NRG Systems TallTower 34 m User manual

Global leader in wind measurement technology
110 Riggs Road · Hinesburg · VT 05461 USA · TEL [phone] · FAX [phone] · EMAIL [email protected]
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
NRG 34 m TallTower™
Installation Manual & Specifications

2
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
Specifications are subject to change without notice.

3
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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.

4
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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

5
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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

6
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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.

7
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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.

8
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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)

9
NRG_34m_TallTower_Installation_Manual_and_Specifications_Rev_1.05.docx 19 April 2011
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