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Raum Energy Inc.

15m Lattice Tower Construction Guide

Raum Energy Inc. 3718A Millar Ave. N Saskatoon, SK S7P 0B1 PH: (306) 651-0586

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

WARNING!
The tower construction guidelines contained herein is a result of careful design and consideration. Raum Energy Inc. will not warrantee any tower installed by the customer in contradiction of these guidelines. In addition, Raum Energy is not liable for any damage to the Raum Energy wind turbine system or any collateral damage or injury as a result of a faulty or defective tower installation.

IMPORTANT!
Read this manual entirely before you start. Failure to accurately follow these steps may results in damage to the tower, turbine or foundation. This tower has been designed to meet the loading requirements of the Raum Energy 1.4kW wind turbine. The construction of the foundation for this tower must be completed before the tower is installed. This tower was designed with the following notes and assumptions: - there is no seismic activity in the area - max wind loading is designed for Saskatchewan, areas of higher wind require additional design by a structural engineer Raum Energy recommends that you consult a qualified structural engineer concerning specific requirements for your tower location. DO NOT CLIMB THE TOWER. Climbing the tower is extremely dangerous and can lead to serious injury or death. Raum Energy recommends you attach climb shields on the tower using 4x8 sheets of plywood (or other suitable material) cut to the tower width and attached to the tower so that the lower lattice struts cannot be accessed.

Before you start:


Assembly of this tower will likely take approximately 5 person-hours of time. By reviewing the tools required before you start construction, you can ensure that you have all the tools ready before you start to ensure that the construction proceeds smoothly.

Tools required:
Torque wrench capable of reading up to 25 ft-lbs (35 Nm) Torque wrench capable of reading up to 80 ft-lbs (108 Nm) 1/2 socket and wrench 3/4 socket and 3/4" wrench Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009 2

Introduction:

The Raum Energy 50ft tower consists of five main sections. At the top, a 60mm (2 3/8) diameter pipe connects the tower to the bottom of the turbine. This part of the tower is called the mast. Below the mast are 4 tower sections. Each tower section has three vertical tubes and a series of diagonal trusses that transmit wind loads to the ground. These 4 sections are labelled section 1 which is the nearest the ground, up to section 4 which connects to the mast. Each tower section is assembled separately and then they are all connected to each other before the tower is attached to the foundation by two hinge connections while still lying horizontally. After the tower is connected to the foundation, the wind turbine is installed on the mast, and finally, the completed tower with wind turbine is lifted into a vertical position. Before assembling the tower, separate the tower section tubes into 4 groups so that the tubes are separated according to what tower section they belong in. The tubes are identified by a number which can be found on the inside top of the tube. Each tower section required 3 identical tubes.

NOTE:
It is very important that the tubes are grouped correctly and that they are in the correct direction.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Tower Section 1 Assembly


Step 1: Section 1 of the tower consists of 3 tubes that have tabs that are welded in place. There are 11 diagonal braces which on each of the three sides of the tower. To start assembly, lay 2 tubes down on the ground beside each other. Make sure that they are facing the correct direction the number 1 should be on the inside top of each tube. Then find 11 diagonal braces and place them between the two tubes. The correct diagonal braces can be found by looking at the diagram on the right of this page. Each end of the diagonal braces is attached to the tubes through welded tabs. Place the braces such that the rounded edge of the brace is facing towards the outside of the tower.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Step 2: To attach the diagonals to the welded tabs, use a 5/16 x 3/4 bolt as well as two washers and a nylock nut as shown below.

NOTE:
Only fasten the nuts loosely onto the bolts for now final tightening will be performed afterwards.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Step 3: Next, get the third tube which is part of Tower section 1 and fasten the remaining diagonal braces. This step may be easier to perform if one person holds the tube in the proper position while the second person installs the diagonal braces with 5/16 fasteners. Be careful not to bend the welded tabs or the diagonal braces. When this step is completed, the tower section 1 should resemble the image below.

NOTE:
After all three tubes are assembled together, there should be no free tabs on the tubes that are not being used. Step 4: Locate and identify the three hinge components that attach to the bottom of Tower section 1. Although they may appear the same, they are slightly different and they must be installed in a specific configuration. Refer to the figure below to identify the three hinges.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Step 5: Slide the left and right hinges into the bottom of two Tower section 1 tubes so that they align and form a common axis. The center hinge then goes in the bottom of the remaining leg as shown below.

Step 6: Fasten the hinges into the tubes with 7/16 Bolts, washers and nylock nuts as shown below. Tighten to 50 ft-lbs. TIGHTENING ALL BOLTS TO PROPER TORQUE SPECIFICATIONS IS EXTREMELY IMPORTANT!

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Step 4: Repeat steps 1 to 3 for Tower section 2. The only difference to note when assembling Tower section 2 is that there are only 10 diagonal braces for Tower section 2 while there are 11 braces for Tower section 1. The diagram to the right shows which diagonal braces are the correct ones to use for Tower section 2.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Step 5: Repeat steps 1 to 3 for Tower section 3. The diagram to the right shows which diagonal braces are the correct ones to use for Tower section 3.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

Step 6: Tower section 4 is assembled slightly different because it has two mounting plates which hold the mast in place. Start assembling Tower section 4 the same way you did with the first three sections. The diagram to the right shows which diagonal braces are the correct ones to use for Tower section 4.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

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Step 7: Before you install the third tube on Tower section 4, locate and install the lower mast mounting plate as shown below. It can be attached to the horizontal tabs that are 1060 mm (42) down from the top of the Tower section 4 tubes. Fasten using the same 5/16 Bolts, washers and nuts that are used on the diagonal braces as shown below.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

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Step 8: Locate and install one mast mounting bracket to the lower mast mounting plate as shown below.

Step 9: Locate and loosely install the lower U bolt.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

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Step 10: Install the third tower leg on tower section 4. Make sure to install the remaining bolt onto the lower mast mounting plate. Now locate the upper mast mounting plate and install in the end of the three tower tubes. Attach the upper mast mounting plate using six 7/16 bolts.

Step 11: Complete the installation of the upper mast mounting plate by installing a mast mounting bracket and a U-bolt using the same procedure as used in Step 9.

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

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Step 12: Connect tower sections 1 and 2 together using three tower section connectors. Each tower section connector is bolted in 4 places using a 7/16 bolt, 2 washers and a nylock nut. Tighten the fasteners loosely until the tower is completely assembled.

Step 13: Repeat step 12 and connect tower section 2 to tower section 3 and repeat step 12 to connect tower section 3 to tower section 4.

(No image for Step 13)

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

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Step 14: Slide the mast down into the top of tower section 4 as shown below. Use the U bolts to secure the mast in place. The mounting flange at the top of the mast should be 1.67m (66) higher than the top of the upper mast mounting plate. Tighten the U bolts to 19 ft-lbs. TIGHTENIING ALL BOLTS TO PROPER TORQUE SPECIFICATIONS IS EXTREMELY IMPORTANT!

Step 15: Go back to all the bolts installed in the tower and tighten all 5/16 bolts to 19 ft-lbs. Make sure that the fasteners on the mast mounting plates are tightened to 19 ft-lbs. Double check all 7/16 bolts and tighten to 50 ft-lbs. TIGHTENING ALL BOLTS TO PROPER TORQUE SPECIFICATIONS IS EXTREMELY IMPORTANT!

(No image for Step 15)

Raum49L Tower Construction Guideline Rev2 Raum Energy Inc. Proprietary 2009

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