Owners Manual External Drive Latching Unit Models: 422, 512, 522 CHM Industries Fort Worth, Texas 76179 682-286-0046 ph Content: Packing List Assembly Instructions Operating Instructions Troubleshooting Assembly Prints Note: A portable (external) drive motor unit must be ordered separately for the External Drive units. Only one portable drive unit is required for any number of CHM High Mast Service Hoists. The portable drive can be moved from pole to pole as needed. Caution: Ring and arm assembly supporting fixtures cannot be reoriented on the pole. To assure proper fixture aiming, make sure an anchor bolt circle template is used to install anchor bolts in each foundation in the orientation specified for that particular pole. WARNING: DANGEROUS VOLTAGES EXIST WITHIN THESE UNITS AND ALL PRECAUTIONS USUALLY OBSERVED IN HANDLING HIGH VOLTAGE EQUIPMENT SHOULD BE OBSEREVED. MAKE CERTAIN POWER IS OFF BEFORE STARTING INSTALLATION OR BEFORE ATTEMPTING ANY MAINTENANCE. These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection to installation, operations and maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to Carolina High Mast. 1 Table of Contents PACKING LIST ASSEMBLY INSTRUCTIONS HIGH MAST POLE AND SERVICE HOIST 3 Variations in pole protection …………………………………………………….……………………. 4 Pole preparation ……………………………………………………………………………………….. 5 Service hoist layout and preparation ………………………………………………………………... 6 Mounting the head frame assembly ……………………………………………………………….… 6 Installing hoist cables .…………………………………………………………….……………...…… 8 Installing safety chain………………………………………………………………………...……..…. 10 Raising the pole………………………………………………………………………………...………. 10 Wiring the base……………………………………………………………………………………...….. 11 Assembly with luminaries………………………………………………………………………...……. 11 Ring alignment………………………………………………………………………………...………... 13 Completing the installation…………………………………………………………………...………... 13 OPERATING INSTRUCTIONS Set up for operation……….. …………………………………………………….……………………. 14 Lowering the ring……………………………………………………………………………………….. 14 Lighting equipment lowered ring…... ………………………………………………………………... 15 Raising the ring …………………….. ……………………………………………………………….… 15 Finishing the service .…………………………………………………………….……………...…….. 15 TROUBLESHOOTING AND LUBRICATION Un-hanging latches……………………………..………………………………….……………………. 16 Lubrication…... ….……………………………………………………………………………………….. 16 Miscellaneous Prints for record and prints for approval……..………………………………….……………………. 16 Renewal parts ….……………………………………………………………………………………….. 16 Assembly prints Index……………….……….. …………………………………………………….……………………. 2 17 Packing List Cover Assembly: 1. Head Cover 2. Head Frame Assembly 3. Hoist and Power Cable 4. Transition Assembly 5. Pre-wired Support Ring Hardware Pack: 1. Locking-type Plug and Power Cable Clamps 2. Three (3) Strand Vices 3. Plug Protector 4. (3) Split washers 5. (3) Indicator flags 6. Instructions 7. (3) Split tennis balls 8. Springs Fixture Mounting Arms with Mounting Hardware (per fixture): 1. (1) 1/2-13 Bolt, Locknut, and Spacer; 3.75 inches long 2. (2) 1/2-13 Bolt, Locknut, and Washer ; 1.75 inches long Winch Plate Assembly 1. Pole plate with pre-wound winch and circuit breaker box assembly* 2. (3) Studs with six (6) nuts and lock washer *NOTE: Contractor is to provide bushing for connection to breaker box in pole. Safety Chains** 1. (1) Chain assemblies **NOTE: Safety chain is an option to the High Mast System. Your device may not include these Items. Assembly Prints: Representational prints of basic models. Parts and assembly options are available upon request from the factory. 3 Assembly Instructions High Mast Pole and Service Hoist Variations in Pole Protection As the support ring and luminaires are lowered and raised, they can be blown against the pole causing damage to pole, ring and luminaires. Consequently, four methods of pole protection are offered on the CHM Service Hoist– BUMPER TYPE, ROLLER TYPE, SPRING ARM TYPE. All units will have at least one method of pole protection. The following assembly instructions are written with reference to the spring arm system as this is the most complicated method to assemble. The three variations are described below. Figure 2: Roller type Roller Type: This type provides rollers fixed to the inside of the ring. This enables the ring to roll when in contact with the pole. Figure 1: Bumper type Bumper Type: This type is simply an extruded rubber strip that lines the inside of the ring. It provides a buffer between the pole and the ring and protects from impacts and friction as the ring is lowered and raised. Figure 3: Spring Arm Type Spring Arm Type: This type provides three rollers on spring loaded arms that limit the lateral motion of the ring by maintaining contact to the pole shaft. The spring loaded arms absorb shock when bumping does occur. 4 NOTE: In the MOUNTING THE HEAD FRAME ASSEMBLY section, the instructions and illustrations refer to the Three Roller– Arm System. If you have a bumper or roller type ring, ignore the reference to “pulling the arms open” when placing the support ring on the pole. Simply slide the ring onto the top of the pole. 12 IN. Mark beyond overlap Male shaft Min. Slip (1.5 x top Dia. of male shaft) Female shaft 1/32 IN. max gap Pole Preparation Figure 6: Mark reference line CAUTION: To avoid problems and complications in the rigging of the cables, it is important that the pole be assembled according to these instructions. 2. All sections should be properly aligned and then forced together until the average gap between overlapping sections is 1/32 inch (0.79mm) or less. Measure the distance from the pencil, crayon, or tape mark to the edge of the overlapped section to verify that the sections are completely together (Figure 6). 1. The Pole section should be laid out on blocks, elevating them above the ground, to prevent dirt and other contaminates from washing into pole, cribbage or horses are required to support the sections so that the top end will be at least 5 feet (1.5 meters) above the ground, as shown in Figure 5. The top end must be clear of obstructions for at least five feet to permit installation of equipment. Sections should be placed in order of matching piece marks. The top of each section should be marked with a pencil, crayon, or piece of tape a measured distance (12 inches/305mm) beyond the minimum overlapping distance for the section above it-1 1/2 diameters minimum overlap. This mark will be used as a reference to determine how far the pole sections are overlapping (Figure 6). 3. Forcing together can be done by several methods. The preferred method is by using a pair of jacking devices such as come-alongs (Figure 7) or hydraulic jacking devices (Figure 8). One end of each jack is attached to the base plate or to the ends of a steel bar across the bottom of the base plate. The other end of each jack is attached to a steel bar (backed by wood to avoid damage to the pole) across the open end of the section being tightened. Proper alignment is maintained by even pull from both jacks. Jamming results from uneven rate of pull; straighten by pulling opposite jack. NOTE: Telescoping should be done section by section starting at the base. NOTE: Be certain that there are no projections, sharp burrs or dirt in the telescoping sections of the pole BASE SECTION TOP SECTION 5 ft SUPPORTS Another way to force sections together is to use a bulldozer or loader pushing axially against the end of the pole toward a fixed barrier such as an abutment or truck tailgate. JOINT LUBRTICATION SUCH AS LIQUID SOAP OR DETERGENT SHOULD BE USED, NOT OIL OR HEAVY GREASE. Weathering steel poles will not weather evenly at joints where oil or grease has been used. Dirt and dust will collect on galvanized poles. Figure 5: Supporting pole sections for assembly Come along device Choker cable BASE SECTION TOP SECTION Top view Note: Come alongs should be 180 Deg. apart. Base plate Figure 7: Choker cable and come along method 5 Steel plate Stud assembly Base plate Nut Wood block Lock washer Base section Winch plate Top section Lock washer Jack Pole plate Figure 8: Hydraulic jack method Nut CAUTION: When jacking pole joints together, comealongs or jacks must be 180° apart. Figure 10: Winch plate connection Mounting the Head Frame Assembly 4. Lay the pole with the hand hole facing straight up. Support the pole so that the top end is about five feet off the ground and the pole is not bowed (Figure 9). Hand hole, (Facing up) 5 ft Figure 9: Supported assembled pole 1. While pulling the roller arms open (on roller– arm models only), place the support ring assembly on the pole. The roller-arms should be toward the bottom of the pole, and the latch shafts should project toward the top of the pole. The junction box should be on the same side of the pole as the hand hole, i.e., facing up (Figure 11). On scrub ring and caster ring models without roller arms, simply lift the ring over the top plate with the junction box on the same side of the pole as the hand hole. Strand vice Service Hoist Layout and Preparation 1. Remove high mast assembly from the package. Place the pole plate and winch assembly at the base of the pole and the head frame and ring at the top of the pole. 2. A light rope or electrician's “fish line” should be strung through the pole. It is easier to push the fish line starting at the tope of the pole. The fish line will be used to pull the cable through the pole. 3. Insert the three 1/2 inch (13mm) studs into the holes in the support plate welded inside the pole base. Using lock washers and nuts, tighten each stud securely to the plate (Figure 10). There will be no stud in the hole at the position behind the circuit breaker box on the pole plate. 4. Slide the pole through the hole in the pole base plate and into position on the three studs. Use lock washers and nuts to secure the pole plate to the support plate (Figure 10). It may be necessary to remove the winch from the pole plate if the hole in the base plate is too small. If so, after the pole plate has been mounted in the pole, then the winch may be remounted to the plate through the pole hand hole. CAUTION: If winch is removed during installation, it must be securely refastened to the pole plate by torquing the bolts to 50 foot-pounds. 6 Junction box, same side as hand hole Top end of pole Ring assembly Pull back spring arm To clear pole top Latch/guide shaft Figure 11: Ring assembly installation 2. Remove the cover from the head assembly by removing the connecting bolts. Place the head assembly near the top of the pole and set the dome head cover out of the way (Figure 12). Cover fastener Cover Head frame Figure 12: Head frame assembly 3. Keep cables separate and in their proper positions. Uncoil hoist cables hand over hand straight away from the head frame in the direction from which they come out of the head frame center hole (Figure 13 & 14). Top of pole IMPORTANT: To layout power and hoist cables, always unroll the coils. Do not uncoil by pulling from the side of the coil as this will cause twisting and kinking that may result in cable damage and cause improper operation. CORRECT Head frame assembly Support NOT CORRECT Cord pulley Ring assembly Grade Hoist cable pulley Figure 15: Do not pull out Unroll Figure 13: Cable roll out Head frame Hoist cable Head frame Transition assembly Fish line Figure 16: Transition assembly with fish line 5. While holding the head frame assembly in position as in Figure 15, pull the fish line at the pole base and insert the transition assembly into the top end of the pole. Be sure cables are not crossed or kinked. Figure 14: Hoist cable as packaged at shop 6. While pulling the fish line (to avoid slack in the cables), pick up the head frame and match to top plate, connect with bolts. (Figure 17). The head frame should be turned so that the power cable sheaves are on the top side corresponding to the position of the junction box on the support ring and the hand hole in the pole base. Tighten the connecting bolts. (Figure 18) 4. Balance the head frame assembly on its edge with the latch cams facing the top of the pole and the power cable sheaves turned upward (Figure 15). Pull the transition assembly toward the pole. Uncoil the power cable and remove any tape or labels from it. Tape the “fish line”, that was strung through the pole, securely to the transition assembly (Figure 16). 7 Pole top plate Head frame assembly Transition assembly Power cable Transition assembly Ring assembly Locate swivel 2 ft above Winch center line Support Figure 17: Installing the head frame assembly Pole top plate Winch Head frame Figure 19: Transition assy. to winch connection Installing Hoist Cables 1. Insert the end of the hoist cable through its latch cam, latch shaft, and support ring (Figure 20). 2. Place one ring suspension spring, one spring plunger and one spring plug over the end of each cable guide (Figure 21). Bolt assembly (4 required) Figure 18: Fastening the head frame Cable keeper 7. Pull the transition assembly to a point in the base of the pole where it is accessible through the hand hole and just above the winch (Figure 19). Remove the fish line. While allowing no slack in the winch cable, loosen the swivel attached to the winch cable from its tied-down position and attach it to the bail of the transition assembly using the swivel pin and cotter key. At the head frame assembly, pull the four cables as the winch is unwound until the swivel is two feet above the center of the winch drum. Head frame Hoist cable Latch cam Latch shaft Ring assembly Indicator flags Suspension spring Plunger Strand vise Support washer Cable clamp Figure 20: Hoist cable thru device 8 8. At the head frame assembly, feed the main power cable through the two cable clamps in the ring flange (Figure 23). Leave 10 inches (254mm) of slack in the cable and tighten the clamps. Hoist cable Ring assembly Suspension spring Plunger Support washer Strand vice Cable clamp Figure 21: Hoist cable thru spring/strand vice assembly 3. Remove any tape from the ends of the hoist cable before inserting them into the strand vices, and be sure the cables are not frayed. Place a strand vice on each of the three cables. (Figure 21). Figure 23: Main power cable attachment 4. Place a split washer around each of the hoist cables and slide them down over the top of the latch shafts so that they rest on the upper latch pin. Use a small amount of tape to secure the washers temporarily to the latch shafts (Figure 22). The split washers prevent the device from latching during the pole erecting. 9. Pull the main power cable until it extends 20 inches below the bottom of the junction-box. Remove the junction-box cover. Feed the power cable end through the cable connector and into the junction box (Figure 23). Wire the power cable to the terminal strips per the wiring diagram. Latch cam 10. After making sure that all cables are properly seated in their sheaves, remount the head cover onto the head frame assembly using the (6) connecting bolts. Split washer Latch shaft Fastener, 6 places Figure 21: Split washer placement Dome cover 5. While pulling the cable through the strand vice, lift the ring toward the head frame and insert the taped slit washer into the cam. Pull as much slack as possible through the vice. Head frame 6. Begin to tighten the hoist cables and compress the suspension springs by turning the hand crank on the winch. Continue to tighten the cables until they are tight enough to hold the ring in place against the head frame. Figure 24: Dome cover to head frame 11. Tie two light ropes to the support ring, 180° apart. One tied at a point near the junction box. 7. Using about two feet of cable and cable clamp. form a loop at the bedroom of each strand vice and cut off excess cable (Figure 21). 9 Their lengths must be at least the length of the pole. This will be used to pull on the ring in case the weight of the power cord and cable impairs the lowering of the relatively lightweight mounting ring. 12. String the pre-wired distribution wires through each mounting arm and then bolt the arm to the support ring using the hardware supplied (Figure 25). When tightening the three (2) 1/2-13 bolts that hold the arms on, torque each of the three (2) nuts to 60 foot-pounds. Transition assembly Safety chain Ring assembly S.S. fasteners Tenon assembly Figure 25: Mounting the tenon Figure 26: Safety Chain Installing Optional Safety Chain NOTE: Safety chains are optional on High Mast Systems. Consult your specification and order to verify that you have purchased the safety cable option. If you have not, ignore this section of the instructions. 2. AFTER ERECTING THE POLE AND COMPLETING THE INSTALLATION (see the next two sections), the safety chain must be installed and adjusted. First, latch the device. Then attach the snap hook to the transition bail and connect the other end of the safety cable to the safety chain. 1. Luminaire support rings can be secured at the base of the pole with optional safety chain. This option is provided as a redundant safety feature in case the latches and hoist cable fail. If a safety chain is used, attach one end of the chain to the attachment provision inside the pole shaft and the other end to the transition assembly. (Figure 26) 3. Loosen the two (2) saddle cable clamps on the cable. Pull the free end of the cable through the clamps until the cable is snug. Tighten the clamps to 40 foot-pounds. 4. Make sure the hook can be removed from the ring. If not, loosen the clamps and adjust. 5. Cut off or tape excess cable. Raising the Pole CAUTION: Do not use the lowering device cables to tether to pole. 1. Erect the pole in the normal manner. Either lash joints securely together to prevent slipping apart (come-alongs with tight cable lashings can be used), or use a tethering cable to the base of the pole as shown in Figure 27. 10 Assembly with Luminaires CAUTION: Ring and arm assembly supporting fixtures cannot be reoriented on the pole after installation. For proper fixture aiming, follow instructions carefully. DO NOT USE SERVICE HOIST CABLES TO TETHER THE POLE 1. Follow specific OPERATING INSTURCITONS (FOUND IN THIS BOOKLET) and lower the support ring. Read the operating instructions fully before lowering. Start with step 2 of operating instructions because latches are not yet functional. CAUTION: Latches are not yet functional because split washers are still in place. 2. During Lowering, pull on the rope that was attached to the ring if necessary. Stop when the rollers are within 2 feet (0.6 meters) of the top of the hand hole. For models without roller– arms (scrub rings or caster rings), stop the ring about 3 to 3 1/2 feet above hand hole (Figure 28). After the ring is down, remove the split washers and discard them. Figure 26: Raising the pole 2. Level the pole carefully. This can be done in any one of three ways: (1) Turn one of the leveling nuts on the anchor bolts down to approximately 1/2 inch (13mm) from the bottom edge of the nut to the top surface of the concrete base. Rest a 3 or 4 foot. (.9 or 1.2 meter) level on top of this (2) Sight the pole along a plump line from two locations 90° apart and at least 1 pole height away from the pole. (3) Use a transit to shoot from two positions 90° apart. 3. If the installation is being done during the heat of the day in sunlight, the first approach for leveling is the best. The other two approaches can only be done properly in the early or late hours of the day, because in sunlight the pole may curve away from the sun due to the temperature differences from one side of the pole to the other side. Ring assembly 4. Secure the Anchor bolts. 3 to 3.5 ft Wiring the Base 1. Wire the circuit breaker to achieve the appropriate circuit. Hand hole NOTE: The contractor is to provide a bushing for connection to the circuit breaker box in pole. 2. Energize and test the circuit to the load side of the circuit breaker at the pigtail connector. 3. CHECK CABLES: SHINE A SPOTLIGHT UP THE INSIDE OF THE POLE AND INSPECT THE CABLES. IF THEY ARE TWISTED (WHICH HAPPENS WHEN CALBES ARE PULLED INTO THE POLE), REMOVE THE TWIST BY HOLDING THE SWIVEL AND ROTATING THE TRANSITION ASSEMBLY. THIS SHOULD BE DONE WITHOUT A LOAD ON THE RING, THAT IS. BEFORE THE LUMINAIRES ARE MOUNTED. Figure 27: Ring distance from hand hole 11 2. Install indicator flags in the unlatched position, as in Figure 29. Be certain reflective tape side of flag is down and screws are tight. Ring assembly (flange) Flag unlatched position Is tangent to ring flange Figure 29: Indicator flag (unlatched position) 3. Follow manufacturer’s instructions for each specific luminaire and Pole to mount and wire the high mast luminaires or floodlights on the arms. Use counterweights to balance out unequally loaded arms. CAUTION: Do not exceed the maximum number of fixtures per pole, as recommended by the fixture manufacturer (Table 1, 2, and 3). When determining totals, count each counterweight as a fixture. Reference drawing: Ring with tenons Table 1: Typical ring tenon position configurations Table 2: Typical tenon types Ring configuration Tenon positions Spacing (deg.) 3 120 Straight tenon T-tenon J-box 4 90 Straight tenon with flange Tenon position 5 72 6 60 T-tenon with flange 12 4. Make sure the arms are equally spaced around the ring to balance the load on the ring. 3. Raise the ring until all three balls touch the three latch cams. See OPERATING INSTRUCTIONS, raising the ring section, for instructions on using the portable drive unit to raise the ring. After the balls reach the latch cams, cautiously raise the ring a few more inches to make sure the balls are in the same plane as the head plate. 5. When the luminaires are mounted to the arms, check for vertical and horizontal alignment. See instructions packed with luminaire for mounting and alignment details. CAUTION: Do not allow the latch shafts to contact the latch cams at this point. 6. Test the lighting circuit by following OPERATING INSTRUCTIONS, Testing Lighting Equipment on the Lowered Ring Section. 4. Lower the ring back to maintenance level. Measure from the top of the ring to the bottom of the balls to determine which cable has the shortest distance to the ring. raise the other two points on the ring to the same length thereby putting them in the same plane. This can be done by tapping the bottom of the strand vise with a hammer or by releasing the grip of the vise using a screwdriver through a slot in the side of the strand vise. Dimension “A” in Figure 32 should be the same for all three hoist cables. WARNING: THIS IS NOT A LOAD- RATED DEVICE. DO NOT ATTEMPT TO MAKE AND BREAK THE CIRCUIT WITH THE PLUG AND RECEPTACLE. Leveling the ring (square with the head frame) IMPORTANT: This step must be completed correctly for lowering device to operate properly. 1. For smooth operation during raising and lowering, the ring will need to be aligned with the top plate. This should be done after the pole is standing and the ring has been lowered and the luminaires and counterweights installed. Be certain that the split washer used for rigging have been removed and discarded. Hoist cables, 3 places Leveled ring A 2. Remove the three split balls from the Hardware Pack (Figure 30). Each ball will have a small slot. Push the balls onto the hoist cable carefully until the cable is in the center of the ball. Slide the three balls up the hoist cable about two feet (0.6 meters) above the ring (Figure 31). Strand vice Ring in Lowered position Uneven ring Figure 32: Leveling the ring 5. Recheck the measurements from the balls to the top of the ring. Realign if necessary. Remove the balls and discard. Figure 30: Spit leveling ball Head frame at Top of pole 6. This procedure aligns the ring with the top plate and is not intended to be a leveling operation for the ring. Proper alignment with the top plate is necessary for smooth operation. Ball location after ring is raised 18 in. at each hoist cable Ball, placed while ring is in lowered position (3 Plcs.) Completing the Installation CAUTION: Before raising the ring, check each latch to be sure that the latch indicator flags are in the unlatched position as shown in Figure 29. If not, rotate them manually. 1.Raise the ring to the top of the pole as described in OPERATING INSTRUCTIONS, Raising the Ring. 2. Attach optional safety cables, if used (see INSTALLING OPTIONAL SAFETY CABLE section for specific instructions). Figure 31: Ball placement oh hoist cables 13 3. When ring is initially raised with a full load of luminaires and latched at the top of the pole, the transition assembly, hoist cables and power cable may rotate and twist a few rotations because the wire cables are new. This twist must be removed by hand rotation of the transition assembly until the hoist cables and power cable are hanging STRAIGHT. Use a high-power light source to visually check cables. The cables should be under a small amount of tension to prevent damage from contact with the pole in high wind conditions. 4. Disconnect and remove the main power receptacle from the circuit breaker box in the pole base. Remove the portable drive unit. Operating Instructions 7. Install the handhold cover. WARNING: ANYONE WHO INTENDS TO OPERATE THIS EQUIPMENT SHOULD READ COMPLETLEY AND UNDERSTAND FULLY THESE OPERATING INSTRUCTIONS. The Carolina High Mast service hoist is to be power operated only with the Carolina High Mast Portable Drive Unit. BE SURE THE INPUT RATING for your device unit assembly is MATCHED TO THE VOLTAGE OF THE DISTRIBUTION SYSTEM at this installation. Set Up for Operation 1. Remove the hand hole cover. 2. Turn OFF the circuit breaker. Unhook the optional safety cable, if installed. 3. Lift the portable drive unit to the hand hole and insert the drive support arm into the support tube. Slide the unit until the slots in the drive shaft fully engaging the pins on the winch drive shaft (Figure 33). Drop the retaining pin through holes in the support tube and support arm to lock them together. Transition assy. Main power plug Main power supply Receiver hitch Portable Drive Unit (PDU) Remote control Transformer Main power Supply input Supply to PDU 5. Pull at the electrical cable through the transition plated to be sure there is no slack. If necessary, adjust the position of the power cable clamp so that it is 8 to 10 inches (203 to 254mm) below the hole in the transition assembly 6. Connect the plug of the power cable to the main power receptacle on the circuit breaker box and close the circuit breaker. WARNING: THIS IS NOT A LOAD-RATED DEVICE. DO NOT ATTEMPT TO MAKE AND BREAK THE CIRCUIT WITH THE PLUG AND RECEPTACLE. 4. If an auxiliary transformer is required, connect the main power receptacle to the plug on the transformer, and the motor power plug to the transformer receptacle. If there is no need for a transformer, connect the main power receptacle directly to the motor power plug (Figure 33). 5. Place all excess length of main power receptacle cable down behind the pole mounting plate. 6. Turn ON the circuit breaker. Lowering the Ring WARNING: IT IS IMPORTANT TO STAND CLEAR OF THE POLE WHILE RAISING AND LOWERING THE RING. THE REMOTE CONTROL SWITCH HAS BEEN PORVIDED FOR THIS PURPOSE. NEVER STAND UNDER THE RING ASSEMBLY WHEN RAISING OR LOWERING. CAUTION: Do not lower the ring too far. The rollers should be at least two and a half feet above the top of the hand hole. For units without roller– arms (using bumper type or roller type), stop the ring about 3 to 3 and a half feet above the hand hole (Figure 28). If the ring appears to hesitate and then drop several inches as it nears the bottom of the pole, some twisting may have occurred in the cables. Stop the decent of the ring. Raise it about five feet, then proceed with lowering it. CAUTION: When lowering the ring BEFORE luminaires are installed, latches are not yet functional; start with Step 2 of operating instruction. 1. Turn the remote control switch to FOR and raise the ring until the indicator flags rotate 45°. Release the switch to the Figure 33: Portable drive unit 14 OFF position. All three latch indictors should have rotated 45° and should appear as shown in Figure 34 (In transition) when viewed from the ground. Raising the Ring WARNING: IT IS IMPORTANT STAND CLEAR OF THE POLE WHILE RAISING AND LOWERING THE RING. 1.Verify that all three latches are in the unlatched position, as shown in Figure 28. If not, rotate them manually. Unlatched position In transition at 45 deg. 2. Lubricate the Latch Pins with a coat of white lithium grease. 3. Turn the remote control switch to FOR position and raise the ring until it is near the head frame assembly, and the transition assembly can be reached through the hand hole. Stop the ring and inspect the cables with a spotlight. Use a mirror for small hand holes if necessary. I the cables are twisted, remove the twist by rotating the transition assembly. Turn the remote control switch to the FOR position and raise the ring until indicator flags rotate 45°. Release the switch to the OFF position. Figure 34: Latch indicators (as viewed from below) 2. Turn the remote control switch to REV. As the ring is lowered, the three latch indicator will align with the ring as shown in Figure 34 (Unlatched). The unlatched ring will descend the pole supported by the cables. If all three latch indicators are not tangent then the unit is still latched. See the TROUBLESHOOTING section, Un-hanging Latches. 4. All three indicator flags will have rotated 45° as shown in Figure 34 (in transition). Turn the remote switch to REV position. Release it to OFF as soon as the three latch indicators have turned to positions shown in Figure 35 which indicate that the latches are in the latched position. If all three latches are not in the latched position, see TROUBLESHOOTING section, Un-hanging Latches. 3. Release the remote control switch to the OFF position when the device reaches the desired working height. Testing Lighting Equipment on the Lowered Ring WARNING: THIS IS NOT A LOAD-RATED DEVICE. DO NOT ATTEMPT TO MAKE AND BREAK THE CIRCUIT WITH THE PLUG AND RECEPTACLE. Latched position 1.Turn OFF the circuit breaker. 2. If the main power receptacle on the pigtail from the circuit breaker box is connected to the transformer or to the motor power supply cable, disconnect it. Connect the main power receptacle to the inlet plug of the junction box on the support ring, after removing the plug protector. Figure 35: Latch indicators (as viewed from below) CAUTION: Allow only a slight amount of slack in the winch cable. Once the cable shows any slack, the latches carry all the ring load, as intended. DO NOT UNWIND EXCESS SLACK from the winch as loops of cable may become entangled on the winch drum and damage the cable, resulting in reduced cable life. 3. Turn ON the circuit breaker to test the luminaires. Allow about 20 minutes from warm-up, then visually check all luminaires for proper lamp functioning. 4. After completing test, turn OFF the circuit breaker . 5. Disconnect the main power receptacle from the junction box and reconnect it to the transformer box or to the motor power supply cable, as applicable. Replace and secure the plug protector. Finishing the Servicing 1. Turn OFF the circuit breaker. Disconnect the main power receptacle from the transformer plug or from the motor power plug. 6. Turn ON the circuit breaker. 15 2. If used, reconnect the optional safety cable to the transition assembly (see Installing the Optional Safety Cable section of the installation instructions). excess cable down behind the pole plate assembly. 4. Remove the retaining pin from the support tube and drive support arm and remove the portable drive unit. 3. Connect the main power plug to the main power receptacle. Turn ON the circuit breaker. Place all 5. Replace the hand hole cover. Troubleshooting and Lubrication 4. Turn the remote control switch to the REV position. Release it to the OFF as soon as all three latch indicators have turned to the latched position, as shown in Figure 35. Un-hanging Latches NOTE: If properly operated according to these instructions, it is unlikely that any latch will get out of sequence and “hang up”. The design of the latches, suspension springs, and drive unit act together to assure latching a wide range of support ring loading. If a “hand up” occurs, it can be worked out as follows: Lubrication Winch: The winch is lubricated and sealed at the factory and needs no further lubrication. It should give many years of service without attention. 1. Raise the ring very slowly by a succession of short “ON” intervals in the FOR position. Watch the sets of latch indicators until the first set appears to have rotated 45° a bit sooner than the other two. Do not continue to raise the ring. The full torque of the limiter is not used. Latch Pins: Lubricate with a coating of white lithium grease at each service interval. Aircraft Cable. The winch and hoist cables come from the manufacturer with a very light coating of lubricant. This lubricant is desirable and should not be removed. The winch cable should be checked for wear and corrosion and cleaned with a soft, absorbent cloth, then re-lubricated with a good quality acid-free grease on a regular service interval. In normal environments the service should be performed every five years or at relamping intervals. In highly corrosive environments the cable should be serviced every two years or at relamping intervals. 2. Drop the ring slowly while observing if all three latch shafts drop from the lock plate. If all three latches are now unlatched, continue to lower the ring or go to Step 3 as required. If the ring is still “hung”, do not lower the ring further. Repeat steps 1 and 2. It may be necessary to operate the first two latches to obtain a sequence that will free all three. 3. Raise the ring fully until the indicator flag rotate 45°. Release the switch to the OFF position. All three latch indicators should now have rotated 45° as shown in Figure 34. CAUTION: If during inspection, it is found that there are more than 12 broken wires in one lay of the cord, the cable should be replaced. Miscellaneous Prints for Record and Prints for Approval to “Prints for Record”. Assembly prints in this book are identified with drawing numbers. They are suitable for use as “Prints for Record” or “Prints for Approval” for a standard lowering device. Drawings indicate all the necessary part to make up a standard lowering device model. Renewal Parts Contact the factory for renewal parts. Use the assembly prints in this instructions book for an accurate description of part names. There are many options available from factory representatives. When a non-standard model is required, these requirements should be discussed prior 16
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