Operation and Maintenance

Manual

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Operating Instruction for High Masts:

- High Masts are provided for illumination of large areas. High mast lights operate automatically after the
installation as per the set timing in the control panels Although the equipment is generally maintenance free a
few simple instructions followed will ensure safe operation of the system for a long time.
-
- The equipment needs to be operated only for change of electrical components for maintenance purpose.
Following below simple steps will ensure smooth operations.
-

Lowering LANTERN CARRIAGE (LC)

- Disconnect power supply to the lighting circuit.

- Place the resting brackets in the slots provided(these are at about 1.5 m above mast base)
- Check oil level in the winch.
- Disengage the electrical trailing cable by disconnecting the cable at the terminal block.
- Lower the first 0.3m with manual handle.
- Press the push button on High Masts control panel ‘REVERSE’. This operates the power-tool for lowering of
the lantern carriage. The power-tool then operates the winch which through a chain and sprocket mechanism
- Check that direction of wire ropes movement is correct. The wire ropes inside the mast should be moving in
the upward direction. Outside the mast, lantern carriage (LC) should be coming down.
- Operate the power tool by holding the ‘REVERSE’ button till the LC comes to a distance of about 0.75 m
above the resting bracket.
- Ensure to see that when the LC seats on the resting brackets, the CG boxes, wires and JB don’t directly hit
the resting brackets when further lowered. If such a situation is happening just turn the resting brackets/LC
slightly to avoid resting of wires, JB and CG box on the resting brackets.
(take care that after LC has rested on resting bracket no further lowering should not be done. The wire ropes
should be ‘just tight’. If wire ropes get loose then the lay on drums get disturbed and further resetting of wire
ropes needs to be done.)

Precautions for Lowering of lantern Carriage

• Check oil level in the winch oil compartment. Top up if required before operating winch. (In no case the
winch should be operated without oil). See the wear and tear of the winch gear.
• In case of abnormality please report.
• Disengage the electrical trailing cable by disconnecting it from the terminal block at the mast base; Fix
lantern carriage resting pads on the mast (pockets for the same are provided on the mast body)
• Align the power tool properly with the operating shaft.

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 • Ensure that wires do not come between the lantern carriage and its resting pads.
• Never stand directly below the lantern carriage, stand at least 3 meters away from the mast in operation.
• Lowering should be done to the extent that the LC just sits on resting pads, further loosing of wier ropes
by operating power tool will disturb lay of wire ropes on winch and then wire ropes resetting would be
required.
• Check the winch for abnormal heating. In case abnormality is found, then by using manual handle the
mechanism has to be checked for any jam or ‘stuck up’

Testing of Luminaires at lowered position of Lantern Ring

- Disconnect trailing cable at the incoming terminals of Junction box (on the LC).
- Check the terminals in the junction box and in the CG boxes. In case of any abnormality clean/replace them
- Connect a temporary cable of 4 sq mm copper at the incoming side of the terminal block in the JB. The other
end of the temporary cable is to be connected to the terminal block inside the mast from where trailing cable
has been disconnected.
- Switch on the power supply and check for luminaires glowing.
- Note down the luminaire no. and lamp no. that are not glowing.
- Analyze and fix the lamp/luminaire by necessary replacement of ballasts/ ignitor or lamp. These analysis and
fixing needs to be done by a trained electrician.
- After all luminaires are tested, repaired and are now glowing the LC can be taken up.
- Disconnect temporary power supply cable at the JB and reconnect the trailing cable.
- For the installation in flameproof area, check only the continuity of the circuit.
- Testing of luminaires, control gearboxes are to be done in the workshop for flame proof area.

RAISING LANTERN CARRIAGE

- After testing and repair of the luminaires is completed now the lantern carriage has to be taken up.
- Slowly inch the power tool by pressing ‘FORWARD’ push button. Check direction of movement of wire ropes.
Wire ropes inside the mast should move in downward down. If not report to electrician and get the fault fixed.
- While raising the LC at the start ensure that wires or cables are not getting stuck in the resting brackets as
the lantern carriage is moving up.
- Observe the laying of wire ropes on the winch drum, they should be getting laid orderly.
- Once the LC has almost reached the top (about 0.5 metre) stop operation of power-tool. Dock the LC by using
manual handle.
- Remove handle.
- Connect the trailing cable into the terminal blocks.
- Switch on the power supply.

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Precautions for Raising of lantern carriage

• Check oil level in the winch, top up if required. Use same grade oil, preferably same brand every time.
• Check for tools or any foreign parts on the lantern carriage / luminaires and remove them.
• Watch the winch gear for any uneven wear and tear in the worm gear. In case of any abnormality it is to be
reported.
• Raise the lantern carriage for the last 0.5 metre by manual handle.
• Proper docking of the lantern carriage is very important for two reasons- (1) by proper docking of the lantern
carriage we prevent the ropes and winch from impact loading. (2) The LC will not swing.
• Dock the lantern carriage properly and check tension on the individual wire ropes by hand. If required align by
lowering the LC and adjusting wire rope on drums of winch.
• Keep a check on the trailing cable while raising the lantern carriage, Cable will come through the door at least
1metre before the lantern carriage reaches the docking arm.
• Keep a watch on the power-tool motor for any abnormal heating. In case of any abnormality manual handle
has to be used and reason for jam to be found and fixed.

High Mast Control Panel:

The High Mast Control panel is provided for auto ON and OFF the luminaires at the times set. The ON and OFF
times can be set by operating the dual dial timer provided. Also there is a provision given with a toggle switch by which
the luminaires can be switched ON and OFF.

The control panel contains 2 nos. 9A contactors for operation of the power-tool for raising and lowering of mast lantern
carriage. Operating the push Button FORWARD takes the LC up and operating the push button REVERSE takes the
LC down

Precaution: Before operation of the power-tool the trailing cable terminations should be disconnected at the
mast bottom by a trained electrician.

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MAINTENANCE OF HIGH MASTS

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The High Masts are designed to give a long trouble-free service, requiring minimum maintenance. However, it is
important that regular inspection and maintenance is carried out at your end to ensure continued efficient working of
all components. We recommend that this work he carried out to a prescribed schedule of operations (half yearly).

MAINTENANCE SCHEDULE – ROUTINE

1 Winch
(a) Remove any dirt or foreign matter that may have accumulated on top of the winch or on wire ropes. And clean
thoroughly.

(b) Check oil bath level (check each time the winch is used).

(c) Check proper fastening of bolts at the end of the first year of operation.

(d)Check the condition of the gear teeth when the LC is in lowered position

(e) Open the terminal box of motor and check motor connections. Check whether mounting the motor is firm. Check
alignment of winch with motor.

2 Wire Rope

(a) Inspect, rope. lay on winch, and section [trope visible at mast door opening for kinks, or corrosion.
(b) Inspect anchorage point of winch rope at compensating disc.
(c) Inspect winch rope throughout its length frays for any damage
(d) Inspect rope anchorage points on winch and lantern carriage. Check Thimble and D clamps tightness
(e) From the base of the mast observe ropes lantern carriage in lowered position to mast for any obvious defects.

A3 Lantern Carriage

(a) Inspect general condition and welded /bolted joints. Tighten all bolts, it necessary, Inspect PVC Buffer
arrangement for damage
(b) Inspect interconnecting cables and junction boxes for damage.
(c) Check electric supply cable anchorage, check for physical damage to cable. Additional length of cable is provided
in the compartment. If damaged, adjust the length from the extra length provided in the base compartment.
(Instruction with procedure is given separately).
(d) Check entries of junction box, CG boxes and luminaires and seal, if required.

4 Luminaires

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(a) Clean all luminaires, and boxes.
(b) Remove lamps from holders and check contact for arcing.
(c) Inspect all electrical connections, and tighten, Where necessary. Avoid use of abrasive materials
for cleaning.

6 General

(a) With luminaires returned to mast head, check whether all lamps glow.
(b) Check foundation bolts and tighten nuts.
(c) Check earthing and lightening protection connections in base compartment and earth resistance of earth station.
(d) Lubricate the locks of mast door.
(e) Ensure all CG boxes and luminaires covered are properly fixed.

7 High Mast Control Panel

(a) Clean the panel internal with blower once in 3 months

(b) Observe the various components for any abnormal colour change or signs of overheating. In case of
abnormality analyze and take corrective action
(c) Check the terminations for abnormality and tightness.

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