladder (for reaching end of ginpole on sloped sites)
Rebar, rock bolts, or steel cable to secure tower base
8 wood posts (10 cm x 10 cm x 1 m / 4 in. x 4 in. x 3 ft.) to support tower
Sawhorse to support ginpole
Wire cutters

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Unpack your tower
Description of the packaging
The 34 m TallTower packaging was designed to reduce cardboard waste, protect the tower components and allow
for more economical shipment. All the tower components including anchors and ground kit are now included in one
package. If you purchased this tower as part of an NRG-NOW System, the electronics, sensors and associated
accessories are packaged separately.
It is very important that you understand how to unpack the contents of the packaging safely. The recommended
sequence to unpack the tower is described in this section of the manual.
The tubes may shift position suddenly when bands are cut, so please read this section carefully to avoid
serious injury.
Tools required to unpack the 34 m TallTower
5/16 inch nut driver or electric drill with 5/16 inch bit
1/2 inch wrench for bolts
Band cutters
Gloves

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Access and Orientation
Ideally, you will want access to both ends of the packaging to unpack the contents. If a forklift is available, that is
also ideal. Remove the 34 m TallTower package from the truck with the forklift and set it on an unobstructed flat area
before unpacking.
It is also possible to unpack the contents with access to only one end of the tower packaging. For example, the 34 m
TallTower may have been placed into a truck with one end against the front wall of the truck‟s cargo area and no
forklift available to remove it from the truck. In this case, you will be able to follow instructions in this section of the
manual to unpack the contents and unload from the truck by hand.
Note: You will NOT be able to unpack the contents if the tower package has been loaded into a truck sideways. If it
has been loaded into a truck sideways, you will not have required access to the ends and will need a forklift to
remove the tower package.
Unpack Sequence –Very Important!
Once you are ready to unpack the contents, follow these steps. With the banding cutters, cut the single horizontal
band (#4) and discard.
Figure 1

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With the nut driver (or powered screwdriver), remove the 4 wood screws that fasten each end plate assembly down
to the wood pallet. Set aside the 2 end plate assemblies. If you can only remove one end plate assembly, that is OK.
Remove the end plate and set aside.
The tube contents will now be exposed. Beginning at the top, remove the contents of the tubes. These contents will
include: screw-in anchors, coils of cable, ground rods, guy rings, rocker plates, and the hardware kits.
At this point, there should only be 152 mm (6 inch) diameter tubes remaining on the pallet. With the band cutters, cut
the outer bands (#2 & #1) and center band (#3) as shown. Remove tubes.

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Site Layout
Pre-installation Planning
It is a good idea to visit the site before you order your wind measurement system. You will need to make
arrangements regarding how to unload your tower system. Some site preparation may also be necessary.
During the first lift of a tower, the many slip joints will settle to the full engagement. During this settling, the distances
from the base to any given point on the tower will shorten, and the individual tubes may rotate. Therefore, it is
recommended that the tower be “pre-lifted” before the sensors are permanently attached. The “pre-lift” can be only a
few feet, but the entire tower should leave the ground. Doing this also is a good way to avoid endangering the
booms, sensors, and cabling should there be an unforeseen problem.
Soil Type and Anchors
Before ordering your tower, research the site soil and anchor type required. It is your responsibility to determine
which type of anchor is appropriate for your specific site. Depending on the soil type, anchoring can take varying
levels of planning, effort and time. Be sure to know what soil types you are dealing with as part of your pre-
installation planning process.
Note: (5) 6 inch diameter screw anchors are included with the tower. Other anchor types must be ordered
separately. Please refer to the anchoring guidelines in Appendix B of this manual for more information.
Tip: Cellular Coverage
This is also a good opportunity to identify what type of cellular service is available at the site for those who will be
using an NRG iPack to transmit data. Contact us for more information on NRG iPacks.
Site Layout Map
Lay out locations for the tower baseplate, guy anchors and the winch anchor. Lay out the site so that the tower is
laid out downwind of the baseplate so that the tower will be lifted into the wind. If the site is on a steep slope, lay out
the site so that the tower is laid out uphill of the baseplate. Unless the slope is steep, it is more important to have the
tower lifted into the wind.
Measure carefully to place the anchor points, paying extra attention to the placement of the winch anchors. Verify
that the anchor radii and the diagonal distances between anchors are correct.

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Figure 3: Site Layout Map (bird’s eye view)
NOTE: TallTowers can be installed on slopes up to 10°. When laying out a TallTower installation on a slope,
measure the calculated distances along the ground to place the anchors. It is not necessary to compensate for the
slope. TallTower guy wires are cut long enough to allow for installation on slopes up to 10° while maintaining the
ideal angle between the tower and the guys.
NOTE: The side guy anchors and the base plate should be on a straight line. If it is not possible to place them in the
locations shown, it is better to move them in or out along the line to the baseplate than to move them off the line. Do
not move them more than 1 m (3 feet) off the line, although some sites may require a compromise because anchors
may not be able to be located at the preferred spot.
NOTE: Extra care will have to be taken while raising the tower if:
anchor placement is not perpendicular to the tower as it lays on the ground.
anchors are not at the same elevation.
side anchors and base plate are not in a straight line.
NOTE: Any of these conditions will affect the side guy wire tension as the tower is raised. Tension will have to be
adjusted periodically as the tower is lifted.
Placement of the winch anchor is critical. Make sure that you measure carefully and set the anchor heads close to
ground level. Angle all the anchors toward the tower at 45 degrees.
All this is important for proper distribution of forces and for clearance and proper operation of the ginpole. See Site
Layout Map and Anchor the Winch for more information.

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Tower Assembly
Assemble the Baseplate
The baseplate will be located according to the site layout map described in the previous section. It is often easiest to
assemble the baseplate in this location. Assemble 4 of the 6 large triangular baseplate sections as shown below,
inserting (8) 5/16” x 3/4” carriage bolts in holes closest to the center of each triangular baseplate section. Leave nuts
somewhat loose; tighten by hand only.
Flip over the baseplate assembly, and prop up on one edge with a block of wood to allow access to underside of
baseplate. Attach vertical pieces to the center of the baseplate as shown below, with bent edges facing outward.

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Install the gussets (4) as shown below. Be sure to install the gusset bolts with the carriage bolt head away from the
gussets. Tighten all bolts in the baseplate.
At the beginning of a lift, particularly for the gin pole, the winch forces are largely horizontal. These forces tend to
slide the baseplate toward the winch and/or tip the baseplate up on edge. To counteract these forces, it is highly
recommended that the baseplate be anchored against sliding and tipping. There are several possible techniques
depending on the terrain, soil, and subsequent operations under the tower.

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Rods driven through the baseplate into the soil –With firm, deep soil, drive several pieces of rebar through the holes
in baseplate into the soil. Angle them away from the winch and place as many as practical along the baseplate front
edge (farthest from the winch).
Rock anchors to the baseplate –On rock, or shallow soils, attach rock anchors to the baseplate, particularly along
the front edge. These should be positioned and attached to hold the edge of the baseplate down as well as keep it
from sliding.
Cable to the Guy Anchor –A cable made up as a bridle connected to the tower bolt can be run to the inner anchor
opposite the winch or to an anchor nearer the baseplate. See below for details.
Figure 4
Drive ground rods through the baseplate holes so they can provide additional anchoring for the baseplate.

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Install the Anchors
See Appendix B: Anchoring Guidelines at the end of this manual for more information on installing anchors.
Depending on the soil type, anchoring can take varying levels of planning, effort and time. Be sure to know what soil
types you are dealing with as part of your pre-installation planning process.
Leave the eye of screw-in anchors about 150 mm (6 inches) above ground.
Tube Layout
Lay out the disassembled tube sections on the ground according to sequence described, beginning at the baseplate.
Pay close attention to the location of the guy rings.
SI Units
Sequence of tubes in each section
A guy ring is placed over the last tube listed in each section.
Section 1
Section 2
Section 3
Section 4
Base Tube +
(4) 2.2 m,
152 mm dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
Red
(4) 2.2 m,
152 mm dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
White
(4) 2.2 m,
152 mm dia.
Lifters
attached to
this guy ring
are color
coded:
Black
(4) 2.2 m,
152 mm dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
Yellow
Table 1
Imperial Units
Sequence of tubes in each section
A guy ring is placed over the last tube listed in each section.
Section 1
Section 2
Section 3
Section 4
Base Tube +
(4) 87 inch,
6 inch dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
Red
(4) 87 inch,
6 inch dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
White
(4) 87 inch,
6 inch dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
Black
(4) 87 inch,
6 inch dia.
tubes
Lifters
attached to
this guy ring
are color
coded:
Yellow
Table 2

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Install the Base Tube
Identify the base tube. The base tube has a hole drilled through the flared (wider) end. Attach the base tube to the
baseplate using the ¾” x 8” bolt through the lower holes in the center of the baseplate sides. Secure the bolt with the
provided nut.
Slide tube sections together until the end of the interior tube is inserted all the way into the outer tube‟s flare. The
inner tube will be stopped. Aligning the weld seams (visible in interior of tube) of each tower section will make it
easier to slide the sections together. Continue to assemble the tubes and place guy rings over the tubes according
to the sequence above. Make sure the guy ring is placed so the guy ring corners are bent towards the baseplate,
and the guy ring corners are in line with each anchor point. Place wood blocks every 5 to 6 meters (15 –20 feet) to
support the tower above the ground, keeping the tower as straight as possible.
Note: Do not use oil on tower joints. This can cause tower failure if the tubes self-flare.