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HybridLight 200 HYBRID TOWER Installation And User Instructions Manual

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

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Summary of Contents for HybridLight 200 HYBRID TOWER

  • Page 1 Installation and User Instructions MODEL 200 HYBRID TOWER Lighting, Surveillance and Communications Tower 2018-12-V1 October 2017 Version 1.05...
  • Page 2 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    Table of Contents PREFACE Description of the User Conventions Used in This Manual Explanation of Safety Warnings Retaining Instructions Obtaining Documentation and Information Description of the product Product specifications Control Panel Setup process How to use safely How to Tow the Product Maintenance...

  • Page 5: Preface

    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.

  • Page 6: Explanation Of Safety Warnings

    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.

  • Page 7: Obtaining Documentation And Information

    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.

  • Page 8: Description Of The Product

    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.
  • Page 9 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...
  • Page 10 2.2 Product Dimensions...
  • Page 11 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 6 on 6.5, ⅝” Studs, Grease or Oil Hubs Parameter Unit...
  • Page 12 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...
  • Page 13 2.3 Product elements...

  • Page 16: Control Panel

    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.

  • Page 17: Setup Process

    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;...
  • Page 18 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.
  • Page 19 Status Page: Active Fault Page:...
  • Page 20 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 ●...

  • Page 21: How To Tow The Product

    2.7 How to Tow the Product HLS-200-D towers are large mobile piece of equipment designed to be portable, these machines are large and heavy by design to tolerate higher wind load conditions. Appropriate care must be placed on transporting this product safley: take turns and unlevel ground conditions with care and low speeds.

  • Page 22: Maintenance

    3 MAINTENANCE 3.1.1 Planned maintenance of Model 200 Maintenance tasks shall be done according to the following plan: Task Frequency Change Oil Every 200 hours Change Oil Filters Every 200 hours Check hydraulic system Monthly/Weekly with Frequent Use Inspect Mast and Tower Assembly Daily Be Awesome Daily...
  • Page 23 3.2 Inspection Tasks 3.2.1 Weekly inspection tasks Task Action Visual inspection of mast Utilize Murphy level gauge Check engine oil Ensure engine level within spec Hydraulic System Oil and Pump Remove and check fluids / condition 3.2.2 Annual Inspection tasks Task Action Mast and Frame Weldment Inspection...
  • Page 24 3.3 Exporting Data Logs 3.3.1 Data Log Export...
  • Page 25 3.4 Battery Management System 3.4.1 The BMS protects and monitors a battery pack by monitoring sensors and using outputs to control charge and discharge into the battery. The BMS measures inputs from cell voltage taps, the total pack voltage tap, a shunt current sensor, thermistors, and a multi-purpose input. Using the programmed settings, the BMS then controls the flow of current into and out of the battery pack through broadcasting charge and discharge current limits via the CAN bus, analog reference voltages, or simple on/off digital signals depending on which style is appropriate for the...
  • Page 26 3.4.5 Temperatures - The BMS measures battery temperatures directly from up to 3 thermistors (2 thermistors for revisions A & B) to determine the average temperature of the battery pack. If additional temperature sensing, such as measuring the temperature of each individual cell, is required, the BMS can be connected to a thermistor expansion module which can allow measuring up to 80 thermistors.
  • Page 27 3.4.8 Charge Enable Flow Chart...
  • Page 28 3.4.9 Discharge Enable Flow Chart 3.4.10 Troubleshooting Battery or BMS Issues:...
  • Page 29 3.4.11 Understanding Failure Modes 3.4.12 The Orion Jr. BMS has several failsafe software modes to ensure that the batteries are protected against internal and some external failures of the BMS. These modes are designed to place the priority on protecting the battery. 3.4.13 1.
  • Page 30 3.4.15 Charge and discharge current limits switch to a voltage failsafe calculation mode and may be higher or lower than they should be. However, they will rapidly adjust if voltages approach minimum or maximum levels. Cell protection based exclusively on cell voltages which may not provide full over-current protection.
  • Page 31 This error is triggered when the difference in voltage between the two measurements exceeds the ‘Pack Voltage Mismatch Threshold’ setting in the BMS profile (under Pack Settings). If this error is triggered, the BMS will assume that it cannot accurately measure the voltage of the battery pack and will go into a voltage failsafe mode.
  • Page 32 3.4.29 turn off and will NOT cause the BMS to go into any degraded operating mode. While this error code will 3.4.30 not impact the operation of the BMS, this error message likely indicates a problem exists and the actual 3.4.31 Orion Jr.
  • Page 33 3.4.47 of each cell (this is the voltage as if the cell were setting at rest (no load) even when a load is 3.4.48 applied to the cell). The BMS compares each cell’s open circuit voltage to the pack average 3.4.49 open circuit voltage and if they differ more than the preset value in the profile, a weak cell fault 3.4.50 is triggered.
  • Page 34 3.4.67 http://www.orionbms.com/troubleshooting. 3.4.68 Orion Jr. BMS Operation Manual 3.4.69 43 3.4.70 P0A0B – Internal Logic Fault Code 3.4.71 This error code indicates that the Orion Jr. BMS has determined that an internal hardware fault has occurred. If this error message occurs, please download the associated freeze frame data and contact the 3.4.72 factory or authorized dealer for assistance.
  • Page 35 3.4.83 This error code indicates that the Orion Jr. BMS has determined that an internal hardware fault has occurred. If this error message occurs, please download the associated freeze frame data and contact the 3.4.84 factory or authorized dealer for assistance. Please save the freeze frame data and send it along with 3.4.85 any other relevant information to the factor as it may be crucial for appropriately repairing the unit.
  • Page 36 3.4.99 This fault code is triggered if the voltage of an individual cell (as measured by the BMS) exceeds 3.4.100 volts. This fault code will only trigger after a number of samplings over the period of 1 minute to 3.4.101 prevent false positives. If this fault triggers, it will cause the BMS to enter into a voltage failsafe 3.4.102 condition disabling all charge and discharge.
  • Page 37 3.4.115 This fault code is set if the total pack voltage sensor reads zero volts. This error will also cause a voltage redundancy fault code. This fault code may be the result of the voltage tap connection not being 3.4.116 connected when the BMS was turned on, a wiring error on the total pack voltage sensor, a voltage tap 3.4.117 that is wired to the wrong location or an internal BMS error.
  • Page 38 3.4.131 Important Note: Weak pack faults are informational errors only and have NO DIRECT IMPACT on 3.4.132 the operation of the BMS. This error code will NOT cause the charge or discharge enable outputs 3.4.133 turn off and will NOT cause the BMS to go into any degraded operating mode. While this error code will 3.4.134 not impact the operation of the BMS, this error message likely indicates a problem exists and the actual...
  • Page 39 3.4.148 output and any current is discharged after the set amount of time passes. Charge limit enforcement corresponds to charge current; discharge limit enforcement corresponds to discharge current. This error 3.4.149 can be falsely triggered if the current sensor polarity is backwards. 3.4.150 When this error is triggered, the BMS is put into a failsafe mode and all 3 charge / discharge / charger 3.4.151 enable outputs are turned off in the event the outputs are wired backwards.
  • Page 40 3.4.166 These 3 fault codes are caused when charge or discharge current (respectively) either exceeds the limit set by the BMS or continues after the digital on/off outputs are turned off. For example, if the BMS 3.4.167 has set a discharge current limit (DCL) of 50 amps and the BMS measures 100 amps for an amount of 3.4.168 time exceeding the limit in the profile, it will set the discharge limit enforcement fault since more current...
  • Page 41 3.4.182 (Also P0A06 – Charge Limit Enforcement Fault and P0A07 – Discharge Limit Enforcement Fault) 3.4.183 These 3 fault codes are caused when charge or discharge current (respectively) either exceeds the limit set by the BMS or continues after the digital on/off outputs are turned off. For example, if the BMS 3.4.184 has set a discharge current limit (DCL) of 50 amps and the BMS measures 100 amps for an amount of...

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