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NIGHT SCAN POWERLITE, POWERLITE XTREME, AND POWERLITE HDT

OPERATING INSTRUCTIONS

TP-4723701-U

MAY 2021

5 Installation

This section describes the physical and electrical installation of the Night Scan Powerlite, Night

Scan Powerlite Xtreme, and Night Scan HDT and provides the general procedures that must be

followed to ensure a successful installation. Be sure to read and understand the entire installation

procedure and the Safety Summary Section 1 before beginning installation.

5.1 Mounting Location Requirements

The following factors must be included when selecting an appropriate mounting location.

1. Your system is designed to withstand adverse weather conditions, however it cannot be

submerged in water. If the system is mounted in a well, provide adequate drainage. A

minimum of four 1 inch (25mm) diameter drain holes (one per corner) are recommended.

2. Ensure that the mast base and saddle are on a flat surface and in the same plane. The

Stowed Limit Switch is set at the factory based on a level surface. If the system is not level,

these switches may need adjusted as described in Section 7.5.3.

3. The installed elevation of the bottom of the mast base shall be at least 2.7 meters (8.8 feet)

above ground level to prevent reach of upper extremities during operation. Alternatively,

lower elevations are permitted if the mast is properly guarded by the installer or offset

towards the middle of the roof with reach limited by vehicle structure to prevent contact with

the mast during operation.

4. It is important that both the base and the saddle be securely mounted to a sturdy roof or

platform which will not overturn during operational loading of the mast. The surface must be

reinforced to withstand the load at the different points on the mast that can be expected

during operation as shown in Figure 5-1. These are maximum load estimates placed

downward and sometimes upward on the vehicle top by the mast. Note the loading is

reduced for the 2.3 model (see TP-4602001).

Figure 5-1 Reaction Loads on Mounting Structure

Saddle: 120 lb (55 kg)

650 lb (295 kg)

1250 lb (567 kg)

(single point load in center)

(load at each mounting hole) (load at each mounting hole)

Summary of Contents for Night Scan Powerlite

Page 1: ...P 4723701 U May 2021 2021 The Will Burt Company Original Instructions Authorized Representative Will Burt Germany GmbH Co KG Fischergasse 25 D 91344 Waischenfeld Germany Night Scan Powerlite Night Scan Powerlite Xtreme and Night Scan Powerlite Heavy Duty Towing HDT Operating Instructions Night Scan Powerlite Night Scan Powerlite HDT ...

Page 2: ......

Page 3: ...N CONNECTION WITH THE MANUFACTURE OR SALE 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 e...

Page 4: ...rol HHRC 33 5 6 2 Panel Mount Remote Control PMRC 35 5 6 3 Wireless Hand Held Remote Control WHHRC 36 5 7 Electrical Installation 37 5 7 1 Wiring Remote Control Cable to the Base Board 38 5 7 2 Wiring DC Source Power to the Mast Control Circuit 39 5 7 3 Wiring Source Power to the Light Circuits 39 5 7 4 Wiring Vehicle Safety Interconnect Circuit 43 5 7 5 Wiring Optional Enable Circuit 44 5 7 6 Sec...

Page 5: ...justing the mast 90 Limit Switch 60 7 5 3 Adjusting the Mast Stowed Limit Switch 61 7 5 4 Adjusting the Mast Magnetic Down Switch 62 7 6 Adjusting the RCP Home Position 63 7 7 System Disposal 64 8 Reference Information 65 8 1 DIP Switch Definitions 65 8 2 Strobe Beacon Light 65 8 3 D TEC Sensor 66 8 3 1 D TEC Sensor Location 66 8 3 2 D TEC Functionality 67 8 4 Nycoil Optional 69 8 5 Bulb Replaceme...

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Page 7: ...ion that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or equipment damage It is also used to alert against unsafe practices 1 2 Safety Instructions Electrocution Hazard Contact with high voltage will result in death or serious injury Observe general safety precautions for handli...

Page 8: ... up Do not move vehicle until mast has been securely nested and isolated from power Power up and operate mast only if the vehicle is stationary and securely parked with the parking brake properly applied Do not put mast in service or operate without the vehicle interlock warning circuit or magnetic warning kit installed to provide confirmation mast is nested prior to moving the vehicle Contact The...

Page 9: ...as that have been classified as hazardous as defined in Article 500 of the National Electric Code or equivalent national standards Do not use in the presence of flammable gases or liquids such as paint gasoline or solvents Do not use in areas of limited ventilation or where high ambient temperatures are present Safety Equipment PPE Proper personal protective equipment PPE like hard hats gloves and...

Page 10: ... power and operating mast be certain there is sufficient clearance above and to all sides of the expected location of the fully extended mast and payload Keep all persons clear of mast and mast extension Do not lean directly over mast Locate the operator station such that the operator has a clear view of the operating space of mast and payload prior to deployment to avoid contact with overhead obj...

Page 11: ... Lines verify the Guy Anchor point strength is adequate to support the Guy Line forces Lubrication Do not lubricate the exterior of mast moving tubes The lubricant will attract dust and other environmental contaminants into mast Equipment Damage Forces Before unloading the system be certain the unloading region is capable of resisting forces generated from unloading the system including but not li...

Page 12: ...rolled rate until power is restored or mast fully retracts Masts that fold down will not initiate any tilt motion 1 3 Symbols Used on Product Labels The following symbols are displayed on the product The symbol meanings are as follows This symbol indicates an electrocution hazard or hazardous voltage hazard There is voltage present inside mast and control box Do not operate mast near electrical li...

Page 13: ... XTREME AND POWERLITE HDT OPERATING INSTRUCTIONS TP 4723701 U MAY 2021 This symbol indicates an electrical ground connection point This symbol is used to indicate the center of gravity COG of a fully nested mast in a horizontal transport position ...

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Page 15: ...iance 2 1 NFPA 1901 2016 The mast systems are designed to be compliant with the following sections of National Fire Protection Agency NPFA 1901 2016 Edition 22 14 Powered Operated Light Masts 23 13 Power Operated Masts 2 2 CE Declaration of Conformity Refer to the Product page at www willburt com for the latest Declaration of Conformity ...

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Page 17: ...ore performing any procedure outlined in this manual The views depicted in this manual are provided for clarification and are subject to change without notice Views are not to scale The different Night Scan Powerlite mast models tilt to vertical and extend upwards to provide directional scene lighting and surveillance The masts retract and fold down for transport The following models are covered i...

Page 18: ... Scan Powerlite Xtreme and Night Scan Powerlite HDT are intended for use by professionals in the fire rescue first responder security industries to provide elevated and directional emergency scene lighting and surveillance or communication capabilities It is not intended for use by non professionals Do not use the mast to lift personnel The mast systems are intended to be installed on the roof or ...

Page 19: ... 2 are used throughout this manual Stowed is the horizontal position in which the mast is firmly seated in the saddle This position is sometimes referred to as the nested position 90 is the position that the mast electrically goes to from the stowed position At 90 the mast has angled up but no mast sections have risen The mast remains retracted Extended is the partial or full raised position that ...

Page 20: ... show for camera or other accessory cables RCP The Remote Control Positioner RCP pans and tilts the lights The RCP does not become active until the mast tilts up to the 90 position Standard Night Scan Powerlite Night Scan Powerlite Xtreme and Night Scan Powerlite HDT masts come equipped with a dual tilt RCP This means the left and right lights tilt independently to direct light at a desired positi...

Page 21: ...ler and provides landing points for customer power supply and vehicle interlock cables The PCB also distributes DC and optional AC light power to components in the system Figure 3 5 Base Board P N 4311701 Wiring Air Access Panel The wiring air access panel provides interface points to attach supply air and power data cables Optional Camera or Strobe Location Magnetic Down Switch Base Mast Lights R...

Page 22: ...6 Night Scan Powerlite HDT Parts Saddle The saddle supports the RCP and lights when nested for stable vehicle transit The saddle position varies by model Lights The Night Scan Powerlite Night Scan Powerlite Xtreme and Night Scan Powerlite HDT systems can come with a variety of LED or Halogen lighting packages Go to www willburt com for additional information on available light packages Camera Stro...

Page 23: ...t Switch This limit switch activates when the mast reaches the 90 vertical position The mast is driven into a rubber pad under the mast It is activated by a magnet located on the tilt mechanism The lights and RCP functions are disabled until this 90 limit switch is activated Once activated the RCP and lights are active for use The limit switch is adjustable and set at the factory See Section 7 5 2...

Page 24: ...valve prevents over pressurization of the mast system Air Control Valve Assembly The air control valve assembly consists of the extend and exhaust valve and factory set regulator to control pressure into the mast Optionally an air compressor can replace the air control valve assembly The mast does not have a switch indicating the mast has reached its full extended height When the mast is deployed ...

Page 25: ...PMRC This option mounts to a panel and has LED display 3 Wireless Hand Held Remote Control WHHRC This option comes with a separate control box that contains the transceiver This control box is mounted separately from the mast A HHRC can be plugged into the wireless control box and used with the wireless control Refer to operating instructions TP 5543301 for installation and operation for the optio...

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Page 27: ... 6 6 0 19 Number of Tubes 3 5 Tube Diameter Range in mm 3 5 to 2 5 89 to 64 5 to 3 127 to 76 System Operating Temperature 22 to 149 F 30 to 65 C System Storage Temperature 40 to 149 F 40 to 65 C Maximum Deployment Angle 10 17 6 Grade 5 9 Grade Deployment Wind Speed mph km h 40 max 64 max Altitude Above Sea Level ft m 15 000 4572 Max Time to Light seconds 8 12 14 17 21 Survival Wind Speed mph km h ...

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Page 29: ...at the factory based on a level surface If the system is not level these switches may need adjusted as described in Section 7 5 3 3 The installed elevation of the bottom of the mast base shall be at least 2 7 meters 8 8 feet above ground level to prevent reach of upper extremities during operation Alternatively lower elevations are permitted if the mast is properly guarded by the installer or offs...

Page 30: ... Glasses Safety Gloves Safety Shoes Hard Hat or Helmet Hearing Protection Crimping Tool or Solder Set Wrenches Screwdrivers Multimeter to verify power is turned off Torque Wrench Drill Knife or Scissors to Cut Crate Band Wire Cutter Stripper RTV Silicone 1 2 inch or M12 Mounting Hardware 6 each Shop Rags Hoist minimum 500 lb 227 kg capacity Note Depending on the national and local standards and co...

Page 31: ...ency stow the mast If necessary it can also be used in conjunction with the 1 5 mm wrench to assist in disassembling the actuator Contact The Will Burt Company s Service for detailed instructions on this process 4 Inspect for any shipping damage If damage has occurred notify the carrier 5 Unbolt for wooden crates and remove any banding fixing the mast to the shipping crate or carton Remove any ban...

Page 32: ...iner by the mast tube at the labeled center of gravity symbol Figure 5 2 position Do not lift using the RCP or lights camera Lifting from locations other than those indicated could result in equipment damage Use two point contact for slings to keep the load stable while moving Figure 5 2 Center of Gravity Hoisting Position Lift with a Hoist Here at Label Lifting Point ...

Page 33: ...ied by the customer Stainless steel or stronger bolts are recommended It is up to the installer to ensure proper thread locking methods are used to keep the bolts from backing out due to vehicle vibration Attach the base and saddle to the mounting surface in six locations using 1 2 inch or M12 bolts washers Torque all hardware as appropriate for its material and size The recommended installation t...

Page 34: ... feet 6m of air hose labeled SUPPLY to designate the pressurized air to be routed to the INLET of the unit The exhaust fitting is to be used with a inch or equivalent metric inside diameter air hose The unit is supplied with 20 feet 6 m of air hose labeled EXHAUST to designate its use to route exhausted air to a location where it will not expel air or water onto personnel or equipment sensitive to...

Page 35: ... for the wireless control option This section will describe how to install the Wired HHRC with a bulkhead The bulkhead connector is provided to remotely install the connection point for the HHRC at the operator control location The operator station should be located where the operator has line of sight to the mast operating space The bulkhead and HHRC should be located in a protected dry location ...

Page 36: ...PAGE 34 OF 98 NIGHT SCAN POWERLITE POWERLITE XTREME AND POWERLITE HDT OPERATING INSTRUCTIONS TP 4723701 U MAY 2021 Figure 5 5 HHRC Bulkhead Bracket Installation Dimensions ...

Page 37: ...thread locking techniques to prevent the screws from backing out due to vibration Mount the holder ensuring the wedged side in the groove is facing upward to mate to the HHRC 3 Place the HHRC on the holder Warning labels are shipped loose with the mast These labels should be posted in view of the operator Figure 5 6 HHRC Holder 5 6 2 Panel Mount Remote Control PMRC If your system was not ordered w...

Page 38: ...ted wire the connector and attach the connector to the back of the PMRC To wire the PMRC connector 1 See the Wiring Diagrams provided in the Appendix 2 Ensure power is properly disconnected from the system 3 Connect the wires from the Control Cable to the supplied PMRC plug according to the wiring diagram 4 Plug the cable into the back of the PMRC 5 6 3 Wireless Hand Held Remote Control WHHRC Refe...

Page 39: ...l To electrically connect the mast system proceed as follows 1 Remove the screws from the left cover of the base as viewed from the back of the unit and remove the cover 2 Run the Bulkhead Cable from the HHRC connected to the bulkhead or the PMRC Control Cable into the base through the access panel Run all power data cables into the base through the access panel Figure 5 8 Wiring Access Panel Ligh...

Page 40: ...se Board The Bulkhead Cable or PMRC Control Cable connects the bulkhead Remote Control and Base Board 3 Connect the wires from the Bulkhead Cable or PMRC Control Cable to the green J4 connector located on the top left of the Base Board ensuring the wires match the color strip on the J4 connector Connect the J4 connector to the Base Board Figure 5 9 Wiring J4 ...

Page 41: ...VIN red or white and COM black connections on terminal block TB4 on the lower left side of the Base Board 5 7 3 Wiring Source Power to the Light Circuits The lighting circuits consist of two 2 independently powered circuits left and right Depending on the light package installed on the unit the source power for the left and right light circuits will change to match the light fixtures Be sure to co...

Page 42: ...w for the installed lights and not based on wire size current capacity It is also the responsibility of the installer to provide a means to remove isolate power from the mast light circuits and permit the operator to follow proper lock out tag out procedures for maintenance or troubleshooting There are two inputs on the base Board LEFT POWER and RIGHT POWER To wire the Light Power to the Base Boar...

Page 43: ...t enters the base This ferrite provides EMI electromagnetic interference filtering 6 Replace the base cover Light power cables can be purchased from The Will Burt Company or provided by the installer For CE conformity the installer must provide the light power cables in conformance with applicable Directives Cables supplied by The Will Burt Company do not have blue color for conductor identificati...

Page 44: ...y includes a separate terminal block to land the 12 VDC light power Connect the left and right light power to the terminal block as shown in Figure 5 11 following the polarity listed on the terminal block label Note this only applies to 12 VDC high current applications The solenoid valve is not installed for systems under Condition 1 Figure 5 11 Solenoid Valve Light Power Connection Point for 12VD...

Page 45: ...xtended This relay output is from a bi stable latching relay whose contacts either open or close switch selectable when the mast is active not stowed Its state is not affected by whether or not there is power to the mast This contact is capable of carrying up to two 2 amperes and is available on pins J4 8 and 9 data cable supplied by the installer Figure 5 12 shows an example vehicle safety interc...

Page 46: ...ng the mast when the parking brake is released the mast is again prohibited from energizing until the parking brake is set Note Using this parking brake feature is the same as pushing the E stop button Power to the control is opened the mast immediately exhausts air and the mast comes down without regard to the proper RCP alignment stowing to the home position The parking brake should not be relea...

Page 47: ...wer Converter Mounting 5 8 Test the Installation Review the Operation Section 6 and Safety Summary Section 1 and observe all safety dangers warnings and cautions before proceeding to test the installation If any part of the testing fails check the LEDs on the controller and Base Board To test the installation proceed as follows 1 Reconnect power to the mast and light circuits 2 Turn the E Stop but...

Page 48: ...t is properly sealed while the mast is fully extended watch for any type of mast lowering 13 Press and hold the Mast Down button until the mast has completely stowed and then release the button once the LED indicators turn off on the HHRC The mast will power off automatically upon reaching the stowed position 14 Restart the system and rapidly press the Mast Up button two times to invoke the Auto U...

Page 49: ...m an emergency stop move the mast up and down tilt the lights up and down pan the lights right and left turn the lights on and off and turn the optional strobe light on and off The following are the Remote Control buttons 6 3 Quick Operation Summary Following is a quick summary of the operation of the system Detailed steps follow the quick summary If an emergency stop E Stop is required at any tim...

Page 50: ...he mast by pressing Mast Down 10 Stow the mast by performing one of the following steps Quickly press Mast Down twice Auto Stow feature It is recommended to use the Auto Stow feature to stow the mast To abort Auto Stow press any controller button Press and hold Mast Down until all LEDs on the controller turn off Ensure that Mast Down is released only after the controller LEDs turn off which means ...

Page 51: ...lly turns on the lights at 90 whereas using the Mast Up button does not The Auto Up feature is the quickest and most reliable method to raise the mast to 90 and turn on the lights Using the Auto Up feature does not require the operator to stop the mast exactly at 90 before turning on the lights Two common operator errors can occur when the operator does not use the Auto Up feature 1 On uneven grou...

Page 52: ... operator input from the controller 6 5 2 Using the Mast Up Button Raise the mast to 90 using the Mast Up button as follows 1 Press and hold Mast Up until the mast is at 90 Press the button until the software stops the mast to ensure 90 has been reached 2 Release Mast Up button when the additional controller LEDs like Tilt Down and Pan Right light The lighting of the LED indicators indicate the ma...

Page 53: ...Lowering the Mast Once the mast has been extended pressing Mast Down will lower the mast Continue to press Mast Down until the mast reaches the desired height and then release the button 6 9 Stowing the Mast The stowed position is also called the nested position The stowed position is the position of the mast when it is folded down and firmly seated in the saddle The mast is considered stowed when...

Page 54: ...ore Remote Controls if used so they will not be damaged during transportation 6 9 2 Using the Mast Down Button Another method used to stow the mast is to press and hold Mast Down on the controller This method is not as reliable as using the Auto Stow feature Care must be taken to ensure that the operator does not release the button before the mast is completely stowed and powered down If the mast ...

Page 55: ...ssing and holding S4 will drive the tilt actuator to stow the mast The mast will continue to tilt and drive in the saddle until S4 is released Do not over drive the actuator into the saddle To stow the mast using the emergency stow button 1 Remove the left side cover as viewed from the back of the mast 2 Tap S4 on the Base Board Do not hold down S4 just press then immediately release S4 once This ...

Page 56: ...stem 2 Adjust the pan and tilt if necessary to place the payload in the stow position Ensure that the payload will not make contact with the saddle or mounting surface when the mast stows If your system includes lights make sure any lights have cooled completely before manually panning and tilting Lights should be rotated so they will be facing down when the mast is stowed 3 Remove the base right ...

Page 57: ... mast Note the mast will descend if extended as air will be removed from the mast 3 Disconnect all power sources using lock out tag out procedures It is recommended that the vehicle ignition keys be held by the maintenance engineer as an additional precaution to prohibit unexpected power up 4 Unplug the mast hand held remote control and keep it with the maintenance engineer during maintenance to a...

Page 58: ...ize the mast just enough to extend the desired mast section A second person may have to hold down the larger mast section collars to ensure the desired tube extends Release Mast Up button as soon as the desired mast section is fully exposed 2 Wipe down the desired mast section using a non abrasive cleanser or solvent such as lacquer thinner Do not allow the cleaning fluid or solvent to run down in...

Page 59: ... Clean the mast per the procedure in section 7 2 During Operation Inspect for damage during operation If damage is apparent do not use the mast and have it serviced prior to use Monthly Visually observe tube motion during extension and retraction to ensure the tubes move smoothly and do not cause excessive impact loads when each tube fully extends or retracts Clean and lubricate the mast per the p...

Page 60: ... environment Exercise mast Every 6 Months With the mast fully stowed carefully lift up on the RCP housing do not lift by the light fixtures The RCP housing should not have any mechanical play allowing it to bounce when being transported on a vehicle If mechanical play is observed adjust the mast stowed limit switch position to allow the RCP to drive tightly into the saddle according to Section 7 5...

Page 61: ...wing the mast in the stowed position is shown in Figure 7 1 These diagnostic LEDs can be used to help determine if an adjustment is necessary for example if D7 D8 shows Yellow when the mast is supposed to be stowed They are also useful in assisting to determine when the switches have been properly adjusted Figure 7 1 Diagnostic LEDs stowed position example Table 7 2 Mast Positions Shown by Diagnos...

Page 62: ... Switches and Base Board 3 Loosen the lock nuts to adjust the switch position in the slot 4 Raise the mast to 90 by holding the Mast Up button until the mast is at 90 Do not use the Auto Up feature to raise the mast to 90 5 Check that the mast is at 90 by using a level ensuring that the mast is square to the sheet metal side plate on the base A value range of 89 5 to 90 5 is acceptable 6 Adjust th...

Page 63: ...n access to the Mast Stowed Switch 4 Loosen the lock nuts to adjust the switch position in the slot 5 Lower the mast to the stowed position by holding the Mast Down button until the mast is stowed Immediately release the Mast Down button when the mast is stowed If you drive the mast too far into the saddle you may receive a 1 04 error excessive amp draw during actuator decline Do not use the Auto ...

Page 64: ...ds the Magnetic Down Switch and lower the clamp to the bottom of the mast 3 Remove the left base cover to expose the base PC Board diagnostic LEDs see Figure 7 1 4 Ensure the mast is fully nested no gaps between collars While observing the Base Board diagnostic Mast Down LED slowly move the band clamp up until the Mast Down LED turns green 5 To test a Initiate the mast b Press the Mast Down button...

Page 65: ...ect all light power to the system using proper lock out tag out procedures see Section 7 1 Keep the DC power connected to the mast control system 2 Initiate the mast and raise the mast to the 90 position Ensure that the Pan Right and Tilt Down controller LEDs turn on 3 Remove the RCP cover to access the flags The flags are attached to the timing rings on the horizontal and vertical shaft gears Fig...

Page 66: ...en the adjustment screws to secure the ring 7 Tilt the unit until the second set screw for the tilt flag is accessible Tighten the second set screw 8 Stow the mast watching for the RCP and lights to become oriented as described in the beginning of this section If it does not look like the RCP is properly positioned during stowing use the Emergency Stop to stop motion and re adjust the flags 9 Once...

Page 67: ...ion on the DIP Switches and their settings see the wiring diagram in the Appendix Note The controls check the status of the DIP switches only during initialization After flipping a DIP switch the system will need restarted for the change to take effect 8 2 Strobe Beacon Light The optional strobe beacon light Figure 8 1 provides visibility and safety by mounting on top the RCP and brightly showing ...

Page 68: ...rm threshold 8 3 1 D TEC Sensor Location When using the D TEC Sensor with a Will Burt RCP the unit will be mounted on the side of the RCP cover plate opposite of the RCP circuit board This typically is installed by The Will Burt Company The Sensor unit must be mounted in the upright position with the look up light pointing up Figure 8 2 D TEC Sensor Installed on RCP The cable used to connect the S...

Page 69: ...n or lowering the mast to the bottom of the 90 position for fold down models This will clear the alarm and allow the operator another chance to raise the mast to its full extension The following messages may be displayed on the Remote Control s The following table contains possible D TEC messages Table 8 1 D TEC Messages Message Meaning Root Issue D TEC Testing The D TEC Sensor is performing a sel...

Page 70: ...t is not the fault occurs 5 03 SPI Fault A communications bus internal to the D TEC Sensor has failed during self test Defective Sensor 5 07 Unrecoverable Communication Error No successful communication for 250ms Check connection data lines ground for continuity This error may also be displayed on systems without a D TEC if the Base Board is missing the 4710801 DIP Switch Shunt Board 5 09 E Field ...

Page 71: ...he coil being 8 inches 3 4 inch inside diameter of the conduit with the outside diameter of the coil being 13 inches Consult engineering on specific applications for other Nycoil sizes Note Nycoil is a registered trademark of the Nycoil company 8 5 Bulb Replacement This section contains bulb replacement procedures provided by Fire Research Corporation FRC Focus Optimum Lights and Magnafire Note Th...

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Page 78: ...PAGE 76 OF 98 NIGHT SCAN POWERLITE POWERLITE XTREME AND POWERLITE HDT OPERATING INSTRUCTIONS TP 4723701 U MAY 2021 8 6 The Will Burt Company Mast Oil Safety Data Sheet ...

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Page 83: ...wn on the status light as three flashes pause seven flashes Table 9 1 Error and Warning Codes for Base Board Message Meaning Root Issue Potential Cause WRN 1 04 Look Up Light is burned out The control circuit is not sensing the Look Up Light current Look up Light is burned out or disconnected WRN 1 05 Well cover switches indicate closed when they should be open This stops all vertical movement of ...

Page 84: ... updated with the mast at 90 1 04 Excessive amp draw during actuator decline Current sensor indicating it has exceeded 12v systems 10A for 100ms 24v systems 6 0 amps AND less than 10 amps for 100 msec If mast stops at 70 and issues error replace Base Board Current sense circuit has failed If error occurs during nesting check LED D7 MAST STOWED near 0 Once the sensor sees the magnet it allows 0 5 s...

Page 85: ...ed to a Non NFPA J box Note if the unit is in Non NFPA mode and connected to an NFPA junction box the unit will look normal UP led on HHRC on but will not respond to the HHRC The software is expecting to see the init signal always on No error message is generated 2 Wiring short in the control cable or defective switch wiring 1 10 Memory Error Memory Error Memory Error 1 11 Actuator current has une...

Page 86: ... go up and the sensor indicates it did not move after 8 seconds v7 2 or 15 seconds v7 3 3 Sensor is not seeing magnet when mast is fully retracted 1 There may be a wiring problem or a defective magnetic sensor or 2 Defective magnetic sensor air supply inadequate or external magnet affecting sensor 3 Sensor not seeing magnet sensor needs to be re aligned 1 15 At 90 Actuator Sensor State Error Check...

Page 87: ...ng Root Issue Potential Cause WRN 2 04 Single tilt Tilt Stuck Dual tilt Left Tilt Stuck Checked only when moving out of a limit position The software indicates the state of the left tilt photo sensor has not changed even though the motor has been told to move for more than 1 2 second Something is preventing movement of left tilt mechanism the motor is defective or the RCP board is defective WRN 2 ...

Page 88: ... wrong way miswire or the P T drive board is defective 2 04 Positioner Only PAN pot stuck 2 07 Communication Timeout The RCP or P T Drive board has not sent out communications recently Bad board or connection in communications link 2 08 Microprocessor error The RCP board has sent an invalid message Indicates a software problem 2 09 RCP Only Left Tilt Up wrap around The software indicates the same ...

Page 89: ...or is defective 2 14 Pan Left wrap around 2 15 Left Tilt Limit Overlap The software indicates both tilt photo sensors appear to be blocked simultaneously Foreign material in one of the photo sensors or faulty photo sensor 2 16 Right Tilt Limit Overlap Table 9 3 Error and Warning Codes for HHRC Message Meaning Root Issue Potential Cause WRN 3 02 Dual HHRC simultaneous inputs Two HHRCs are sending c...

Page 90: ...data lines from the DC power cable connector to the HHRC connector Refer to System schematic Also check that the shield in the junction box has a good electrical connection to the electronics common at one end or the other but not both 3 08 Microprocessor Error Internal firmware detected error Replace HHRC or HHRC Display pcb 3 09 RF module Error Wireless Transmitter Receiver did not properly init...

Page 91: ...HHRC unit 6 J Box unit 8 System can have a panel mount remote and an HHRC or 2 HHRCs but never 3 remote units Negotiation happens every time the Base unit is powered up Wireless HHRC is not plugged in during power up 8 12 In system reprogramming failed Dip switch activated in system reprogramming of attached devices was not able to successfully complete Table 9 5 Mechanical Symptoms and Troublesho...

Page 92: ...connect wire lead 2 Replace motor Mast fails to fully nest in saddle and disconnects power Binding of actuator software fault or control erroneously sensed an increase in current 1 Check that Base Board has software version 2 6 or later Contact Will Burt if update is required 2 Check actuator or mast for binding Replace actuator if binding or remove source of binding Mast will not begin to lower f...

Page 93: ...Yes TP 4723701 Q Oct 2016 Updated Sections 2 3 and 2 9 Yes TP 4723701 R Nov 2016 Updated Section 4 3 1 Yes TP 4723701 S Dec 2020 Reformatted including section number and page number changes updated Look Up light location updated to latest wireless control added 2 3 model to technical data added inspection interval table added high current solenoid Yes for all but the wireless HHRC No longer covers...

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Page 95: ...PAGE 93 OF 98 NIGHT SCAN POWERLITE POWERLITE XTREME AND POWERLITE HDT OPERATING INSTRUCTIONS TP 4723701 U MAY 2021 11 Appendix 11 1 System Wiring Diagram The system wiring diagrams are as follows ...

Page 96: ... 7 7 5 RU 7 3 5 B 22 83 7 7 7 7 55 7 3 1 5 3 27 2 5 9 5281 7 55 7 21 7 0 6 85 5 6 7 27 1 6 2 7 55 7 25 7 5 7 6 0 237 21 75 0 2035 6625 5 1 25 2 5 32 5 1 2035 6625 32 5 0867 6 3 5 7 5816 72 92 92 7 6 7 2035 6625 67 57 9 17 9 9 5 51 5 51 5 5 7 7 62 12 167 5 5 1 520 120 9 6285 3527 7 7 9 17 9 9 7 7 20 1 2 1 0 51 5 1 8 237 21 9 2035 6625 32 5 7 21 6 67 06 7 9 76 211 7 72 7 1 86 1 7 7 5 1 8 725 5 1 127...

Page 97: ...7 5 3 3 2 17 51 2 25 72 6 _ _ 51 _ _ 51 127 86 21 352 5 51 76 _ _ 9 2 _ _ 9 2 _ _ 25 _ _ 25 51 76 _ 31 _ _ 31 _ _ 5 _ _ 5 1 _ _ _ _ 9 2 _ _ 5 _ _ 5 5 7 1 1 5 _ _ 9 2 _ _ 5 _ _ 5 _ _ 1 0 5 92 7 5 17 7 1 6 67 0 92 7 237 21 0 5 1 62 7 21 5 5 2 0867 0 7 6 67 0 92 7 0 5 92 7 6 0 6 6 67 0 92 7 5 1 25 9 7 76 6 62 12 60 _ _ _ _ 5 _ _ _ _ 31 _ _ _ _ 25 _ _ _ _ 9 2 7 32 5 62 12 5 5 5 5 5 5 5 72 7 7 32 5 72 ...

Page 98: ...PAGE 96 OF 98 NIGHT SCAN POWERLITE POWERLITE XTREME AND POWERLITE HDT OPERATING INSTRUCTIONS TP 4723701 U MAY 2021 ...

Page 99: ...TPUT CONTACTS 2 AMPS MAX 10 2 SJOOW or Equiv 18 2 SJOOW or Equiv DC BOARD POWER BLK WHT GRN WHT BLK RECOMMENDED MOUNTING TERMINALS FACING UP INVERTER 12VDC 120VAC 1500W FOR LOGISTICAL SUPPORT ONLY APP BY CK BY DR BY SURFACES ON ALL MACHINED BREAK ALL SHARP CORNERS 125 FINISH DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED FRACTIONS 0 1 2 DECIMALS ANGLES TOLERANCES ON 000 00 ORRVILLE OHIO AN EM...

Page 100: ...MAX 10 2 SJOOW or Equiv 18 2 SJOOW or Equiv DC BOARD POWER RED GRN WHT BLK RECOMMENDED MOUNTING HEAT SINK FINS VERTICAL RIGHT POWER LEFT POWER IF USING WB SUPPLIED 10 6 CABLE FROM VERTICAL SYSTEM USE RED AND BLK FOR RIGHT LIGHT POWER USE ORG AND BLU FOR LEFT LIGHT POWER FOR LOGISTICAL SUPPORT ONLY APP BY CK BY DR BY SURFACES ON ALL MACHINED BREAK ALL SHARP CORNERS 125 FINISH DIMENSIONS ARE IN INCH...

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