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Will Burt Night Scan Vertical 4.3-15, Operating Instructions Manual

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PAGE  48  OF  126

NIGHT SCAN VERTICAL, VERTICAL COMPLETE, AND VERTICAL HDT 

OPERATING INSTRUCTIONS

TP-4836201-H

MAY 2021

5.5 Attaching the Control Box

5.5.1

Night Scan Vertical

The  control  box  may  be  surface  mounted  using  four  M6  or  1/4  inch  screws,  nuts,  and  lock

washers provided by the installer. To install the control box:

1. Disconnect any attached cables before installation.

2. Open the cover and mount the unit through the four clearance holes located on the rear side

of the control box (Figure 5-14).

3. Attach the bolts, lock washers and nuts to  secure  the unit. The recommended  installation

torque  for  an  M6  or  1/4  inch  stainless  steel  fastener  is  7-8  Nm  (60-72  in.-lb.).  It  is

recommended to use low strength thread-locking compound.

4. Reconnect  any  cables  and  replace  the  cover.  Be  sure  to  secure  the  green  ground  wire

provided on the bulkhead to vehicle ground. 

Figure 5-14 Night Scan Vertical Control Box Mounting Hole Locations

5.5.2

Night Scan Vertical Complete

See Section 5.4.2 to see how to attach the Night Scan Vertical Complete control box. 

Summary of Contents for Night Scan Vertical 4.3-15

Page 1: ...lvd Orrville OH 44667 USA Phone 1 330 684 4000 E Mail info willburt com Website www willburt com TP 4836201 H 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 Vertical Complete Night Scan Vertical Night Scan Vertical Heavy Duty Towing ...

Page 2: ......

Page 3: ...NUFACTURE 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 evidence that the product...

Page 4: ...te Mounting Instructions 35 5 4 3 Night Scan Vertical HDT Mounting Instructions 36 5 4 4 Attach Internal Mounting Kit 37 5 4 5 Attach the Base Plate to the Mast 39 5 4 6 Attach the Base Plate to the Vehicle 40 5 4 7 Attach the Support Bracket 41 5 4 8 Attach Optional Shelf Bracket 42 5 4 9 Attach the RCP Saddle Brackets 44 5 4 9 1 Night Scan Vertical 45 5 4 9 2 Night Scan Vertical HDT 47 5 5 Attac...

Page 5: ...the Auto Stow Feature 72 6 8 2 Using the Mast Down Button 73 6 8 3 Emergency Stow with Power 74 6 8 4 Emergency Stow without Power 74 7 Maintenance Adjustments and Disposal 75 7 1 Power Isolating Procedure 75 7 2 Cleaning and Lubricating the System 75 7 3 Spare Parts 76 7 4 Periodic Inspections 77 7 4 1 Adjusting the Mast Magnetic Switches 78 7 5 Adjusting the RCP Home Position 80 7 5 1 Single Til...

Page 6: ...26 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 11 2 2 Night Scan Vertical Complete Drawings 118 11 2 3 Night Scan Vertical Heavy Duty Towing HDT Drawings 122 ...

Page 7: ...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 handling equipment using high voltage Do not locate or operate mast near electrical lines cables or other unwanted sources...

Page 8: ... 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 Will Burt Company Engineering for special on the move situations for military only use on specialized products Burst Hazard For pneumatically operated masts do no...

Page 9: ... 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 safety shoes shall be properly worn while working on mast or near the deployment area of mast In addition eye protection shall be worn during maintenance procedures Foll...

Page 10: ... 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 objects Manual Retraction For powered masts make sure all power sources have been disconnected from the system prior to manually lowering mast to av...

Page 11: ...le of resisting forces generated from unloading the system including but not limited to system weight Ensure the unloading region is level and has sufficient room and strength to hold the system If the unloading region is incapable of meeting the requirements of the system damage to the system and or unloading region could occur Equipment Damage Support Bracket For masts using an upper support bra...

Page 12: ...d or hazardous voltage hazard There is voltage present inside mast and control box Do not operate mast near electrical lines or during electrical storms Contact with high voltage will result in death or serious injury This symbol indicates a pinch point hazard Keep fingers and hands clear of moving parts This symbol indicates a tip over hazard The mast must be properly supported during transport h...

Page 13: ... NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 This symbol is used to indicate the center of gravity COG of a fully nested mast in a horizontal transport position ...

Page 14: ...PAGE 12 OF 126 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 ...

Page 15: ...liance 2 1 NFPA 1901 2016 The mast system is 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 ...

Page 16: ...PAGE 14 OF 126 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 ...

Page 17: ... and dual tilt of the masts These operating instructions are intended for professionals who are qualified by their appropriate training and experience to perform the procedures Review this document in its entirety Contact The Will Burt Company with any questions before performing any procedure outlined in this manual The views depicted in this manual are provided for clarification and are subject ...

Page 18: ...ght Scan Vertical Complete and Night Scan Vertical HDT mast systems are intended to be used only when the vehicle is stationary and the vehicle parking brake is properly applied Do not supply input supply voltage or operate the mast system when the vehicle is in motion The mast must remain in the powered down nested position during vehicle motion 3 3 Mast Position Definition The mast is pneumatica...

Page 19: ... system Figure 3 4 shows major components of the Night Scan Vertical HDT system Figure 3 2 Night Scan Vertical Stowed View Figure 3 3 Night Scan Vertical Complete Model 720087040 shown Optional Camera or Strobe Location Light Bar Mast Lights RCP RCP Saddle Look Up Light top of RCP Light RCP Light Bar Saddle Magnetic Switch Mast Magnetic Switch Control Box Note Depending on the model the control bo...

Page 20: ...nnects to the air source The top of the mast connects to the Remote Controlled Positioner RCP Each tube and collar is protected by low friction synthetic bearings for smooth operation and long life Bumpers reduce shock on extension and retraction The exterior surfaces of the tubes are anodized and sealed for long life The fasteners are corrosion resistant stainless steel The mast Figure 3 5 contai...

Page 21: ... to secure the assembly to the roof Bolt length will depend on the specific application and is to be determined by the installer Figure 3 6 Internal Mounting Kit External The external support bracket assembly Figure 3 7 is a painted weldment that can be bolted into a mounting structure and used to position and support an externally mounted mast Bolts lock washers and hex nuts 3 8 inch or M10 not p...

Page 22: ... of the RCP and various mounting methods Remote Controlled Positioner RCP The RCP Figure 3 10 mounts on top of the mast and between the lights The RCP contains gears and gear motors to position the lights The RCP also contains the RCP Board which receives data through the base board from the controllers This allows the RCP to control the lights to pan and tilt The single tilt RCP tilts both sets o...

Page 23: ...d air supply are connected Figure 3 11 Night Scan Vertical Control Box Figure 3 12 Night Scan Vertical Complete Control Box Setups Base Board Air Control Valve Assembly To Mast HHRC DC Control Light Power In Air to Mast Coil Cord Power In Coil Cord In Magnetic Switches In DC AC HHRC Control AC Cable In Coil Cord and Cable In Cable In Cable In Magnetic Switches In Base Board HHRC Control Base Board...

Page 24: ...nd 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 that indicates the mast has reached its full extended height When the mast is deployed the operator should release the extension button on the hand held control If the operator keeps the button pressed the system will continue to build p...

Page 25: ...ached with a band clamp on the base tube of the mast see Figure 5 21 It indicates when the mast has reached the stowed position Upper Magnetic Switch not shown This magnetic switch is attached with a band clamp on the base tube of the mast and is located above the lower magnetic switch see Figure 5 21 It indicates when the lights have reached a height sufficient to clear all vehicle obstructions t...

Page 26: ... assembly is connected to the mast and is used to secure the vertical HDT to the mounting structure Figure 3 15 The optional adjustable mounting plate can assist in securing the mast Figure 3 15 Night Scan Vertical HDT Mounting View from Front View from Side Adjustable Mounting Plate Base Assembly Adjustable Mounting Plate Base Assembly ...

Page 27: ...ions of the system and are as follows 1 Wired Hand Held Remote Control HHRC This option includes a 25 foot 7 6 meters quick connect coil cord and LED display It also contains an integrated emergency stop button 2 Panel Mount Remote Control PMRC This option mounts to a panel and has LED display It also contains an integrated emergency stop button 3 Wireless Hand Held Remote Control WHHRC This optio...

Page 28: ...GHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 Figure 3 17 HHRC Bulkhead Connection Ground Wire Attached to Bulkhead Control Cable Attached to Bulkhead 7 pin Connector ...

Page 29: ...e 22 to 149 F 30 to 65 C System Storage Temperature 40 to 149 F 40 to 65 C Deployment Angle 5 Maximum Deployment Wind Speed mph km h 40 max 64 max Altitude Above Sea Level ft m 15 000 4572 Maximum Survival Wind Speed mph km h 119 140 191 225 100 121 160 195 87 104 140 167 73 86 117 138 63 73 101 117 119 140 191 225 100 121 160 195 Auto Stow Yes Number of Lights Available 4 or 6 2 or 4 6 Light Type...

Page 30: ...PAGE 28 OF 126 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 ...

Page 31: ...ate drainage A minimum of four 1 inch 25 mm diameter drain holes one per corner are recommended 2 Ensure that the mounting surface is flat and has sufficient room and strength to hold the system Reinforce as necessary Table 5 1 shows the shear force and the bending moment load acting at the base plate bottom of mast of the mast due to wind loading The load values correspond to the maximum wind loa...

Page 32: ...eas beneath the floor must be free of obstructions to allow for accessibility to base plate fasteners and air inlet port 5 The installed elevation of the bottom collar of the mast this is where moving parts are located must 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 g...

Page 33: ...ommended Installation Tools Materials Tools and Materials Safety 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 Shop Rags Hoist minimum 500 lb 227 kg capacity Night Scan Vertical 3 8 inch or M1...

Page 34: ...addle Kit RCP Assembly Lights Controller Selected from the following HHRC with Bulkhead WHHRC PMRC Mast Control Power Cable Light Cable Air Hose Magnetic Switches Control Box Label Kit Strobe Light Optional D TEC Optional Operators Manual Mast Hardware Kit Night Scan Vertical Complete Mast Saddle RCP Assembly Lights Wired HHRC with Bulkhead Board Power Cable Light Cable Ferrite Label Kit Strobe Li...

Page 35: ...rizontal Remote Controlled Positioner RCP shafts and the vertical shaft Figure 5 1 Lifting from locations other than those indicated could result in equipment damage Figure 5 1 Lifting Points on the Night Scan Vertical and Night Scan Vertical Complete RCP Night Scan Vertical HDT Lift the base out with a hoist Lift the unit from the shipping container by the two struts and the lower portion of the ...

Page 36: ...he Night Scan Vertical Complete to the vehicle see Section 5 4 2 5 4 1 Night Scan Vertical Mounting Instructions Physically attach the system as follows 1 Drill six 3 8 inch mounting holes into the mounting structure Figure 5 11 2 Attach the mast using 3 8 inch studs or M10 bolts customer provided Torque all hardware as appropriate for its material and size 3 The saddle is adjustable to accommodat...

Page 37: ...he operator or bystanders 3 Reference Figure 5 3 and Figure 5 4 for mounting hole locations for your system These locations will vary based on which system you are using Drill two 5 16 inch clearance holes into the vehicle mounting structure where the saddle part of the mast will mount Drill four 1 4 inch clearance holes into the vehicle mounting structure where the control box part of the mast wi...

Page 38: ...e adequate drainage A minimum of four 1 inch diameter drain holes one per corner are recommended 2 Drill eight 9 16 inch mounting holes into the mounting structure Section 5 4 9 Figure 5 13 3 Attach the mast using 9 16 inch or M14 studs or bolts customer provided Torque all hardware as appropriate for its material and size 4 The saddle must be attached so that it is centered with the RCP and mast ...

Page 39: ...t application the drain kit provided with the mast can redirect the water exiting the weep hole Water will exit the weep hole as the mast extends Do not orient the weep hole toward any personnel or sensitive equipment The holes in the roof for the internal mounting kit should align with the mounting location at the base of the mast for the base plate Before installing the base plate or any pneumat...

Page 40: ...he base plate while the mast is still supported by the lifting device see section 5 4 5 Once the base plate is installed lower the mast into its final position and loosely install the base plate mounting bolts to locate the base of the mast and fix the mast orientation 7 Lift up the gasket and apply silicone sealant to both sides Place the gasket into position with the mounting holes aligned Place...

Page 41: ...commended installation torque for an M6 or 1 4 inch stainless steel fastener is 7 8 Nm 60 72 in lb Note This torque assumes the roof structure is firm It is recommended to use a low strength thread locking compound 10 Remove any excess silicone A bead of silicone sealant can be added to the top of the bracket where the V Seal mates if desired Slide the V Seal down over the bracket to complete the ...

Page 42: ...ounting position noting the desired mast orientation Bolts lock washers and hex nuts 3 8 inch or M10 not provided can be used to secure the base plate to the support structure Bolt length depends on the specific application and is to be determined by the installer The recommended installation torque for an M10 stainless steel fastener is 28 33 Nm 245 290 in lb The recommended installation torque f...

Page 43: ...ld be as high as possible on the mast and not block the weep hole Figure 5 8 Support Bracket Mounting Dimensions 2 Remove all the support bracket bolts holding the clamp halves together 3 Install the clamp around the mast base tube and loosely re install the six 3 8 16 bolts washers lock washers 4 Loosely install the customer supplied 3 8 inch or M10 bolts lock washers and flat washers Bolt length...

Page 44: ...lowing steps 1 Drill holes according to the dimensions shown in Figure 5 9 or use the shelf bracket as a template 2 Locate the shelf bracket into position and install customer supplied 3 8 inch or M10 bolts lock washers and flat washers The installer should determine the proper bolt length for the application The recommended installation torque for an M10 stainless steel fastener is 28 33 Nm 245 2...

Page 45: ...PAGE 43 OF 126 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 Figure 5 9 Shelf Bracket Installation Dimensions ...

Page 46: ...the RCP structure to prevent vibration damage to the mast and RCP Leaving a gap may result in damage to the mast system The bolt pattern between the two brackets is square so the bracket can be deck mounted vertically or rotated 90 to bolt to a vertical support structure as shown in Figure 5 12 Figure 5 10 Saddle Brackets shown in two optional orientations The support structure must be rigid enoug...

Page 47: ... The recommended installation torque for a 3 8 inch stainless steel fastener is 21 27 Nm 190 240 in lb It is recommended to use low strength thread locking compound 3 The saddle is adjustable to accommodate all models of the RCP as well as variations in mounting Figure 5 12 The saddle must be attached so that it is centered with the RCP and mast base tube The height should be adjusted to firmly co...

Page 48: ...ETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 Figure 5 12 Mounting Variations Clockwise from upper left Saddle Deck Mount Saddle Wall Mount Saddle and RCP Assembly Lights Stowed Horizontally Saddle and RCP Lights Stowed Vertically ...

Page 49: ...re as appropriate for its material and size It is recommended to use low strength thread locking compound 3 The saddle is adjustable to accommodate all models of the RCP as well as variations in mounting The saddle must be attached so that it is centered with the RCP and mast base tube The height should be adjusted to firmly contact the RCP when the mast is nested To adjust the saddle height loose...

Page 50: ... four clearance holes located on the rear side of the control box Figure 5 14 3 Attach the bolts lock washers and nuts to secure the unit The recommended installation torque for an M6 or 1 4 inch stainless steel fastener is 7 8 Nm 60 72 in lb It is recommended to use low strength thread locking compound 4 Reconnect any cables and replace the cover Be sure to secure the green ground wire provided o...

Page 51: ...nd lock washers provided by the installer To install the control box 1 Mount the unit through the clearance holes located on the back of the control box Figure 5 15 Figure 5 15 Night Scan Vertical HDT Control Box Clearance Holes 2 Attach the lock washers and nuts to secure the unit 3 Be sure to secure the green ground wire provided on the bulkhead to vehicle ground Hidden Clearance Hole Clearance ...

Page 52: ...d sealant can be used on the hose barb threads Route the air hose and connect both ends to the fittings The hose can be cut to the desired length When nesting the mast exhaust air will exit the control box through the port labeled Air Exhaust see Figure 5 14 The exhaust air hose and fitting are supplied by the customer The port is a female 1 4 inch NPT It is recommended to use a larger inner diame...

Page 53: ...TICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 Figure 5 16 Control Box Valve Layout Cover Removed Figure 5 17 Mast Air Inlet Hardware Kit Assembly Detail Mast Coil Cord HHRC DC Control Light Power Air Inlet Air Exhaust Air Exhaust Air to Mast Air to Mast ...

Page 54: ...abeled 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 13 mm inside diameter air hose The unit is supplied with 6 1 meters 20 feet 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 moisture The different siz...

Page 55: ... 126 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 Figure 5 18 Night Scan Vertical HDT Valve Assembly Figure 5 19 Mast Air Inlet Hardware Kit Assembly Detail ...

Page 56: ...Attach the 10 circuit male plug from the RCP to the 10 circuit female plug from the mast This is the power cable 4 Tuck the wires in and place the RCP on the mast while being careful not to pinch the wires 5 Orient the RCP in the desired direction noting the RCP shipped in the Auto Stow position for panning Connect the RCP and mast with the four provided screws and washers see Figure 5 20 Torque t...

Page 57: ...switches so the mast will fit through the opening in the roof The magnetic switches are shipped loose with the mast The upper magnetic switch defines the trigger point to make the RCP functions active The goal is to have this trigger point high enough to clear all vehicle obstructions before panning or tilting the lights First install the upper magnetic switch at the top of the mast per Figure 5 2...

Page 58: ...tom of the mast again noting the proper orientation shown in Figure 5 21 The final height of this switch will be adjusted after the control systems are wired and powered up see Section 5 10 7 This switch is used to confirm the mast is in the nested position for the vehicle interconnect circuit and mast logic Figure 5 21 Upper and Lower Magnetic Switches ...

Page 59: ...unting 5 9 Installing Remote Control This section provides information to install the remote control Several options are available Follow the instructions appropriate for your system 5 9 1 Wired Hand Held Remote Control HHRC Go to section 5 9 2 to if you are installing the Panel Mount Remote Control PMRC or section 5 9 3 for the wireless control option This section describes how to install the Wir...

Page 60: ... be selected according to the space available 2 Using the screws washers and nuts provided attach the bulkhead to the vehicle Torque the 1 4 20 screws to 62 70 in lb 7 8 Nm Alternative M6 stainless steel hardware not provided can be used 3 Attach the ground wire to the vehicle 4 Attach the HHRC connector to the bulkhead connector by rotating the lug until it locks in place Figure 5 23 HHRC Bulkhea...

Page 61: ... techniques to prevent the screws from backing out due to vibration Mount the holder to ensure 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 24 HHRC Holder 5 9 2 Panel Mount Remote Control PMRC If your system was not ordered with the opti...

Page 62: ...ed 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 9 3 Wireless Remote Control Refer to TP 5543301 f...

Page 63: ...ter does not match the cable grip diameter to install if needed Refer to the wiring diagrams contained in the Appendix section Be sure to follow the recommended torque requirements found in the wiring diagram Remove the screws on the control box lid and open the lid to expose the base board mounted to the back of the lid Note The Night Scan Vertical HDT comes pre wired internally from the factory ...

Page 64: ... connector located on the top left of the base board ensuring the wires match the color strip on the J4 connector and the wiring diagram Connect the J4 connector to the base board Figure 5 26 Wiring J4 5 10 2 Wiring Magnetic Switches to the Base Board The cables for the upper and lower magnetic switches installed on the mast can be routed through one of the cable grips These cables may need to be ...

Page 65: ...ype SJOOW or equivalent Be 10 AWG or 6 mm2 conductors Have a maximum length for acceptable voltage drop of 70 feet 21 meters Connect the DC battery power to the VIN red or white and COM black connections on terminal block TB4 on the lower left side of the base board The source must be capable of delivering the maximum current as defined in the Technical Data table Note The mast RCP and control box...

Page 66: ...oting 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 identification If the cables are supplied by the installer the cables must Be type SOOW or equivalent Be 10 AWG or...

Page 67: ...ther arrangements are possible Figure 5 27 Example Vehicle Safety Interconnect Circuit The contact output is set at the factory to be OPEN when the mast is active not stowed by setting the S2 1 Dual In Line Package DIP Switch to the OFF OPEN position To change the contact output to be CLOSED when the mast is active set the S2 1 DIP Switch to the ON CLOSED position Mast power needs to be cycled for...

Page 68: ... reached the location of the magnet inside the mast Move the magnetic switch up 6 mm 1 4 inch from this activation point this accounts for temperature variations in magnetic field and magnet physical position and tighten the band clamp Be sure the magnetic switch bracket is still oriented properly and the LED light is still green after the band is tightened The upper magnetic switch does not need ...

Page 69: ...dicator lights on the RCP for the pan and tilt functions lighting up At the lowest point of activation test the panning and tilting motions to ensure the lights do not contact any vehicle structures 6 Press each Light button several times to turn the lights on and off 7 Press Tilt Up and Tilt Down buttons one at a time Press Pan Left and Pan Right buttons one at a time Check the lights on each sid...

Page 70: ...e the Auto Stow feature that places the mast into the saddle and turns power off Confirm the power automatically turns off when nested 14 Ensure the RCP is in firm contact with the saddles when nested Adjust the saddle height if they are not contacting according to Section 5 4 9 15 Visually confirm the safety over pressure relief valve is installed at the mast air inlet ...

Page 71: ...llers are available on your system Dual Tilt Wired Hand Held Remote Controller HHRC Dual Tilt Panel Mount Remote Controller PMRC Dual Tilt Wireless Hand Held Remote Controller WHHRC Single Tilt Hand Held Remote Controller HHRC Single Tilt Panel Mount Remote Controller PMRC Using the Remote Control the operator can perform an emergency stop move the mast up and down tilt the lights up and down pan ...

Page 72: ... Stop until the cause of the event is corrected Turn the red E Stop button if needed Then press NFPA Start to power up the mast 4 Raise the mast by pressing and holding the Mast Up button Then press the Lights to turn the lights on 5 If desired raise the mast further by pressing Mast Up 6 Position the lights vertically by pressing Tilt Down and Tilt Up 7 Position the lights horizontally by pressin...

Page 73: ...p button is not released the mast will reach its fully extended height the air pressure will rise to 20 psi 1 4 bar and then the exhaust valve will open and exhaust any more air that enters the mast leaving the mast at its maximum extended height 6 6 Controlling the Lights The lights can be turned on and off from the remote control after the first tube section has been extended far enough to activ...

Page 74: ...ith Power The best method is to stow the mast with the Auto Stow feature It does not require the operator to stop the mast exactly in the saddle The mast can be auto stowed from any position including partially extended or fully extended If the mast loses power it will lower 6 8 1 Using the Auto Stow Feature To use the Auto Stow feature 1 Press Mast Down twice quickly in successive depressions two...

Page 75: ...pletely stowed equipment may be damaged during transportation To stow the mast using Mast Down 1 Press and hold Mast Down until the mast stops and the Mast Down LED is turned off indicating the mast has powered down The mast will lower if not already there then go to the RCP home position and then stow the mast Once stowed the Mast Stowed Safety Interlock Contact signals it is safe to move the veh...

Page 76: ...es with the RCP Exhaust all air from the mast which lowers the mast to its nested position To stow the mast using the emergency stow button 1 Open the control box lid to expose the base board 2 Tap S4 on the base board Do not hold down S4 just press then immediately release S4 once This causes the controller to show an ERR 1 20 The error causes the RCP to go to its home position and exhausts all a...

Page 77: ... that the vehicle ignition keys be held by the maintenance engineer as an additional precaution to prohibit unexpected power up 2 Unplug the mast Hand Held Remote Control HHRC and keep it with the maintenance engineer during maintenance to avoid unexpected mast operation Be sure the HHRC is attached before powering up the system again to avoid a communications error Refer to section 6 4 for power ...

Page 78: ...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 inside the collar 3 Inject approximately oz of TMD Mast Lubricant or lightweight machine oil into the weep hole drain of the exposed mast section The weep holes are located approximately 10 below th...

Page 79: ...on 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 procedure in section 7 2 If the condition remains after lubrication cease all mast use and contact Will Burt Service immediately Monthly Inspect for any damage to electric cables and pneumatic tubes Replace cables tubes as required Monthly Test ...

Page 80: ...ked with no gaps between them If a switch is found to require adjustment it will most commonly need to be moved upward toward the RCP on the mast The magnet is located at the lower end and side of the top tube It is not visible outside the mast Figure 7 1 Night Scan Vertical Upper and Lower Magnetic Switches Every 6 Months With the mast fully nested check to ensure the RCP is firmly in contact wit...

Page 81: ...er Magnetic Switches Figure 7 3 Night Scan Vertical Heavy Duty Towing HDT Upper and Lower Magnetic Switches Follow the instructions in Section 5 10 2 and Section 5 10 7 for adjusting the Magnetic Switch positions Upper Magnetic Switch Lower Magnetic Switch Control Box Attached Below Mast Control Box Attached to Side of Mast Upper Magnetic Switch Lower Magnetic Switch ...

Page 82: ...e RCP home position should be done indoors Adjusting the home position outside can cause improper RCP operation due to sunlight reaching the photo sensors Before delivery of a new system the RCP home position is tested and normally no adjustment is necessary A dual tilt RCP and single tilt RCP have slightly different adjustment procedures If an adjustment is required adjust the RCP home position a...

Page 83: ...moved 4 Once the set screws are loose pan and tilt the unit to the correct home position Be careful that the flags do not come into contact when panning and tilting or they may be bent 5 The pan and tilt functions have two photo sensors for each function It is important that the flags engage the correct photo sensor from the proper direction when setting the home position To set the Tilt Home Posi...

Page 84: ...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 proper positioning is achieved replace the RCP cover Figure 7 5 RCP PCB Phot...

Page 85: ...al Tilt Photo Interrupter and Flag cover removed 4 Once the set screws are loose pan and tilt the unit to the correct home position Be careful that the flags do not come into contact when panning and tilting or they may be bent 5 The pan and tilt functions have two photo sensors for each function It is important that the flags engage the correct photo sensor from the proper direction when setting ...

Page 86: ...e 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 proper positioning is achieved replace the RCP cover Figure 7 7 RCP PCB Photo Sensors Dual Tilt 7 6 System Disposal Dispose of the mast in accordance with the national environmental regulations Tilt Sensor Home Approach this photo s...

Page 87: ...iler unit and if the system stows before or while lowering For additional information on the DIP Switches and their settings see the wiring diagram in the Appendix By default the RCP becomes active when the upper magnetic switch is sensed If this is too early and there is a possibility that the RCP may be accidentally turned and hit the vehicle and the upper magnetic switch cannot be adjusted high...

Page 88: ... beacon light can be used at any voltage from 12 to 48 VDC The strobe beacon lights are available in amber blue clear red and green The strobe beacon light can be turned on by pressing the AUX controller button when the RCP is high enough to be active Pressing the button again would turn the strobe beacon light off When ordered the optional strobe beacon light is shipped already installed and no a...

Page 89: ...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 90: ...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 2 D TEC Messages Message Meaning Root Issue D TEC Testing The D TEC Sensor is performing a sel...

Page 91: ...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 92: ... of the 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 No...

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Page 99: ...PAGE 97 OF 126 NIGHT SCAN VERTICAL VERTICAL COMPLETE AND VERTICAL HDT OPERATING INSTRUCTIONS TP 4836201 H MAY 2021 8 6 The Will Burt Company Mast Oil Safety Data Sheet ...

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Page 103: ...nally if the controller for your system has a display errors and warnings will typically be shown there 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 ...

Page 104: ...s 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 ...

Page 105: ...ted 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 un...

Page 106: ...o 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 Chec...

Page 107: ...ing 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 108: ...e 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 109: ...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 110: ... 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 ini...

Page 111: ...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 112: ...econnect 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 ...

Page 113: ... formatting Yes TP 4836201 D Mar 2016 General update Yes TP 4836201 E Apr 2016 Updated Sections 1 5 6 2 7 7 1 and 8 Removed Section 7 4 Fixed formatting issue in Section 1 Yes TP 4836201 F Oct 2016 Updated Section 2 12 Yes TP 4836201 G Mar 2021 Reformatted including section number and page number changes updated to latest wireless control added inspection interval table Added 4 3 15 model Yes for ...

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Page 115: ... moves off the Hatch Closed limit the switch opens and the warning light comes on The Hatch Closed limit switch is wired to take the place of the system mast inactive contacts Once the hatch is fully opened the Hatch Open limit switch closes which allows the up valve of the mast part of the system supplied by The Will Burt Company to be energized and the mast extends Stowing the mast reverses this...

Page 116: ...OPEN S2 MAIN FUNCTIONS ON CLOSED OFF OPEN ON CLOSED 4 4 in lbs 0 5 N m 1 9 8 7 6 5 2 3 4 BLK WHT BLK RED GRY VIO GRN BLK WHT init com kill OPTIONAL CUSTOMER SUPPLIED WELL COVER LIMIT SWITCHES AND INDICATOR DIP SWITCHES S3 2 AND S3 4 MUST BE CLOSED 1 J2 1 2 3 VBAT 4 7 6 5 J7 1 2 3 NOT OPEN OPEN NOT CLOSED CLOSED GND VBAT CONTROL LINES FROM BULKHEAD MAST ACTIVE CONTACTS 14 2 SJOOW OR EQUIV SEE SW2 1...

Page 117: ... C B A POINTER SET TO HOME POSITION 3 PLACES POINTERS ON THE TIMING RINGS MUST BE SET TO THE HOME POSITION GRN WHT BLK RED OPTIONAL STROBE AND 204001 CAPACITOR CAMERA VOLTAGE SAME AS SYSTEM VOLTAGE OPTIONAL CAMERA AND ISOLATION RELAY RELAY COIL MUST MATCH SYSTEM VOLTAGE CAMERA VOLTAGE DIFFERENT THAN SYSTEM VOLTAGE 87 30 86 85 13 BLK 12 VIO 11 GRY 14 RED BLK RED 912760 CE NS3 0 4 5 RCP OR 912761 CE...

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Page 119: ... C DJB JDN NOTES 1 TORQUE 4 4in lbs 0 5Nm 2 MAST ACTIVE CONTACTS J K OR J4 9 10 USE SW2 1 ON BASE BOARD TO SELECT OPEN OFF OR CLOSED ON WHEN NESTED SW2 1 OPEN CONTACTS CLOSED WHEN NESTED SW2 1 CLOSED CONTACTS OPEN WHEN NESTED 2 AMPS MAX CURRENT 20 GA MINIMUM CONDUCTOR CUSTOMER SUPPLIED WIRING 3 SW2 2 ON BASE BOARD MUST BE OPEN OFF FOR NFPA MODE 4 SW2 2 ON BASE BOARD MUST BE CLOSED ON STANDARD MODE...

Page 120: ...SWITCH SHUNT CONNECT SHIELD GROUND TO J4 2 MAST ACTIVE CONTACTS 18 2 SJOOW OR EQUIV WHT SEE SW2 1 BLK BATT BLK BATT RED or WHT DC BOARD POWER 10 2 SJOOW OR EQUIV LEFT DC RIGHT DC LEFT DC RIGHT DC USED WITH 600W 12 VDC LIGHTS FOR LOGISTICAL SUPPORT ONLY APP BY CK BY DR BY SURFACES ON ALL MACHINED BREAK ALL SHARP CORNERS 125 MATERIAL FINISH DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED FRACTIO...

Page 121: ...RN YEL 18GA 18GA BLK RED 12V 9W LED LOOK UP LIGHT M M FOR LOGISTICAL SUPPORT ONLY APP BY CK BY DR BY SURFACES ON ALL MACHINED BREAK ALL SHARP CORNERS 125 MATERIAL FINISH DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED FRACTIONS 0 1 2 DECIMALS ANGLES TOLERANCES ON 000 00 ORRVILLE OHIO AN EMPLOYEE OWNED COMPANY SHEET OF DJB DWG No SIZE SCALE NTS W LL WILL BURT COMPANY WRITTEN CONSENT OF THE PART...

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Page 124: ...571 FOR CONNECTIONS LOWER UPPER 48 VDC LED WIRING 14 4 48v F 1 2 3 WHT 5 PNK 6 PNK 4 WHT RED BLK GRN WHT GRN YEL ALTERNATE WIRING USING 46666xx COIL CORD STANDARD COIL CORD 5 FOR LOGISTICAL SUPPORT ONLY APP BY CK BY DR BY MATERIAL FINISH ORRVILLE OHIO AN EMPLOYEE OWNED COMPANY SHEET DWG No SIZE SCALE NTS WILL NEXT ASS Y WILL BURT COMPANY WRITTEN CONSENT OF THE PART WITHOUT THE PRIOR DISCLOSED IN W...

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Page 126: ...UTPUT 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 E...

Page 127: ... 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 INC...

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