ABACUS HL250 Page 2 Product Manual Download

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Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: (+44) 01623 511111, www.abacuslighting.com

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Product Manual

November 2022

Safety ........................................................................................................................ 2

Installation ................................................................................................................ 3

2.1.

General ....................................................................................................................................... 3

2.2.

Mast Positioning ........................................................................................................................ 3

2.3.

Mast Assembly ........................................................................................................................... 4

Operation .................................................................................................................. 7

3.1.

General ........................................................................................................................................ 7

3.2.

Moving the Counterbalance (RLH5 only) ................................................................................ 8

3.3.

Checks Before Use ..................................................................................................................... 8

3.4.

Fitting the Ram to the Mast ...................................................................................................... 9

3.4.1.

HL250 Mast (RLH5 only) ..................................................................................................... 9

3.4.2.

HL250 Mast (RLH7 only) ...................................................................................................... 9

3.4.3.

HL330 Mast ........................................................................................................................... 9

3.5.

Lowering the Mast .................................................................................................................... 10

3.6.

Raising the Mast ....................................................................................................................... 11

3.7.

Removing the Ram ................................................................................................................... 12

3.7.1.

HL250 Mast .......................................................................................................................... 12

3.7.2.

HL330 Mast .......................................................................................................................... 12

3.7.3.

Depressurising Procedure .................................................................................................... 12

Maintenance ........................................................................................................... 14

4.1.

Mast Type Identification .......................................................................................................... 14

4.2.

Masts ......................................................................................................................................... 15

4.2.1.

Every Time the Mast is Lowered .......................................................................................... 15

4.2.2.

Every 12 Months ................................................................................................................... 15

4.2.3.

As Required ........................................................................................................................... 15

4.3.

Counterbalances ....................................................................................................................... 16

4.4.

Hydraulic Hoses ....................................................................................................................... 19

EN 1090 Certificate of Conformity .......................................................................... 20

CE Marking ............................................................................................................. 21

Environmental Advice ............................................................................................. 22

7.1.

General ..................................................................................................................................... 22

7.2.

Information .............................................................................................................................. 22

Equipment Classification ........................................................................................ 23

Summary of Contents for HL250

Page 1: ... 2022 Part No INS HL High Lume HL Masts Applicable products HL250 HL250E HL330 RLH5 RLH7 RLH11 WE STRONGLY RECOMMEND THAT THESE INSTRUCTIONS ARE READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE AND MAINTAIN THIS EQUIPMENT ...

Page 2: ... 1 HL250 Mast RLH5 only 9 3 4 2 HL250 Mast RLH7 only 9 3 4 3 HL330 Mast 9 3 5 Lowering the Mast 10 3 6 Raising the Mast 11 3 7 Removing the Ram 12 3 7 1 HL250 Mast 12 3 7 2 HL330 Mast 12 3 7 3 Depressurising Procedure 12 4 Maintenance 14 4 1 Mast Type Identification 14 4 2 Masts 15 4 2 1 Every Time the Mast is Lowered 15 4 2 2 Every 12 Months 15 4 2 3 As Required 15 4 3 Counterbalances 16 4 4 Hydr...

Page 3: ...se items of clothing are kept away from moving parts both on the mast and counterbalance unit vi Head protection must be worn at all times when operating a counterbalance unit on a raise and lower mast vii When manhandling or lifting the counterbalance the operator should ensure that they are physically capable of carrying out the task Ensure good manual handling techniques are employed at all tim...

Page 4: ...re finished galvanised with small fasteners being from stainless steel In the following instructions mention is made of the minimum permissible shaft overlap distances relating to tapered octagonal shafts In addition because these masts are designed for specific applications it is essential that reference is made to the engineering drawings during assembly These will give details of the shaft desi...

Page 5: ...Nm on the HL330 Timber supports and packers 2 The holding down bolts are each fitted with two nuts and washers The upper nuts and washers and template should be removed The threads should be examined for any damage and rectified using a die nut if necessary The nuts should be set in a level plane using a steel bar and spirit level across each opposing pair of nuts Check referring to the counterbal...

Page 6: ...imum overlap distance must be achieved It may be necessary to tap the shaft as illustrated to achieve this Repeat this exercise until all the shaft sections are in position 6 7 Fit the floodlight mounting bracket to the top shaft section and secure with the screws provided It should be noted that the power supply cable can be installed during assembly or if preferred after assembly is completed bu...

Page 7: ...Abacus Lighting Sutton in Ashfield Nottinghamshire NG17 5FT England Tel 44 01623 511111 www abacuslighting com 6 ...

Page 8: ...RLH11 counterbalance unit Both counterbalance units consist of a double acting hydraulic ram mounted on a trolley which also houses the electric motor driven pump unit or on the RLH7 the manual pump The ram on the counterbalance is individually colour coded see section 4 3 In the event of a hose failure a flow control valve integral with the ram ensures that the mast lowers at a safe rate RLH5 cou...

Page 9: ... particular the area around the seals for signs of damage and leakage of oil 3 Check the oil level is to the centre of the level gauge with the tank top horizontal and the ram closed 4 Check the hydraulic hoses for damage and loose connections 5 Check the electrical flex for damage or loose connections Connect to a 240v supply and switch on 6 Check the function of the pump and control valve by ext...

Page 10: ...le to insert the upper end of the ram between the two gussets and secure with the upper ram anchor pin Fit the retaining clips to the upper and lower ram anchor pins 3 4 2 HL250 Mast RLH7 only Fitting of the RLH7 ram is as per the RLH5 except the ram is operated manually 3 4 3 HL330 Mast Connect the unit to a suitable power source either from within the column base or via a portable generator mini...

Page 11: ...late has a locking screw withdraw it using the door key sufficient distance to allow the bearing plate to rotate Turn the bearing plate through 90º so that the projection on the inside of the bearing plate clears the fixed lug The relative positions of the pivot bearing plates for the various stages of the lowering and raising operation are shown in the operating sequence diagrams at the end of th...

Page 12: ...d at an overlap joint 3 6 Raising the Mast Operate the control valve or operate the manual pump such that the ram extends and the hinged part of the shaft is raised into a vertical position ENSURE AS THE RAISING PROGRESSES THAT THE FLEXIBLE CONDUITS DO NOT GET TRAPPED BETWEEN THE FIXED AND HINGED PARTS OF THE MAST Fully extend the ram and wait for any shaft oscillations to decay Swing the bearing ...

Page 13: ...gussets and refit the anchor and retaining pin Support the ram against the column and operate the control valve to retract the ram Release the control valve when the ram is about 100mm short of being fully closed Offer the lower location bracket on the counterbalance up to the ram support lifter bracket by swinging the ram backwards and tilting the motor pump unit handles upwards as necessary With...

Page 14: ...Abacus Lighting Sutton in Ashfield Nottinghamshire NG17 5FT England Tel 44 01623 511111 www abacuslighting com 13 ...

Page 15: ...tion with tapering slip joint type octagonal shafts They can be identified by measuring the width of the base at flange level The width should be approximately 250mm on the HL250 and 330mm on the HL330 The illustrations below show the typical arrangement of the HL250 and HL330 mast bases HL250 HL330 Maintenance requirements are minimal but the following checks are recommended at the intervals stat...

Page 16: ...nt and tight 3 Check that the foundation bolts have not worked loose The foundation bolt torque setting is 310Nm M30 grade 4 6 on the HL250 and 850Nm M30 grade 8 8 on the HL330 4 Check that the upper and lower ram anchor gussets are not damaged 5 Check warning label is attached to the base 6 Check the door cover is secure and that the screw functions satisfactorily Lightly grease the screw thread ...

Page 17: ...mpty and the tank must be filled with oil before use The correct oil level is 30mm below the upper face of the filler port with the tank horizontal Note that if this level is exceeded with the ram extended oil will be ejected during operation of the equipment The pump incorporates a breather unit filler port in the top of the tank and when not in use the counterbalance should be stored with the ta...

Page 18: ...hould be smooth and jerk free Before attempting any work on the flow control valve ensure the ram is fully closed and supported in the vertical position with the flow control valve uppermost Switch off the electric motor and operate the flow control valve back and forth several times to depressurise the hydraulic circuit Clean the area around the large plug Removing it will expose the spring and v...

Page 19: ...e pressure relief valve setting as follows The relief valve is located below or adjacent to the control valve Some valves are fitted with a screwed cap which must be removed to allow the adjustment to be made Hold the centre adjusting screw with an Allen key and slacken the locknut With the ram fully closed operate the control valve such that the relief valve pressure can be read on the pressure g...

Page 20: ...and must be inspected tested and replaced in accordance with the table below Age Recommendation Up to 3 years Use without further testing 3 to 5 years Use after representative samples subjected to a proof pressure test 5 to 8 years Use after representative samples subjected to proof impulse and burst pressure tests and cold bend and electrical tests Over 8 years Scrap ...

Page 21: ...Abacus Lighting Sutton in Ashfield Nottinghamshire NG17 5FT England Tel 44 01623 511111 www abacuslighting com 20 5 EN 1090 Certificate of Conformity ...

Page 22: ... S275 S355 Fracture toughness 27J at 0 C Fracture toughness 27J at 0 C Reaction to fire Class A1 Reaction to fire Class A1 Release of cadmium NPD Release of cadmium NPD Emission of radioactivity NPD Emission of radioactivity NPD Durability Galvanised Durability Galvanised Structural characteristics Structural characteristics Standards ILP PLG07 Standards ILP PLG07 Load bearing capacity See calcula...

Page 23: ...counterbalance unit will have an oil reservoir whether this will be separate on a trolley usually for raising and lower bigger masts or on the same assembly as the hydraulic ram Each reservoir will have a breather cap on top of the tank which is required for using a hydraulic system the breather cap will leak out oil if the unit is tipped at any point therefore it must be kept upright to prevent t...

Page 24: ... the mast cannot be readily altered It should not therefore be considered as lifting equipment in the normal sense of the term such as a crane fork lift truck or accessories such as chains slings or eye bolts and as such does not fall under the Lifting Operations and Lifting Equipment Regulations LOLER 1998 Abacus appreciates however that some customers may make an internal decision to classify th...

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