SKYLEVEL INSTALLATION Manual

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1 SKLEVEL INSTALLATION Manual Southwest Windpower, Inc. 80 West Route 66 Flagstaff, Arizona 8600 USA Phone: Fax: June 2009 Southwest Windpower, Inc. All Rights Reserved

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3 TABLE OF CONTENTS INTRODUCTION 4 prior to installation 4 Precautions 4 Included With This Kit 4 Tools and Materials Needed 4 Installing Skylevel Viewer Software 5 In this manual IMPORTANT: Please take note TIP: Helpful information to ease the installation Installation and Adjustment 5-5 Step : Install Skylevel Cable 5 Step 2: Install the Skylevel Support Structure 6 Step 3: Test Skylevel Communication 8 Step 4: Install Skystream 9 Step 5: Calibrate Skylevel and Raise the Tower 0 Step 6: Leveling PREPARING TO LEVEL 2 Leveling the x axis 3 leveling the y axis 4 Step 7: Finishing 5 Skylevel Installation Manual 3-CMLT-375 Revision: A

4 Introduction Skylevel is the Skystream installer s tool for ensuring the precise level of the tower-top mounting flange. The product consists of a mountable, tower-top accelerometer leveling sensor and cable. When used with the Skylevel Viewer software, it allows for viewing and accurately leveling the tower-top flange. Skylevel is recommended for all Southwest Windpower monopole towers. Special considerations for non-tilting type towers are within the body of the instructions and are indicated by **. For hinged, tilting towers, begin with a tower that is lying horizontally in the pre-raising position. See the Skystream Owner s Manual for specific Skystream installation instructions. Precautions Read all instructions prior to installation in order to completely prepare. Level the tower on a calm day to minimize the movement of Skystream and tower. For the most reliable results, use Skylevel on a calm day and in temperatures between -4 F to 3 F (-20 C to 45 C). Never use the strain-relief hooks on the Skylevel device for anything other than the CAT-5 Ethernet cable included. The Skylevel Kit includes: Skylevel Device Cat-5 ethernet cable Cable tie The Skylevel Viewer Kit includes: Skylevel USB converter USB cable CD containing Skylevel Viewer software Tools and Materials Needed No additional special tools or materials are needed to install the Skylevel device. Refer to the Skystream Owner s Manual and Skystream Segmented Tower Manual for complete Skystream installation instructions, tools, and materials needed. A Windows-based laptop PC (running P or Vista) is all that is required to install and run the Skylevel Viewer. TIP: This system is best installed with at least two people. IMPORTANT: Never unscrew the cap of the Skylevel support structure or attempt to remove the circuit board. This will destroy the calibration of the unit and will require replacement. 4 Skylevel Installation Manual, Rev A

5 Installing Skylevel Viewer Software Installation requires a PC-based laptop running Windows P or Vista. Skylevel Viewer software is included on the CD supplied with the kit and is included in the Installer Utilities folder on the current version of Skyview, the Skystream monitoring and data logging software. Locate the CDM exe file and double-click to install the Skylevel device drivers. Insert the USB cable into the USB converter and into the target Windows-based PC. Insert the CAT-5 Ethernet cable into the USB converter and Skylevel device. Double-click the Skylevel_Viewer_.exe program icon to start the program. Save a copy of the Skylevel_Viewer_.exe program to a local directory for future use. If Skyview is installed, copy the program to the Southwest Windpower directory in the Programs folder. Step Install Skylevel Cable Thread the Skylevel CAT-5 Ethernet cable through the tower. To avoid tangling during insertion, completely uncoil the cable before inserting it with the wire snake. Insert the CAT-5 Ethernet cable into the socket, located on the bottom of the Skylevel support structure (See Figure a). Listen for a click to ensure that the cable is securely fastened. Ensure that the plug is securely locked into the socket with a light pull. Double twist a section of cable as shown in Figure b, and loop over one of the the molded strain relief hooks. Press the cable firmly into the receiving slots on one of the strain relief hooks and use the cable tie provided to secure. Figure a Strain relief hook Cable tie Figure b Socket Plug contacts CAT-5 cable Skylevel Installation Manual, Rev A 5

6 Step 2 Install the Skylevel Support Structure Note: If Skylevel is retrofitted to an existing installation, it is necessary to separate the yaw cover from the turbine and transmission wiring before installing the Skylevel support structure. The Skystream turbine s transmission (yaw) wires must be threaded through the center opening of the support structure. Before mounting the Skylevel support structure to the tower-top flange, orient the -axis markings on Skylevel as close to parallel with the tower pivot axis as is possible. The Skylevel s circuit should be positioned on the tower pivot axis side of the tower base. (See figure 2a). Note location of circuit Skylevel Orientation ( Axis) Tower Pivot Axis Hinge Side Note: Some towers are fabricated with a 22.5 offset of the towertop flange holes, and it will not be possible to align the Skylevel axis with the tower pivot axis. The Skylevel Viewer program contains a utility to compensate for this offset. Align the Skylevel device as close to horizontal as possible. Install Skylevel by flexing the retaining clips around the outer edge of the tower top flange as in Figure 2b. IMPORTANT: Noting the location of the Skylevel circuit box is crucial to the effectiveness of the Skylevel (Orient this as close to the bottom of the axis as possible). Note the relative position of the circuit as in 2b below. Feed the CAT-5 cable down the tower. Allow at least 8 ft (2.5 m) of the cable to extend from the tower base to allow for working space and wrench clearance. Coil the unused cable and secure it to the Skystream s transmission wires inside the tower or otherwise secure the wire using a zip-tie or other method. Figure 2a Ground Contact Pad Retaining Clip Press down on each of the eight arms so that the contact pads rest against the top flange. Take care not to over-flex the retaining clips in a way that might cause breakage. Figure 2b (Tilting towers) 6 Skylevel Installation Manual, Rev A

7 Figure 2c (Non-tilting towers) **For installation at the tower top of non-tilting towers, use chalk or similar material to mark the tower to indicate the position of the circuit in the Skylevel assembly relative to the tower. Align the Skylevel device to the foundation bolts as in Figure 2c. Mark the corresponding and -axes adjusting bolts. Skylevel Installation Manual, Rev A 7

8 Step 3 Test Skylevel Communication SOFTWARE Plug the Skylevel CAT-5 cable into the down tower USB converter, and plug the USB converter into a laptop USB port. Once the Skylevel interface box has been connected, run the Skylevel Viewer application (Skylevel_Viewer_. exe). Wait for the application to initialize as it calculates the tower s current position. The viewer will display the tower position as it relates to angles in an and coordinate system. Leveling Bead Leave the Skylevel attached for the remainder of the installation taking care not to damage the cable as the tower is being raised. **For non-tilting tower installations or pick-and-plant crane installations with pre-mounted Skystreams, the leveling bead will appear similar to Figure 6b (page ) when the program initializes. Figure 3a (Communicating) When the Skylevel Viewer is properly connected to the Skylevel up-tower device and the tower is tilted, a yellow, diamond-shaped bead will appear on the perimeter of the viewer s axis display. Figure 3b (Not Communicating) If the viewer fails to initialize or the bead appears black and in the center of the display, the Skylevel device and computer are not communicating. 8 Skylevel Installation Manual, Rev A

9 Step 4 Install Skystream Install the Skystream turbine on the tower with the yaw strain relief positioned on the opposite side of the Skylevel circuit enclosure to prevent interference of the Skstream s power cables with the Skylevel support structure (see Figure 4a). Ensure the yaw strain relief screws are positioned as shown (screw heads face out). Refer to the Skystream Owner s Manual for specific instructions on installing Skystream. When fully installed, the assembly should appear as it does in Figure 4b. Double-check the Skylevel placement to ensure prongs are in place and circuit has not moved during yaw installation. Figure 4b aw strain relief IMPORTANT: To avoid damage as the working unit engages the yaw, ensure the screw heads away from the Skylevel device circuit. aw strain relief positioned opposite of circuit Figure 4a Skylevel Installation Manual, Rev A 9

10 Step 5 Calibrate Skylevel and Raise the Tower IMPORTANT: This step is very important if the device is mounted at the 22.5 offset. **For non-tilting tower installations, skip to Step 6 Using Skylevel Viewer. Use the rotate buttons on the Skylevel Viewer to position the yellow, diamond-shaped leveling bead as close to the 2:00 position as possible as shown in Figure 5. Raise the tower according to normal procedures taking care not to damage the Skylevel s CAT-5 Ethernet cable. Refer to the Skystream Owner s Manual for complete installation instructions. Leveling Bead Rotate Buttons Release the tension on the gin-pole assembly or remove the gin pole before beginning leveling. Figure 5 0 Skylevel Installation Manual, Rev A

11 Step 6 - Leveling IMPORTANT: Be sure that tension on the gin pole is released, or remove the gin pole before proceeding. Position the computer and operator on the gin-pole side of the foundation opposite the hinged side of the tower base and with the rear of the computer screen facing the tower. Figure 6a Figure 6b **For non-tilting tower installations, position the computer and operator on the side of the tower opposite (80 ) from the chalk mark indicating the position of the Skylevel device s circuit. This position will allow the operator to see the tower and computer screen simultaneously from the gin-pole side of the installation. In this orientation, movement of the Skylevel device will correspond to the movement of the leveling bead. The outer rings serve as degree indicators that help visualize the movement of the tower as it approaches center (level). When the tower is raised, the Skylevel Viewer will display similarly to Figure 6b (right). Skylevel Installation Manual, Rev A

12 PREPARING TO LEVEL At the Foundation Loosen all the top and bottom corner nuts two full turns to prevent them from affecting the adjustment. On the Skylevel Viewer Figure 6c Use only the four bottom foundation nuts located near the edges of the tower base to make adjustments. 2 Bottom nut on this bolt Figure 6d Loosen only the top adjusting nuts of the two -axis foundation bolts two full turns. 3 3 Figure 6g Snug the top -axis adjusting nuts wrench-tight (~0-20 lb-ft / N m). Figure 6e 4 4 Use the Mark button to mark the starting position of the bead before making adjustments. This control gives the ability to mark the current position of the tower before the next adjustment is made. The new position of the tower can be seen in relation to its last position. NOTE: Clicking Done will exit the program. ou will need to restart and reset the mark. Figure 6f 2 Skylevel Installation Manual, Rev A

13 Leveling the -Axis At the Foundation Bottom nut on this bolt On the Skylevel Viewer Working in only the -axis, adjust the bottom nuts of the -axis foundation bolts either up or down until the leveling bead on the Skylevel Viewer is centrally positioned on that axis and the data field for that axis reads zero (0.00 +/-.5) Figure 6h Corresponsds to this 2 Snug the top -axis adjusting nuts wrench-tight (~0-20 lb-ft / N m). 2 Figure 6i Figure 6k Prepare to level the tower in the -axis by loosening only the top adjusting nuts of the two -axis foundation bolts two full turns. 3 3 Refer to the Offset field data to make fine adjustments and achieve readings from 0.5 to Figure 6j Skylevel Installation Manual, Rev A 3

14 Leveling the -Axis At the Foundation On the Skylevel Viewer Working in only the -axis, adjust the bottom nuts of the -axis foundation bolts either up or down until the leveling bead on the Skylevel Viewer is centrally positioned on that axis and the data field for that axis reads zero (0.00 +/-.5). Figure 6l Corresponsds to this 2 Snug the -axis adjusting nuts wrench-tight (~0-20 lb-ft / N m). 2 Figure 6m Figure 6n As the bead approaches the center of the -axis, it will turn from yellow to green to indicate that level is within Refer to the Offset field data to make fine adjustments and achieve readings from 0.00 to 0.5. Leave the computer attached to the Skylevel device for the remainder of the procedure. 4 Skylevel Installation Manual, Rev A

15 Step 7 Finishing Leave the computer attached to the Skylevel device for the remainder of the procedure. Snug each of the four top adjusting nuts wrench-tight (~0-20 lb-ft / N m). It is recommended that the tower level be checked after the first year of installation to adjust for settling of the foundation. Tower level should also be checked if it is noticed that the Skystream rests in a specific yaw position when there is no wind or any time that service is performed that requires lowering or removing the tower. Snug each of the four bottom and top corner nuts wrench-tight (~0-20 lb-ft / N m). Apply final torque to all 6 nuts by the following method: 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 /3 to 2/3 turn. Use the Skylevel Viewer to check the level once more and ensure readings of 0.00+/-0.5 on both axes. Repeat the leveling procedure above as necessary. Close the program, or select Done and disconnect the CAT-5 Ethernet cable from the USB Converter. Place the rubber cap on the exposed CAT-5 Ethernet cable connector. Neatly coil the cable and insert between the foundation bolts so it will be protected from the elements and moisture until the next use. If standing water and/or pests present a problem, do not leave the unprotected coil under the tower. Skylevel Installation Manual, Rev A 5

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20 Southwest Windpower, Inc. 80 West Route 66 Flagstaff, Arizona 8600 USA Phone: Fax:

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