1. Manuals
  2. Brands
  3. Will Burt Manuals
  4. Desktop
  5. Stiletto AL 4-Meter
  6. Operating instructions manual

Will Burt Stiletto AL 4-Meter Operating Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
S
TILETTO
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, U.S.A.
AL O
PERATING
(6-Meter Stiletto AL P/N: 711990692 Shown)
Phone: +1 330 682 7015
E-Mail:
contact_us@willburt.com
Website:
www.willburt.com
Authorized Representative:
GEROH GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany
I
NSTRUCTIONS
TP-5418901-F, August 2020
© 2020 The Will-Burt Company
Original Instructions

Advertisement

Table of Contents
loading

Summary of Contents for Will Burt Stiletto AL 4-Meter

  • Page 1 AL O TILETTO PERATING NSTRUCTIONS (6-Meter Stiletto AL P/N: 711990692 Shown) The Will-Burt Company Phone: +1 330 682 7015 TP-5418901-F, August 2020 401 Collins Blvd E-Mail: contact_us@willburt.com © 2020 The Will-Burt Company Orrville, OH 44667, U.S.A. Website: www.willburt.com Original Instructions Authorized Representative: GEROH GmbH &...
  • Page 3 AL O TILETTO PERATING NSTRUCTIONS Warranty ® Will-Burt warrants its Stiletto AL masts to be free from defects in material and workmanship for a period of two (2) years, with such time period running from the date of shipment by Will-Burt. Will-Burt shall not be responsible for any damage resulting to or caused by its products by reason of failure to properly install, maintain or store the product;...
  • Page 4 AL O TILETTO PERATING NSTRUCTIONS Document History Document Numbers Dates Remarks TP-5418901-00 August 23, 2017 Initial Release TP-5418901-A May 24, 2018 Updated to reference the Roof Seal Kit (Sections 1.6.4.3 and 2.6). Updated Extension Nut cycles to 5,000. TP-5418901-B August 2, 2018 Updated Section 1.6.4.2 and the D-TEC references throughout.

  • Page 5: Table Of Contents

    AL O TILETTO PERATING NSTRUCTIONS Table of Contents Safety Summary ........................vii Signal Word Definitions ..........................vii General Safety Instructions ........................vii Symbols ..............................xii Section 1 Introduction & Intended Use ................1-1 1.1 Specification Compliance ......................... 1-2 1.2 Safety Precaution Notification ......................1-3 1.3 Manual Organization ........................
  • Page 6 AL O TILETTO PERATING NSTRUCTIONS 2.4.1 Mast Installation Dimensions ....................2-6 2.4.2 Support Bracket Assembly Dimensions ..................2-8 2.4.3 Universal Control Box Dimensions ................... 2-9 2.4.4 EMI Filter Dimensions (optional equipment) ................2-11 2.5 Power Supply Requirements ......................2-11 2.6 Mast System Installation ........................ 2-12 2.6.1 Installation Quick Summary ....................
  • Page 7 AL O TILETTO PERATING NSTRUCTIONS Section 5 Maintenance ......................5-1 5.1 Pre-Maintenance Check ........................5-1 5.2 Maintenance Equipment ........................5-3 5.3 Spare Parts ............................5-3 5.4 Preventative Maintenance Checks and Services (PMCS) ............... 5-3 5.4.1 Schedule ........................... 5-4 5.4.2 Lubricate the Drive Screw ......................5-6 5.4.3 Special Instructions ........................
  • Page 8 AL O TILETTO PERATING NSTRUCTIONS Figure 1-19 D-TEC (P/N: 5354901 Shown) .................... 1-28 Figure 2-1 Mast Installation Dimensions (Not to Scale) ................2-7 Figure 2-2 Support Bracket Assembly Bolt Hole Pattern ................2-8 Figure 2-3 Universal Control Box Installation Dimensions (Measurements in Inches) ......2-10 Figure 2-4 Drain Hole Location .......................

  • Page 9: Safety Summary

    AL O TILETTO PERATING NSTRUCTIONS Safety Summary This section describes safety precautions for the Stiletto AL. These are recommended precautions that personnel must understand and apply throughout many phases of installation, operation, transportation, maintenance, storage, and troubleshooting. Be sure the read and understand the entire manual, and contact The Will-Burt Company with any questions, before performing any procedure outlined in this manual.
  • Page 10 AL O TILETTO PERATING NSTRUCTIONS Relocating the system during operation or after mast is extended could result in death or serious injury. Contact Will-Burt Engineering for special on-the-move situations for military only use. Safety Instruction – Read Manual! Failure to follow operating instructions could result in death or serious injury.
  • Page 11 AL O TILETTO PERATING NSTRUCTIONS Fire Hazard! Cleaning solvent, used for maintenance, is flammable and can be explosive resulting in death or serious injury. Do not smoke. Use cleaning solvent in a well-ventilated area. Keep cleaning solvent away from ignition sources. Always store cleaning solvent in the proper marked container.
  • Page 12 AL O TILETTO PERATING NSTRUCTIONS Safety Instruction – Observe Proper Lifting Procedures! Use extreme caution while lifting the Mast System and when Mast System is suspended to avoid injury and equipment damage. Be certain the Mast System is properly secured. All operators should be aware of and follow the applicable local, regional, and national standards and codes of practice for slinging and transporting equipment.
  • Page 13 AL O TILETTO PERATING NSTRUCTIONS Safety Instruction – Roof Access! If mast will be mounted to a vehicle, the operator must provide safe means to access the roof of the vehicle during installation and maintenance. Safety Instruction – Mast Access! The operator must provide safe means to access the top of the mast during installation and removal of the payload.

  • Page 14: Symbols

    AL O TILETTO PERATING NSTRUCTIONS Symbols The following are symbols that are used with the system and their meaning. Contact The Will- Burt Company with any questions before performing any procedure outlined in this manual. This symbol indicates an electrocution hazard or hazardous voltage hazard. There is DC voltage present inside the mast and control box.

  • Page 15: Section 1 Introduction & Intended Use

    AL O TILETTO PERATING NSTRUCTIONS Section 1 Introduction & Intended Use Review this manual in its entirety. Contact The Will-Burt Company with any questions before performing any procedure outlined in this manual. The views depicted in this manual are provided for clarification and are subject to change without notice. Views are not to scale. This manual describes installation, operation, transportation, maintenance, storage, and troubleshooting procedures for the Stiletto AL Mast System.

  • Page 16: Specification Compliance

    AL O TILETTO PERATING NSTRUCTIONS 1.1 Specification Compliance Original Instructions TP-5418901-F August 2020...

  • Page 17: Safety Precaution Notification

    AL O TILETTO PERATING NSTRUCTIONS 1.2 Safety Precaution Notification Refer to the Safety Summary for precautions to be observed while installing, operating, or maintaining this equipment. 1.3 Manual Organization This manual is organized into the following sections: Section 1 Introduction Section 2 Installation Section 3 Operation Section 4 Transportation...

  • Page 18: Specifications

    AL O TILETTO PERATING NSTRUCTIONS 1.5 Specifications This section describes specifications for the Mast System. The specifications listed in this section are for catalog masts only. Masts with other heights, capacities, and finishes are available. For more information on additional mast sizes, capabilities, and finishes, see www.willburt.com.
  • Page 19 AL O TILETTO PERATING NSTRUCTIONS Table 1-2 Stiletto AL Mast System Specifications Continued Specifications* 4-Meter 6-Meter 8.54-Meter 10-Meter 15-Meter 311 x 203 mm Universal Control Box Footprint 12.23 x 8.0 inches Mast Type Electro-Mechanical Drive System SSTL Drive Screw Emergency Operation Manual Hand-Crank Collar Type Auto Self-Locking with Integrated Icebreakers...
  • Page 20 AL O TILETTO PERATING NSTRUCTIONS Table 1-2 Stiletto AL Mast System Specifications Continued Specifications* 4-Meter 6-Meter 8.54-Meter 10-Meter 15-Meter Extension and Retraction Performance (See Note Below) Approximate Extension < 35 < 60 < 85 < 100 < 150 Time seconds seconds seconds seconds...

  • Page 21: Finishes

    AL O TILETTO PERATING NSTRUCTIONS 1.6 Finishes The Will-Burt Company offers a variety of finishes designed to prolong the life of the mast and reduce maintenance. The Drive Assembly Cover and the Base Tube will be painted the appropriate colors. Typically, the top and intermediate tubes will not be painted but will have an anodized finish, however paint finishes for these tubes are available.

  • Page 22: Major Components

    AL O TILETTO PERATING NSTRUCTIONS 1.7 Major Components This section describes major components of a Mast System assuming the use of standard catalog Mast Systems. Characteristics of components customized to meet customer-specific needs may vary. If necessary, contact The Will-Burt Company for additional details. Major components of the Mast System include: •...

  • Page 23: Figure 1-1 Mast (6-Meter Stiletto Al P/N: 711990692 Shown)

    AL O TILETTO PERATING NSTRUCTIONS 1.7.1 Telescoping Mast The telescoping mast (Figure 1-1): • Is the structure used to raise the payload to an operational height • Consists of concentric, nesting mast tubes • Extends and retracts electro-mechanically • Is self-locking •...

  • Page 24: Figure 1-2 Drain Hole (Base Of 6-Meter Stiletto Al P/N: 711990692 Shown)

    AL O TILETTO PERATING NSTRUCTIONS Support Bracket Assembly Base Tube 600 Watt 28 VDC Motor Drain Hole Figure 1-2 Drain Hole (Base of 6-Meter Stiletto AL P/N: 711990692 Shown) The mast includes: • Collars (Section 1.7.1.1) • Top Tube Ring (Section 1.7.1.2) •...

  • Page 25: Collars

    AL O TILETTO PERATING NSTRUCTIONS Collars Collars are fitted to the top end of each tube except the Top Tube which has a Top Tube Ring (Section 1.7.1.2). The collars have: • Automatic locks • Integrated dirt/dust wipers and icebreakers. The taper on the collars also reduces the pinch points.

  • Page 26: Figure 1-4 Top Tube Ring (Top Tube Ring For 6-Meter Stiletto Al P/N: 711990692 Shown)

    AL O TILETTO PERATING NSTRUCTIONS 8.2mm Through Holes with 15.5mm Ø Counterbore Note: Diameters will vary per model top tube size. Figure 1-4 Top Tube Ring (Top Tube Ring for 6-Meter Stiletto AL P/N: 711990692 Shown) 1-12 Original Instructions TP-5418901-F August 2020...

  • Page 27: Drive Assembly

    AL O TILETTO PERATING NSTRUCTIONS Drive Assembly The Drive Assembly (Figure 1-5) extends and retracts the mast tubes. Drive Screw 600 Watt 600 Watt 28 VDC Motor 28 VDC Motor Mast Drive Housing Drive Assembly Location Drive Assembly (Mast Tubes Removed) Figure 1-5 Drive Assembly (Not to Scale) The Drive Assembly includes: •...
  • Page 28 AL O TILETTO PERATING NSTRUCTIONS Motor The Motor is used, in powered operation, to rotate the Drive Screw. When power is removed from the Motor, the spring-loaded brake is applied. The brake is always on when power is removed from the system in order to prevent the mast from back driving. Mast Drive Housing The Mast Drive Housing: •...

  • Page 29: Support Bracket Assembly

    AL O TILETTO PERATING NSTRUCTIONS Support Bracket Assembly The Support Bracket Assembly (Figure 1-6) secures the mast to the support structure. Along with the mounting holes in the base of the mast, it is an essential part of mounting the Mast System.

  • Page 30: Fully Extended Limit Switch (P/N: 913217)

    AL O TILETTO PERATING NSTRUCTIONS Fully Extended Limit Switch (P/N: 913217) The Fully Extended Limit Switch is used to detect when the mast is fully extended (Figure 1-7). Fully Extended Limit Switch Figure 1-7 Fully Extended Limit Switch Motor and Brake Cable (P/N: 5433101 for 3M Cable) The Motor and Brake Cable (Figure 1-8): •...

  • Page 31: Mast Sensor Cable (P/N: 5433201 For 3M Cable)

    AL O TILETTO PERATING NSTRUCTIONS Mast Sensor Cable (P/N: 5433201 for 3M Cable) The Mast Sensor Cable (Figure 1-9): • Transfers signals to the mast • Is ten feet (three meters) long as standard (other lengths available) • Connectors and cables are environmentally sealed to prevent dust, sand, or moisture intrusion •...

  • Page 32: Emi Filter (Optional Equipment)

    AL O TILETTO PERATING NSTRUCTIONS EMI Filter (optional equipment) The EMI Filter (Figure 1-11): • Is required for Military EMC/EMI compliance. (not required for CE compliance) • Is ordered separately from the mast assembly. • Includes a shielded cable (multiple lengths available) to the Control Box J1 connector. •...

  • Page 33: Identification Plate (P/N: 451830Xx)

    AL O TILETTO PERATING NSTRUCTIONS Identification Plate (P/N: 451830xx) Information pertaining to the mast can be found on the Identification Plates (Figure 1-13): • On the Mast Drive Housing (P/N: 4518302) • On the side of the Universal Control Box (P/N: 4518301) The information on the Identification Plates is the same.

  • Page 34: Grease Gun (P/N: 4288501)

    AL O TILETTO PERATING NSTRUCTIONS Grease Gun (P/N: 4288501) The Grease Gun is used to lubricate the Drive Screw with a super-premium aerospace lubricant which is available from The Will-Burt Company in three fluid ounce cartridges (P/N: 4288601). Figure 1-15 Grease Gun Label Kit (English) (P/N: 5428301) The Label Kit is used to identify potential hazards and connection points within the Mast System.

  • Page 35: Universal Control Box (P/N: 4453901)

    AL O TILETTO PERATING NSTRUCTIONS 1.7.2 Universal Control Box (P/N: 4453901) This section describes the standard Universal Control Box. Additional options are available. Contact The Will-Burt Company for additional information. Stiletto AL masts are designed to work with Control boxes operating version 3.0 or later software.

  • Page 36: Display

    AL O TILETTO PERATING NSTRUCTIONS The Universal Control Box works with input from the: • “Nested Limit Switch” which: o Prevents the mast from being over-nested o Installed in the mast o An electronic switch triggered by a probe attached to the bottom of the center tube •...
  • Page 37 AL O TILETTO PERATING NSTRUCTIONS Display The Universal Control Box has an eight-digit, infrared secure, green LED alphanumeric display. The Display shows the: • Mast Status and software version • Cycle Count of the Mast • Error Codes Mast Status Masts Status is shown as: •...

  • Page 38: Up/Down Switch

    AL O TILETTO PERATING NSTRUCTIONS In order to output the most accurate intermediate extension height, the mast should: 1. Be returned to the fully nested position where the intermediate extension height automatically returns to zero. 2. Then be taken to the height required with little or no additional up and down movement as this additional movement can add inaccuracies within the intermediate extension height output.

  • Page 39: Bulkhead Connectors

    AL O TILETTO PERATING NSTRUCTIONS Bulkhead Connectors The Universal Control Box contains the following military screw-type connectors: • J1 which is a 9-pin connector for customer power and handshake lines • J2 which is a 24-pin connector for sensor interface •...

  • Page 40: Pc Interface

    AL O TILETTO PERATING NSTRUCTIONS 1.7.3 PC Interface The Mast System ships standard with SCRAM (Stiletto Control Remote Access Management) software enabled. If desired, this allows the operator to control the Mast System through a PC or proprietary control system. SCRAM provides the same functionality as the Universal Control Box, plus additional functions and information not directly accessible through the standard hardware interface.

  • Page 41: Accessory Options (Sold Separately)

    AL O TILETTO PERATING NSTRUCTIONS 1.7.4 Accessory Options (Sold Separately) This section describes accessory options available for the Mast System as follows: • Hand-Held Remote Control (Section 1.7.4.1) • ® D-TEC (Section 1.7.4.2) • Additional Accessory Options (Section 1.7.4.3) Hand-Held Remote Control The optional Hand-Held Remote Control (HHRC): •...

  • Page 42: Figure 1-19 D-Tec (P/N: 5354901 Shown)

    AL O TILETTO PERATING NSTRUCTIONS The optional HHRC comes in multiple configurations including: • Black HHRC with 20 ft. Cable (P/N: 912202) • White HHRC with 20 ft. Cable (P/N: 912254) • Black HHRC with 50 ft. Cable (P/N: 4214201) •...

  • Page 43: Table 1-3 D-Tec Specifications

    AL O TILETTO PERATING NSTRUCTIONS The D-TEC Features: • Two detection modes that operate simultaneously: o Electric Field (E-Field) detection to sense the presence of nearby high voltage o Magnetic Field (H-Field) detection to sense the presence of nearby high current •...

  • Page 44: Additional Accessory Options

    AL O TILETTO PERATING NSTRUCTIONS Additional Accessory Options Table 1-4 describes a number of additional accessory options available for the Mast System. Table 1-4 Additional Accessory Options Accessory Description Lift Brackets (P/N: 4674902) Used to aid in lifting and transporting the mast vertically during installation.
  • Page 45 AL O TILETTO PERATING NSTRUCTIONS Table 1-5 Additional Accessory Options Continued Accessory Description Power Supply Kits 110 VAC Power Supply Kit Converts 110 VAC input to 24 VDC output. (P/N: 4655201) 220 VAC Power Supply Kit Converts 220 VAC input to 24 VDC output. (P/N: 4655202) Stiletto Capacitor Bank Kits Used when the customer power supply is not strong...
  • Page 46 AL O TILETTO PERATING NSTRUCTIONS 1-32 Original Instructions TP-5418901-F August 2020...

  • Page 47: Section 2 Installation

    AL O TILETTO PERATING NSTRUCTIONS Section 2 Installation This section describes the installation of the Mast System and provides general procedures that must be followed to ensure a successful installation. Use care to understand and follow all precautions while installing. 2.1 Pre-Installation Check Before installing the system, ensure: •...
  • Page 48 AL O TILETTO PERATING NSTRUCTIONS Mounting Structure Hazard! Before installation, ensure the mounting structure is capable of resisting forces generated from all loading and environmental conditions, including, but not limited to, Mast System size and weight, payload size and weight, vehicle dynamic loads, sail size, wind speed, support bracket or roof line location and base plate assembly.

  • Page 49: Installation Equipment

    AL O TILETTO PERATING NSTRUCTIONS 2.2 Installation Equipment Table 2-1 lists equipment recommended for installation. Table 2-1 Equipment Recommended for Installation Recommended Equipment* Personal Protective Safety Glasses Work Gloves Nitrile or Vinyl Gloves Hearing Protection Hard Hat or Helmet Safety Shoes Hand Tools Appropriate Hardware Drill...

  • Page 50: Installation Hardware

    AL O TILETTO PERATING NSTRUCTIONS 2.3 Installation Hardware Table 2-2 describes hardware that may be used during installation. Depending on the specific installation application, all hardware may not be used. Table 2-2 Installation Hardware Hardware* Supplied By Notes Support Bracket Assembly (Together) (6) 10.5x20.0x2.2 18-8 Will-Burt Ships with Mast System...

  • Page 51: Installation Dimensions

    AL O TILETTO PERATING NSTRUCTIONS Table 2-2 Installation Hardware Continued Hardware* Supplied By Notes Payload (To the Mast System) (6) M8 Sets of Customer The standard Payload Attachment Interface comes with (6) M8x1.25 – 6H ↧12 mm holes. When using stainless Hardware steel hardware, use an anti-seize to prevent galling.

  • Page 52: Mast Installation Dimensions

    AL O TILETTO PERATING NSTRUCTIONS 2.4.1 Mast Installation Dimensions Table 2-3 Mast Installation Dimensions Model inch inch inch inch inch 4-Meter 517.5 20.37 213.5 8.41 152.4 304.8 12.0 771.3 30.36 517.5 20.37 213.5 8.41 152.4 304.8 12.0 948.3 37.33 6-Meter 8.54-Meter 517.5 20.37...

  • Page 53: Figure 2-1 Mast Installation Dimensions (Not To Scale)

    AL O TILETTO PERATING NSTRUCTIONS Top Down View Side View Bottom Up View Figure 2-1 Mast Installation Dimensions (Not to Scale) TP-5418901-F Original Instructions August 2020...

  • Page 54: Support Bracket Assembly Dimensions

    AL O TILETTO PERATING NSTRUCTIONS 2.4.2 Support Bracket Assembly Dimensions Measurements in: [inches] Figure 2-2 Support Bracket Assembly Bolt Hole Pattern Original Instructions TP-5418901-F August 2020...

  • Page 55: Universal Control Box Dimensions

    AL O TILETTO PERATING NSTRUCTIONS 2.4.3 Universal Control Box Dimensions Table 2-4 Support Bracket Assembly Bolt Hole Pattern Dimensions inch inch inch inch inch 5.75 Ø F inch inch inch inch inch 0.28 inch inch inch inch inch 7.49 inch inch inch 12.23...

  • Page 56: Figure 2-3 Universal Control Box Installation Dimensions (Measurements In Inches)

    AL O TILETTO PERATING NSTRUCTIONS Figure 2-3 Universal Control Box Installation Dimensions (Measurements in Inches) 2-10 Original Instructions TP-5418901-F August 2020...

  • Page 57: Emi Filter Dimensions (Optional Equipment)

    AL O TILETTO PERATING NSTRUCTIONS 2.4.4 EMI Filter Dimensions (optional equipment) Inch [mm] 2.5 Power Supply Requirements This mast requires a 28VDC power supply that meets the characteristics set forth by MIL-STD- 1275. If the application or installation does not allow for such a power supply, storage batteries or a power supply supplemented with a capacitor bank are also viable options.

  • Page 58: Mast System Installation

    AL O TILETTO PERATING NSTRUCTIONS 2.6 Mast System Installation This section describes installation of the Mast System, assuming an external mounting application. For internal mounting applications (i.e. mounting inside an enclosure or vehicle), The Will-Burt Company recommends: • Using a Roof Seal Kit (P/N: 4794602) •...

  • Page 59: Select A Suitable Mounting Location

    AL O TILETTO PERATING NSTRUCTIONS Select a Suitable Mounting Location To select a suitable mounting location, consider the following: • The mounting structure must have sufficient room to mount the system. Ensure the installation site does not interfere with the cables or crowd them into the mast where during retraction they can be pinched between collars or speared by trigger posts.

  • Page 60: Unpack The Mast System

    AL O TILETTO PERATING NSTRUCTIONS Unpack the Mast System During installation, it will be necessary to lift the mast. The process described in this manual represents a possible method of lifting the mast. Depending on the environment and equipment available, other methods may work better. Use the best and safest method for your circumstances.

  • Page 61: Secure The Support Bracket Assembly

    AL O TILETTO PERATING NSTRUCTIONS 6. Slowly lift the mast until just free of the mast saddles. If necessary, lower the mast and adjust the sling as necessary to balance the mast. 7. Ensuring the sling does not catch on anything, lift the mast without any sharp or jerking motions until it is free of the shipping crate.

  • Page 62: Secure The Base Of The Mast

    AL O TILETTO PERATING NSTRUCTIONS Secure the Base of the Mast To secure the base of the mast: 1. Use the base of the mast as a template to drill holes through the mounting surface. 2. Loosely secure the Mast System to the mounting surface with four ½ inch (M12) sets of customer-provided stainless steel hardware.

  • Page 63: Figure 2-6 Ground Stud Locations

    AL O TILETTO PERATING NSTRUCTIONS Ground Stud Locations Top Down View of Mast Electrical Ground Label Figure 2-6 Ground Stud Locations 4. Attach the other end of the Ground Strap to a known earth ground such as the chassis of the vehicle.

  • Page 64: Secure The Universal Control Box

    AL O TILETTO PERATING NSTRUCTIONS Secure the Universal Control Box The Universal Control Box may be installed outside or inside an enclosure such as the cab of a vehicle. To install the Universal Control Box: 1. Use the Universal Control Box as a template, drill six M6 (¼ inch) holes into the mounting structure.

  • Page 65: Electrically Install The Mast System

    AL O TILETTO PERATING NSTRUCTIONS Electrically Install the Mast System Power must be disconnected before connecting or disconnecting any system connector. For example, power must be disconnected when connecting or disconnecting J1, J2, J3, and J4 on the Universal Control Box. To electrically install the Mast System: 1.

  • Page 66: Figure 2-9 Universal Control Box Schematic (Revision M)

    AL O TILETTO PERATING NSTRUCTIONS Figure 2-9 Universal Control Box Schematic (Revision M) 2. Plug the 24-pin Mast Sensor Cable into bulkhead connector J2 on the Universal Control Box and bulkhead connector J6 at the base of the mast. Screw both connectors in place so that the cable is secure.

  • Page 67: Connect Power To The Mast System

    AL O TILETTO PERATING NSTRUCTIONS 5. The Fully Extended Limit Switch Cable will ship installed. Ensure the 3-pin Fully Extended Limit Switch Cable is securely in place between the Fully Extended Limit Switch and bulkhead connector J7 at the base of the mast. Connect Power to the Mast System Power and the handshake lines enter the Universal Control Box through bulkhead connector J1.

  • Page 68: Figure 2-11 Power Cable Connector Wiring

    AL O TILETTO PERATING NSTRUCTIONS To connect customer power to the Mast System: 1. Wire the Power Cable Connector and Emergency Stop Switch according to Figure 2-11. Figure 2-11 Power Cable Connector Wiring 2. Plug customer power into J1 on the Universal Control Box. Screw the connector in place so that the cable is secure.

  • Page 69: Additional Accessory Installation

    AL O TILETTO PERATING NSTRUCTIONS 2.7 Additional Accessory Installation Depending on the configuration of the Mast System, optional components selected, or the installation environment, additional accessories such as PC Interface, Capacitor Bank, or positioners may need to be installed. Install any additional accessories as appropriate. General installation procedures to keep in mind when installing optional accessories include: •...

  • Page 70: Test The Installation

    AL O TILETTO PERATING NSTRUCTIONS 2.8 Test the Installation Follow all precautions while testing the Mast System installation. Equipment Damage! Verify that a power source capable of delivering the specified Mast System voltage and current has been properly connected to the Control Box. Polarity! Ensure the electrical mains polarity is correct before initializing the Mast System.

  • Page 71: Install Payload

    AL O TILETTO PERATING NSTRUCTIONS 2.9 Install Payload The exact installation procedures for payload will vary based on the customer-specific payload and any adaptor being used. For optimal performance, center the payload as best as possible. If the payload will be offset a significant amount, contact The Will-Burt Company. Contact The Will-Burt Company with any questions before performing any installation procedures.

  • Page 72: Figure 2-13 Mounting Hole Pattern

    AL O TILETTO PERATING NSTRUCTIONS 3. Properly secure the payload to the mast with customer-provided M8 high strength hardware. Choose the appropriate length of screw in order to allow maximum thread engagement with the threaded inserts. The standard Payload Interface has six M8x1.25 –...

  • Page 73: Section 3 Operation

    AL O TILETTO PERATING NSTRUCTIONS Section 3 Operation This section describes operation of the Mast System. The exact operating procedures will vary based on the configuration of your Mast System. Follow the appropriate operation procedures for your Mast System. This section assumes the mast is not guyed. See Section 9.2 for information pertaining to guying of the mast.
  • Page 74 AL O TILETTO PERATING NSTRUCTIONS Safety Instruction – Operation! Mast is recommended for outdoor operation. If used indoors, ensure overhead area is free of power lines or other overhead obstructions. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code (United States).

  • Page 75: Operation Equipment

    AL O TILETTO PERATING NSTRUCTIONS Voltage and Current! Verify that a power source capable of delivering the specified Mast System voltage and current has been properly connected to the Control Box. Damage to the Control Box may occur if voltage drops below 18 volts during operation of the mast. Do not disconnect the power cable from J1 on the Control Box or from the power source while the mast is in motion (extending or retracting).

  • Page 76: Controls

    AL O TILETTO PERATING NSTRUCTIONS 3.3 Controls The Mast System can be operated with the: • Universal Control Box (Powered Operation) (Section 3.4) • PC Interface (Powered Operation) (Section 3.5) • Crank Handle Assembly (Manual Operation) (Section 3.6) 3.3.1 Universal Control Box (Powered Operation) Controlling the Mast System with the Universal Control Box allows for: •...

  • Page 77: Universal Control Box Operation

    AL O TILETTO PERATING NSTRUCTIONS 3.4 Universal Control Box Operation This section describes operation of the Mast System using the Universal Control Box. If an emergency stop is required at any time, release the UP/DOWN Switch or press the emergency stop button. This will cause the mast to stop extending or retracting. Quick Reference The following is a quick summary of operation of the Mast System using the Universal Control Box.

  • Page 78: Extend The Mast With Up/Down Switch

    AL O TILETTO PERATING NSTRUCTIONS Extend the Mast with UP/DOWN Switch To extend the mast with the UP/DOWN Switch: 1. Push back the switch guard covering the UP/DOWN Switch. 2. Hold the UP/DOWN Switch in the up position (Figure 3-1). As long as the UP/DOWN Switch is held in the up position, the mast will extend and the Display will show the appropriate intermediate extension height.

  • Page 79: Extend The Mast With Override Switch (Emergency Operation)

    AL O TILETTO PERATING NSTRUCTIONS Extend the Mast with OVERRIDE Switch (Emergency Operation) The OVERRIDE Switch is used with the UP/DOWN Switch to ignore any errors returned by the Universal Control Box in order to extended and retract the mast. Use the OVERRIDE Switch only for emergency operation of the mast to complete a mission.

  • Page 80: Retract The Mast With Up/Down Switch

    AL O TILETTO PERATING NSTRUCTIONS 3. Release the UP/DOWN Switch and OVERRIDE Switch when the desired height is reached. 4. Push both switch guards back into position to protect the UP/DOWN and OVERRIDE Switches. Retract the Mast with UP/DOWN Switch To retract the mast with the UP/DOWN Switch: 1.

  • Page 81: Retract The Mast With Override Switch (Emergency Operation)

    AL O TILETTO PERATING NSTRUCTIONS Retract the Mast with OVERRIDE Switch (Emergency Operation) The OVERRIDE Switch is used with the UP/DOWN Switch to ignore any errors returned by the Universal Control Box in order to extended and retract the mast. Use the OVERRIDE Switch only for emergency operation of the mast.

  • Page 82: Access The Cycle Count And Temperature With Up/Down Switch

    AL O TILETTO PERATING NSTRUCTIONS 3. Release the UP/DOWN Switch and OVERRIDE Switch when the desired height is reached. 4. Push both switch guards back into position to protect the UP/DOWN and OVERRIDE Switches. Access the Cycle Count and Temperature with UP/DOWN Switch The cycle count and temperature: •...

  • Page 83: Crank Handle Operation

    AL O TILETTO PERATING NSTRUCTIONS 3.6 Crank Handle Operation This section describes operation of the Mast System using the Crank Handle Assembly. Safety Instruction – Electrical Hazard! Never manually operate the mast while power is still applied to the system. Ensure the Mast System is de-energized and the power source is properly tagged out.

  • Page 84: Detailed Instructions

    AL O TILETTO PERATING NSTRUCTIONS 3.6.2 Detailed Instructions The following are detailed instructions describing the operation of the Mast System using the Crank Handle Assembly. Use manual operation for emergency situations only. The normal limit switches and software limits are not in effect during manual operation. There are mechanical hard stops just beyond both the upper and lower limit switch locations that will stop the mast safety, however it is good practice to stop the mast at the normal positions.

  • Page 85: Extend The Mast With Crank Handle Assembly

    AL O TILETTO PERATING NSTRUCTIONS Extend the Mast with Crank Handle Assembly When power is removed from the Mast System, the brake is applied to the Motor. This prevents the mast from back driving. When manually operating the Mast System, the operator should expect resistance by the brake.

  • Page 86: Retract The Mast With Crank Handle Assembly

    AL O TILETTO PERATING NSTRUCTIONS Retract the Mast with Crank Handle Assembly When power is removed from the Mast System, the brake is applied to the Motor. This prevents the mast from back driving. When manually operating the Mast System, the operator should expect resistance by the brake.

  • Page 87: Section 4 Transportation

    AL O TILETTO PERATING NSTRUCTIONS Section 4 Transportation Before transporting the Mast System, the Mast System needs to be secured. The exact procedures for transportation will vary based on the Mast System configuration. The process described in this manual represents a possible method of transporting the mast. Depending on the environment and equipment available, other methods may work better.

  • Page 88: Shipping

    AL O TILETTO PERATING NSTRUCTIONS 4.2 Shipping When shipping the Mast System, The Will-Burt Company recommends shipping the mast bolted down in the original shipping crate. If the original shipping crate is not available, contact The Will-Burt Company to order a replacement. Safety Instruction –...

  • Page 89: Section 5 Maintenance

    AL O TILETTO PERATING NSTRUCTIONS Section 5 Maintenance This section describes maintenance procedures required to keep the system operational. Use care to understand and follow all precautions while performing these procedures. Disconnect power to the mast system and any devices mounted to the mast with lock out tag out procedures as appropriate before performing mast maintenance.
  • Page 90 AL O TILETTO PERATING NSTRUCTIONS De-Energized! Always ensure all electrical circuits to the Mast System are de-energized and properly tagged and locked out prior to performing maintenance or repair procedures. Remove Payload! Remove payload before performing maintenance on the Mast System. Safety Instruction –...

  • Page 91: Maintenance Equipment

    AL O TILETTO PERATING NSTRUCTIONS 5.2 Maintenance Equipment Table 5-1 lists recommended equipment for maintenance. Table 5-1 Equipment Recommended for Maintenance Recommended Equipment* Personal Protective Safety Glasses Work Gloves Nitrile or Vinyl Gloves Hearing Protection Hard Hat or Helmet Safety Shoes Hand Tools Paint Brushes Screwdrivers...

  • Page 92: Schedule

    AL O TILETTO PERATING NSTRUCTIONS 5.4.1 Schedule Table 5-2 provides a schedule of preventative maintenance inspections and procedures required to keep the Mast System in good operating condition. Table 5-2 Preventative Maintenance Schedule Frequency Inspection Action Keep Clean – Inspect to ensure the As Needed Clean as you work and as needed.
  • Page 93 AL O TILETTO PERATING NSTRUCTIONS Table 5-2 Preventative Maintenance Schedule Continued Frequency Inspection Action Mast Cables – Inspect Mast System Weekly Replace cables as required. Tighten cables. Look for cracked, frayed, or loose connections. If the bulkhead broken insulation; bare wires; loose connectors are unable to mate with or broken connectors.

  • Page 94: Lubricate The Drive Screw

    AL O TILETTO PERATING NSTRUCTIONS 5.4.2 Lubricate the Drive Screw This section describes how to lubricate the Drive Screw. The Drive Screw should be lubricated every 500 cycles. Equipment Damage! Do not substitute any grease for the Will-Burt drive screw lubricant (P/N: 4288601).
  • Page 95 AL O TILETTO PERATING NSTRUCTIONS 5. Prime the Grease Gun by pumping the handle a few times until grease is seen to exit the tube. 6. Insert the tube through the access holes to touch the Drive Screw directly. 7. Apply a generous dab of grease (two strokes of the handle or approximately 1/14 of the cartridge) onto the Drive Screw.

  • Page 96: Special Instructions

    AL O TILETTO PERATING NSTRUCTIONS 5.4.3 Special Instructions This section describes less common maintenance procedures related to the following: • Corrosive Environments (Section 5.4.3.1) • Mast Damage (Section 5.4.3.2) Corrosive Environments This section describes procedures to be done when the Mast System is in a corrosive environment.

  • Page 97: Section 6 Long-Term Storage

    AL O TILETTO PERATING NSTRUCTIONS Section 6 Long-Term Storage This section describes the best practice for long-term storage (longer than one month) of the Mast System. Safety Instruction – Mast Access! The operator must provide safe means to access the top of the mast during removal of the payload.
  • Page 98 AL O TILETTO PERATING NSTRUCTIONS Original Instructions TP-5418901-F August 2020...

  • Page 99: Section 8 Troubleshooting

    AL O TILETTO PERATING NSTRUCTIONS Section 8 Troubleshooting This section describes troubleshooting for the Mast System. Use care to understand and follow all precautions while troubleshooting the Mast System. This section provides troubleshooting information as follows: • Error Conditions (Section 8.1) •...
  • Page 100 AL O TILETTO PERATING NSTRUCTIONS Table 7-1 Troubleshooting Continued Problem Possible Cause Possible Solution Inspect for and remove The mast has stopped obstructions or tangled moving upward, or is Interference to the mast. payload cables, or lighten moving very slowly. the payload.
  • Page 101 AL O TILETTO PERATING NSTRUCTIONS Table 7-1 Troubleshooting Continued Problem Possible Cause Possible Solution The mast has stopped Damaged Motor Disconnect the Motor and moving downward. and Brake Cable. Brake Cable from the mast. Inspect the cable for continuity and shorts. Replace faulty cable.

  • Page 102: Error (Fault) And Warning Codes

    AL O TILETTO PERATING NSTRUCTIONS Table 7-1 Troubleshooting Continued Problem Possible Cause Possible Solution Power to the mast is Refer to shelter or vehicle Nothing works and the interrupted at the shelter or level maintenance Display does not light. vehicle level. procedures.

  • Page 103: Error (Fault) Codes

    AL O TILETTO PERATING NSTRUCTIONS 8.2.1 Error (Fault) Codes Table 8-2 shows error (fault) codes that may appear on the Control Box Display. Reoccurrence of error codes is possible if trigger conditions are met. Table 8-2 Error (Fault) Codes Error Trigger System Response Latch Until...
  • Page 104 AL O TILETTO PERATING NSTRUCTIONS Table 7-2 Error (Fault) Codes Continued Error Trigger System Response Latch Until Possible Cause Code Condition • Local Up Switch • Switch is being held on 0004 Local Up Switch Local Up Switch Stuck active for Fault is no longer •...
  • Page 105 AL O TILETTO PERATING NSTRUCTIONS Table 7-2 Error (Fault) Codes Continued Error Trigger System Response Latch Until Possible Cause Code Condition • 5 OVERRIDE • Switch requires 0040 From Nested Down Limit Switch position, Up Failed/Stuck Fault Switch adjustment or Switch active (ERR 0040): activations...
  • Page 106 AL O TILETTO PERATING NSTRUCTIONS Table 7-2 Error (Fault) Codes Continued Error Trigger System Response Latch Until Possible Cause Code Condition • System power 1000 CAN Output CAN Output Buffer CAN Bus cannot be Buffer Overflow Overflow (ERR 1000): written to as queued is cycled and information has not been trigger...

  • Page 107: Warning Codes

    AL O TILETTO PERATING NSTRUCTIONS 8.2.2 Warning Codes Table 8-3 shows warning codes that may appear on the Universal Control Box Display. Reoccurrence of warning codes is possible if trigger conditions are met. Table 8-3 Warning Codes Warning Trigger System Response Latch Until Possible Cause Code...
  • Page 108 AL O TILETTO PERATING NSTRUCTIONS Table 7-3 Warning Codes Continued Warning Trigger System Response Latch Until Possible Cause Code Condition • Temperature • High ambient 0004 Temperature High Temperature Sensor reading Warning reading is temperature (direct above 80°C (WRN 0004): below 78°C sunlight) Allow all normal...
  • Page 109 AL O TILETTO PERATING NSTRUCTIONS Table 7-3 Warning Codes Continued Warning Trigger System Response Latch Until Possible Cause Code Condition • Valid • Temperature Sensor 0010 Invalid (or no) Temperature response from Sensor Failure temperature failed and requires Temperature Warning reading replacement Sensor...
  • Page 110 AL O TILETTO PERATING NSTRUCTIONS Table 7-3 Warning Codes Continued Warning Trigger System Response Latch Until Possible Cause Code Condition • Valid signal • If seen in current 0040 Extend/Retract String (Legacy) movement (50 Potentiometer detected control boxes, it mm) not Failure Warning likely means the DIP - or -...

  • Page 111: Section 9 Reference

    AL O TILETTO PERATING NSTRUCTIONS Section 9 Reference This section provides reference information for the system as follows: • Extended Glossary of Terms (Section 9.1) • Guying (Section 9.2) • Drawings (Section 9.3) 9.1 Extended Glossary of Terms This section defines terms used within this manual as follows: •...

  • Page 112: Mounting Position Terms

    AL O TILETTO PERATING NSTRUCTIONS • “MOSFET” stands for metal-oxide semiconductor field-effect transistor. • “NEMA 4X” refers to watertight enclosures as defined by the National Electrical Manufacturers Association. • “Nested” refers to the position of the mast were no tubes have risen. The mast remains retracted.

  • Page 113: Guying

    AL O TILETTO PERATING NSTRUCTIONS 9.2 Guying Stiletto AL masts are not typically guyed, however light guying is possible and can help with deflection. Only one level of guying is recommended. In general, to guy the mast: 1. Prepare the Mast System for Operation (Section 3). 2.
  • Page 114 AL O TILETTO PERATING NSTRUCTIONS Original Instructions TP-5418901-F August 2020...

This manual is also suitable for:

Stiletto al 6-meterStiletto al 8.54-meterStiletto al 10-meterStiletto al 15-meter711990491711990692 ... Show all

Table of Contents