Southwest Windpower SkyStream 3.7 User manual

Southwest Windpower, Inc.
1801 West Route 66
Flagstaff, Arizona 86001 USA
Phone: [phone]
Fax: [phone]
www.skystreamenergy.com
sectional MonoPole
toWeR FoUnDation &
installation ManUal
 March 2009 Southwest Windpower, Inc.
All Rights Reserved.
TOP OF PIER
TOP OF ANCHOR BOLT
TOP OF WASHER
THESE DIMENSIONS
MUST BE OBSERVED
7.00"
(17.8cm 1)
.38
(11.1cm .3)
4.38" .12
Southwest Windpower
54321
--
--
ECO#--
NC
REVISIONS
REV.
.XXX ± .002
.XX ± .05 HINGE-PIER CONNECTION
T. George 01/12/09
Flagstaff, Arizona U.S.A.
MONOPOLE TOWER
do not manually update
scale 1: 8 size A
CAD file :
dwg #
sheet 1 of 1rev. NC
DATE
APPROVALS
DRAWN
R&D
PROD EGR
MFG
QUAL
MATERIAL:
FINISH:
DO NOT SCALE DRAWING
DWG #-------------------
CAD-generated drawing
.X ± .1 ± 30 '
decimals angles
other purpose except as specifically authorized in writing by Southwest Windpower.
APPROVED
DATE
DESCRIPTION
unless otherwise specified
dimensions are inches
tolerances are :
Proprietary rights are included in the information disclosed herein. This information is
submitted in confidence and neither the document nor the information disclosed here-
in shall be reproduced or transferred to other documents for manufacturing or for any
--
For 33.5 ft (10.2 m) & 45 ft (13.7 m)
Sectional Monopole Towers

2 Sectional Monopole Tower Foundation & Installation Manual, Revision A
Table of Contents
Important Safety Instructions ______________________________ 3
PRIOR TO INSTALLATION _______________________________ 4
Introduction_________________________________________ 4
Building Permits & Zoning Requirements ________________ 4
Installation Personnel ________________________________ 5
Siting - Finding the Best Location for Skystream__________ 6-7
CONSTRUCTING THE FOUNDATION _____________________ 8
Foundation Drawings_________________________________ 8
Wind Zones ________________________________________ 8
Soil Conditions _____________________________________ 9
Selecting A Foundation Configuration ___________________ 10
Foundation Bolts & Templates (Pier & Mat Foundations) ___ 10
Foundation Bolts & Templates (SMarT Foundation) _________10
Positioning the Foundations Bolts (Pier & Mat Foundations)__11-12
Positioning the Foundations Bolts (SMarT Foundation) ____ 13
Electrical Conduit____________________________________ 13
Completing the Foundation____________________________ 13
TOWER INSTALLATION _________________________________ 14
Introduction_________________________________________ 14
Hinge Plate Installation _______________________________ 14-15
Gin Pole Installation _________________________________ 16
Sectional Monopole Tower Foundation
and Installation Manual
Document : 3-CMLT-1367-01
Revision: A
Raising the Tower ___________________________________ 17-18
Adjusting Cable Length ______________________________ 17-18
Lowering the Tower__________________________________ 19
Leveling the Tower __________________________________ 20
Tightening Foundation Bolts __________________________ 20
APPENDICES
Appendix A: 33.5 ft (10.2 m) Monopole Tower Foundations
Appendix B: 45 ft (13.7 m) Monopole Tower Foundations
Appendix C: SMarT Foundation Assembly and Drawings

Sectional Monopole Tower Foundation & Installation Manual, Revision A 3
IMPORTANT SAFETY INSTRUCTIONS
READ THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE INSTALLING.
TIP: Helpful information
to ease the installation
Warning: Risk of injury or
death - proceed with extreme
caution
Professional installation
highly recommended
In this manual
IMPORTANT:
Please take note
1) SAVE THESE INSTRUCTIONS. This manual contains important instructions for constructing
foundations, and raising, lowering and leveling towers that MUST be followed.
2) Read, Understand and Follow all warnings.
3) Read these instructions in their entirety before starting foundation construction and tower
installation.
4) Install foundation and tower in accordance with National Electric Code, and all local building
and zoning codes and requirements.
5) Obtain building and construction permits prior to starting construction.
6) Foundation concrete must be completely cured prior to installing tower [Minimum 2500 PSI,
(17235 kPa) 28 day strength].
7) Skystream uses high voltage and is potentially dangerous. Follow all safety precautions at all times.
8) Follow proper grounding procedures for tower, foundation and windturbine.
9) Remain at a safe distance when raising and lowering tower. NEVER stand or walk under
tower while it is being raised or lowered.
10) Be aware of overhead power lines.
11) Do not attempt to raise tower on a windy day.
12) Always wear personal protection equipment – closed toe shoes, work gloves, safety glasses, and hardhat.

4 Sectional Monopole Tower Foundation & Installation Manual, Revision A
PRIOR TO INSTALLATION
Introduction
This manual provides information for the construction of a foundation suitable for installing Southwest Windpower’s Skystream 3.7 on one of the following
Southwest Windpower towers:
• 33.5 ft (10.2 m) Monopole Sectional Tower, part number 3-CMBP-3218
• 45 ft (13.7 m) Monopole Sectional Tower, part number 3-CMBP-3219
Information for four different “styles” of foundation is provided. The choice of foundation will depend on local building conditions, available construction
equipment, and local regulations. The four styles of foundation include:
• Pier Foundation – A “column” shaped foundation; diameter and depth vary depending on soil conditions and maximum wind speed.
• Mat Foundation [33.5 ft (10.2 m) tower only] – A “square” shaped foundation; length, width and depth vary depending on soil conditions and maximum wind
speed.
• Pad and Pier Foundation [45 ft (13.7 m) tower only] – An alternative to the Pier foundation – may be easier to construct than Pier foundation if an auger is
not available.
• SMarT Foundation™ - manufactured by AnemEronics Inc. , this foundation utilizes a “kit” that is specially designed to construct a foundation for
Southwest Windpower’s Monopole Towers.
For the Pier and Mat foundations, the information in the manual is sufficient for individuals knowledgeable in working with concrete to construct the founda-
tions. The manual provides useful tips about critical areas of construction, however it does not provide “step by step” instructions for these
foundations. It assumes constructor is has the knowledge and experience to complete the foundation.
Detailed instructions are provided for the SMarT Foundation in Appendix C. The SMarT Foundation kit was designed specifically for Southwest Windpower’s
Monopole towers and may be utilized by both experienced and amateur installers. The unique design of the SMarT foundation provides material and construc-
tion time savings compared to a conventional foundation.
Directions for raising, leveling, and lowering the tower are provided in this manual, refer to the Skystream Owner’s Manual for instructions for installing
Skystream on the tower.
IMPORTANT NOTE:
The foundation drawings contained in the Appendices of this manual present foundations designed in accordance with the 2006
INTERNATIONAL BUILDING CODE (IBC 2006) and ASCE 7-05 MINIMUM DESIGN LOADS FOR BUILDINGS AND OTHER STRUCTURES. These
drawings may therefore not be appropriate in localities with construction requirements that differ from these standards.

Sectional Monopole Tower Foundation & Installation Manual, Revision A 5
Installation Personnel
Southwest Windpower strongly recommends professional construction of the foundation. Constructing the foundation requires specialized equipment,
experience constructing concrete forms and knowledge of local zoning and building codes and inspection requirements.
Skystream Dealer
Skystream Owners who are considering constructing “any or all” of their foundation, or raising their own tower
should completely review this manual and the Skystream Owners manual before proceeding. Working with high
voltage electricity, constructing foundations and raising and lowering towers can be dangerous. And mistakes can
be expensive. Understand what you are getting into before starting.
Owners should also be aware that many localities require installation by “certified installers” or by licensed contrac-
tors to qualify for clean energy monetary rebates.
If you decide not to install the tower yourself, dealers displaying the “Skystream Dealer” insignia shown here, have
completed factory training on the correct and safe installation of the tower (and Skystream).
IMPORTANT: Do not pour concrete before
all required permits are obtained, inspec-
tions completed, and you are authorized
to proceed.
Building Permits and Zoning Requirements
Building codes and installation requirements may vary greatly depending on state, city, and local town-
ships. Be sure to obtain all required building permits BEFORE beginning the installation.
Be sure you understand all installation and inspection requirements. Many localities require inspections
at key phases of the installation before additional work can proceed.

6 Sectional Monopole Tower Foundation & Installation Manual, Revision A
Siting – Finding the best location for Skystream
The optimum location to install any wind turbine, including Skystream, is often a compromise. Local building restrictions, the height of surrounding
structures, wire length, and available open space may require Skystream be installed in a less than optimum location. At a minimum try to observe
the following general rule for siting the turbine.
TIP: Your dealer can help you determine the
best location for Skystream on your property.
75 m
6.5 m
Prevailing Wind
Optimal Skystream location.
The General Rule: for optimum performance, install
Skystream 20 ft (6.5 m) above any surrounding object
within a 250 ft (75 m) radius. See figure to left.
20 ft (6.5 m)
250 ft (75 m)

Sectional Monopole Tower Foundation & Installation Manual, Revision A 7
When raising the 45 ft (13.7 m) tower using the Gin Pole Kit a minimum of approximately 110 ft (37 m) are required. Slightly over 50 ft (17)
are required on one side of the foundation for the tower and Skystream blades. Depending on the length of vehicle used to raise the tower,
over 60 ft (20 m) may be required on the other side of the foundation for the vehicle, pulling cable and gin pole. Slightly less space is required
to raise the 33.5 ft (10.2 m) tower. Refer to the accompanying figure.
TIP: Approximately 110 ft (37 m) are
required to raise the tower vertically into
position. 50 ft (17 m) are required on one
side of the foundation for the tower and
wind generator. An additional 60 ft (20 m)
are required on the other side of the foun-
dation for the gin pole and pulling vehicle.
110’ (37 m)
50’
(17 m)
60’
(20 m)

8 Sectional Monopole Tower Foundation & Installation Manual, Revision A
CONSTRUCTING THE FOUNDATION
Foundation Drawings
Detailed technical drawings for the Pier, Mat and SMarT foundations are
provided in Appendices A, B and C respectively. The drawings are also
available on Southwest Windpower’s website (www.skystreamenergy.com).
The drawings were prepared by Tower Engineering Professionals (TEP),
Raleigh, North Carolina and reviewed and certified by a State of Arizona
Registered Professional Engineer.
The drawings are provided as a reference to assist with obtaining building
permits and with the construction approval process.
Note the foundation dimensions for the Pier and Pad, and Pier founda-
tions will vary based on the Soil Class and Wind Zone. The dimensions
for the SMarT and Mat foundations do not vary based on soil conditions.
These foundations assume Soil Class 5 (worst case) conditions exist and
are sized accordingly.
Wind Zones
The foundation dimensions are in part dictated by the maximum anticipat-
ed wind speed the turbine will experience. A larger (or deeper) foundation
is required to withstand higher speed winds.
The dimensions and construction details for each of the foundations will
change based on the anticipated wind speed. Refer to the accompanying
tables to determine your Wind Speed Zone and the location of the foun-
dation dimensions for your tower height and foundation type.
Wind Zones
Zone Wind Speed
1120 – 150 mph / 54 – 67 m / sec
290 – 120 mph / 40 – 54 m / sec
3< 90 mph / 40 m / sec
TIP: Excellent wind speed information is available on the internet at
http://www.awea.org/faq/usresource.html as well as other websites.
Tower Height Foundation Wind Zone For Dimensions See
33.5 ft (10.2 m) Mat 1Appendix A, Sheet S-4A
33.5 ft (10.2 m) Mat 2Appendix A, Sheet S-4B
33.5 ft (10.2 m) Mat 3Appendix A, Sheet S-4C
33.5 ft (10.2 m) Pier 1, 2 & 3 Appendix A, Sheets S-5 & S-6
33.5 ft (10.2 m) SMarT 1, 2 & 3 Appendix C, Sheet S-1
45 ft (13.7 m) Pier & Pad 1, 2 & 3 Appendix B, Sheet S-5 & S-7
45 ft (13.7 m) Pier 1, 2 & 3 Appendix B, Sheets S-8 & S-10
45 ft (13.7 m) SMarT 1, 2 & 3 Appendix C, Sheet S-1
Local building codes may specify the wind speed the foundation must with-
stand. If the building code does not specify a wind speed the local weather
service can provide maximum wind speed information.
TIP: If your installation requires “Wet Stamped” Foundation Drawings
for your state they may be purchased from Tower Engineering
Professionals, Raleigh , North Carolina. Phone: [phone].

Sectional Monopole Tower Foundation & Installation Manual, Revision A 9
Soil Conditions
As with the Wind Zones described above the size of a foundation required to support a wind turbine and tower is in part determined by the soil
conditions in which the foundation is constructed. Loose sandy soil will require a larger foundation than bedrock.
Refer to the following tables to determine your Soil Class and the location of the foundation dimensions for your tower height and foundation type.
Soil Class Description
1 Crystalline Bedrock
2 Sedimentary and Floated Rock
3 Sandy Gravel and / or Gravel
4 Sand, Silty Sand, Clayey Sand, Silty Gravel, and Clayey Gravel
(SW, SP, SM, SC, GM, and GC)
5 Clay, Sandy Clay, Silty Clay, Clayey Silt, Silt and Sandy Silt
(CL, ML, MH, and CH)
Tower Height Foundation Wind Zone For Dimensions See
33.5 ft (10.2 m) Mat 5 ** Appendix A, Sheet S-4A
33.5 ft (10.2 m) Pier 1,2,3,4,5 Appendix A, Sheet S-4B
33.5 ft (10.2 m) SMarT 5 ** Appendix A, Sheet S-4C
45 ft (13.7 m) Pier & Pad 1,2,3,4,5 Appendix B, Sheet S-5 & S-7
45 ft (13.7 m) Pier 1,2,3,4,5 Appendix B, Sheet S-5 & S-7
45 ft (13.7 m) SMarT 5 ** Appendix B, Sheet S-5 & S-7
** Note the foundation dimensions and construction details for the SMarT and Mat foundations do not vary as a result of the soil conditions. These
foundations assume Soil Class 5 (worst case) conditions exist and are designed accordingly.

10 Sectional Monopole Tower Foundation & Installation Manual, Revision A
Selecting a Foundation Configuration – Pier, Mat or SMarT
The choice of foundation – Pier, Mat or SMarT foundation – will depend on a number of factors including soil conditions, the depth of the local
water table, frost line and available excavation equipment.
If, for example, a contractor has the correct size auger, installing a Pier foundation may be a more economical choice than a Mat foundation since
it may use substantially less concrete. Alternately, the SMarT foundation does not require reinforcing bars which can be expensive to purchase and
form into the required shapes.
Regardless of the type of foundation, the foundation must extend below the frost line and must also be above the water table. Engineering profes-
sionals must be consulted prior to construction if the frost line is known to be greater than the foundation depth or the water table is less than the
foundation depth.
In summary consult with a number of contractors and with local building inspectors to achieve the best foundation value.
Foundation Bolts and Templates
Two foundation bolt kits are available. The difference between the two kits is the length of the bolts. The Mat foundation bolts are 32 in (81 cm)
long and the Pier foundation bolts are 42 in (107 cm) long. Each kit includes hot dipped galvanized bolts, nuts and washers constructed of the ap-
propriate steel alloys.
A paper bolt circle template is provided with the bolt kit to assist in constructing a rigid frame to secure the foundation bolts while pouring the
foundation concrete. The foundation bolts MUST be positioned correctly in the foundation or it may be extremely difficult if not impossible to mount
the tower to the foundation.
Foundation Bolts and Templates (SMarT Foundation)
The SMarT foundation kits includes all the fastener hardware (nuts, bolts, washers) required to assemble the SMarT foundation. The kit also
includes a bolt template to position the foundation bolts in the form. Refer to the SMarT Foundation instructions located in Appendix C of this
manual.

Sectional Monopole Tower Foundation & Installation Manual, Revision A 11
Positioning the Foundation Bolts (Pier and Mat foundations)
Regardless of the foundation – Pier or Mat - it is vital the foundation bolts are correctly positioned in the foundation or it may be extremely difficult if
not impossible to mount the tower to the foundation.
Using the paper template supplied with the foundation bolt kit as a guide, construct a wooden template to position the foundation “J” bolts – 1/ 2 in
(13 mm) or 3/4 in (19 mm) plywood works well to construct the wood template. Refer to gure below for a dimensional representation of the founda-
tion bolt pattern template.
17.00in
43.2cm
2.49in
6.3cm
6.01in
15.3cm
2.49in
6.3cm
6.01in
15.3cm
45
8.50in
21.6cm
1.25in x 8
3.2cm
Bolt template for 33.5 ft (10.2 m) and 45 ft (13.7 m) towers [17”].

12 Sectional Monopole Tower Foundation & Installation Manual, Revision A12 Sectional Monopole Tower Foundation & Installation Manual, Revision A
Secure the “J” bolts to the wooden template using the foundation nuts. RTemplates may
be fabricated using a single piece of plywood or using two pieces of plywood separated
by 2 x 4 in (0.6m x 1.2 m) lumber. Refer to the accompanying figures.
Note the foundation bolts MUST project above the foundation 7.0 +/- 0.38 in (18.0
cm +/- 10 mm) and be vertical and parallel to each other. These dimensions are
critical to mount the tower and for proper operation of the hinge plate.
7.0in
17.8cm
17in BOLT CIRCLE
[43.2cm]
TEMPLATE
TOP OF PIER
7.0in
17.8cm
17in BOLT CIRCLE
[43.2cm]
TOP OF PIER
2 x 4
[5 x 10]
TEMPLATE
IMPORTANT: Do not exceed 7.0 +/- 0.38 inches (18.0 cm +/- 10 mm)
dimension or bolts may interfere with hinge plate.
TOP OF PIER
TOP OF ANCHOR BOLT
TOP OF WASHER
THESE DIMENSIONS
MUST BE OBSERVED
7.00"
(17.8cm 1)
.38
(11.1cm .3)
4.38" .12
Southwest Windpower
54321
--
--
ECO#--
NC
REVISIONS
REV.
.XXX ± .002
.XX ± .05 HINGE-PIER CONNECTION
T. George 01/12/09
Flagstaff, Arizona U.S.A.
MONOPOLE TOWER
do not manually update
scale 1: 8 size A
CAD file :
dwg #
sheet 1 of 1rev. NC
DATE
APPROVALS
DRAWN
R&D
PROD EGR
MFG
QUAL
MATERIAL:
FINISH:
DO NOT SCALE DRAWING
DWG #-------------------
CAD-generated drawing
.X ± .1 ± 30 '
decimals angles
other purpose except as specifically authorized in writing by Southwest Windpower.
APPROVED
DATE
DESCRIPTION
unless otherwise specified
dimensions are inches
tolerances are :
Proprietary rights are included in the information disclosed herein. This information is
submitted in confidence and neither the document nor the information disclosed here-
in shall be reproduced or transferred to other documents for manufacturing or for any
--

Sectional Monopole Tower Foundation & Installation Manual, Revision A 13
Positioning the Foundation Bolts (SMarT Foundation)
The SMarT Foundation includes a template as part of the foundation kit therefore the construction of a template is not required. Refer to the
SMarT Foundation instructions located in Appendix C of this manual.
Electrical Conduit
Electrical conduit may be cast into the foundation such that the conduit continues below grade to electrical panel. Alternately
wire may be routed between tower base plate and foundation. Refer to local building codes BEFORE pouring concrete.
Building codes typically require direct burial cables be buried to a minimum depth of 24 in (61 cm) while cables in conduit may be buried at a
depth of 18 in (46 cm). Additionally, most codes prohibit embedding cables directly in concrete. Refer to local codes for conduit size and mini-
mum depth requirements.
Tower Grounding
Refer to the Skystream Owner’s Manual for complete directions on grounding the tower. It is vital the tower be properly grounded to minimize risk
of electrical shock.
Completing the Foundation
Refer to the foundation technical drawings contained in the appendices of this manual for complete notes including; foundation dimensions, con-
struction notes and grading and concrete requirements. Regardless of the foundation 28 days are required for the concrete to cure to a minimum
compressive strength of 2500 PSI (17230 kPa).

14 Sectional Monopole Tower Foundation & Installation Manual, Revision A14 Sectional Monopole Tower Foundation & Installation Manual, Revision A
TOWER INSTALLATION
Tower Installation Introduction
This Manual provides directions for raising the following towers – do not attempt to use the information in this manual to raise any other towers or to con-
struct a foundation for different towers:
• 33.5 ft (10.2 m) Monopole Sectional Tower, part number 3-CMBP-3218
• 45 ft (13.7 m) Monopole Sectional Tower, part number 3-CMBP-3219
Using:
• Gin Pole (2 piece), part number 3-CMBP-3221
• Gin Pole Kit Part Number 2-TWS-102
• Hinge Plate Kit, part number 3-CMBP-3220
• Hinge Plate Kit Part Number 2-TWS-103
Notes:
• Foundation concrete must be cured 28 day minimum with compressive strength
of 2500 PSI (17235 kPa).
• These instructions assume use of a Southwest Windpower foundation bolt kit with
correct number and type of fasteners.
Hinge Plate and Gin Pole Installation
• Place the hinge plate on the foundation and fully against the bolts that will be used to secure the hinge plate and thread three nuts and washers
(washer below nut) to secure the hinge plate in place.
• Fully tighten the hinge plate to the foundation using the “Turn of the Nut” method described on the following page.
Turn of the Nut Method of Tightening
• First tighten each nut to a “snug tight” condition to bring the hinge plate in full contact with the foundation. “Snug Tight” is dened as the tightness at
tained by a “few” impacts of an impact wrench or the full effort of a man using an ordinary spud wrench (see accompanying figure).
• Following the initial snug tightening, tighten each nut an additional 1/3 to 2/3 turn.
5
4
3
2
1
unless otherwise specified
dimensions are inches
tolerances are :
decimals angles
.X ± .1 ± 30 '
.XX ± .05
.XXX ± .002
MONOPOLE TOWER
HINGE-BOLT CONFIG
T. George
01/20/09
Flagstaff, Arizona U.S.A.
CAD-generated drawing
do not manually update
scale -- size A
CAD file :
dwg #
sheet 1 of 1 rev. NC
DATE
APPROVALS
DRAWN
R&D
PROD EGR
MFG
QUAL
MATERIAL:
FINISH:
DO NOT SCALE DRAWING
DWG #-------------------
Proprietary rights are included in the information disclosed herein. This information is
submitted in confidence and neither the document nor the information disclosed here-
in shall be reproduced or transferred to other documents for manufacturing or for any
other purpose except as specifically authorized in writing by Southwest Windpower.
APPROVED
DATE
DESCRIPTION
REV.
REVISIONS
NC
ECO#--
-- --
Southwest Windpower
--

Sectional Monopole Tower Foundation & Installation Manual, Revision A 15
Hinge Plate and Gin Pole Installation -(continued)
• Install eight nuts and washers (washers on top of nuts) onto each of the remaining foundation bolts. Make sure the tops of the washers are 4.5 in
(11 cm) above the foundation. Refer to accompanying figures.
• Install the Hinge Plate Links between the tabs of the tower base using two 1/8 x 6 in (0.3 x 15 cm) hex head bolts supplied with the hinge plate kit.
Make sure the threaded ends of the bolts face outward to ease disassembly.
• Assemble the lower half of the gin pole to the Hinge Plate / Tower Base assembly and install nuts – hand tight is sufcient.
• Assemble the upper section of the gin pole to the lower section using the 5/8-11 x 4 in (1.6-28 x 10 cm) hex head bolt – tighten securely.
Assembling Tower Sections
At this point the lowest tower segment – the base - should be bolted to the hinge plate and foundation and gin pole. Perform the following steps to join the
tower segments using the gin pole to assist with the process. Refer to accompanying figure.
TOP OF PIER
TOP OF ANCHOR BOLT
TOP OF WASHER
THESE DIMENSIONS
MUST BE OBSERVED
7.00"
(17.8cm 1)
.38
(11.1cm .3)
4.38" .12
Southwest Windpower
54321
--
--
ECO#--
NC
REVISIONS
REV.
.XXX ± .002
.XX ± .05 HINGE-PIER CONNECTION
T. George 01/12/09
Flagstaff, Arizona U.S.A.
MONOPOLE TOWER
do not manually update
scale 1: 8 size A
CAD file :
dwg #
sheet 1 of 1rev. NC
DATE
APPROVALS
DRAWN
R&D
PROD EGR
MFG
QUAL
MATERIAL:
FINISH:
DO NOT SCALE DRAWING
DWG #-------------------
CAD-generated drawing
.X ± .1 ± 30 '
decimals angles
other purpose except as specifically authorized in writing by Southwest Windpower.
APPROVED
DATE
DESCRIPTION
unless otherwise specified
dimensions are inches
tolerances are :
Proprietary rights are included in the information disclosed herein. This information is
submitted in confidence and neither the document nor the information disclosed here-
in shall be reproduced or transferred to other documents for manufacturing or for any
--

16 Sectional Monopole Tower Foundation & Installation Manual, Revision A16 Sectional Monopole Tower Foundation & Installation Manual, Revision A
To join the tower sections together :
• Inspect the mating sections of the tower sections for burrs and roughness and smooth and repair as necessary.
• Mark the base section 26 in (66 cm) from the upper end of the section. This mark will be used to determine full insertion of the base section.
• Lubricate the base section using a liquid dish soap (do not use grease or oil as this will stain the tower) and LOOSELY assemble the base and mid
sections. Lifting tab on tower center section MUST face upward.
• Run a 5/16 in (8.0 mm) grade 70 transport chain with slip hooks at each end through the tower sections and secure a 4 x 6 x 14 in (10 x 15 x 36
cm) wood block at the end of the pole.
• Support the tower midsection at its center of gravity – approximately 110 in (279 cm) from the bottom of the section – this will aid keeping the sections
aligned axially.
• Raise the gin pole approximately 10 to 20 degrees above horizontal and insert chain links into the slotted plates positioned on either side of the gin
pole’s central support tube.
• The gin pole should maintain its position under its own weight. Apply a downward force [maximum 200 lb (91 kg)] at the far end of the gin pole to draw
the tower sections together.
• Repeat the above process by readjusting the chain links as necessary until the tower mid section is fully seated against the base section.
• After the tower mid section is fully seated onto the tower base; mark the upper end of the tower mid section 21 in (53 cm) from upper end of the section.
Use this mark to determine full insertion mid section into the top section.
• Join the top and mid sections using the same procedure that was used to join the base and mid sections.
If difficulties are encountered getting the tower sections to seat fully a few blows from a sledge hammer on wood block while a second person applies
pressure using the gin pole will usually result in fully seating the tower sections.
IMPORTANT: Make sure lifting tab on tower mid-section is facing upward
and in line with the pull direction before seating the tower sections together.

Sectional Monopole Tower Foundation & Installation Manual, Revision A 17
TIP: The tower is now set to be raised. Southwest Windpower recommends raising the
tower once without the wind turbine installed. This permits checking the proper opera-
tion and installation of the hinge and gin pole and also allows inexperienced installers an
opportunity to practice raising the tower without risking damage to the wind turbine.
Raising the Tower
Refer to the Skystream Owners Manual for instructions on completing the electrical connections and mounting Skystream on the tower. If you have not
raised a tower before Southwest Windpower recommends first raising the tower without the windturbine installed. This provides the opportunity to practice
the procedure without risking damage to the windturbine.
Follow these steps to raise the tower:
• Tilt the gin pole to the vertical position and using the wire rope cable (with the adjustable end) connect the end of the gin pole to the lifting tab located
at the tower mid section.
• Note that it may be necessary to adjust the length of this cable when switching between the 33.5 ft (10.2 m) and 45 ft (13.7 m) towers or because of
variations in the location of the lifting tab. Refer to the accompanying Adjusting Cable Length section for instructions.
Adjusting Cable Length
READ ALL INSTRUCTIONS BEFORE BEGINNING
• Determine the required cable length taking into account the two shackles needed to connect the cable to the gin pole and the tower.
• Turn back the cable over the thimble and install the rst U-Bolt clip such that the “U” section of the bolt is in contact with the “dead” end of the cable and
is approximately 6 in (15 cm) from the base of the thimble. Refer to the accompanying figure.
• Tighten the nuts evenly, alternating from one nut to the other until reaching 30 lb-ft (41 N-m) of torque.
WARNING: When using U-Bolt clips, extreme care must be exer-
cised to make certain they are installed correctly. The U-Bolt clip
must be installed so that the “U” section is in contact with the
“dead” end of the cable. Refer to the accompanying figure.
WARNING: The TIGHTENING and RETIGHTENING of the U-Bolt
clip nuts must be accomplished as described in the instructions.
Only use forged U-Bolt clips – never use malleable clips in criti-
cal heavy duty applications such as raising the tower.

18 Sectional Monopole Tower Foundation & Installation Manual, Revision A
• Install the second U-Bolt clip as near the thimble as possible. As with the previous U-Bolt clip, tighten the nuts evenly, alternating from one nut to the
other until reaching 30 lb-ft (41 N-m) of torque.
• Install the third U-Bolt clip midway between the other clips and tighten the nuts to 30 lb-ft (41 N-m) of torque.
• Apply a load to the cable equal or greater than the maximum anticipated load (DO NOT USE THE TOWER AND TURBINE AS THE LOAD) and retighten
the nuts to 30 lb-ft (41 N-m) of torque. This step is very important as the cable may stretch and shrink in diameter when a load is applied effectively loos
ing the U-Bolt clip nuts. Note the maximum load the cable will experience is approximately 2400 lb (1100 kg).
Raising the Tower - (continued)
• Connect the second wire rope cable to the base of the gin pole and to the “lifting” vehicle using the shackles provided.
• Start to “raise’ the tower by slowly driving the “lifting” vehicle away from the tower to take the slack out of the cable – keep the vehicle “in line” with the
tower – avoid loading the tower in a lateral direction.
• The vehicle should stop pulling as the end of the gin pole approaches 3-4 ft (1-1.3 m) above ground level. At this point two full size adults can complete
raising the tower by pushing down on the end of the gin pole or by pushing down on the cable.
• Observe that the anchor bolt closest to the hinge pivot axis clears the slot in the tower base. This is normally not an issue unless the anchor bolt projec-
tion from the foundation exceeds 7.5 in (19 cm).
• As the tower nears the fully vertical position it will be necessary to “lift” the gin pole to slow the tower as it assumes the fully vertical position. Two people
are required for this operation.
• When the tower is completely vertical install the remaining nuts and washers to secure the tower to the foundation.
If the tower was raised without the turbine, refer to the section on lowering the tower. If the tower was raised with the turbine proceed to the section on
Leveling the Tower.
CORRECT
6 in (15 cm)
WRONG
WRONG

Sectional Monopole Tower Foundation & Installation Manual, Revision A 19
WARNING: Someone MUST be in the vehicle at all times to control lowering the tower. The
“pulling”force the tower exerts greatly increases as the tower approaches the horizontal. In
other words the tower is lowered using the vehicle brakes to slow the descent of the tower.
During lowering keep the vehicle engine running to provide power brake assistance.
WARNING: Use extreme caution when lowering the tower.
Keep well away and to sides of tower and cable.
Lowering the Tower
Lowering the tower is essentially the reverse of raising the tower. Observe the same precautions including not passing under the tower as it is lowered
and standing well clear of cables. As with raising the tower, a minimum of three people are recommended.
• Turn OFF power to the turbine.
• If not already in place install the hinge plate following the directions in Gin Pole and Hinge Plate Installation section of this manual. Observe the
recommended bolt tightening procedure.
• Connect the gin pole to the lifting tab at the mid section of the tower using the wire rope cable and shackles provide with the gin pole kit.
• Position suitable bracing to support the tower top and keep the turbine from contacting the ground after the tower is lowered. The bracing should
be located approximately 8 ft (2.4 m) from the tower top to clear the turbine blades.
• Connect the second wire rope cable to the gin pole and lowering vehicle.
• Position the vehicle so there is approximately 1-2 ft (30-60 cm) of slack in the cable and the vehicle is in line with lowering path of the tower.
• Remove the foundation nuts and washers.
• Start the lowering process by having two people lift the gin pole to take up the cable slack. Continue lifting the gin pole as the vehicle keeps the
cable taught.
• Once the tower passes the “balance point” the vehicle will be in control of the tower lowering and the individuals at the holding the gin pole should
clear the area.
• Note pulling force the tower exerts on the vehicle greatly increases as the tower approaches horizontal.

20 Sectional Monopole Tower Foundation & Installation Manual, Revision A
Leveling the Tower
Leveling the tower is most easily accomplished using only four of the eight foundation bolts. Once the tower is leveled the remaining bolts can be fully
tightened to secure the tower.
Be aware that leveling the tower may require some trial and error adjustments – even though the base is level, the upper tower flange may be off level
due to manufacturing tolerances.
To level the tower:
• Level the tower on a calm day to minimize movement of Skystream. Start by loosening all the upper foundation nuts about a full turn.
• Loosen and lower the four nuts on the “sides” of the foundation base plate. In other words the tower should be supported by the four “corner” nuts of
the tower base plate. (refer to Fig. 8, Bolts A and B are “corner” bolts)
• Using two bubble levels set perpendicular to each other on the base plate adjust the foundation nuts until the tower is level. Magnetic bubble levels
may make this process easier.
• Once the tower is level tighten all nuts and recheck level.
Observe the position of Skystream on calm days. If the wind turbine seems to favor a single position with no wind, the tower may require fine tuning even
if it appears level using the bubble leveling technique.
To fine tune the tower realize that the nose cone of the wind turbine will “point” in the direction of the tower low side. Therefore, to level the tower, slightly
raise the side of the tower under the nose cone or lower the side of the tower opposite the nose cone. Make fine adjustments. Approximately one turn of
a foundation nut equates to slightly more than 1/8 in (3.2 mm) so even a half turn adjustment will make a difference.
Tightening Foundation Bolts
Tighten the foundation bolts by using the Turn of the Nut Method as described below.
Turn of the Nut Method of Tightening
• First tighten each nut to a “snug tight” condition to bring the hinge plate in full contact
with the foundation. “Snug Tight” is defined as the tightness attained by a “few” impacts
of an impact wrench or the full effort of a man using an ordinary spud wrench.
• Following the initial snug tightening, tighten each nut an additional 1/3 to 2/3 turn.
WARNING: Never leave foundation bolts loose.
Foundation bolts may be temporarily loosened during
tower leveling – however, never leave tower unless
ALL foundation bolts are FULLY tightened.