Technical Instruction

Doc. No: EPS-TI 014 Issue: 2 Date: 11-06-2009

High Mast Lowering System

Installation, Operation & Maintenance
Thank you for choosing an IngaL EPS High Mast System. Before commencing installation, please read this manual carefully. If youre unsure of any of the information provided, please contact IngaL EPS prior to any work being carried out. Please always print an up-to-date copy at the time of installation. The contents of this procedure are not to be copied, distributed or electronically saved without written permission from IngaL EPS.

Contents
1.0 2.0 Illustration of Major Components Assembly & Installation of High Mast System Installation of Pulley Shelf & Fixture Mounting Ring Installation of Enclosed Pulley Shelf & Lightning Rod Installation of Windlass & Electric Motor Securing the Main Lowering Cable Installation of the alignment System Fixture Mounting Ring Junction Box & Cable Termination Installation of Indicator Discs & Fixtures Installation of Fixture Plug & Electrical Control Panel gearbox Oil Connecting Remote Control Box Levelling the Fixture Mounting Ring Terminating the Lowering Cables Testing Fixture Operation 3.0 4.0 5.0 6.0 7.0 Operation of the High Mast System Completing the Installation Bill of Materials Maintenance Tools List 2 2 2 2 3 3 4 4 5 5 5 6 6 7 7 8 9 9 11 11

IngaL EPS

Technical Instruction

High Mast Lowering System

Page 1

Technical Instruction: High Mast Lowering System

1.0

Illustration of Major Components

Lightning Rod

Enclosed Pulley Shelf Locking Base Locking Pin Indicator Discs Fixture Alignment System Termination of Lowering Cables Main Lowering Cable Pole Electrical Control Panel Windlass Raise & Lower Control Box Electric Motor Remote Control
Illustration 1.

Fixture Mounting Arm Fixture Mounting Ring Removable Support Arm (3 off equi-spaced)

2.0

assembly & Installation of High Mast System

Before installation of the High Mast System, the pole must be assembled in accordance with the relevant assembly instructions. Please refer to EPS-TI007 Column Mast assembly and Installation Technical Instruction, which is available from IngaL EPS. Before commencing assembly of the High Mast System, remove the lid of the crate and referring to the bill of materials, check off each item.

Installation of Pulley Shelf & Fixture Mounting Ring

2.1 Lay the assembled pole with the top of the pole elevated using a truss or frame so the Fixture Mounting Ring can pass over the top of the pole (Illustration 2).
Illustration 2.

Installation of Enclosed Pulley Shelf & Lightning Rod

2.2 Run the Main Lowering Cable through the top of the pole to the base of the pole (you may need to use a rope to pull it through). as a guide, align the transition plate (that joins the Main Lowering Cable to the three smaller lowering cables) near the top of the door inside the pole. This will provide approximately the correct length of cable to maintain during threading through the Enclosed Pulley Shelf. Position the Enclosed Pulley Shelf near the top of the pole, stabilise it in preparation for threading and remove the pulley caps. (Illustration 3)

2.3

Illustration 3.

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

2.4 2.5 2.6 2.7

Feed the stainless steel cables and the power cable through their respective rollers (power cable pulley has the wide plastic rollers) ensuring the cables are not entwined on the inside of the pole. Bolt the Enclosed Pulley Shelf to the top of the pole, ensuring the cables dont become entwined inside the pole and replace the pulley caps. Bolt the Lighting Rod to the top of the system. Finish off by installing the decorative cover plate for the Lightening Rod and ensuring the Lightening Rod is parallel to the pole. (Illustration 4)

Illustration 4.

2.8 2.9

Once the above is complete, temporarily secure the power and lowering cables to the Fixture Mounting Ring to ensure they dont feed back through the rollers when lifting the pole. This has the added benefit of securing the Fixture Mounting Ring during the same process. Lift and install the pole into position and complete the pole installation.

Installation of Windlass & Electric Motor

2.10 Mount and secure the Windlass on the upper mounting plate inside the base of the pole. 2.11 Position the Electric Motor on the lower mounting plate inside the base of the pole and fit the drive belts ensuring the pulleys are aligned. (Illustration 5) 2.12 Position the Electric Motor so that the belts are taut and then secure.

Illustration 5.

Securing the Main Lowering Cable

2.13 Embed the end of the Main Lowering Cable under the cable clamp plate as shown and secure firmly with the hex screw. (Illustration 6) 2.14 Using the crank handle supplied, wind the main lowering cable (in the correct direction) around the Windlass. The lowering cable must be wound on for six full turns. These six turns are to be maintained for the life of the system and never be unwound during normal operation. (Illustration 7)

Illustration 6.

Illustration 7.

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

Installation of the Alignment System

2.15 attach the Removable Support arms and rest the Fixture Mounting Ring on them. 2.16 Pass the lowering cables through the Locking Pin and guide arms all the way through and out the bottom of the shock absorbing spring. (Illustration 8) 2.17 With the three wires pulled through fully, tighten the three screws on each of the large nuts to clamp the lowering cables. (Illustration 9)

Illustration 9. Illustration 8.

2.18 Following this, secure the lowering cables to the cable termination clamps and adjust to make the Fixture Mounting Ring as level as practical. (Illustrations 10 & 11)

Illustration 10.

Illustration 11.

2.19 assemble the remaining components of the guide arms as shown, paying particular attention to where each component is installed. (Illustrations 12,13 &14)

Illustration 12.

Illustration 13.

Illustration 14.

Fixture Mounting Ring Junction Box & Cable Termination

2.20 attach the bracket for the Fixture Mounting Ring junction box to the fixture mounting ring and feed the power cable through the junction box bracket that is mounted on the Fixture Mounting Ring and tighten the cable clamp. (Illustration 15) 2.21 Mount the junction box onto the junction box bracket. (Illustration 16) 2.22 Feed the power cable through the back of the junction box and terminate to the terminal strip enclosed.
Illustration 15. Illustration 16.

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

Installation of Indicator Discs & Fixtures

2.23 attach the three sets of indicator discs to the Locking Pins. (Illustration 17) 2.24 attach Fixture Mounting arms to the Fixture Mounting Ring ensuring they are equally spaced around the ring to evenly distribute the weight on the system. (Illustrations 17 & 18) 2.25 Connect all fixtures to the Fixture Mounting arms then run and terminate the cables from the fixtures to the Fixture Mounting Ring junction box. This should be carried out by a certified electrician. 2.26 Terminations to the junction box are now complete and the junction box cover should be secured.

Illustration 17.

Illustration 18.

Installation of Fixture Plug & Electrical Control Panel

2.27 Connect the plug supplied to the power cable inside the pole. This should be carried out by a certified electrician (Illustration 19). The plug should hang with enough clearance from the windlass. This is the height at which it will remain during normal operation. 2.28 Secure the Electrical Control Panel to the inside of the pole door. (Illustration 20) 2.29 Terminate the supply cable to the main terminal strip. This should be carried out by a certified electrician.

Illustration 19.

Illustration 20 (wiring shown for illustration purposes only).

Gearbox Oil
2.30 Remove the top plug of the gearbox and add the machine oil provided.

Illustration 21.

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Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

Connecting Remote Control Box

2.31 Make connections as per the illustration below. (Illustration 22) 2.32 Test the switches to ensure all is in working order.The switch should be operated enough to ensure the direction of the rotation of the Windlass is still correct.

Illustration 22.

Levelling the Fixture Mounting Ring

2.33 attach the wooden levelling plates on to the lowering cables so they hold but are not too tight. You should be able to slide them up and down by hand. (Illustration 23) 2.34 Operating the system electrically, raise the Fixture Mounting Ring until the all three levelling plates rise are butted up against the Locking Base.

Illustration 23.

2.35 Lower the Fixture Mounting Ring, measure the distance of the three levelling plates to the top of Locking Pin. If the distance is the same, the ring is level, otherwise adjust the corresponding levelling nuts until the distance measured on all three is the same (Three levelling plates should be within 5mm of each other). Only use the levelling nuts if the adjustment required is small (25mm or less). If it is greater than this distance then the relevant cable termination clamp needs to be loosened to make the adjustment and then resecured. (Illustration 24 & 25) Repeat this process until the difference between the three levelling plates are no more then 5mm. NB: Repeating this procedure several times also has the added benefit of stretching out the lowering cables so no creep is expected in the future.

Illustration 24.

Illustration 25.

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

2.36 Once the Fixture Mounting Ring is level, remove the pin on the compressed spring. (Illustration 26)

Illustration 26.

Terminating the Lowering Cables

2.37 Install the belaying box for the lowering cables. Wind excess lowering cable within the belaying box as shown. (Illustration 27) 2.38 attach the second half of the cover for the belaying box using five screws as shown. Make sure to include the two screws that secure the belaying box to the cable termination clamp. (Illustration 28)

Illustration 27.

Illustration 28.

Testing Fixture Operation

2.39 To test the fixtures for correct operation, set up the testing cable as shown. (Illustration 29) 2.40 Having finished the assembly and installation procedure fully to this point, you can now perform the raising and lowering operation of the system.

Illustration 29.

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Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

3.0
3.1

Operation of the High Mast System

Connect the Raise & Lower Control Box to the Electrical Control Panel and Electric Motor. (Illustration 30)

Illustration 30.

3.2 3.3

Take the Remote Control to a position more than 5 metres away from the pole. Press the up button on the Remote Control and hold until the unit reaches the top of its travel. Press the up button in short bursts until the Indicator Discs rotate to a 45angle and do not rotate any further. allow the head frame to travel up until the springs compresses and the noise of clutch slipping can be heard. The indicator disks should rotate to be parallel to the lowering headframe. This shows that the Locking Pins are in the correct position for lowering onto their respective hooks. now press the down button until all three sets of Indicator Discs show that the Locking Pins are in the home position in the Locking Base. Confirmation that the locking pins are in the locked position can be made by the slackness of the main lowering cable at the base of the pole. (Illustrations 31 & 32)

3.4

Illustration 31.

Illustration 32.

3.5 3.6 3.7 3.8

To bring the system down for fixture maintenance, first install the Removable Support arms. Press the Up button until the springs compress and the noise of clutch slipping can be heard. The indicator Discs will rotate to a 45 angle and should not rotate any further. This shows that the Locking Pins are disengaged from their hooks and the unit is ready to be lowered. now press the down button until the unit is resting on the Removable Support arms. Carry out fixture maintenance and repeat the ascending process as above.

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

4.0
4.1 4.2 4.3

Completing the Installation

as a final check that the unit is in the home position, check that the Main Lowering Cable is slack as it should have no load on it. Connect the socket from the Electrical Control Box to the plug inside the pole base as this provides the power for the fixtures. (Illustration 33) Close the pole door and secure.

Illustration 33.

5.0

Bill of Materials
Qty 1 1 2 1 1 1 1 1 1 1 1 1 1 1 3 1 3 2 1 3 1 2 10mm (6 x 37) 6mm (6 x 19) 4 core & earth * * * * * *10mm Hot dip galvanised Hot dip galvanised Stainless steel Stainless steel Cold galvanised Stainless steel Stainless steel 1.5m Includes gearbox, clutch & pulley Stainless steel Description 920mm 920mm Yellow Yellow Yellow 70mm x 30mm x 3mm 380V 910rpm 70mm 42mm x 25mm x 58mm Cold galvanised Cold galvanised Material Hot dip galvanised Hot dip galvanised Hot dip galvanised Hot dip galvanised Hot dip galvanised

Part Name Enclosed pulley shelf Fixture mounting ring alignment system brackets Junction box bracket Junction box cable clamp Electric motor Pulley Crank handle insert Four pin plug Electric motor power cable Windlass Junction box Machine oil Main lowering cable Lowering cables Power cable Lowering cable clamps Plastic bush Termination plate Cable termination wedge Main lowering cable yoke Main lowering cable clamp

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

Part Name Main lowering cable clamp Button head bolts Electrical control panel Clamping bar Lowering cable termination system sheath Lowering cable termination system wedge Lowering cable termination system belaying box Lowering cable termination system clamp Indicator discs Drive belts Lightning rod decorative cover plate Compression spring Screws Connecting nut guide arm Connecting bar Connecting rod guide arm spring alignment system connecting pin alignment system split pin alignment system bush Windlass mounting bolt Electric motor mounting bolt 9mm square washer Electrical control panel mounting nut Electrical control panel cable clamp bolt Lightning rod mounting bolt Enclosed pulley shelf mounting bolt 21mm square washer Indicator disc mounting bolt Lightning rod decorative cover plate mounting bolt Insulation tape Removable support arm Crank handle Raise & lower control box Fixture testing lead Wooden levelling blocks
* ** *** are individual subcomponents that come preassembled.

Qty 1 7 1 1 3 3 3 3 3 2 1 3 9 3 3 3 2 2 6 6 2 4 4 4 4 1 3 6 6 6 3 1 3 1 1 1 6

Description *12mm *M6 x 25mm 500mm x 220mm x 130mm 180mm x 25mm x 1mm

Material Stainless steel Stainless steel Cold galvanised Stainless steel Hot dip galvanised Hot dip galvanised Stainless steel

6mm Reflective red

Hot dip galvanised Stainless steel

208mm ** **M6 x 12mm **M32 Includes plastic roller 30mm x 6mm x 827mm ***20mm x 590mm ***28mm x 657mm 12mm x 62mm 3.2mm x 20mm 20mm M16 x 40mm 60mm M8 x 45mm 40mm x 40mm x 3mm M8 M6 x 30mm M10 x 30mm M20 x 70mm 40mm x 40mm x 3mm M5 x 8mm M8 x 25mm Roll

aluminum Hot dip galvanised Stainless steel Stainless steel Hot dip galvanised Hot dip galvanised Hot dip galvanised Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Cold galvanised Stainless steel Stainless steel

Hot dip galvanised Cold galvanised Cold galvanised Four pin to five pin Includes bolts & wing nuts

IngaL EPS

Technical Instruction

High Mast Lowering System

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Technical Instruction: High Mast Lowering System

6.0

Maintenance

IngaL EPS recommend the following maintenance routine to ensure regular checking of the operating HMS. This routine may vary for individual organisations if they see fit to reduce or increase the frequency of the following procedure. 6.1 Pole Maintenance a. 6.2 Visual inspection of the pole may be carried out to check for any signs of corrosion or structural damage. For a more in depth look at steel pole inspection, please refer to the Steel Pole Inspection Procedure, which is available from IngaL EPS. The manufacturer of the IngaL EPS High Mast System recommends that the headframe is lowered every 12 months using the following procedure. Please note that the first two years after the installation, maintenance is not required. That is, regular maintenance should start on the third year after initial installation. Disconnect the headframe from the main power so the lights are not operating. Connect the manual control system to main power and the motor. The headframe is now ready to be lowered. as per the instruction manual, lower the headframe checking to ensure the windlass, motor, bolts and lowering cables are all in working order. Lower the headframe to the designated level on the Removable Support arms. Connect the light testing lead to ensure all fixtures are in working order. It is also recommended that the machine oil in the gearbox is changed every two years.

High Mast Lowering System a. b. c. d. e. f. g. h.

7.0

Tools List
1. 2. 3. 4. 5. 6. 7. 8. 9. Crimping tool (4mm+) Screw driver set (Phillips Head) allen Key (5mm) Stanley Knife Shifting spanners x 2 Five pin power plug with 4mm cable ( for main power plug) Pliers Tape Measure Spirit Level

This is a recommended list of tools required during assembly and installation.

For more information please contact INGAL EPS: Tel 1800 623 302 | Email sales@ingaleps.com.au or visit www.ingaleps.com.au

Disclaimer

The instructions included in this document have been written to provide guidance only for the assembly of the equipment therein described. Industrial galvanizers Corporation Pty Ltd is not liable for any direct, indirect or consequential loss or damage to property or personal injury that may arise in tort, equity or otherwise at law as a result of following these instructions. | Copyright 2011 Industrial galvanizers Corporation Pty Ltd, trading as IngaL EPS.