ARI Hybrid Solar-Wind Generator

ARI-450 and ARI-600 Wind Turbine Tower Kit

Owners Manual

TableofContents

Introduction.3 1. Safety Precautions....3 2. Parts in the Package.4 3. Site Selection........6 4. Hardware Selection......7 5. Step-by-Step Installation........8 6. Maintenance and Lowering the Tower12 7. Junction Box and Lightning Arrestor ..12

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Introduction
This tower kit is specifically designed for ARI-450 and ARI-600 wind turbines. ARIs tower kit is easy to install and economic effective. Included are all the necessary parts and bolts to erect your tower. You will need to purchase a fence pipe or tubing from your local store (please refer to the Hardware Selection). In this manual, you will be provided with demonstrative graphics and step-by-step instructions. Please read your manual thoroughly before you begin to assemble your tower kit.

I Safety Precautions
1. During tower setup, under no circumstance should any human being stand near the construction site. 2. Important! It is important for you to consult with a local specialized tower installation contractor or the local planning and zoning office for your area regarding regulation details. 3. Even though the ARI tower kit is designed for easy installation, you will need someone to help you during the installation process. At least two people must be available to erect the tower. 4. The turbine installation should take place on the ground level prior mounting the turbine to the tower. 5. WARNING: DO NOT ALLOW ANY PERSON UNASSOCIATED WITH THE INSTALLATION OR ANY UNINVOLED BYSTANDER NEAR THE TOWER DURING THE INSTALLATION PROCESS. 6. Choose tubing or pipe according to the recommendations of this manual. Make sure that you choose tubing or pipe that is strong enough to support your wind turbine when it is spinning in strong wind. 7. WARNING: All welded and bolted connections must be fastened tightly and guy wires and anchors must be adjusted to fit your terrain. 8. Important! Choose a clear and calm day to raise your tower. A gust of wind at the wrong moment could cause serious injury.

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II. Parts Included in the Package

Unpack and check the packing list to ensure every part is included in the packing box.

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Part name Tower Base Guy Wire Set Hooping Rope Rigger Dumping Clamps Cable Clamps x 4 Pivot Bolts Lock-Nuts Tower Pipe* Anchors Sheathing Elbow Traverse Sheathing Tube Tube Clamp Tower Base Coupler Rigger Spiral Links M16x400 Foundation Screws Foundation Lock-nuts

Quantity 1 4 1 4 16 3 3 1 4 1 1 1 1 4 4 4

Note: Tower pipe is not provided in this package. It is listed here only for demonstration purposes. Items Not Included In This Kit: Pipe for Tower and Gin Pole Ground Rod and Clamp Lightning Arrestor Flex Conduit and Fitting Junction Box Pipe Insulation (to prevent wire from rattling inside pole) Tools Needed: 1. Round or Half Round File 2. Pliers 3. 12-14mm Open End Wrench, Socket or Nut Driver 4. 17-19mm Open End Wrench, Sockets or Torque Wrench 5. 22-24mm Open End Wrench, Sockets or Torque Wrench 6. Sledgehammer

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III Site Selection

Site selection is very important for both effective performance and safe operation of your wind turbine. Because wind power is a cube function of the wind speed, a 10% increase in wind speed will result in approximately a 37% increase in the wind power available from the wind and a similar increase in turbine performance. For example, wind energy at a wind speed of 5 m/s is twice as much as wind energy at a wind speed of 4 m/s. And it is always true that as the tower gets higher off the ground, the wind speed grows stronger. As a rule of thumb, therefore, your wind turbine will get a better performance as the tower erects higher. In order to ensure the normal operation of your wind turbine, please refer to the following rules: 1. The wind turbine will generate greater energy power at a higher wind speed as the tower gets taller. 2. The wind turbine will be severely damaged and its operational life span can be affected if it is installed in a site where there is unstable air flow or severe turbulence. Furthermore, turbulence can substantially reduce the capacity of the wind turbine to generate power. Therefore, a site with severe turbulence should not be chosen but avoided at all cost. 3. The recommended tower height should be at least 27 feet above ground. Trees and various objects can block the air flows. The following data are provided for your reference: (1) The tower should be at least 20 feet higher than the highest obstacle. (2) The tower should be at least twice as high as surrounding obstructions (trees, buildings, etc.) if they must be located close together. (3) If there are houses or trees in the surrounding area, a good rule of thumb is to choose a tower site that is at least 15 feet away from any obstructions. Note: A shorter distance requires less wire as well as reduces the amount of power lost in the wires and voltage drop through the wire.

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IV. Hardware Selection

Because the height of the tower, i.e., the length of the pipe or tubing depends on the height of any surrounding obstacles and the distance between the tower and the obstacles, and also because the tubing or pipes are heavy yet readily available through most fence suppliers or plumbing companies, it makes more sense to purchase locally. ARI-450 and ARI-600 wind turbines are designed to be mounted on a 2.5 inch inner diameter and 2.97 inch outside diameter pipe. Before setting up your tower, purchase from your local store tubing or pipes with a 2.5 inch inner diameter and a 2.97 inch outside diameter.

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V. STEP-BY-STEP INSTALLATION 1. Anchor Layout

Choose a center point (point A) for the tower base in the chosen site. Draw a circle that has a center point (point A) and radius of 15 feet. Then choose four points that partition the circle to four equal arcs. The four points are the site at which to install anchors. See the picture below:

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Dig a 1m x 1m x 1.5m (3 x 3 x 4.5 feet) hole at each anchor site; place the anchor in the hole. Note: the direction of the anchor should be aimed toward the tower base. Pour 0.8m (2.5 feet) deep of concrete or cement around the anchor, and then fill with 0.7m of clay. See the diagrams below:

2. Tower Base Installation Dig a 3 x 3 x 3 feet (L x W x deep) hole, place each of the four M16*400mc foundation screws in the hole, and then pour concrete around the foundation screw. Note: place the foundation screws at the distance that each of foundation screws must be for the four holes on the tower base. Wait for seven days until the concrete is completely dry, then place the tower base on the four foundation screws, use 22-24mm open-end wrench to lock the foundation screws with the foundation nuts. See picture 1 below:

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3.

Assembly the Tower and Pipe

(1) Take out the pipe that you have purchased from the local store. At the end of the pipe (about 1 inch away from the end), drill 4 holes at the cross of the diameter. The size of each hole should be 8.5 mm in diameter. At the other end of the pipe (about 1.5 inch away from the end), drill 2 holes cross through the pipe. The size of the hole should be about 12.5 mm in diameter. (See picture 2.) (2) Enter the pipe (the side with two holes) into the tower base coupler; make sure you aim the two oval holes of the tower base coupler at the two holes of the pipe. (See picture 2.) (3) Hang each of the four rigger dumping clamps onto the hooping rope and place the hooping rope into the pipe at about six feet away from the top. Let the guy wire pass through rigger dumping clamps, and then lock them by cable clamps. (See picture 3.) (4) Insert the pipe into the tower base, and use a pivot bolt to loosely lock the pipe into the tower base. Note: there are three screw holes on the tower basetwo on the top and one on the bottom. At this point, only
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(5) Take the 3-wire cable out of your pipe from the space between the pipe and the tower base. Let the 3-wire cable pass through sheathing elbows and traverse sheathing tube sequentially. (6) Pass the 3-wire cable out of your wind turbine through the pipe (Refer to the Wind Turbine Owners Manual, Step-by-Step Instructions, step 3). Mount your wind turbine on the top of the pipe on the side with 4 holes and lock the wind turbine with four 3/8 inch screws provided with your wind turbine parts. (7) Hang the hooks of the four rigger spiral links to the anchors and insert each of the guy wires into the circle hole of the four rigger spiral links and lock it with cable clamps. (See picture 5.) (8) Raise the tower by tools. See the picture below:

(9) Check whether the tower is plumb and straight upper. If not, use four rigger spiral links to make the adjustment. (10) Take the tail of the 3-wire cable out of the traverse sheathing tube through the semi-circle hole of the tower base coupler and make it ready for the connection to the charge controller. Then strike the tower base coupler and make it cling to the tower base. Lock the two M8*25 screws of the tower base coupler, lock the two pivot bolts through the top two holes of the tower base, and tighten the pivot bolts on the bottom hole of the tower base. Finally, use the tube clamp to lock the traverse sheathing tube onto the M5 screw hole on the tower base. Adjust the tightness of the guy wires through the four rigger spiral links. Note: a tower with a slightly loose guy wire is safer than a tower with tight wires. (See picture 6.)

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VI. MAINTENANCE AND LOWERING THE TOWER When there is a typhoon, the four rigger spiral links and guy wire set should be released. Disconnect your wind turbine wires from the charge controller first, then disconnect the wires at the tower base and remove the junction box and lightning arrestor if you have installed them. Twist the disconnected turbine wires (at the tower base) together to short the wind turbine to stop it from rotating. Remove the two top pivot bolts of tower base and then lower the tower. (Warning: The bottom pivot bolt of the tower base should never be loosened or removed). Pull down the tower pipe slowly by tool. See the picture below:

Check the tightness of the guy wires regularly and make sure the tower is straight and upright. If it is not, adjust the guy wires.

VI. JUNCTION BOX AND LIGHTNING ARRESTOR A junction box with a lightning arrestor is recommended. Please purchase a junction box and a lightning arrestor from your local store. You can set up the junction box on the base of your tower and place the lightning arrestor in the junction box. Follow the instructions that come with your purchase to install the junction box and lightning arrestor.

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