ABACUS HL250 User manual

Product Manual
November 2022
.
Part No: INS-HL
High Lume (HL) Masts
Applicable products:
•HL250
•HL250E
•HL330
•RLH5
•RLH7
•RLH11
WE STRONGLY RECOMMEND THAT THESE
INSTRUCTIONS ARE READ CAREFULLY BEFORE
ATTEMPTING TO INSTALL, OPERATE AND MAINTAIN
THIS EQUIPMENT

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
1 
Product Manual
November 2022
1. Safety ........................................................................................................................ 2
2. Installation................................................................................................................ 3
2.1. General ....................................................................................................................................... 3
2.2. Mast Positioning ........................................................................................................................ 3
2.3. Mast Assembly ........................................................................................................................... 4
3. Operation .................................................................................................................. 7
3.1. General ........................................................................................................................................7
3.2. Moving the Counterbalance (RLH5 only) ................................................................................ 8
3.3. Checks Before Use ..................................................................................................................... 8
3.4. Fitting the Ram to the Mast ...................................................................................................... 9
3.4.1. HL250 Mast (RLH5 only) ..................................................................................................... 9
3.4.2. HL250 Mast (RLH7 only)...................................................................................................... 9
3.4.3. HL330 Mast ........................................................................................................................... 9
3.5. Lowering the Mast ....................................................................................................................10
3.6. Raising the Mast ....................................................................................................................... 11
3.7. Removing the Ram ...................................................................................................................12
3.7.1. HL250 Mast ..........................................................................................................................12
3.7.2. HL330 Mast ..........................................................................................................................12
3.7.3. Depressurising Procedure ....................................................................................................12
4. Maintenance ........................................................................................................... 14
4.1. Mast Type Identification ..........................................................................................................14
4.2. Masts ......................................................................................................................................... 15
4.2.1. Every Time the Mast is Lowered.......................................................................................... 15
4.2.2. Every 12 Months ................................................................................................................... 15
4.2.3. As Required ...........................................................................................................................15
4.3. Counterbalances .......................................................................................................................16
4.4. Hydraulic Hoses .......................................................................................................................19
5. EN 1090 Certificate of Conformity ..........................................................................20
6. CE Marking ............................................................................................................. 21
7. Environmental Advice............................................................................................. 22
7.1. General ..................................................................................................................................... 22
7.2. Information.............................................................................................................................. 22
8. Equipment Classification ........................................................................................ 23

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
2 
1. Safety
WE STRONGLY RECOMMEND THAT THESE REQUIREMENTS ARE READ
CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE AND MAINTAIN THIS
EQUIPMENT.
i) It is essential that all operators are trained and authorised in the safe use of the counterbalance unit.
ii) It is recommended that certified operator training be carried out by Abacus personnel.
iii) The counterbalance unit must only be used for the purpose intended, as described in these
operating instructions. Abacus Lighting Limited will not be held responsible for any misuse or abuse
of the unit. Similarly no repair, modification or maintenance work, other than that specified in these
instructions, must be carried out unless authorised by Abacus.
iv) During the lowering and raising operation the operator must ensure that all non essential
personnel and members of the public are kept clear from the areas adjacent to and in front of the
mast. These areas should be clearly defined and cordoned off to prevent access.
v) It is important that hands and loose items of clothing are kept away from moving parts, both on the
mast and counterbalance unit.
vi) Head protection must be worn at all times when operating a counterbalance unit on a raise and
lower mast.
vii) When manhandling or lifting the counterbalance the operator should ensure that they are
physically capable of carrying out the task. Ensure good manual handling techniques are employed at
all times and for heavy units two people should carry out the task.
viii) Refer to the appropriate performance data sheet, supplied on request, for details of maximum
permitted head-load weights and wind areas.
ix) The counterbalance must be visually checked, before and after use, for signs of damage or worn
parts. If repairs are necessary they must be carried out prior to using the counterbalance unit. For
hydraulic units it is essential that the ram be closed after use. Failure to do so could result in damage
to the piston rod and seals, which in turn could compromise the safe working of the unit.
x) It is recommended that the counterbalance unit be stored indoors when not in use.
xi) When using hydraulic counterbalance units it is essential that the operator is aware of the COSHH
regulations relating to the safe handling of hydraulic oil. Reference should be made to the COSHH
data sheet supplied in these instructions.

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
3 
2. Installation
2.1.General
The masts are used for sports lighting and general floodlighting applications typically up to 20m
in height. Each mast is supplied in kit form for on-site assembly. The foundation bolts should be
cast in concrete not less than 1 week prior to erection of the mast to allow time to cure sufficiently.
Foundation block sizes for a variety of ground conditions can be supplied on request.
Masts are constructed from steel to EN10025 grade S275 and S355, pressed to form a tapering
octagonal shaft. The shafts are slotted together and require no on site welding or bolting. The
mast and foundation bolts are finished galvanised with small fasteners being from stainless steel.
In the following instructions mention is made of the minimum permissible shaft overlap distances
relating to tapered octagonal shafts. In addition, because these masts are designed for specific
applications it is essential that reference is made to the engineering drawings during assembly.
These will give details of the shaft design overlaps. The overlaps achieved on site will vary due to
manufacturing tolerances.
For shafts of 5mm or less in thickness the minimum permissible overlap can be determined
from Fig 1.
2.2.Mast Positioning
It is essential that the area around the base is kept clear of obstructions at all times to allow for the
safe operation of mast and counterbalance. The illustration below gives details of the minimum
clearance zone around the mast, assuming a gear cabinet is installed and that the counterbalance
is positioned adjacent to the base.

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
4 
2.3.Mast Assembly
Reference should be made to the illustrations which follow the text.
1. Before commencement of assembly examine the items and ensure that there are no missing or
damaged parts. The following items of equipment will be required (not Abacus supply);
•Telescopic handler or similar to erect the base (typically 0.5 tonne)
•Torque wrench suitable for 310Nm on the HL250 and 850Nm on the HL330.
•Timber supports and packers
2. The holding down bolts are each fitted with two nuts and washers. The upper nuts and washers
and template should be removed. The threads should be examined for any damage and rectified
using a die nut if necessary. The nuts should be set in a level plane using a steel bar and spirit
level across each opposing pair of nuts. Check, referring to the counterbalance operating
instructions (see section 3.6), that the base section is fully closed and locked. Using a tele-handler,
lift the mast base and place over the foundation bolts and on to the lower set of nuts, ensuring the
direction of lowering is as required and that the mast will clear any obstructions.

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
5 
3. If the mast is supplied with a gear cubicle this should now be fitted. Ensure that the box sits on
the rear pair of bolts and that the cable entry gland between the box and mast is in place. Using
the fixing bracket as a guide, drill and tap M8 holes in the mast, as required, and secure the box
with the stainless steel screw provided. Fit the retaining washers and nuts to the 4 bolts and
roughly ‘plumb up’ the base section. Referring to the operating instructions fit the counterbalance
unit and lower the mast base to the horizontal.
4 - 5. Before assembly lay the shaft sections end to end on the ground and ensure by sighting from
one end that the shafts are straight. Check the overlap area for any signs of damage, excess zinc or
weld that may impede fitting of the shafts together and rectify if necessary. It may be necessary to
rotate one or all of the sections to achieve the best alignment. The orientation of the shaft seam
weld relative to the joining section is not important.
With the base section lowered, pick up, locate and slide home as far as possible the larger shaft
section. The minimum overlap distance must be achieved. It may be necessary to tap the shaft as
illustrated to achieve this. Repeat this exercise until all the shaft sections are in position.
6 - 7. Fit the floodlight mounting bracket to the top shaft section and secure with the screws
provided. It should be noted that the power supply cable can be installed during assembly or, if
preferred, after assembly is completed, but prior to fixing the floodlight bracket.
8 - 9. Follow the counterbalance operating instructions (see section 3.6) and raise the mast into its
vertical position and close the mast. Remove and store the counterbalance unit.
After completion of assembly and with the mast raised, recheck for vertical alignment. Use the
levelling nuts to accurately ‘plumb up’ the mast shaft. It should be noted that the shafts taper
approximately 14mm per metre overall, 7mm per side.
Once satisfactory, all bolts should be tightened to a torque setting of 310Nm on the HL250 and
850Nm on the HL330.
If the gap below the flange is to be grouted it is essential that adequate provision is made for
ventilation and drainage of any water collecting inside the base.
The mast can then be commissioned.
‘Plumbing up’ in hot weather or climates. To minimise the effect of the sun on one side of
the mast, which can cause considerable temporary curvature of the mast it is recommended that
the ‘plumbing up’ be carried out very early or late in the day.

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
6 

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
7 
3. Operation
3.1.General
The HL250 mast is lowered using the RLH5 counterbalance unit (electric) or the RLH7 (manual).
The HL330 mast is lowered using the RLH11 counterbalance unit. Both counterbalance units
consist of a double acting hydraulic ram mounted on a trolley, which also houses the electric
motor driven pump unit or, on the RLH7, the manual pump.
The ram on the counterbalance is individually colour coded (see section 4.3). In the event of a
hose failure a flow control valve, integral with the ram ensures that the mast lowers at a safe rate.
RLH5 counterbalance (for HL250 masts)
RLH7 counterbalance (for HL250 masts)

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
8 
RLH11 counterbalance (for HL330 masts)
3.2.Moving the Counterbalance (RLH5 only)
The upper ram anchor pin is lengthened to serve as a handle. To move the unit, pull the ram
backwards so that the weight bears on the axle of the chassis and, with the weight being balanced
by the pump unit, wheel the unit in the normal manner. The unit must never be moved with the
ram in the extended position.
3.3.Checks Before Use
1. Examine the trolley framework for damage. Check that the wheels are operating and retained in
position.
2. Examine the ram in particular the area around the seals for signs of damage and leakage of oil.
3. Check the oil level is to the centre of the level gauge with the tank top horizontal and the ram
closed.
4. Check the hydraulic hoses for damage and loose connections.
5. Check the electrical flex for damage or loose connections. Connect to a 240v supply and switch
on.
6. Check the function of the pump and control valve by extending the ram for a short distance i.e.
100mm. Retract the ram at the same time observe the pressure gauge. During extension it should
be 0 to 300psi and 1000psi minimum during retraction. As the ram reaches fully closed the
reading should build up to the relief valve pressure of 2500psi.
7. Check that the upper and lower ram anchor pins are the correct diameter and colour code.
IF ANY OF THESE CHECKS ARE FAILED THE COUNTERBALANCE MUST NOT BE USED.

Abacus Lighting, Sutton-in-Ashfield, Nottinghamshire, NG17 5FT, England. Tel: [phone], www.abacuslighting.com
9 
3.4.Fitting the Ram to the Mast
The ram attachment procedure differs between the HL250 and HL330 masts.
3.4.1. HL250 Mast (RLH5 only)
Wheel the unit up to the mast and park it conveniently to one side. Remove the mast door and
connect the unit to a suitable power source either from within the mast base or via a portable
generator, minimum 2.5Kva. Remove the upper and lower ram anchor pins and place next to
the base of the mast. Lift the ram from the trolley and place between the gussets at the base of
the mast.
Fit the lower ram anchor pin through the ram and gusset and insert the retaining pin. Support
the ram against the mast. Operate the control valve to extend the ram until it is possible to
insert the upper end of the ram between the two gussets and secure with the upper ram
anchor pin. Fit the retaining clips to the upper and lower ram anchor pins.
3.4.2. HL250 Mast (RLH7 only)
Fitting of the RLH7 ram is as per the RLH5 except the ram is operated manually.
3.4.3. HL330 Mast
Connect the unit to a suitable power source either from within the column base or via a
portable generator, minimum 2.5Kva. With the ram attached to the motor/pump unit as
described in the previous section, switch on the power supply and remove the lower ram
anchor pin. Wheel the unit up to the mast and align the ram with the ram anchor gusset on
the mast. Tilt the handles upwards and offer the lower end of the ram to the anchor gusset as
indicated. Align the holes and insert the lower ram anchor pin and secure with the retaining
pin provided. With the pump unit still inclined, operate the control valve to extend the ram
and allow the upper ram anchor pin to be released. Grasp the upper end of the ram and lift it