ASSEMBLED FOUNDATION SYSTEM (150-130 AFS)

Installation Manual
Telecom-Small Wind
(Above Grade)

1043 Grand Avenue, # 213

St. Paul, MN 55105
Ph: (651) 330-1263
www.arerenewables.com
www.aretelecom.com

rev H
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 Specifications
• Shipping 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 Tools
• 2x - 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 Included

• Ground 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.
 150-130 AFS Dimensions and Weights
11

16
21
535 Component Weight
12
Weight
Part# Description kg
17 (lbs)
Lower
1 Tower 100 (220)
149 112 Section
3774 2850
2 Mid Tower 70 (154)
58 Section
1472
130 39 3
3 Top Tower 48 (106)
3295 82 995 section
337
2082
8550 Upper
11 Hinge 24 (53)
Plate
360 Lower
9153 12 Hinge 26 (57)
41 Plate
1041 2 Main
16 Support 16 (35)
Ballast Baskets Leg

17B 17 150-Ballast 34 (75)

Basket
1
17B 130-Ballast 17.5
Basket (38.5)

150 130
 21-22 Universal Tower Top Flange
1
7 20
2 19 Light Fixture Flange (optional)
23 18
6
3
5 9 4
14
11 17 13
16 15

150-130 AFS Bill of Materials

12
Part # Qty Description
1 1 Base Section
2 1 Mid Section
3 1 Top Section
10
4 1 5 Ton Screw Jack
8 5 1 Jack Handle
6 2 20mm dia. x 80mm Clevis Pin
7 1 15mm dia. x 295mm Tower Pivot Pin
8 4 M24x3 x 445mm Hex Bolt
9 12 M24 Nut
10 16 M24 Washer 72x26x5
11 1 Upper Hinge Plate
12 1 Lower Hinge Plate
13 54 M12x1.75 x 55mm Hex Bolt
14 54 M12 Nut
15 108 M12 Washer 24x14x2.5
16 4 Main Support Leg
17 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 Bolt
22 2 M6 Washer
23 3 4mm Spring Clip
Optional Components
24 16 26" (660mm) Earth Anchor
25 8 Right Angle Bracket
26 1 48mm (1.9") OD Spigot
27 1 119mm (4.7") ID Adaptor
28 1 Light Fixture Mount 10deg
29 16 GEO-Bag
 Light Fixture Mount and Tower Top Wind Turbine Adaptors (Optional Components)

1.9 Turbine Adaptor #26

1.9 Light Fixture Mount #28 48
48

80.00°
• Air Breeze
• Air X
31.5 • Chinook
800 • Zephyr Dolphin
28
8.3
211

Turbine Adaptor #27 Tower Top and Light Fixture Flange Dimensions

7.48
230 190
4.8 29 Bolt Circle
121 1.57 6.7
40 170

5.4
138 5.1 6.7
130 170

5.24 .55
133 6x 14
4.37 .55
111 4x 14
5.1
• Bergey XL1 130
 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

Concrete Block (8"x8"x16") GEO-Bag Optional (Earth Anchor)

• Qty. - (32) blocks, per basket
• Min. individual block weight -
38lb (17.3kg)
• Min. weight per basket -
1320lbs (600kg)
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.
• To be filled native soil, rock, etc.
• Most anything that provides
the required weight per basket
can be placed into the GEO-Bag
for ballast.
• Each GEO-Bag holds up to
400lbs (182kg)of fill.
• 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 information
on the P-26 visit American Earth
Anchor @ www.americanea.com
24

29

Securing Ballast
• Ballast can be secured to basket using cam straps 25
or other suitable means.
• Straps not included

Slotted holes in basket

provide connection
point for cam straps
Detail A
 Foundation Assembly M24 Torque Spec
678 N-m (500 ft-lb) - Dry
552 N-m (407 ft-lb) - Lubed
1. Assemble foundation upside-down. Make sure hinge
plates are properly oriented (Figure 1).
2. A support block, or other suitable means, should
be used to raise the upper hinge plate beyond the
length of the projected bolt thread (Figure 2)
3. Flip foundation upright once assembled
4. Attach ballast baskets to support legs using four (4) M12
hex head bolts per leg (Figure 3)
5. Before installing tower, weight all four baskets using
recommended ballast weight.

Support Block 8
200mm
10mm Thru Hole
for Earth-Ground Lower Hinge Plate
Connection Figure 2

Detail B

M12 Torque Spec

Upper Hinge Plate 81 N-m (60 ft-lb) - Dry
66 N-m (49 ft-lb) - Lubed

Figure 1 Figure 3
 Tower and Screw Jack Assembly
1. Pin tower base section to foundation using
15mm x 295mm clevis pin. (Detail C)
2. Pin screw jack to lower hinge plate and tower using
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)
Leveling Nut 3. Align all longitudinal welds
and Washer 4. Bolt tower flange using six (6) M12 hex head bolts/ nuts
Note: upper tower section not shown in Figure 4.
5. Before raising tower adjust all leveling nuts to the
recommended height and assemble lowering brackets
and link (Detail C)

M12 Torque Spec

81 N-m (60 ft-lb) - Dry
66 N-m (49 ft-lb) - Lubed
Lifting Screw

2.66 Worm Gear

67.5 Housing

Detail C

Support Pedestal
Detail D

Align Longitudinal Welds

Figure 4