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Will Burt 711990491 Operating Instructions Manual Download Page 47

S

TILETTO 

AL

 

O

PERATING 

I

NSTRUCTIONS

 

TP-5418901-F 

Original Instructions

 

2-1 

August 2020 

Section 2 

Installation 

This section describes the installation of the Mast System and provides general procedures that 
must be followed to ensure a successful installation. Use care to understand and follow all 
precautions while installing. 

 

2.1 Pre-Installation Check 

Before installing the system, ensure: 

•

  All installers read and understand the entire installation procedure 

•

  Only a properly trained and qualified certified electrician performs electric installations 

and maintenance 

•

  All components are included (Section 1.7) 

•

  All required equipment is readily available (Section 2.2) 

•

  The mounting structure is level with sufficient room to mount the system (Section 0) 

•

  When installing in a vehicle, that the vehicle is stationary and on a level surface 

•

  That the following precautions are understood and followed: 

 

Equipment Damage!

 At survival wind speed, an extended mast can generate 22,500 lb.-ft. 

(270,000 lb.-in. or 366,120 N-m) at the Base. The mounting structure must be designed 
accordingly. Before installation, ensure the mounting structure is capable of resisting forces 
generated from all loading and environmental conditions, including, but not limited to, Mast 
System size and weight, payload size and weight, sail size, wind speed, Guy Line arrangement, 
support bracket or roof line location and base plate assembly. Mounting the Mast System into a 
structure unable to resist the forces generated from the customer-specific loading scenario could 
result in death or serious injury and could damage the Mast System. 

 

Trained Personnel Only!

 Only trained and qualified personnel should perform installation 

procedures. Only a properly trained and qualified certified electrician should perform electric 
installations. Death or serious injury could result if proper installation procedures are not 
observed. All persons installing and maintaining this equipment should be suitably qualified and 
work to local, regional, and national standards and codes of practice. 

 

Mounting Structure Hazard!

 The mounting hardware must include proper means to resist 

vibration loosening such as thread-locking compound or locking hardware. Mounting the Mast 
System to a structure unable to resist the forces generated from customer-specific loading 
scenario could result in death or serious injury and could damage the Mast System. 

Summary of Contents for 711990491

Page 1: ...t Company Phone 1 330 682 7015 TP 5418901 F August 2020 401 Collins Blvd E Mail contact_us willburt com 2020 The Will Burt Company Orrville OH 44667 U S A Website www willburt com Original Instructions Authorized Representative GEROH GmbH Co KG Fischergasse 25 D 91344 Waischenfeld Germany ...

Page 2: ......

Page 3: ...E OF ITS PRODUCTS NO EMPLOYEE DISTRIBUTOR OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF WILL BURT Claims for defects in material and workmanship shall be made in writing to Will Burt within thirty 30 days of the discovery of defect Failure to provide notice as required hereby shall be conclusive evidence that the product was in conformi...

Page 4: ...2018 Updated Section 1 6 4 2 and the D TEC references throughout TP 5418901 C January 21 2019 Updated Section 5 4 2 Minor verbiage and grammatical changes throughout manual TP 5418901 D December 4 2019 Updated Section 1 5 1 6 1 2 2 9 3 1 3 4 2 6 and 4 TP 5418901 E February 17 2020 Update to Table 1 2 Minor grammatical changes throughout manual TP 5418901 F August 7 2020 2020 Update to Table 1 2 Mi...

Page 5: ...e Cable P N 5433101 for 3M Cable 1 16 Mast Sensor Cable P N 5433201 for 3M Cable 1 17 Fully Extended Limit Switch Cable P N 5427901 1 17 EMI Filter optional equipment 1 18 Power Cable Connector P N 213075 1 18 Identification Plate P N 451830xx 1 19 Crank Handle Assembly P N A3209918 1 19 Grease Gun P N 4288501 1 20 Label Kit English P N 5428301 1 20 1 7 2 Universal Control Box P N 4453901 1 21 Dis...

Page 6: ...n 2 24 2 9 Install Payload 2 25 Section 3 Operation 3 1 3 1 Pre Operation Check 3 1 3 2 Operation Equipment 3 3 3 3 Controls 3 4 3 3 1 Universal Control Box Powered Operation 3 4 3 3 2 PC Interface Powered Operation 3 4 3 3 3 Crank Handle Assembly Manual Operation 3 4 3 4 Universal Control Box Operation 3 5 3 4 1 Detailed Instructions 3 5 Prepare the System for Powered Operation 3 5 Extend the Mas...

Page 7: ...Guying 9 3 9 3 Drawings 9 3 Table of Figures Figure 1 1 Mast 6 Meter Stiletto AL P N 711990692 Shown 1 9 Figure 1 2 Drain Hole Base of 6 Meter Stiletto AL P N 711990692 Shown 1 10 Figure 1 3 Collars Collars from the 6 Meter Stiletto AL P N 711990692 Shown 1 11 Figure 1 4 Top Tube Ring Top Tube Ring for 6 Meter Stiletto AL P N 711990692 Shown 1 12 Figure 1 5 Drive Assembly Not to Scale 1 13 Figure ...

Page 8: ...ure 3 2 OVERRIDE Switch Engage Position and UP DOWN Switch Up Position 3 7 Figure 3 3 UP DOWN Switch Down Position 3 8 Figure 3 4 OVERRIDE Switch Engage Position and UP DOWN Switch Down Position 3 9 Figure 3 5 Manual Override 3 13 Figure 5 1 Grease Port 5 6 Figure 9 1 Lay Out Guy Lines 9 3 Table of Tables Table 1 1 Catalog Mast Part and Model Numbers 1 4 Table 1 2 Stiletto AL Mast System Specifica...

Page 9: ...elated to any specific procedures These are recommended precautions that personnel must understand and apply throughout installation operation transportation maintenance storage and troubleshooting Additional precautions that apply to specific procedures and steps may be listed with the procedure or step to which they apply Electrocution Hazard Contact with high voltage will result in death or ser...

Page 10: ...c could be dislodged from the mast and fall Death or serious injury could result if proper safety equipment is not properly worn Crush Hazard Mast Failure Do not stand directly beneath the mast or its payload Be certain the payload is properly installed and secured Death or serious injury could result if mast fails suddenly Equipment Damage Lock Mechanism Do not modify the mast lock mechanism or l...

Page 11: ...ate assembly The lower structure at the base plate shall be sized to support all vertical loads from the mast and payload The support bracket is not intended to carry vertical loads The support bracket mounting structure and the base plate mounting structure shall be tied to the same vehicle structure frame i e do not mount the support bracket to vehicle body and the base plate to the vehicle chas...

Page 12: ...nnect Power Power must be disconnected before connecting or disconnecting any Mast System connector For example power must be disconnected when connecting or disconnecting J1 J2 J3 and J4 on the Control Box Do not disconnect the power cable from J1 on the Control Box or from the power source while the mast is in motion extending or retracting This could result in damage to the Control Box Equipmen...

Page 13: ...y out as mast is extended Frozen Water Hazard Water freezing inside mast may render mast inoperable and cause major equipment damage such as tube deformation Ensure the mast drain at the base plate is not obstructed The following list contains reasonably foreseeable misuses of the mast system according to EN ISO 12100 5 3 2 These uses shall be avoided Operating the mast with an obstruction in the ...

Page 14: ...ng transport installation maintenance and operation System tip over could result in death or serious injury This symbol indicates a general warning In this unit this symbol indicates a frozen water hazard Do not block the mast drain port at the base of the unit Water must be permitted to exit the mast to avoid ice damage to the mast This symbol is used to remind users to read and understand the op...

Page 15: ...eter Stiletto AL 8 54 Meter Stiletto AL 10 Meter Stiletto AL 15 Meter Stiletto AL This manual is not for the following masts Stiletto 3 4 6 10 or 15 Meter Stiletto HD 4 6 or 10 Meter See www willburt com for information on these and other Will Burt products A typical Stiletto AL Mast System consists of A telescoping mast with a 28 VDC Drive Assembly and a Support Bracket Assembly Universal Control...

Page 16: ...STILETTO AL OPERATING INSTRUCTIONS 1 2 Original Instructions TP 5418901 F August 2020 1 1 Specification Compliance ...

Page 17: ...ance Section 6 Long Term Storage Section 8 Troubleshooting Section 9 Reference 1 4 Definitions of Terms Throughout this manual the following terms are used Mast to refer to the mechanical telescoping mast Mast System to refer to the entire Stiletto AL Mast System telescoping mast Universal Control System and additional accessories Payload to refer to the object or equipment being raised by the mas...

Page 18: ... 6 Meter 8 54 Meter 10 Meter 15 Meter Physical Characteristics Fully Extended Height 50 50 mm 2 0 2 0 inches 4 m 6 m 8 54 m 10 m 15 m 13 1 feet 19 6 feet 28 feet 32 8 feet 49 2 feet Fully Nested Height 2 0 5 0 mm 0 08 0 2 inches 1 28 m 1 58 m 1 88 m 2 10 m 2 65 m 50 4 inches 62 2 inches 74 02 inches 82 68 inches 104 4 inches Rated Payload Capacity center of gravity within 300 mm of mast centerline...

Page 19: ...250 to 130 mm 250 to 130 mm 250 to 110 mm 9 84 to 6 69 inches 9 84 to 5 91 inches 9 84 to 5 12 inches 9 84 to 5 12 inches 9 84 to 4 33 inches Number of Keys 1 Tube Material Aluminum Height Readout Meters or US Customary Request when ordering Defaults to meters Electrical Characteristics Operating Voltage Range 18 1 33 VDC Optimal Voltage MIL STD 1275 28 VDC Steady State Current Draw Maximum Operat...

Page 20: ...C to 70 C 60 F to 158 F Airborn Noise Emissions measured according to EN ISO 3744 2010 Deploying Retracting A weighted sound pressure level 71 dB A C weighted instantaneous pressure level 72 dB A weighted sound power level 79 dB A Guying Is guying required No Is guying an option Yes Consult factory Continued Note Dimensions and specifications are provided for reference only and are not intended fo...

Page 21: ...mediate tubes will not be painted but will have an anodized finish however paint finishes for these tubes are available Contact Will Burt for details CARC finish is available for the Drive Assembly Cover and Base Tube The keyway on the external surface of each tube may discolor from black oxide finish to a dull grey finish this is considered normal and may occur over the course of time This does n...

Page 22: ...Collars o Top Tube Ring o Drive Assembly o Support Bracket Assembly o Fully Extended Limit Switch P N 913217 o Motor and Brake Cable P N 5433101 o Mast Sensor Cable P N 5433201 o Fully Extended Limit Switch Cable P N 5427901 o Power Cable Connector P N 213075 o Identification Plate P N 451830xx o Crank Handle Assembly P N A3209918 o Grease Gun P N 4288501 o Label Kit English P N 5428301 Universal ...

Page 23: ...ular key along the length of each tube except the Base Tube This key aligns with the keyway in the next larger adjacent tube s collar and is used to establish azimuth rotational integrity Is designed to drain water through a 14 NPT threaded port Figure 1 2 at the base of the mast and does not require a drain plate Figure 1 1 Mast 6 Meter Stiletto AL P N 711990692 Shown Base Tube Grease Port Suppor...

Page 24: ...xtended Limit Switch 913217 Section 1 7 1 5 Motor and Brake Cable P N 5433101 Section 1 7 1 6 Mast Sensor Cable P N 5433201 Section 1 7 1 7 Fully Extended Limit Switch Cable P N 5427901 Section 1 7 1 8 Power Cable Connector P N 213075 Section 1 7 1 10 Identification Plate P N 451830xx Section 1 7 1 11 Crank Handle Assembly P N A3209918 Section 1 7 1 12 Grease Gun P N 4288501 Section 1 7 1 13 Label...

Page 25: ...on each collar for the mounting of accessories The Accessory Contact Points each have two M6x1 threaded holes 10 mm deep These holes are 15 mm center to center apart Figure 1 3 Collars Collars from the 6 Meter Stiletto AL P N 711990692 Shown Top Tube Ring Is attached to the Top Tube Contains an Air Filter P N 5417801 used to prevent dirt from entering the mast Has a Payload Interface to attach the...

Page 26: ...ONS 1 12 Original Instructions TP 5418901 F August 2020 Figure 1 4 Top Tube Ring Top Tube Ring for 6 Meter Stiletto AL P N 711990692 Shown Note Diameters will vary per model top tube size 8 2mm Through Holes with 15 5mm Ø Counterbore ...

Page 27: ...rive Housing Drive Screw The mast is driven by a stainless steel electro mechanical Drive Screw Each moving tube all except the Base Tube has an Extension Nut attached to its bottom which rotates on the Drive Screw The Drive Screw Is located in the center of the mast Extends and retracts the tubes sequentially as it rotates Responds to either input from the Universal Control Box or by manually cra...

Page 28: ...s applied The brake is always on when power is removed from the system in order to prevent the mast from back driving Mast Drive Housing The Mast Drive Housing Contains the gear drive Has connectors for the Mast Sensor Cable and the Fully Extended Limit Switch Cable Section 1 7 1 8 Contents can be accessed for maintenance and repair through the Cover Plate Only appropriate trained repair and servi...

Page 29: ...ential part of mounting the Mast System Hardware to secure the Support Bracket Assembly to the mast ships with the Mast System Hardware to secure the Support Bracket Assembly to the support structure varies based on the customer specific mounting application and is customer provided Support Bracket Clamp P N 5325101 Support Bracket Assembly Location Support Bracket Weldment P N 5324901 Figure 1 6 ...

Page 30: ...lengths available Connectors and cables are environmentally sealed to prevent dust sand or moisture intrusion Has 4 pin military screw type connectors on each end for ease of installation and to prevent environmental intrusion Is unshielded and not rated for Military Specification EMI EMC compliance For Military Specification EMI EMC shielded cables should be specified at the time of the order Fig...

Page 31: ... to prevent environmental intrusion Is unshielded and not rated for Military Specification EMI EMC compliance For Military Specification EMI EMC shielded cables should be specified at the time of the order Figure 1 9 Sensor Cable Fully Extended Limit Switch Cable P N 5427901 The Fully Extended Limit Switch Cable Figure 1 10 transfers signals between the Fully Extended Limit Switch and the Mast Dri...

Page 32: ...s a shielded cable multiple lengths available to the Control Box J1 connector Mates with customer supplied shielded cable to power supply and customer control Figure 1 11 EMI Filter Power Cable Connector P N 213075 The Power Cable Connector Figure 1 12 Is a MS3106E24 11S Connector Connects the customer supplied power cable to the Universal Control Box at J1 or on the optional EMI Filter input side...

Page 33: ... N 4518302 On the side of the Universal Control Box P N 4518301 The information on the Identification Plates is the same Figure 1 13 Identification Plate P N 4518302 Shown Crank Handle Assembly P N A3209918 The Crank Handle Assembly Figure 1 14 can be used to manually crank the Motor to extend and retract the mast When manually cranking the Motor it is necessary to remove all power from the Mast S...

Page 34: ...n three fluid ounce cartridges P N 4288601 Figure 1 15 Grease Gun Label Kit English P N 5428301 The Label Kit is used to identify potential hazards and connection points within the Mast System These labels come installed on the Mast System Additionally the Label Kit includes a Ground Straps P N 299053 and hardware used to ground the Mast System and control box Contact The Will Burt Company for inf...

Page 35: ...iversal Control Box Figure 1 16 Combines customer input power input sensor input and power output to allow the customer to extend and retract the mast without running past sensor or software limits Contains power MOSFETs to control Motor direction and to dynamically brake the Motor When a directional command is terminated the Universal Control Box automatically shorts the Motor leads for a second ...

Page 36: ...switch mounted outside the base tube that detects a permanent magnet attached to the bottom of the largest moving tube Proximity Sensor o Counts the teeth on a sprocket attached to the Drive Screw o Interprets this data as an extension distance to generate the intermediate extension height Components of the Universal Control Box Figure 1 16 include Display UP DOWN Switch with Waterproof Boot OVERR...

Page 37: ...on height is shown In metric mode as XX XX M where o XX XX is the extension of the mast in meters o Resolution is 0 002 meters o Accuracy is 0 05 meters In US customary mode as XX XX F where o XX XX is the extension of the mast in feet o Resolution is 0 01 feet o Accuracy is 0 17 feet Note Extension shown on the display of the Universal Control Box is measured from the top of the mast Height reado...

Page 38: ...ycle count of the mast and the temperature inside the Universal Control Box The cycle count is used during Periodic Maintenance Section 5 4 Error Codes In the event of any unexpected switch feedback communication errors or amp draws on the mast the Display will show the associated error message UP DOWN Switch The UP DOWN Switch is Used to extend and retract the mast Located on the side of the Univ...

Page 39: ...ol Box contains a printed circuit board The printed circuit board has three pairs of handshakes contacts as follows An enable input For a hatch switch vehicle stationary or other precondition contact closure located between pins A and B on J1 o An open circuit will cause the Universal Control Box to display its software version and will inhibit extension o A closed circuit is required between thes...

Page 40: ...te with the Universal Control Box to operate the Mast System This is particularly useful when integrating the Mast System into a proprietary control system When using the Application Notes the customer must write their own software using the commands provided in the Application Notes When using a PC or proprietary control system to operate the Mast System it will be necessary to connect the PC or ...

Page 41: ... DOWN protected by a switch guard and waterproof boot to extend and retract the mast Uses three LED lights to backlight text to indicate the status of the system as follows o EXTENDED to indicate the mast is fully extended o PARTIAL to indicate the mast is partially extended o NESTED to indicate the mast is fully nested Includes a cable with a MS3106 8 pin screw type connector that attaches to the...

Page 42: ...ee www willburt com D TEC The D TEC Safety System Figure 1 19 is a safety device which Mounts at the highest point of the mast payload configuration Provides overhead power line field detection Provides above the mast illumination The D TEC system automatically stops mast extension when an electric field above the sensing threshold is detected providing added protection for the operator and equipm...

Page 43: ...tes all communication The D TEC only allows or disallows the operator to extend the mast and does not provide direct power to the mast Both the D TEC and the Universal Control Box perform self diagnostic routines each time the Mast System is powered up Specifications for the D TEC are listed in Table 1 3 Table 1 3 D TEC Specifications Functional Characteristics Operational Parameters Detection Sim...

Page 44: ...nal Input Power Cable Pigtails have a Power Cable Connector with pre wired flying leads of predetermined lengths to simplify the process P N 4674701 Unshielded 5 Meter P N 4674702 Unshielded 8 Meter P N 4784001 Shielded 5 Meter PositionIt Remotely pans and tilts a payload P N 5061001 PI 150 with a payload capacity of 150 lb ft 202 N m P N 5191201 PI 75 with a payload capacity of 75 lb ft 101 N m P...

Page 45: ...h to start the Mast System P N 4534504 Has a 12 inch 30 5 cm cable P N 4534501 Has a 36 inch 91 4 cm cable P N 4534502 Has an 84 inch 213 4 cm cable P N 4534503 Has a 120 inch 304 8 cm cable P N 4534509 Has a 360 inch 914 4 cm cable 110 VAC Stiletto Power Supply Enclosure P N 4663401 A capacitor bank and power supply in a single integrated unit Shelf Bracket P N 46748xx Used to position and suppor...

Page 46: ...STILETTO AL OPERATING INSTRUCTIONS 1 32 Original Instructions TP 5418901 F August 2020 ...

Page 47: ...nsure the mounting structure is capable of resisting forces generated from all loading and environmental conditions including but not limited to Mast System size and weight payload size and weight sail size wind speed Guy Line arrangement support bracket or roof line location and base plate assembly Mounting the Mast System into a structure unable to resist the forces generated from the customer s...

Page 48: ...ge Lock Mechanism Do not modify the mast lock mechanism or lock housing or attach any components to the lock housing Do no remove the locks with the mast extended Equipment damage and dangerous mast collapse could occur if the lock mechanism is modified Disconnect Power Power must be disconnected before connecting or disconnecting any Mast System connector For example power must be disconnected wh...

Page 49: ... Mallet Torque Wrench Wrenches Washers or Spacers For Shimming Equipment Hoist Sling Expendables Anti Seize Loctite Blue 242 243 or Equivalent Rags Clean and Dry Note Depending on the local regional and national standards and codes of practice and the environment additional personal protective equipment may be necessary Depending on the Mast System configuration additional equipment including but ...

Page 50: ...d to length to allow for the thickness of the Support Bracket Assembly support structure any shims and all mounting hardware e g flat washers lock washers and nuts Base of Mast System To the Mounting Surface 4 M12 Inch Minimum Sets of Stainless Steel Hardware Customer The bolts should be sized to length to allow for the thickness of the base of the mast mounting surface any shims and all mounting ...

Page 51: ...e the use of Will Burt provided hardware Depending on the specific installation application all hardware may not be used Additional hardware may be required for additional accessories or customer specific applications 2 4 Installation Dimensions This section describes installation dimensions as follows Mast Installation Dimensions Section 2 4 1 Support Bracket Assembly Dimensions Section 2 4 2 Uni...

Page 52: ...1285 0 50 59 8 54 Meter 546 7 21 52 455 1 17 92 828 32 6 1250 49 2 1530 0 60 24 10 Meter 546 7 21 52 455 1 17 92 889 35 1400 1800 1750 0 68 9 15 Meter 546 7 21 52 455 1 17 92 1173 46 2 55 12 70 87 2209 6 86 99 L Nested L Extended M N mm inch mm inch mm inch mm inch 4 Meter 1280 0 50 39 4000 157 5 446 0 17 56 284 0 11 18 6 Meter 1580 0 62 2 6000 236 2 446 0 17 56 284 0 11 18 8 54 Meter 1880 0 74 02...

Page 53: ...TTO AL OPERATING INSTRUCTIONS TP 5418901 F Original Instructions 2 7 August 2020 Top Down View Side View Bottom Up View Figure 2 1 Mast Installation Dimensions Not to Scale S N L K J H G F E B A D C M R P Q ...

Page 54: ...LETTO AL OPERATING INSTRUCTIONS 2 8 Original Instructions TP 5418901 F August 2020 2 4 2 Support Bracket Assembly Dimensions Figure 2 2 Support Bracket Assembly Bolt Hole Pattern Measurements in mm inches ...

Page 55: ...ly Bolt Hole Pattern Dimensions A B C D E mm inch mm inch mm inch mm inch mm inch 13 0 5 102 4 0 146 5 75 191 7 5 203 8 0 Ø F G H J K mm inch mm inch mm inch mm inch mm inch 7 0 28 13 0 5 102 4 0 165 6 5 191 7 5 L M N P Q mm inch mm inch mm inch mm inch mm inch 13 0 5 191 7 5 203 8 0 190 7 49 203 8 0 R S T mm inch mm inch mm inch 311 12 23 109 4 3 211 8 29 ...

Page 56: ...ERATING INSTRUCTIONS 2 10 Original Instructions TP 5418901 F August 2020 Figure 2 3 Universal Control Box Installation Dimensions Measurements in Inches E A D C B G H J K N M L S T 10 32 UNF 2B Grounding Hole F P Q R ...

Page 57: ...lly briefly milliseconds see as much as 160 amps of inrush current Any impedance in the power supply or leads will reduce this figure and could prevent the mast from operating Table 2 5 lists the specifications for the auto resetting circuit breaker in the system Table 2 5 Circuit Breaker Specifications Functional Characteristic Specification Breaker Current Rating 50 Approximate Open Time 1 8 Sec...

Page 58: ... a Suitable Mounting Location Section 2 6 2 1 2 Unpack the Mast System Section 2 6 2 2 3 Secure the Support Bracket Assembly Section 2 6 2 3 4 Secure the Base of the Mast Section 2 6 2 4 5 Finalize Physical Installation of the Mast Section 2 6 2 5 6 Install the Universal Control Box Section 2 6 2 6 7 Electrically Install the Mast System Section 2 6 2 7 8 Connect Power to the Mast System Section 2 ...

Page 59: ...m is to be attached Reinforce as necessary The support bracket and base support structure shall be mounted to a common frame i e not separated by vehicle suspension elements The area underneath the mast must be free of obstructions to allow for accessibility to the fasteners Do not obstruct the Drain Hole Figure 2 4 for rainwater and condensation at the base of the mast Keep any personnel or sensi...

Page 60: ...of handling the forces generated from lifting the system Observe manufacturer instructions on lifting equipment Death or serious injury could result if proper procedures are not followed Unpack the system as follows 1 Carefully open the shipping crate 2 Inspect for any shipping damage Notify the carrier if damage is evident 3 Remove all loose components 4 Remove the top half of the wooden saddles ...

Page 61: ...ocation Be certain to orient the mast so the operator has a clear view of the hazard labels 2 Ensure the mast is level in all directions If necessary shims may be added to correct the alignment of the mast It is necessary to check the mast in two places 90 apart when leveling 3 Determine the desired location for the Support Bracket Assembly Refer to Section 2 4 1 for the minimum height of the Supp...

Page 62: ...ast loosely secured at the Support Bracket Assembly and at the base of the mast 1 Ensure the mast is level in all directions If necessary shims may be added to correct the alignment of the mast It is necessary to check the mast in two places 90 apart when leveling 2 Torque all hardware as appropriate for its size and grade to secure the mast in place against the support structure and mounting surf...

Page 63: ...ructions 2 17 August 2020 Top Down View of Mast Electrical Ground Label Figure 2 6 Ground Stud Locations 4 Attach the other end of the Ground Strap to a known earth ground such as the chassis of the vehicle Torque to 24 31 in lb 2 7 3 5 N m Ground Stud Locations ...

Page 64: ...less steel fasteners Torque all hardware as appropriate for its material and size The mounting hardware must include proper means to resist vibration loosening such as thread locking compound or locking hardware The recommended torque for stainless steel M6 fasteners is 60 72 in lb 7 8 N m 3 Use 10 32 UNF 2B hardware and a Ground Strap to ground the Universal Control Box from the designated ground...

Page 65: ...schematic optional EMI filter shown Note When using an optional EMI filter customer power will connect through the Power Cable Connector P N 213075 at point A below The EMI filter cable will install between point B below and J1 on the Universal Control Box When NOT using the optional EMI filter customer power will connect through the Power Cable Connector P N 213075 directly at J1 on the Universal...

Page 66: ...e 4 pin Motor and Brake Cable into bulkhead connector J3 on the Universal Control Box and bulkhead connector J5 on top of the Motor Screw both connectors in place so that the cable is secure 4 Depending on the Mast System configuration a data cable may be used For example a data cable is used with optional components including the Hand Held Remote PC Interface or D TEC If used plug in the 8 pin da...

Page 67: ...e Power Cable Connector With cable runs longer than three meters ten feet a lower gauge wire will be needed The enable input circuit hatch switch on J1 Pins A and B require a closed circuit to enable mast operation If no switch is installed to provide a closed circuit a jumper is required to connect J1 Pins A and B The Will Burt Company also offers optional Input Power Cable Pigtails Section 1 7 4...

Page 68: ...0 To connect customer power to the Mast System 1 Wire the Power Cable Connector and Emergency Stop Switch according to Figure 2 11 Figure 2 11 Power Cable Connector Wiring 2 Plug customer power into J1 on the Universal Control Box Screw the connector in place so that the cable is secure ...

Page 69: ...edures to keep in mind when installing optional accessories include Use connector J4 on the Universal Control Box to connect the following optional components o D TEC o Hand Held Remote Control HHRC o PC Interface Note Will Burt offers an adaptor Y Cable to allow for the use of both the PC Interface and an HHRC Each collar on the Mast System has four flat spots with two M6 holes for components suc...

Page 70: ... source capable of delivering the specified Mast System voltage and current has been properly connected to the Control Box Polarity Ensure the electrical mains polarity is correct before initializing the Mast System To test the installation 1 Review the Pre Operation Check Section 3 1 2 Prepare the Mast System for operation 3 Extend the mast 4 Lower the mast See Section 3 for additional details on...

Page 71: ...ail size and wind and ice loading The mounting hardware must include proper means to resist vibration loosening such as thread locking compound or locking hardware Mounting the payload into a structure unable to resist the forces generated from the customer specific loading scenario could result in death or serious injury and could damage the mast and mounting structure Safety Instruction Payload ...

Page 72: ... mount can be used for additional M8 bolts quick release pins or a tether for additional payload security These holes are oriented 30 from the bolt pattern on the top of the payload mount and are at a height of 0 5 inches below the top payload mount surface Please contact Will Burt Engineering to determine if your application requires these precautions Note The Payload Interface has stainless stee...

Page 73: ...ayload security Please contact Will Burt Engineering to determine if your application requires these precautions The Mast System is undamaged If damage is apparent do not use the Mast System and have it serviced prior to use All electrical cables are undamaged and properly terminated All payload cables are not tangled and are free to pay out as the mast extends Any transit tie downs on the payload...

Page 74: ... the expected location of the fully extended mast and payload Check for and remove any objects that might obstruct motion cause binding or hinder function of the system Ensure the operator has full view of the Mast System during use Striking overhead obstructions could result in death or serious injury and can damage the mast and payload and could render the mast inoperable and partially extended ...

Page 75: ...n extending or retracting This could result in damage to the Control Box Polarity Ensure the electrical mains polarity is correct before initializing the Mast System 3 2 Operation Equipment Table 3 1 lists recommended equipment for operation Table 3 1 Equipment Recommended for Operation Recommended Equipment Personal Protective Safety Glasses Work Gloves Nitrile or Vinyl Gloves Hearing Protection ...

Page 76: ...t Nesting the mast Stopping the mast Moving the mast to a specific height manual stop once target height is reached Monitoring the mast parameters and limit switch inputs in real time issued error codes Viewing the cycle count 3 3 2 PC Interface Powered Operation The optional PC Interface allows for Extending the mast Retracting the mast Nesting the mast Stopping the mast Moving the mast to a spec...

Page 77: ...N Switch Section 3 4 1 4 5 Retract the Mast with OVERRIDE Switch Emergency Operation Section 3 4 1 5 6 Access the Cycle Count and Temperature with UP DOWN Switch Section 3 4 1 6 3 4 1 Detailed Instructions The following are detailed instructions describing the operation of the Mast System using the Universal Control Box Prepare the System for Powered Operation To prepare the Mast System for powere...

Page 78: ...xtension height Be sure to stay clear of the collars during operation as they create a pinch point hazard Figure 3 1 UP DOWN Switch Up Position 3 Release the UP DOWN Switch when the desired height is reached If the UP DOWN Switch is released before the maximum extension is reached the mast will quickly stop and the display will show the current extension If the UP DOWN Switch is held long enough t...

Page 79: ...low ends of travel The limit switches typically used to prevent the mast from over travelling at the extreme ends of travel will not function normally Use extreme caution when using the OVERRIDE Switch at the fully extended and fully nested areas of mast deployment Holding the UP DOWN Switch beyond the limits of travel may result in equipment damage When using the OVERRIDE Switch to extend the mas...

Page 80: ...s the UP DOWN Switch is held in the down position the mast will retract and the display will show the appropriate intermediate extension height Be sure to stay clear of the collars during operation as they create a pinch point hazard Figure 3 3 UP DOWN Switch Down Position 3 Release the UP DOWN Switch when the desired height is reached If the UP DOWN Switch is released before the Nested position i...

Page 81: ...typically used to prevent the mast from over travelling at the extreme ends of travel will not function normally Use extreme caution when using the OVERRIDE Switch at the fully extended and fully nested areas of mast deployment Holding the UP DOWN Switch beyond the limits of travel may result in equipment damage When using the OVERRIDE Switch to retract the mast 1 Push back the switch guards cover...

Page 82: ...mast is nested and the UP DOWN Switch is released 2 Hold the UP DOWN Switch in the down position The cycle count and temperature inside the Universal Control Box will alternately show on the Display Note The cycle count drives periodic maintenance procedures The cycle counter increments every time the DOWN Limit Switch is released and then made again This will occur anytime the mast is raised appr...

Page 83: ...ive Equipment Appropriate safety helmet and gloves shall be worn when operating the mast manually Equipment Damage Manual Operation When manually extending or retracting the mast do not drive past the normal extended or nested stops Do not apply in excess of 50 lb ft 68 N m when using the Crank Handle Assembly The normal protections are being bypassed and equipment damage could occur Equipment Dam...

Page 84: ...wer limit switch locations that will stop the mast safety however it is good practice to stop the mast at the normal positions Note When manually operating the mast the intermediate height on the Universal Control Box will not change Prepare the System for Manual Operation To prepare the Mast System for manual operation Ensure the Mast System is stationary on level stable ground Perform the Pre Op...

Page 85: ...erride on top of the Motor Figure 3 5 Figure 3 5 Manual Override 3 Remove the dust cap protecting the Manual Override 4 Insert the Crank Handle Assembly 5 Use the Crank Handle Assembly to extend the mast by turning the Crank Handle Assembly clockwise Be sure to stay clear of the collars during operation as they create a pinch point hazard 6 When the mast has reached the desired height remove the C...

Page 86: ...t System 2 Locate the Manual Override on top of the Motor Figure 3 5 3 Remove the dust cap protecting the Manual Override 4 Insert the Crank Handle Assembly 5 Use the Crank Handle Assembly to retract the mast by turning the Crank Handle Assembly counterclockwise Be sure to stay clear of the collar during operation as they create a pinch point hazard 6 When the mast has reached the desired height r...

Page 87: ... operator must provide safe means to access the top of the mast during installation and removal of the payload 4 1 General Transportation To prepare the Mast System for transportation 1 Ensure the mast is fully nested Do not transport the Mast System with the mast and payload extended Always visually confirm the mast is fully retracted before moving the mast Please contact Will Burt Engineering fo...

Page 88: ...ent Never lift the Mast System over people Ensure lifting equipment including but not limited to lifting straps and hoist are capable of handling the forces generated from lifting the system Observe manufacturer instructions on lifting equipment Death or serious injury could result if proper procedures are not followed When shipping 1 As necessary remove the payload 2 As necessary prepare the Mast...

Page 89: ...d Personnel Only Only trained and qualified personnel should perform maintenance and servicing procedures Only a properly trained and qualified certified electrician should perform electric maintenance and service Death or serious injury could result if proper maintenance procedures and inspections are not observed Tip Over Hazard Before performing maintenance or repair ensure the Mast System is l...

Page 90: ...e local regional and national standards and codes of practice for slinging and transporting equipment Never lift Mast System over people Ensure lifting equipment including but not limited to lifting straps and hoist are capable of handling the forces generated from lifting the system Observe manufacturer instructions on lifting equipment Death or serious injury could result if proper procedures ar...

Page 91: ...r components do so according to any applicable local regional and national standards and codes of practice 5 3 Spare Parts To order spare or replacement parts always refer to the mast model number and serial number The model number serial number and additional information is engraved on the mast Identification Plate Section 1 7 1 11 Throughout this manual P N followed by a number represent the par...

Page 92: ... outer surfaces for damage If damage is apparent do not use the Mast System and have it serviced before use During Operation Binding During extension and retraction of the mast observe mast operation for evidence of binding Remove any foreign material or obstructions as necessary Weekly Damage Inspect all visible surfaces for damage If damage is apparent do not use the Mast System and have it serv...

Page 93: ...d for signs of pinching between the collars or spearing by the trigger posts Replace cables as required Weekly Cycle Counter Check to ensure Cycle Counter is operating properly by noting that during initial cycle of the mast the cycle counter increases by one Refer to Section 3 4 1 6 for cycle counter operation 50 100 Cycles or as Required Corrosive Environment When the Mast System is in a corrosi...

Page 94: ...er premium aerospace grade product and is required for specified performance and life Lubricate the Drive Screw as follows 1 Charge the Grease Gun that shipped with the Mast System with a cartridge of Drive Screw Lubricant P N 4288601 Drive Screw Lubricant can be ordered separately from The Will Burt Company 2 Fully extend the mast 3 Remove the hex shaped access plug from the grease port on the si...

Page 95: ... of the Drive Screw and apply another generous dab two strokes of the handle or approximately 1 14 of the cartridge It is not necessary to use an entire cartridge of grease during a single maintenance procedure The cartridge should last for seven greasing operations 9 Replace the access plug into the access plate Screw the hydraulic coupling cap back onto the output tube of the Grease Gun 10 Retra...

Page 96: ... rust and corrosion While extending and retracting the mast tubes inspect for rust and corrosion on the mast tubes Remove any rust or corrosion with a wire brush Touchup any bare metal with touchup paint or Alodine chemical conversion coating where appropriate Mast Damage If damage to the mast occurs do not use the Mast System and have it serviced before use Servicing the Mast System may require r...

Page 97: ...Look for loose missing bent or broken fasteners Look for chipped paint bare metal or rust around the bolt heads Pay particular attention to the fastener securing the Mast System to the mounting surface the mast to the Drive Assembly the Motor to the Drive Assembly and the payload to the mast Inspect Mast System cables Look for cracked frayed or broken insulation bare wires loose or broken connecto...

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Page 99: ...le Cause Possible Solution Precondition Contact Closure Condition Provisions have been made for a precondition contact handshake circuit If the circuit is open the operation of the mast is prevented and the software revision level is shown on the Display This feature is normally disabled by a jumper installed across the contacts J1 Pins A B The primary application of this capability is a sensor on...

Page 100: ...he Motor Malfunctioning Universal Control Box Contact authorized service center for evaluation and possible return for repair Extension Nuts fail to synchronize with Drive Screw Try retracting the mast 76 mm 3 inches and approach that region again If this does not work the Extension Nuts may be worn out and will need to be replaced Try raising the mast with the Crank Handle Assembly There may be a...

Page 101: ... Universal Control Box Contact authorized service center for evaluation and possible return for repair Extension Nuts fail to synchronize with Drive Screw Try raising the mast 76 mm 3 inches and approach that region again If this does not work the Extension Nuts may be worn out and will need to be replaced Try lowering the mast with the Crank Handle Assembly There may be a burr on the Extension Nu...

Page 102: ...age than anticipated and this should be investigated before trying to further run the mast For additional information please contact Will Burt Customer Service at 330 684 5298 8 2 Error Fault and Warning Codes This section describes error fault codes and warning codes Error fault Codes and Warning Codes will display on the Universal Control Box If SCRAM Section 1 7 3 is used they will also appear ...

Page 103: ...te the mast at excessive low voltage levels to prevent system damage NOTICE Even though outputs are enabled the mast may not be able to move due to the low system voltage System is above 18 volts and no Up Down inputs are active or System power is cycled and is above 18 volts Excessive battery drain without sufficient charge current time Excessive Motor current due to mast resistance excessive pay...

Page 104: ... longer active or System power is cycled and trigger conditions cleared Switch is being held on Switch is damaged Water ingress may be activating switch input Cable or connection failure 0010 Local Down Switch active for excessive time period Local Down Switch Stuck Fault ERR 0010 Ignore the Local Down input except when the OVERRIDE Switch is active Local Down Switch is no longer active or System ...

Page 105: ...e OVERRIDE Switch is also active Can occur on combination with ERR 0001 or ERR 0002 indicated as ERR 0081 or ERR 0082 5 OVERRIDE Switch activations within 3 seconds or System power is cycled and trigger conditions cleared Switch requires adjustment or recalibration Switch failed and requires replacement Drive system damaged 0100 OVERRIDE Switch has been active for an excessive time period Override...

Page 106: ...as written CAN buffer and we have not retrieved the data so currently incoming CAN data cannot be received 8000 Firmware Error User Input Error ERR 8000 Refer to product documentation for valid commands 5 OVERRIDE Switch activations within 3 seconds or System power is cycled and trigger conditions cleared Erroneous user input in the text user interface during debug mode L S ERR Legacy Both Limit S...

Page 107: ...Motor Outputs unless the OVERRIDE Switch is also active One or both of the conflicting switch inputs are no longer active or System power is cycled and trigger conditions cleared One or both Switch es are being held on One or more Switch es are damaged Water ingress may be activating switch input s Cable or connection failure 0002 System voltage has dropped below 20 VDC for 5 consecutive seconds R...

Page 108: ...ormal mast functions Temperature reading is below 78 C or 5 OVERRIDE Switch activations within 3 seconds or System power is cycled and trigger conditions cleared High ambient temperature direct sunlight 0008 Temperature Sensor reading below 40 C Low Temperature Warning WRN 0008 Allow all normal mast functions Temperature reading is above 38 C or 5 OVERRIDE Switch activations within 3 seconds or Sy...

Page 109: ...ower is cycled and trigger conditions cleared Temperature Sensor failed and requires replacement Temperature Sensor Wiring damaged and requires repairs or replacement 0020 Pulses not detected during mast positioning Pulse Counter Warning W0020 Allow all normal mast functions NOTICE Mast height readout will be inaccurate Valid pulse count detected 5 override switch activations within 3 seconds Syst...

Page 110: ...ches in the circuit board are set incorrectly Legacy Potentiometer requires adjustment or recalibration Potentiometer failed and requires replacement Potentiometer wiring damaged and requires repairs or replacement 0080 Legacy Extend Retract movement 50 mm not detected after 2 seconds of continuous extend retract command Encoder Failure Warning WRN 0080 Allow all normal mast functions NOTICE Mast ...

Page 111: ...oefficient of drag Collars attach to the top of each tube except the Top Tube EMC stands for electromagnetic compatibility EMI stands for electromagnetic interference Extended refers to the partial or full raised position of the mast that the mast mechancially goes to from the nested position In the extended position some or all the tubes have risen ID stands for Inside Diameter or the diameter to...

Page 112: ...ne newton applied perpendicularly to a moment arm which is one meter long OD stands for Outside Diameter or the diameter to the outside edge of a circle Payload to refer to the object or equipment being raised by the mast to an operational height P N stands for Part Number These are Will Burt part numbers for various components in the Mast System Top Tube refers to the tube with the smallest diame...

Page 113: ...ng extension Figure 9 1 Figure 9 1 Lay Out Guy Lines 5 Extend the mast Section 3 6 Properly secure and tension the Guy Lines immediately after raising the mast The installer shall verify the Guy Anchor point strength is adequate to support the Guy Line forces All Guy Lines should be equally tensioned Beginning at two locations opposite each other gradually tension each Guy Line Vertical alignment ...

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