Will Burt INFLEXION HD Instructions Manual Download Page 1

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NSTRUCTIONS FOR

IGHT

CAN

ITE

NFLEXION

OBILE

IGHTING

OWER

The Will-Burt Company

Phone: +1 330 682 7015

TP-5554501-B, May 2019

401 Collins Blvd

E-Mail:

[email protected]

Orrville, OH 44667, U.S.A.

Website:

www.willburt.com

Original Instructions

Authorized Representative:

GEROH GmbH & Co. KG
Fischergasse 25

D-91344 Waischenfeld, Germany

Summary of Contents for INFLEXION HD

Page 1: ...ompany Phone 1 330 682 7015 TP 5554501 B May 2019 401 Collins Blvd E Mail contact_us willburt com 2019 The Will Burt Company Orrville OH 44667 U S A Website www willburt com Original Instructions Auth...

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 workm...

Page 4: ...ii Original Instructions TP 5554501 B May 2019 Document History Document Numbers Dates Remarks TP 5554501 00 2 11 2019 Initial Release TP 5554501 A 2 28 2019 Updated Section 2 6 2 and 5 4 TP 5554501...

Page 5: ...1 13 1 7 1 4 Top and Base Sections 1 13 1 7 1 5 Knuckle 1 13 1 7 1 6 Support Struts 1 14 1 7 1 7 Actuator P N 5467502 1 14 1 7 1 8 Gas Springs P N 5537701 1 14 1 7 1 9 Base 1 15 1 7 1 10 Saddle 1 15...

Page 6: ...ower Relay Board 2 24 2 6 2 7 Wire Power for Mast and Control to Power Relay Board 2 26 2 6 2 8 Finalize Electrical Installation 2 27 2 7 Test the Installation 2 28 2 8 Install Payload 2 28 Section 3...

Page 7: ...Lite System Customer Wiring Overview Not to Scale 2 14 Figure 2 8 Grounding Lug Location 2 14 Figure 2 9 Night Scan Lite Power Relay Wiring Diagram 2 15 Figure 2 10 Night Scan Lite Main Control Board...

Page 8: ...ht Scan Lite with RCP and Two X200 LED Lights 1 7 Table 1 3 Night Scan Lite with RCP and No Lights 1 8 Table 1 4 Inflexion HD No RCP No Lights 1 9 Table 2 1 Equipment Recommended for Installation 2 2...

Page 9: ...y CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices General Safety Instructions The follo...

Page 10: ...nd authorized personnel only Proper eye protection shall be worn when servicing the mast Safety Equipment Helmets or hard hats eye protection gloves and safety shoes shall be properly worn while worki...

Page 11: ...ing the mast with an obstruction in the functional space that prevents full extension retraction or panning tilting motion Operating the mast near overhead power lines Operating the mast without the m...

Page 12: ...serious injury This symbol indicates a pinch point hazard or hand crushing hazard Keep hands and fingers clear of moving parts This symbol is used to remind users to read and understand the operator...

Page 13: ...payload for lighting surveillance or communication use only Do not use mast to lift personnel Contact The Will Burt Company with any questions on the intended use 1 1 Intended Use The Night Scan Lite...

Page 14: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 1 2 Original Instructions TP 5554501 B May 2019 1 2 Specification Compliance 1 2 1 CE Declaration of Conformity...

Page 15: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD TP 5554501 B Original Instructions 1 3 May 2019...

Page 16: ...he operator instruction warning label provided with the system at the user control station in view of the operator 2 Install a safety interlock circuit sensor provided with Mast System for driver warn...

Page 17: ...nt being raised by the mast to an operational height This includes the Remote Control Positioner RCP Lights and any additional equipment installed on the RCP See Section 7 1 for an Extended Glossary o...

Page 18: ...tion Rotation Speed 360 19 s Light Tilt Degrees of Rotation Rotation Speed 360 19 s Operating Temperature Range 20 to 70 C 4 to 158 F Storage Temperature Range 40 to 70 C 40 to 158 F Survival Wind Spe...

Page 19: ...tion Rotation Speed 360 19 s Light Tilt Degrees of Rotation Rotation Speed 360 19 s Operating Temperature Range 20 to 70 C 4 to 158 F Storage Temperature Range 40 to 70 C 40 to 158 F Survival Wind Spe...

Page 20: ...19 s Operating Temperature Range 20 to 70 C 4 to 158 F Storage Temperature Range 40 to 70 C 40 to 158 F Survival Wind Speed Payload Total Sail Area 0 28 sq m 3 sq ft CD 1 5 160 km h 100 mph Deployment...

Page 21: ...side Operating Temperature Range 20 to 70 C 4 to 158 F Storage Temperature Range 40 to 70 C 40 to 158 F Survival Wind Speed Payload Total Sail Area 0 28 sq m 3 sq ft CD 1 5 160 km h 100 mph Deployment...

Page 22: ...o Support Struts Section 1 7 1 6 o Actuator P N 5467502 Section 1 7 1 7 o Gas Springs P N 5537701 Section 1 7 1 8 o Base Section 1 7 1 9 o Saddle Section 1 7 1 10 o Control Box Assembly P N 5551801 S...

Page 23: ...ht of two meters 78 7 inches Extends and retracts electro mechanically Is made predominately of steel Is designed to remove mechanical play in the extending section at the extended position to create...

Page 24: ...emote Controlled Positioner RCP P N 5532401 The RCP Figure 1 2 Mounts on top of the mast Contains gears and gear motors to position the lights Contains the RCP Board which receives data through the Ba...

Page 25: ...and Base Sections The Top and Base Sections Figure 1 3 Are raised and lowered by the Actuator to extend and retract the payload Are made of steel Front View Side View Figure 1 3 Top and Base Sections...

Page 26: ...d limit switches Is IP66 rated dynamic for dust and water ingress protection Factory programed soft start and stop in both directions for smooth mechanism operation at travel extremes Nesting motion s...

Page 27: ...pivot join to remove mechanical play in the Base Section and create a stable platform Figure 1 5 Base and Saddle 1 7 1 10 Saddle The Saddle Figure 1 5 Two locations to stabilize the RCP when in the n...

Page 28: ...ctivity while nested Control Box Assembly Location Control Box Assembly Figure 1 6 Control Box Assembly 1 7 1 12 Look Up Light P N 214014 The Look Up Light Figure 1 6 is a safety LED light that illumi...

Page 29: ...perator can view during operation The Operation Label is required for NFPA1901 compliance Contact The Will Burt Company for information pertaining to alternate language label kits 1 7 2 Junction Box P...

Page 30: ...es momentary switches for all motion Is IP54 rated for dust and water ingress protection Figure 1 9 Hand Held Remote Control 1 7 4 Junction Box Cable P N 218103 cut to specified length or P N 5563301...

Page 31: ...showing the top of the mast Can be turned on and off through the Hand Held Remote Control AUX1 or AU Are available in amber blue clear red and green Are available as LEDs Are shipped installed with n...

Page 32: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 1 20 Original Instructions TP 5554501 B May 2019...

Page 33: ...ood and followed Trained Personnel Only Only trained and qualified personnel should perform installation procedures Only a properly trained and qualified certified electrician should perform electric...

Page 34: ...Helmet Safety Shoes Hand Tools Appropriate Hardware Section 2 3 Drill Level Manual Ratchet Wrench Measuring Tape Multimeter To verify power is off Torque Wrench Washers or Spacers For shimming Wire Cu...

Page 35: ...HHRC has a 10 mm 0 394 inch eyelet to allow the HHRC to be hung in place when not in use Unless otherwise indicated the mounting hardware shall include proper means to resist vibration loosening such...

Page 36: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 2 4 Original Instructions TP 5554501 B May 2019 Figure 2 1 Mast System with RCP and Four X200 Lights...

Page 37: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD TP 5554501 B Original Instructions 2 5 May 2019 Figure 2 2 Mast System with RCP and Two X200 Lights...

Page 38: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 2 6 Original Instructions TP 5554501 B May 2019 Figure 2 3 Mast System with RCP and no Lights...

Page 39: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD TP 5554501 B Original Instructions 2 7 May 2019 Figure 2 4 Mast System with no RCP and no Lights Inflexion HD...

Page 40: ...wer cable with maximum length of 15 meters 50 ft 10 2 SJOW cable or equivalent four light models require qty 2 10 2 SJOW cables one to supply the left side and one for the right side May have an amp d...

Page 41: ...o Power Relay Board Section 2 6 2 5 11 Wire Power for Lights to Power Relay Board Section 2 6 2 6 12 Wire Power for Mast and Control to Power Relay Board Section 2 6 2 7 13 Finalize Electrical Install...

Page 42: ...ng reached by upper extremities of operators or bystanders The base of the mast shall be installed at a 2 7 meter 8 8 feet minimum height above ground level or at a lower height with sufficient guardi...

Page 43: ...crate If necessary lower the mast and adjust the sling as needed to balance the mast The slings should not contact the top tube RCP or lights 6 Ensuring the sling does not catch on anything lift the...

Page 44: ...st Assembly Mounting Holes 3 Ensure the Mast Assembly 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...

Page 45: ...ft lb Note An Operation Label P N 5555101 ships loose with the Mast System for Night Scan Lite This label includes important warning symbols also located on the Mast Assembly This label shall be appli...

Page 46: ...afest method for your circumstances Before electrically installing the system review the following Figure 2 7 for an overview of the System Wiring Figure 2 9 for the Power Relay Wiring Diagram Figure...

Page 47: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD TP 5554501 B Original Instructions 2 15 May 2019 Figure 2 9 Night Scan Lite Power Relay Wiring Diagram...

Page 48: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 2 16 Original Instructions TP 5554501 B May 2019 Figure 2 10 Night Scan Lite Main Control Board Wiring Diagram...

Page 49: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD TP 5554501 B Original Instructions 2 17 May 2019 Figure 2 11 Night Scan Lite Remote Junction Box Wiring Diagram...

Page 50: ...s to the Control Box Assembly The manual override shaft is accessible at the back of the actuator Manually extending the mast requires a inch drive 8 inch flexible drill extension Will Burt recommends...

Page 51: ...al remains on the screw during re installation to maintain the IP66 rating for dust water ingress 2 6 2 2 Wire Junction Box to Main Control Board To wire the Junction Box to the Main Control Board 1 R...

Page 52: ...aller shall ensure that voltage is only supplied to the mast system when the vehicle is stationary Vehicle safety circuitry interfaces with the Mast System through a dedicated proximity sensor located...

Page 53: ...the sensor to the other side if necessary Figure 2 15 Proximity Sensor Proximity Sensor Specifications 10 30VDC Input Power 100 mA max Normally Open closes when mast is nested NPN 7mm sensing range IP...

Page 54: ...control box knockout port The cable grip must have a sealing feature against the control box wall For Inflexion HD either the AUX1 AUX2 Left Light or Right Light circuit can be used to control the pa...

Page 55: ...cted power will need to be provided to the device The Power Relay Board allows for up to two auxiliary devices to be installed with a maximum amp draw of 10 amps per device Wire customer power for the...

Page 56: ...shown in Figure 2 19 4 Tighten the cable grip ensuring proper slack inside the control box Note if installing an Inflexion HD the customer specific payload replaces the lights and is subject to the sa...

Page 57: ...s P N 221042 Install 12 to 24 VDC convertor P N 208018 in a protected environment inside the vehicle as close as possible to the 12 VDC source Best practice is to mount with the cooling fins in a vert...

Page 58: ...ustomer power for the mast and control 1 Run a 10 AWG cable 6 mm2 maximum length 15 meters from customer power to the Control Box Assembly through one of the cable grips on the side of the control box...

Page 59: ...Secure the Control Box Assembly lid and ensure the Control Box Assembly is sealed up 5 Secure the Junction Box lid and ensure the Junction Box is sealed up 6 Plug the HHRC cable into the bulkhead con...

Page 60: ...If the payload will be offset a significant amount 300 mm 12 inches contact The Will Burt Company Contact The Will Burt Company with any questions before performing any installation procedures Payload...

Page 61: ...n 2 and Stowed Pin 7 If a unit supplied with an RCP is modified to remove the RCP for a different payload a jumper wire 22 AWG 0 5 mm2 minimum needs to be added as noted above to allow the mast to ret...

Page 62: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 2 30 Original Instructions TP 5554501 B May 2019...

Page 63: ...free of overhead power lines and other unwanted sources of electricity Follow applicable safety regulations when working near energized power lines Operator death may occur by extending the mast into...

Page 64: ...oline or solvents Do not use in areas of limited ventilation or where high ambient temperatures are present Contact with combustible materials can cause ignition resulting in fire or explosion 3 2 Ope...

Page 65: ...off AUX 2 Toggles Auxiliary 2 on and off Light Toggles the Lights on and off or other payload for Inflexion HD There is one Light button for each of the two Light banks Pan Left Pans the RCP and Light...

Page 66: ...follow the quick summary Section 3 4 2 In general operate as follows 1 Initiate the System Section 3 4 2 1 2 Extend the Mast Section 3 4 2 2 3 Operate the RCP and Lights Section 3 4 2 3 4 Operate the...

Page 67: ...the mast 1 Press and hold the Mast Up button until the mast reaches the fully extended position The Look Up Light will illuminate while the mast is in motion Press the button until the control stops t...

Page 68: ...uits To pan and tilt the lights Press and hold the Pan Right button to turn the lights to the right Press and hold the Pan Left button to turn the lights to the left Press and hold the Tilt Down butto...

Page 69: ...ical play during vehicle transit Once nested the system will automatically power down after approximately 5 seconds Once the mast is fully nested the Vehicle Interlock contact signals it is safe to mo...

Page 70: ...of the Actuator There may be a label covering the screw If necessary remove the label to access the screw 3 Remove the screw at the back of the Actuator 4 Once the screw is removed insert a 6 mm hex...

Page 71: ...eight above the nested position or powered up Do not move vehicle until the mast has been securely nested and powered down Power up and operate the mast only if the vehicle is stationary and securely...

Page 72: ...d follow the applicable 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 no...

Page 73: ...ast System is level and secure Injury to personnel or equipment damage could occur if the Mast System tips over Safety Instruction Electrical Hazard Never manually operate the mast while power is stil...

Page 74: ...remote control and keep it with the maintenance engineer during maintenance to avoid unexpected mast operation 5 3 Maintenance Equipment Table 5 1 lists recommended equipment for maintenance Table 5 1...

Page 75: ...System is kept clean and free from foreign material Dirt grease oil and debris may cover up a serious problem Clean as you work and as needed Wipe down with a soft cloth or sponge and a mild solution...

Page 76: ...ectors Inspect the cable protective conduit in the knuckle joint for damage or movement out of the knuckle joint area Inspect all cable grips to ensure they are tight and providing a good seal Replace...

Page 77: ...res with the mast nested The RCP or payload should not have any mechanical play in the upward direction If upward play is observed adjust the RCP saddle height up to remove the mechanical play in the...

Page 78: ...in the proper marked container Freezing Burn Hazard Make sure the lights are completely cool before attempting to clean the light lenses Wear gloves to protect from exposed metal that may be at extre...

Page 79: ...INFLEXION HD TP 5554501 B Original Instructions 6 1 May 2019 Section 6 Troubleshooting This section describes troubleshooting for the Mast System Use care to understand and follow all precautions whil...

Page 80: ...ew masts Over time vibration during transportation and wear may cause the RCP and payload to bounce excessively If excessive bouncing is observed the RCP saddles Figure 6 1 may be adjusted upwards to...

Page 81: ...saddles are adjusted in the factory for new masts and support the mast during side to side vehicle dynamic loading Over time vibration during transportation and wear may cause the RCP and payload to...

Page 82: ...INSTRUCTIONS FOR NIGHT SCAN LITE INFLEXION HD 6 4 Original Instructions TP 5554501 B May 2019...

Page 83: ...neral terms and abbreviations used within this manual Amp stands for ampere which is a unit of electric current ANSI Z535 4 standard refers to the American National Standard for Product Safety Signs a...

Page 84: ...r Newton Meters which is a unit of torque equal to the force of one newton applied perpendicularly to a moment arm which is one meter long Payload to refer to the equipment being raised by the mast to...

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