ASSEMBLED FOUNDATION SYSTEM (150-130 AFS)Installation Manual

Telecom-Small Wind(Above Grade)

1043 Grand Avenue, # 213St. Paul, MN 55105Ph: (651) 330-1263

www.arerenewables.comwww.aretelecom.com

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Important! READ THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE ASSEMBLING THE AFS, TOWER AND BEFORE OPERATING SCREW JACK.•

WARNING: PROPERTY DAMAGE, SERIOUS INJURY OR DEATH MAY RESULT FROM IMPROPER USE. THEREFORE, IT IS HIGHLY •RECOMMENDED THAT TOWER AND RAISING/ LOWERING SYSTEM BE INSTALLED AND OPERATED BY TRAINED PROFESSIONALS

Safety Prior to each use verify that Screw Jack operates correctly UP and Down.•

Machine Screw Jack shall be serviced by authorized personnel only or by customers with written permission from the manufacturer.•

Visually inspect the entire lifting/ lowering system including tower/ foundation connection brackets for wear and damage prior to •each use.

Ensure that all fasteners are properly secured, and that the jack is oriented in the correct position (see Detail C).•

Lifting Screw threads must be kept free of debris and burrs at all times.•

It is the operator’s responsibility to ensure that no one walks underneath the tower during the raising and lowering process and •that common safety measures are taken while operating the Machine Screw Jack. The operator must be observant of any unusual sounds, vibrations or erratic system behavior during normal operating conditions. •If any of the aforementioned is observed, stop immediately and assess the situation. If no obvious solution to the problem can be found, contact ARE Telecom for further assistance.

Maintenance Inspect lifting screw threads for debris and damage before each use. Remove all debris from lifting screw threads. •When needed, carefully remove burrs on the thread surface using a hand file. Do Not use an electric grinder as excess heat can damage the steel surface. Machine Screw Jack should be disassembled and inspected for wear and damage every 100 running cycles •(1 complete running cycle = tower up + tower down) or every 5 years, whichever comes first.

Machine Screw Jack must be lubricated once a year or every 15 running cycles. In extreme operating conditions lubrication may •be required more frequently.

Lubricate the jack and lifting screw while operating in normal service conditions. Worm gear grease port is located on jack housing. •

Recommended Grease: •OMEGA 77, produced by MAGNA industrial Co, LTD. •Mobile Mobilux EP#1 •Shell Aeroshell #22 •

Remove Machine Screw Jack assembly from tower when not in use and store in a dry location to prevent corrosion. •

In humid or coastal regions, grease lifting screw and exposed bear steel surfaces after each use.•

Contact ARE Telecom directly for replacement parts or warranty related issues.•

Product SpecificationsShipping Weight (Tower and Foundation only)..................................................................................... 500 kg (1100 lbs)•

Design Wind Speed .................................................................................................................................. 49.2 m/sec (110 mph)•

Minimum Ballast (per Leg-Basket 150-AFS) ............................................................................................ 600 kg (1320 lbs)•

Minimum Ballast (per Leg-Basket 130-AFS) ............................................................................................ 300 kg (660 lbs)•

Total System Ballast (150-AFS) ................................................................................................................. 2400 kg (5280 lbs)•

Total System Ballast (130-AFS) ................................................................................................................. 1200 kg (2640 lbs)•

Maximum Tower Top Horizontal Thrust Load (150-AFS)......................................................................... 1020 N (230 lbs)•

Maximum Tower Top Horizontal Thrust Load (130-AFS)......................................................................... 665 N (150 lbs)•

Maximum Tower Top Weight, Including Solar •Panels and all other ancillary components........................................................................................... 114 kg (250 lbs)

Minimum Screw Jack Capacity/ Ram Travel......................................................................................... 5 Ton/ 483mm (19 in)•

Note: Contact ARE Telecom for more information on solar panel size and placement on the tower.

Hand Tools2x - Crescent Wrench w/ minimum jaw opening of 44mm (1-3/4 in)•

2x 19mm wrench or socket & ratchet•

Torque wrench (M12 -M24)•

Screwdrivers - Flat head and Phillips•

Pliers•

Required Items not IncludedGround Rod and wire clip•

#2 solid copper wire•

Terminal lug for attaching #2 solid copper wire•

Note: Tower grounding shall be done in accordance with the requirements of the local authority.A 10mm (.375 in) hole is located on the lower foundation hinge plate for connecting the ground wire.

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3774149

3295130

147258

208282

104141

8550337

2850112

9153360

3

2

1

53521

150-130 AFS Dimensions and Weights11

12

16

17

150 130

17B

Ballast Baskets

Component Weight

Part# Description Weight kg (lbs)

1Lower Tower

Section100 (220)

2 Mid Tower Section 70 (154)

3 Top Tower section 48 (106)

11Upper Hinge Plate

24 (53)

12Lower Hinge Plate

26 (57)

16Main

Support Leg

16 (35)

17 150-Ballast Basket 34 (75)

17B 130-Ballast Basket

17.5 (38.5)

1

2

3

1315

21-22

2019

18

45

6

7

8

10

9

11

12

1617

14

Universal Tower Top Flange

Light Fixture Flange (optional)

23

150-130 AFS Bill of MaterialsPart # Qty Description

1 1 Base Section2 1 Mid Section3 1 Top Section4 1 5 Ton Screw Jack5 1 Jack Handle6 2 20mm dia. x 80mm Clevis Pin7 1 15mm dia. x 295mm Tower Pivot Pin8 4 M24x3 x 445mm Hex Bolt9 12 M24 Nut10 16 M24 Washer 72x26x511 1 Upper Hinge Plate12 1 Lower Hinge Plate13 54 M12x1.75 x 55mm Hex Bolt14 54 M12 Nut15 108 M12 Washer 24x14x2.516 4 Main Support Leg17 4 Ballast Basket (XSM or SM)18 1 Hand Hole Cover (Mid Section)19 2 M5x.8 x 15mm Hex Bolt 20 1 Hand Hole Cover (Base Section)21 2 M6 x 1 x 15mm Hex Bolt22 2 M6 Washer23 3 4mm Spring Clip

Optional Components24 16 26" (660mm) Earth Anchor25 8 Right Angle Bracket26 1 48mm (1.9") OD Spigot27 1 119mm (4.7") ID Adaptor28 1 Light Fixture Mount 10deg29 16 GEO-Bag

1214.8

1385.4

1114.37

29

80031.5

481.9

Air Breeze•Air X•Chinook•Zephyr Dolphin•

28

481.9

2118.3

80.00°

1706.7

1706.7

1305.1

1305.1

4x 14.55

401.57

230

1335.24

6x 14.55

190Bolt Circle

7.48

Bergey XL1•

Light Fixture Mount and Tower Top Wind Turbine Adaptors (Optional Components)

Light Fixture Mount #28

Turbine Adaptor #27

Turbine Adaptor #26

Tower Top and Light Fixture Flange Dimensions

29

Securing BallastBallast can be secured to basket using cam straps•or other suitable means.Straps not included •

Note: Filling both inside hollows of the block with concrete adds 30 lbs (13.5 kg) of weight to each block. This will reduce the stack height required when using unfilled blocks.

24

25

Slotted holes in basketprovide connectionpoint for cam straps

Detail A

Concrete Block (8"x8"x16")Qty. - (32) blocks, per basket •Min. individual block weight -•38lb (17.3kg)Min. weight per basket - •1320lbs (600kg)

GEO-BagTo be filled native soil, rock, etc.•Most anything that provides•the required weight per basketcan be placed into the GEO-Bagfor ballast.Each GEO-Bag holds up to •400lbs (182kg)of fill.

Optional (Earth Anchor)To only be used in conjunction with•ballast (concrete block, GEO-Bag)Must be used with right angle brackets•The recommended earth anchor•is the P-26. For more informationon the P-26 visit American EarthAnchor @ www.americanea.com

Ballast Requirements 150 AFS (Minimum Weight per Leg = 600 kg (1320 lbs))130-AFS not shown, see pg. 3 for more details on ballast requirements

Figure 1

Upper Hinge Plate

Lower Hinge Plate10mm Thru Holefor Earth-GroundConnection

200mm8Support Block

M24 Torque Spec678 N-m (500 ft-lb) - Dry552 N-m (407 ft-lb) - Lubed

Figure 2

Figure 3

Detail B

M12 Torque Spec81 N-m (60 ft-lb) - Dry66 N-m (49 ft-lb) - Lubed

Foundation Assembly

Assemble foundation upside-down. Make sure hinge1.plates are properly oriented (Figure 1).A support block, or other suitable means, should2.be used to raise the upper hinge plate beyond the length of the projected bolt thread (Figure 2)Flip foundation upright once assembled3.Attach ballast baskets to support legs using four (4) M12 4.hex head bolts per leg (Figure 3)Before installing tower, weight all four baskets using 5.recommended ballast weight.

Figure 4

Align Longitudinal Welds

67.52.66

Leveling Nutand Washer

Tower and Screw Jack AssemblyPin tower base section to foundation using 1.15mm x 295mm clevis pin. (Detail C)Pin screw jack to lower hinge plate and tower using2.two (2) 15mm x 80mm clevis pins. Make sure lifting screw is connected to tower and support pedestal is connected to lower hinge plate. DO NOT INVERT THE JACK! (Detail C)Align all longitudinal welds 3.Bolt tower flange using six (6) M12 hex head bolts/ nuts 4.Note: upper tower section not shown in Figure 4. Before raising tower adjust all leveling nuts to the 5.recommended height and assemble lowering bracketsand link (Detail C)

Detail C

Support Pedestal

Lifting Screw

Worm GearHousing

Detail D

M12 Torque Spec81 N-m (60 ft-lb) - Dry66 N-m (49 ft-lb) - Lubed