HybridLight 200 HYBRID TOWER Guide

Installation and User Instructions
MODEL 200 HYBRID TOWER
Lighting, Surveillance and Communications Tower
2018-12-V1
October 2017
Version 1.05

DISCLAIMER
Hybrid Light Solutions LLC. makes no representations or warranties with respect to this manual and, to
the maximum extent permitted by law, expressly limits its liability for breach of any warranty that may be
implied to the replacement of this manual with another. Furthermore, Hybrid Light Solutions LLC.
reserves the right to revise this publication at any time without incurring an obligation to notify any
person of the revision.
The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not intended
as a substitute for and is not to be used for determining suitability or reliability of these products for
specific user applications. It is the duty of any such user or integrator to perform the appropriate and
complete risk analysis, evaluation and testing of the products with respect to the relevant specific
application or use thereof. Neither Hybrid Light Solutions LLC. nor any of its affiliates or subsidiaries shall
be responsible or liable for misuse of the information that is contained herein. If you have any
suggestions for improvements or amendments or have found errors in this publication, please notify us.
All pertinent state, regional, and local safety regulations must be observed when installing and using this
product.
When devices are used for applications with technical safety requirements, the relevant instructions
must be followed.
Failure to observe this information can result in injury or equipment damage.
Copyright © 2018 by Hybrid Light Solutions LLC.
All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any
form or by any means, including photocopying, recording, or other electronic or mechanical methods,
without the prior written permission of the publisher. For permission requests, write to the publisher,
addressed “Attention: Permissions Coordinator,” at the address below.
Hybrid Light Solutions LLC
4604 Morehouse Drive, Pequot Lakes, MN, 56472
1-218-568-1188
TRADEMARKS
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Hybrid Light Solutions LLC. has made every effort to supply trademark information about company
names, products and services mentioned in this manual. Trademarks shown below were derived from
various sources. All trademarks are the property of their respective owners.
General Notice: Some product names used in this manual are used for identification purposes only and
may be the trademarks of their respective companies.
Product Modifications
Year
Type
Modifications
2019
1
2019 Model 200
2022
3
2022 Model 230
Document Revisions
Date
Version Number
Document Changes
14-07-2017
1.0
Initial Draft
17-07-2019
2.0
Version Two
01-01-2022
3.0
Version Three
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Table of Contents
1 PREFACE 5
1.1 Description of the User 5
1.2 Conventions Used in This Manual 5
1.3 Explanation of Safety Warnings 6
1.4 Retaining Instructions 6
1.5 Obtaining Documentation and Information 7
2.0 Description of the product 8
2.2 Product specifications 10
2.4 Control Panel 13
2.5 Setup process 17
2.6 How to use safely 19
2.7 How to Tow the Product 20
3.0 Maintenance 21
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1. PREFACE
1.1 Description of the User
This manual is intended to support end users of the Hybrid Light Solutions Model 200 mobile tower. Our
products are designed and intended to provide site support solutions for lighting on a variety of
applications including: construction job site, oil and gas job sites, pipelines, events, security and
government or military operations.
The user will deploy and setup the Model 200, and should be qualified and follow all instructions
contained in this operating manual.
1.2 Conventions Used in This Manual
The following style conventions are used in this document:
Bold
Names of product elements, commands, options, programs, processes, services, and utilities Names of
interface elements (such windows, dialog boxes, buttons, fields, and menus)
Interface elements the user selects, clicks, presses, or types
Italic
Publication titles referenced in text
Emphasis (for example a new term)
Variables
Courier
System output, such as an error message or script
URLs, complete paths, filenames, prompts, and syntax
User input variables
< > Angle brackets surround user-supplied values
[ ] Square brackets surround optional items
| Vertical bar indicates alternate selections - the bar means “or”
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1.3 Explanation of Safety Warnings
Danger indicates a hazard with a high level of risk which, if not avoided, will result in death or serious
injury
Warning indicates a hazard with a medium level of risk which, if not avoided, could result in death or
serious injury.
Caution indicates a hazard with a low level of risk which, if not avoided, could result in minor or
moderate injury.
Indicates information considered important, but not hazard-related.
1.4 Retaining Instructions
Read and understand this manual and its safety instructions before using this product. Failure to do so
can result in serious injury or death.
Follow all the instructions. This will avoid fire, explosions, electric shocks or other hazards that may result
in damage to property and/or severe or fatal injuries.
The product shall only be used by persons who have fully read and understand the contents of this user
manual and understand safe operation of the machine.
Ensure that each person who uses the product has read these warnings and instructions and follows
them.
Keep all safety information and instructions for future reference and pass them on to subsequent users
of the product.
The manufacturer is not liable for cases of material damage or personal injury caused by incorrect
handling or non-compliance with the safety instructions. In such cases, the warranty will be voided.
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1.5 Obtaining Documentation and Information
1.5.1 Internet
The latest version of the documentation is available at the following address:
http://www.hybridlightsolutions.com
1.5.2 Ordering Documentation
Documentation, user instructions and technical information can be ordered by calling Hybrid Light
Solutions LLC. at 1-218-568-1188
1.5.3 Other languages
This is the English user manual. Manuals in other languages are available upon request. Not all
languages are covered.
1.5.4 Documentation Feedback
If you are reading Hybrid Light Solutions LLC. product documentation on the internet, any comments can
be submitted on the support website. Comments can also be sent to: [e-mail]
We appreciate your comments.
1.5.5 Support and service
For information about special tools and materials please contact:
Hybrid Light Solutions, LLC.
Address: 4604 Morehouse Drive, Pequot Lakes, MN 56472
Phone: [phone]
Web: www.hybridlightsolutions.com
For other questions, information, technical assistance, ordering user instructions, and service related
information please contact the manufacturer:
Hybrid Light Solutions, LLC.
Address: 4604 Morehouse Drive, Pequot Lakes, MN 56472
Phone: [phone]
Web: www.hybridlightsolutions.com
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2 Description of the product
2.1 Intended Use and Reasonably Foreseeable Misuse
The machine is a mobile, trailer-mounted light tower. The Hybrid Light Solutions Light Tower consists of
a trailer with a diesel generator, a fuel tank, a control panel, and a hydraulic power system with a
telescoping tower with four lights. An hydraulic cylinder raises and lowers the telescoping tower. As
the engine runs, the generator converts mechanical energy into electric power. The LED lights run off this
power.
This machine has been designed and built strictly for the intended use described above. Using the
machine for any other purpose could permanently damage the machine or seriously injure the operator
or other persons in the area. Machine damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
Operating the machine in a manner that is inconsistent with all federal, provincial and local codes and
regulations
Using the machine as a hoist or hanging items from the tower
Operating the machine outside of factory specifications
Operating the machine in a manner inconsistent with all warnings found on the machine and in the
Operator’s Manual
This machine has been designed and built in accordance with the latest safety standards. It has been
engineered to eliminate hazards as far as practicable and to increase operator safety through protective
guards and labeling. However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
Typical hazards related to towing a trailer on roads and highways
Over speed transportation around corners or rough terrain
Heat, noise, exhaust, and carbon monoxide from the engine
Multiple heat sources: lights, engine, hydraulics
Ultraviolet radiation from the lights
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Overhead hazards presented by items on location
Fire hazards from improper refueling techniques
Electric shock and arc flash
Diesel Fuel and its fumes
Glare from lights (lights may blind drivers of nearby motor vehicles if the lights are incorrectly
positioned)
To protect yourself and others, make sure you thoroughly read and understand the safety information
presented in this manual before operating the machine
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2.2 Product Dimensions
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Trailer
Unit
Gross Vehicle Weight (Fueled)
3712 lbs / 1687 kgs
Max Axle Capacity
2272 kg/ 5000 lbs. per axle
Wheels
6 on 6.5
Tires
ST235/80R16
Tire Pressure
60 PSI
Brakes
Electric, Forward Self Adjust
Hubs
6 on 6.5, ⅝” Studs, Grease or Oil
Parameter
Unit
Device name
HLS
Designation
230D
Type
Mobile Tower
Technical life span
5,000 Engine Hours, 2000 charges
Capacity
60 US Gallons / 226.8 Litres
Energy consumption
0.75 GPH / 2.8 LPH
Weight
3712 lbs / 1687 kgs
Battery chemical composition
AGM and Lithium Ion LIPO4
Performance data
11.7 kWh Battery Bank
Fuel Type
No.2 Ultra Low Sulfur Diesel Only
Sound Pressure
68 dBA @ 7m
Gross Engine Power
17.9 kW @ 3000 RPM
Lighting
Unit
Fixture Type
4 x 200W LED
Nominal Voltage
48 VDC
Ballast
Integrated Intro Fixture
Control Strategy
GPS Automatic or Manual Control
IP Class
65
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Housing Material
Aluminum / Plastic
Engine Generator
Unit
Engine Make/Model
Doosan D10
Voltage
48VDC Nominal
Main Circuit Breaker
200 Amps
Prime Power
12.4 kW @ 3000 RPM
Fuel Consumption
0.75 GPH
Oil Capacity
4 litres
Oil Type
15W-40 Diesel Summer, 5W-40 Diesel Winter
Oil Change Interval
250 hours (recommended full synthetic)
Mast
Unit
Max Wind Speed Full Height
104 kph (50 mph)
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2.3 Product elements
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2.4 Understanding the user interface and control panel
The main user interface is within the main control panel door. The control panel consists of a series of
toggle switches and a graphical user interface to provide control of all operating system - and provide the
user with operating parameters.
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2.5 Setup Process
The setup and deployment process involved for the Model 200 Model 200 Tower involves locating the
machine on level, suitable terrain, deploying outriggers, and raising the mast.
Before using the unit, be sure to read and understand all of the instructions. This equipment was
designed for specific applications; DO NOT modify or use this equipment for any application other
than which it was designed for. Equipment operated improperly or by untrained personnel can be
dangerous.
Before starting to visually inspect the Model 200 Light Tower for leaks or damage. A full walk-around
visual inspection of all mast pivot points, hydraulic system, and LED lights and light distribution panel.
Quick Setup Guide:
1. Read and understand ALL safety sections at the beginning of this manual
2. Ensure all maintenance procedures are up to date
3. Ensure the unit is set up on firm and level ground
4. Extend all four outriggers and level the trailer with jacks, ensure outrigger jacks are in firm
contact with the ground, it is not required or recommended to lift the wheels off the ground
5. Ground unit in accordance with local grounding requirements through ground lug connection
6. Direct as required for surveillance area, ensuring to inspect all camera connections, pin
placements, and secondary retention systems (if equipped), it is important to visually inspect
and review all cameras before deployment on location
7. Turn disconnects to the off position (12V and 48V)
8. Aim solar panels to be at the optimal angle toward the sun, in most of the US and Canada, this is
pointing south
9. Inspect all electrical cords; repair or replace any that are cut, worn, or bare.
10. Ensure all mast cables are in good condition and centred on each sheave. Do not use if cables are
kinked or beginning to unravel
11. Ensure battery connections are secure.
12. Remove cameras from the storage container, installed on the mast cross member, ensure to plug
in all connections securely and utilize secondary retention cables in conjunctions with cam lock
system
13. Turn ON battery disconnect switches (12V and 48V)
14. Turn ON System On switch
15. Direct lights to desired location
16. Raise mast using mast up switch
17. Engine will start and charge batteries to full
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WARNING:
It is the operator’s responsibility to ensure that the light tower trailer is properly and safely positioned at
the lighting location.
DANGER:
Check for overhead power lines and obstructions before raising. Raising the light tower without properly
positioning the outriggers and lowering jacks could cause machine rollover resulting in death or serious
injury.
DANGER:
Entering electrical compartment while equipment is in operation can result in death or serious injury.
WARNING:
ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the area.
DANGER MAX WIND SPEEDS:
Never operate the tower in high wind speeds:
80 kph (50 mph) @ Mast @ Max Height
Main Operating Page:
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Status Page:
Active Fault Page:
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Safety Instructions
Read and understand this manual and its safety instructions before using this product. Failure to do so
can result in serious injury or death.
2.6 How to Use the Product Safely
2.6.1 Safety information
●Electrocution Hazard: Always check for overhead power lines and wires before deploying
mast, allow for a minimum of 50 feet of clearance from all overhead power lines
●High voltage is present in the system while on, never attempt to service the electrical system
while the engine is on, or the system is on - qualified technicians only
●Do not operate the light tower if there are signs of wear or damage
●Never permit anyone to operate the machine without proper training
●Never modify equipment without the written consent of Hybrid Light Solutions
●Do not raise, lower, use the mobile tower without deploying all outriggers and jacks, on firm
ground suitable for the weight of the Model 200 tower
●Never transport or move the tower without lower mast to transport position
●Explosion Hazard: Flammable diesel fuel and combustible gases can be present in mobile
tower
●Never charge a frozen 12V or 48V battery
2.6.2 Technical life span
●Diesel Engine: 5,000+ hours
●Frame and Assembly 5+ Years
●Hybrid Light Solutions recommends that our customers implement an annual inspection
process, utilizing proven non destructive testing inspections on critical overhead
components
2.6.3 Personal protective Equipment
●Always wear personal protective equipment, including appropriate head protection,
clothing, gloves, steel toed boots, eye and hearing protection as required by the task at hand
when operating the HLS-200-D
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