PRIMUS WIND POWER DOCUMENT #0070 REV C 45-FOOT LAND TOWER KIT For AIR WIND MODULES TM Made in the USA by: Primus Wind Power 938 Quail Street Lakewood, CO 80215 USA (303) 242-5820 AIR is a trademark of Primus Wind Power Inc.
PRIMUS WIND POWER DOCUMENT #0070 REV C 45-Foot LAND TOWER KIT CONGRATULATIONS! You have just received the simplest, most economical tower kit available for your AIR wind turbine. This kit is designed to be very easy to assemble and erect, however it is important that you read this manual thoroughly before beginning assembly. If you have any questions on proper installation or usage please call either Primus Wind Power or your dealer for more information.
PRIMUS WIND POWER DOCUMENT #0070 REV C Introduction This tower kit is designed specifically for the Primus Wind Power AIR 40 and AIR 30 wind turbines. To our knowledge this is the most economical and user-friendly tower kit available for the AIR wind turbines. Two level, guy wire supported construction allows the use of lightweight tubing while providing plenty of strength, even in high wind conditions. Two people can easily erect the kits in a few hours.
PRIMUS WIND POWER DOCUMENT #0070 REV C 45 Foot Tower Kit Parts List Your tower kit includes: Tower Base Upper Wire set Lower Wire Set Tower Base Staples 3/8” x 1 ½” Bolts 3/8” Lock-nuts Cable Thimbles Cable Clamps Quantity 1 1 1 2 3 3 8 16 Note: This 45 foot Tower Kit also includes a setup kit to raise the tower. If more than one tower is to be erected a single set up kit can be used for any towers to be installed.
PRIMUS WIND POWER DOCUMENT #0070 REV C Tower Setup Kit Parts List Your tower setup kit includes: Gin Pole Cap 100’ Rope Snap Links – Work Load Rated to 400# 8-foot Cable 3/8” x 1 ½” Bolt 3/8” Lock-nut Quantity 1 1 3 1 1 1 Please inspect the contents to see that all parts are present and to familiarize yourself with the pieces before beginning assembly.
PRIMUS WIND POWER DOCUMENT #0070 REV C Items Not Included In This Kit: Anchors (The type of anchors used will depend on the ground makeup at your tower site. This is explained further in the “Anchors” section of this manual.
PRIMUS WIND POWER DOCUMENT #0070 REV C The other concern with long wires is the voltage drop through the wire. Voltage drop through the wires can be calculated using the formula: Voltage = Current x Resistance The effect of the voltage drop is most apparent when the turbine has good wind and is actively charging the batteries.
PRIMUS WIND POWER DOCUMENT #0070 REV C Use the following table for Pipe / Tubing wall thickness guidelines: Maximum Wind Speed 84 mph. 96 mph. 120 mph. Recommended Wall Thickness .065 inch (1.65 mm) .090 inch (2.3 mm) .140 inch (3.6 mm) Pipe Schedule Tubing Schedule 20 Schedule 40 *UL-Certified Although the design of this tower kit will allow different wall thicknesses of pipe to be used in the same tower, we recommend that the same thickness pipe be used for both the upper and lower sections.
PRIMUS WIND POWER DOCUMENT #0070 REV C If the tower is to be erected on flat ground and there is a breeze blowing the tower should be assembled towards the wind if possible, so that the wind may help slightly as the tower is raised rather than working against you. If your tower is on the side of a hill and there is a breeze blowing ignore the breeze and assemble the tower on the uphill side. Be sure that the anchor points and base position are in a straight line when sighted from anchor to anchor.
PRIMUS WIND POWER DOCUMENT #0070 REV C Step 4: Guy Wire Anchor Installation There are four types of anchors that are most commonly used with our towers; screw in “Auger” type anchors, hammer driven “duckbill” anchors, cast concrete anchors and expansion bolts (for use only in solid rock). What anchor should be used depends on the soil type that the anchors will be placed in.
PRIMUS WIND POWER DOCUMENT #0070 REV C Augers depend on the ability of the soil to hold together for the pullout strength. If augers cannot be screwed in, simply digging a hole and burying them will not work. We recommend buying augers, and if they cannot be screwed in properly, a hole can be dug and the auger cast in concrete. This will provide a good loop for guy wire attachment and make an excellent anchor in the concrete.
PRIMUS WIND POWER DOCUMENT #0070 REV C Buried Concrete: A buried concrete anchor may be the only solution if the ground is loose gravel or sand or if it is too rocky for an auger or duckbill to be driven in. Buried concrete anchors work well in any situation other than solid rock. A hole must be dug in the ground at the desired anchor point. One good tactic is to purchase either augers or duckbills and if they cannot be used as intended, then dig holes and cast them in concrete.
PRIMUS WIND POWER DOCUMENT #0070 REV C Step 5: Tower Base Assembly To assemble the base, a 6 foot long piece of tower tubing is positioned half way through the base tee as shown in the drawing below and the set screw tightened to hold it in position (use the 5/16 inch allen wrench included with your turbine). The base “T” should now be placed in the position chosen for the base of the tower, perpendicular to the direction that the tower will be raised.
PRIMUS WIND POWER DOCUMENT #0070 REV C Depending on the nature of the soil at the site, the ground staples should be driven or cemented into the ground so that the base tube is captured. If cement pads are to be used, the base tube can be supported at its ends and used to hold the staples while the cement is setting. If the base is to be on solid hard rock, expansion bolts and chain should be used. For softer rock the staples can be cut shorter and cemented into holes drilled in the rock.
PRIMUS WIND POWER DOCUMENT #0070 REV C 4) Extend the wires straight from the turbine and tape them together every 3 feet. They will be much easier to push through the pipe as a group than one at a time. 5) If pipe insulation is to be used on the wires, a short piece (6 inches) should be taped securely onto the wires every 3 feet or so. This will keep the wires from contacting the pipe and transmitting turbine noise to the tower.
PRIMUS WIND POWER DOCUMENT #0070 REV C MAKE SURE THAT ALL GUY WIRES ARE SECURE BEFORE PROCEEDING! At this point the turbine should be propped up on a box, chair, stool, block or milk crate so that the blades are not damaged when they are installed. Mount the blades onto the turbine at this time. Step 8: Erecting the Gin Pole MAKE SURE THAT ALL GUY WIRES ARE SECURE BEFORE PROCEEDING! There are three methods for erecting the gin pole and preparing to raise the tower.
PRIMUS WIND POWER Method I DOCUMENT #0070 REV C (Gin Pole to Base, then Tower to Base) This is the simplest method, but can be difficult if large wires (4 gauge or larger) are used. 1) Mount one end of the gin pole in the tower base and tighten the set-screw to hold it. 2) Mount the gin pole cap and install the bolt through its tabs. Snug the nut onto the bolt. 3) Attach the snap links and 8 foot cable as shown in the drawing.
PRIMUS WIND POWER DOCUMENT #0070 REV C 4) Tie the rope to the anchor on the gin pole side and loop it through the snap links as shown. Leave enough slack in the loops so that the gin pole can be raised to vertical. A “figure eight” knot is recommended. This can be tied as shown and then clipped into the snap link on the anchor. 5) Attach the “gin side” guy wires to the gin pole Snap Link as shown. 6) The black and red turbine wires should be shorted together at the tower base end.
PRIMUS WIND POWER DOCUMENT #0070 REV C 8) Have one person hold the gin pole while the electrical wires are pushed up into it (can be difficult with large wires). Slide the assembled tower into the tower base then tighten the set-screw (use hex key from turbine kit). 9) Attach the “gin side” guy wires to the bolts on the coupler and upper guy wire hanger. Tighten the coupler over the joint between the upper and lower tower sections and tighten the upper guy wire hanger about three feet from the turbine.
PRIMUS WIND POWER DOCUMENT #0070 REV C Method III (Gin and Tower to Base on Side, Rotate, then Slide in Base Tube) This method can be fairly easy although the tower base tube must be slid into position and the base anchoring staples installed while the gin pole is being held vertical. 1) Loosen the set-screw and slide the tower base tube so that one end is flush with the tower base fitting. 2) Push the electrical wires into the tower base and attach the tower to the tower base. Tighten the set-screw.
PRIMUS WIND POWER DOCUMENT #0070 REV C 9) Attach the “gin side” guy wires to the gin pole Snap Link as shown. 10) Raise the gin pole to vertical (rotating the tower). 11) With the gin pole being held vertical, slide the tower base tube into the tower base fitting until it is centered. Tighten the set-screw (if you can get to it….not critical). 12) Install the tower base anchoring staples or chains at this time.
PRIMUS WIND POWER DOCUMENT #0070 REV C If the top of the tower is coming up more than the middle, lower the tower back to the ground and move the upper guy wire hanger down the tower a few inches. If the middle of the tower is being pulled up more than the top, lower the tower back to the ground and move the upper guy wire hanger up the tower a few inches. Raise the tower a few feet and check again. Repeat this step until the tower remains straight as it is being raised.
PRIMUS WIND POWER DOCUMENT #0070 REV C At this point the tower should be checked for guy wires that are slightly too tight or too loose. Guy wires that are too tight will cause the tower to bow. The proper pre-tension is essential to avoid buckling the tower. If they are too loose the tower will usually sway back and forth a bit. A simple test for guy wire tension involves pulling or pushing the guy wire with about 15 to 20 pounds approximately 36.00” from the guy attachment.
PRIMUS WIND POWER DOCUMENT #0070 REV C Step 10: Final Adjustment of Guy Wires First look to see if any of the guy wires are too tight and are causing the tower to bow. A tower with slightly loose wires is safer than a tower with wires that are too tight. If there are, determine which wire(s) are too tight (the wires act in pairs) and release the tension on one of the wires. To relieve tension on a wire, loosen the two cable clamps until the cable can be slid through them.
PRIMUS WIND POWER DOCUMENT #0070 REV C for UL-compliance. Refer to the AIR 40 turbine owner’s manual for more information regarding an up-tower j-box configuration. Grounding To properly ground the tower to the earth a ground rod (usually copper plated steel) should be installed as close to the tower base as possible. A #10 AWG or larger wire should be attached to the tower pipe near the bottom of the tower with its other end clamped to the ground rod.
PRIMUS WIND POWER DOCUMENT #0070 REV C 4) Assemble the snap links, rope and 8 foot cable as they were when the tower was raised. 5) Disconnect the guy wires on the gin pole side only. 6) Position a box where the tower is expected to come to the ground to protect the turbine blades from damage. 7) With the tower raising / lowering rope in one hand, push at the base of the tower until the tower starts to tip and the rope/gin pole is holding the tower.
