Acuity Brands Lighting Holophane High Mast System 2 Manual

High Mast System 2
Operation & Maintenance Manual

contents
Safe Lowering
of Highmast
Head Frame
3
Maintenance 2
21
Safe Raising
of Highmast
Head Frame
12
Maintenance
Schedule
22
Maintenance 1
19
foreword
When you purchase a product from Holophane you
purchase more than just a lighting luminaire, you also
get a full pre and post sales solutions in our Field
Service department who are a fully trained and
experienced service team who support our extensive
product range. We offer a complete value added package
ranging from servicing to after-sales care.
We strongly recommend that this instruction sheet, and
the maintenance instructions appropriate to the raise
and lower tool type on site are read carefully before
attempting any maintenance on the equipment and
that a site specific risk assessment is carried out.
2

safe lowering of Highmast Head Frame
2 3

lowering of high mast
lantern carriage
Remove mast door.
Isolate electrical supply.
Disconnect the mains power and
control cable(s) to the headframe.
Ensure the plug and power cable
from the headframe junction box
are free to move up the column
without becoming tangled with the
hoisting cables and/or any of the
other components within the mast.
1
2
3
4 5

Remove winch access cap at the
side of the mast via 6mm Allen
head bolt.
Offer up the elevation cart to the
side of the mast. Adjust the height
of the cart via the handle until the
cart is level with docking rails
around the side hatch.
Attach the cart to the side of the
mast via the 2 securing bolts.
4
5
6
5

Connect the small 4-pin ‘Harting
style’ plug from the cart to the
micro switch assembly inside
the mast.
Connect the elevation cart mains
power cable to the mains power
cable inside the mast.
Turn on the mains at the base of
the mast/or generator and then
power on the elevation cart.
Set the elevation cart to slow
using the handset.
7
8
9
10
6 7

Unwind the cable on the elevation cart and feed the looped end
through the access hatch and under and around the pulley.
Ensure winch cable is centred on pulley.
Whilst holding the clevis plate
balancer remove the wing-bolt
on the shackle whilst holding the
balancer and replace the chain with
the winch cable, then reattach the
wing-bolt.
Hold the balancer at all times during
this part of the process. Letting go
of an unsupported balancer could
lead to sudden collapsing of the
headframe dampener assembly and
hoist cables.
11
12
7

Using the elevation cart to lower
the lantern carriage.
Ensure before beginning any
operation involving the movement
of the winch and headframe, ensure
speed is set to the slowest position.
During lowering operation, the
operative must stand back at full
extension of the remote lead. This
will keep the operator outside the
fall radius of the headframe.
As the headframe is lowered check
that the winch runs smoothly and
rope is undamaged.
14
Place the lantern carriage support
brackets on the mast.
13
8

Unlatching the lantern carriage from
headframe.
• Position of clevis plate balancer
when the headframe is properly
latched.
Unlatching the lantern carriage from
headframe.
• Position of the lantern carriage
when latched with the headframe.
15
• Press together the ‘DESBLOQ’
(OVERIDE) and ‘WINCH WIND’
(Upwards Arrow) buttons until the
balancer trips the lower micro-
switch cutting out the winch motor.
8 9

• Position of clevis balancer plate
when the lantern carriage ring has
been un-latched.
• Lantern carriage ring in ‘Un-
Latched’ position ready to lower.
Note: If for whatever reason the
micro-switch fails to trip do not allow
the balancer to carry on motioning
downwards as this puts undue stress
on the hoisting cables.
10 11

Stop once the headframe is safely
sitting on the support brackets.
16
Power Off the elevation cart.
17
11

safe raising of Highmast Head Frame
12

raising of high mast
lantern carriage
Ensure that the direction of rotation is
correctly set on the elevation to raise
the lantern carriage.
Before raising the headframe check
that no tools, luminaire components
or other items have been left on top
of luminaires or headframe. Check
that all enclosures are securely
fastened.
Using the elevation cart, raise the
head frame.
Ensure the head frame is correctly
docked.
• Correction position of clevis plate
for latching the lantern carriage to
the headframe.
• Lantern carriage ring carriage in
‘ready to latch’ position. Roller
fully not resting in holder.
1
2
3
4
12 13

• Position of clevis balancer plate
when the lantern carriage ring has
been fully latched. Just above the
top micro-switch.
• Lantern carriage in ‘fully latched’
position. Roller fully resting in
holder.
• Toggle the clevis plate balancer
to ensure it is ‘slack’ to
approximately 60-80mm of
movement indicating the lantern
carriage ring has been
successfully latched.
14 15

Whilst holding the clevis plate
balancer remove the wing-bolt on
the shackle whilst holding the
balancer and replace the winch
cable with the chain, then reattach
the wing-bolt.
Hold the balancer at all times
during this part of the process.
Letting go of an unsupported
balancer could lead to sudden
collapsing of the headframe
dampener assembly and hoist
cables.
Set the elevation cart to slow
using the handset.
5
6
15

Wind the winch cable back onto
the elevation cart.
Power Off the elevation cart.
7
8
16 17

Reconnect the mains power and
controls cable(s) to the headframe.
12
Turn off mains power inside the mast.
Disconnect the elevation cart from
mains inside the mast.
Disconnect the 4-pin ‘Harting style’
plug from the cart to the micro switch
assembly inside the mast.
9
10
11
16 17

Un-attach the elevation cart from
the side of the mast.
Replace winch access cap at the side
of the mast via 6mm Allen head bolt.
Turn on mains at the base of
the mast.
13
14
15
Replace mast door.
16
18

maintenance 1
1 Remove mast door.
2 Switch on installation check for any failed LEDs.
3 Isolate the mast electrically.
4 Remove Winch cover (if fitted).
5 Examine winch attachment to the mast for security.
6 Where required, check Winch oil level and condition of oil (replenish if necessary
before operating Winch).
7 If design permits, remove the Winch gear cover; inspect the gear teeth for wear.
8 Inspect Wire Rope anchorage point on Winch drum.
9 Inspect rope lay on Winch drum(s) and visible rope for frays, kinks and corrosion.
10 Inspect rope stops, Cable clamps, bobbin and chain (double drum winches) and
ensure they are secure and correctly positioned.
11 Inspect Compensating Pulley and ensure it is sound, secure and in the correct
position (single drum Winch only).
12 Inspect Security connector from Compensating Pulley (if fitted).
13 Inspect all visible Wire Rope terminations.
14 Inspect Winch-locking device and ensure that it engages and operates correctly.
15 Disconnect the electrical plug and socket. Check condition.
16 Check power Cable(s) are securely clamped at attachment to Wire Ropes.
17 Connect trailing lead(s), if applicable, to power Cable(s) and check clamping at all
plug and sockets.
18. Lower Lantern carriage (See note 1).
19 Ensure that no undue wear is evident in the Winch mechanism.
20 Inspect the Wire Rope as it pays off the Winch for frays, kinks, corrosion, damage
and deterioration.
18 19

21 From the base of the mast, observe ropes from lantern carriage in lowered position
to the mast head for defects.
22 Inspect Winch drum(s) and ensure a minimum of four turns of rope remain on drum
(or that specified by the mast manufacturer).
23 Inspect lantern carriage for general condition, welded and bolted joints for signs of
cracking, rubbing guides or rollers for damage.
24 Inspect Wire Rope attachments to lantern carriage for wear, deterioration, distortion,
corrosion and security.
25 Inspect Luminaire glasses, clips etc. present, secure, undamaged.
26 Inspect electric Cable at carriage, secure, in good condition.
27 Inspect all associated electrical items, secure, undamaged.
28 Remove all lamps and clean or alternatively fit new lamps as required.
29 Check Luminaire optical system for security/condition. Clean with non-abrasive
materials.
30 Check lamp holders/mounting brackets for security/condition. Check lamp holder
contact points for pressure and cleanliness.
31 Carry out functional test of floodlights; if a photocell is fitted carry out functional test
utilising photocell.
32 Remove Denzo tape on foundation studs, check condition and security, and replace
Denzo tape. Where foundation studs are chemically anchored into the concrete,
inspect the grout/resin and surrounding concrete condition for signs of deterioration
or cracking.
33. Check condition of damping quadrants (if fitted).
34 Carry out a visual check of the welds of the Flange Plate, gussets, door frame and
door frame reinforcing for cracking.
35 Report general condition of mast interior and exterior, including any protective
finishes; check for impact damage.
36 Rooted Masts Only. Where possible check the internal surface of the root for corrosion
and whether there are signs of flooding.
37 Raise lantern carriage to mast head and dock.
(see Safe Raising & Lowering of Highmast Head Frame section)
38 Adjust mast rigging if required.
20 21