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Will Burt STILETTO AL HD Operating Instructions Manual

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Stiletto AL HD Operating Instructions
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, USA
(4-Meter Stiletto AL HD P/N: 7121110001 Shown)
Phone: +1 330 684 4000
E-Mail: info@willburt.com
Website: www.willburt.com
Authorized Representative:
Will-Burt Germany GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany
TP-7121110000-00, October 2024
© 2024 The Will-Burt Company
Original Instructions

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  • Page 1 Stiletto AL HD Operating Instructions (4-Meter Stiletto AL HD P/N: 7121110001 Shown) The Will-Burt Company Phone: +1 330 684 4000 TP-7121110000-00, October 2024 401 Collins Blvd E-Mail: info@willburt.com © 2024 The Will-Burt Company Orrville, OH 44667, USA Website: www.willburt.com Original Instructions Authorized Representative: Will-Burt Germany GmbH &...
  • Page 3 OPERATING INSTRUCTIONS Warranty Will-Burt warrants its Stiletto AL HD 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: Table Of Contents

    STILETTO AL HD OPERATING INSTRUCTIONS Contents 1 Safety Summary....................5 1.1 Signal Word Definitions..................... 5 1.2 Safety Instructions ....................5 1.3 Symbols Used on Product Labels ................14 2 Specification Compliance ................. 15 2.1 CE Declaration of Conformity ................. 15 3 Introduction ......................
  • Page 5 STILETTO AL HD OPERATING INSTRUCTIONS 6.4.2 Extend the Mast with UP/DOWN Switch............59 6.4.3 Retract the Mast with UP/DOWN Switch ............60 6.4.4 Retract the Mast with OVERRIDE Switch (Emergency Operation) ....61 6.4.4.1 Retract the Mast Using the UP/DOWN Switch and the OVERRIDE Switch 61 6.4.4.2 Retract the Mast Using the “Mast Down”...

  • Page 6: Document History

    STILETTO AL HD OPERATING INSTRUCTIONS 10 Troubleshooting....................97 10.1 Error Screens......................97 10.1.1 Faults ......................97 10.1.2 Warnings..................... 99 10.2 Troubleshooting Electrical................... 101 10.2.1 Caution Conditions..................101 10.2.2 Warning Conditions................... 102 11 Appendix......................111 11.1 System Wiring Diagrams ..................111...

  • Page 7: Safety Summary

    OPERATING INSTRUCTIONS Safety Summary This section describes safety instructions for the Stiletto AL HD that personnel must understand and apply throughout all product activities such as transportation, handling, installation, operation, maintenance, storage, disposal and troubleshooting. Read and understand this entire document, and contact The Will-Burt Company with any questions, before performing any procedure outlined in this document.
  • Page 8 STILETTO AL HD OPERATING INSTRUCTIONS environmental conditions, including, but not limited to, mast size and weight, payload and cable size and weight, payload sail area, wind speed, guy line arrangement, support bracket or roof line location, and base plate assembly. Do not operate in wind speed conditions exceeding the maximum rated wind speed.
  • Page 9 STILETTO AL HD OPERATING INSTRUCTIONS and maintenance to be performed by trained and authorized personnel only. Only a properly trained and qualified certified electrician should perform electric installations and service. Erratic Mast Operation Impact Hazard! The mast should operate smoothly during extension and retraction.
  • Page 10 STILETTO AL HD OPERATING INSTRUCTIONS Fire Hazard Solvent! Cleaning solvent, used for maintenance, is flammable and can be explosive. Do not smoke near solvent. Use cleaning solvent in a well-ventilated area. Keep cleaning solvent away from ignition sources. Always store cleaning solvent in the proper marked container and in a proper location.
  • Page 11 STILETTO AL HD OPERATING INSTRUCTIONS Safety Instruction – Keep Clear! Keep personnel clear of the system during operation. Safety Instruction - Potential Air Contaminants! If internally mounted in a vehicle, air from mast and any accumulated water will discharge into the vehicle. Install appropriate drainage and venting.
  • Page 12 STILETTO AL HD OPERATING INSTRUCTIONS Lifting Hazard! Manually lifting over 55 lb. (25 kg) is prohibited. In the UK, all lifting equipment must be thoroughly examined annually by a competent person according to the Lifting Operations and Lift Equipment Regulations 1998. Equivalent regulations exist in other EU states.
  • Page 13 STILETTO AL HD OPERATING INSTRUCTIONS size, wind speed, ice loading, support bracket or roof line location and base plate assembly. The lower structure at the base plate shall be sized to support all vertical loads from the mast and payload. The support bracket is not intended to carry vertical loads. The support bracket mounting structure and the base plate mounting structure shall be tied to the same vehicle structure/frame (i.e.
  • Page 14 STILETTO AL HD OPERATING INSTRUCTIONS Equipment Damage – Manual Operation! When manually extending or retracting the mast, do not drive past the normal extended or nested stops. Do not apply in excess of 50 lb.-ft. (68 N-m) when using the Crank Handle Assembly. The normal protections are being bypassed and equipment damage could occur.
  • Page 15 STILETTO AL HD OPERATING INSTRUCTIONS The following list contains reasonably foreseeable misuses of the mast system according to EN ISO 12100 5.3.2. These uses shall be avoided: • Operating the mast with an obstruction in the functional space that prevents full extension or retraction •...

  • Page 16: Symbols Used On Product Labels

    STILETTO AL HD OPERATING INSTRUCTIONS Symbols Used on Product Labels The following symbols are displayed on the product. The symbol meanings are as follows: This symbol indicates an electrocution hazard or hazardous voltage hazard. There is voltage present inside mast and control box. Do not operate mast near electrical lines or during electrical storms.

  • Page 17: Specification Compliance

    STILETTO AL HD OPERATING INSTRUCTIONS Specification Compliance CE Declaration of Conformity Refer to the Product page at www.willburt.com for the latest Declaration of Conformity. TP-7121110000-00 PAGE 15 OF 114 OCTOBER 2024...
  • Page 18 STILETTO AL HD OPERATING INSTRUCTIONS PAGE 16 OF 114 TP-7121110000-00 OCTOBER 2024...

  • Page 19: Introduction

    • Stiletto HD Masts See www.willburt.com for information on these and other The Will-Burt Company products. The Stiletto AL HD mast models are available with many options installed by The Will-Burt Company. A typical Stiletto AL HD mast system consists of: •...

  • Page 20: Intended Use

    The Stiletto AL HD mast system is intended to be used only when the vehicle is stationary and the vehicle parking brake is properly applied. Do not supply input supply voltage or operate the mast system when the vehicle is in motion.

  • Page 21: Mast Component Descriptions

    STILETTO AL HD OPERATING INSTRUCTIONS Mast Component Descriptions Telescoping Mast: The mast is the structure used to raise the payload to an operational height. It consists of concentric tube sections that extend and retract mechanically. The exterior surfaces of the tubes are anodized and sealed for long life. The environmental seals at the top of each tube limit water and dust ingress.
  • Page 22 STILETTO AL HD OPERATING INSTRUCTIONS Drive Assembly: The drive assembly extends and retracts the mast tubes. It includes a ball screw, motor and mast drive housing. 600 Watt 600 Watt 28 VDC Motor 28 VDC Motor Ball Screw Mast Drive...
  • Page 23 STILETTO AL HD OPERATING INSTRUCTIONS Top Tube Ring: The top tube ring is attached to the top tube. It has a Payload Interface to attach the customer payload or payload adapter. The standard Payload Interface is shown in Figure 3-3.
  • Page 24 STILETTO AL HD OPERATING INSTRUCTIONS Support Bracket Assembly: The support bracket assembly 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. Hardware to secure the support bracket assembly to the mast ships with the mast system.
  • Page 25 STILETTO AL HD OPERATING INSTRUCTIONS Motor Cable: The motor cable provides power to the motor. The connectors and cables are environmentally sealed to prevent dust, sand, or moisture intrusion. There is a 6-pin military screw-type connector on each end of the motor and brake cable for ease of installation and to prevent environmental intrusion.
  • Page 26 STILETTO AL HD OPERATING INSTRUCTIONS EMI Filter (Optional): The EMI Filter includes a shielded cable (multiple lengths available) to the Control Box J1 connector. It mates with customer supplied shielded cable to power supply and customer control. It is required for Military EMC/EMI compliance (not required for CE compliance).
  • Page 27 STILETTO AL HD OPERATING INSTRUCTIONS Identification Plate: Information pertaining to the mast can be found on the identification plates. The identification plates are located on the mast drive housing and the Control Box. The information on the identification plates is the same.

  • Page 28: System Controllers

    This section describes the standard Control Box. Additional options are available. Contact The Will-Burt Company for additional information. Stiletto AL HD masts are designed to work with Control Boxes operating version 1.0 or later software. These Control Boxes will indicate if the connected mast is a Stiletto AL HD. Only operate the mast with version 1.0 or later software.
  • Page 29 STILETTO AL HD OPERATING INSTRUCTIONS The Control Box works with input from the: • “Nested Limit Switch” which: • Assists the mast from being over-nested • Installed in the mast • Is a reed switch mounted outside the base tube that detects a permanent magnet attached to the bottom of the largest moving tube •...
  • Page 30 STILETTO AL HD OPERATING INSTRUCTIONS Display The Display controls mast functions and provides full system control. Error Codes In the event of any unexpected switch feedback, communication errors, or amp draws on the mast, the display will show the associated error message. See Troubleshooting (Section 10).

  • Page 31: Pc Interface

    STILETTO AL HD OPERATING INSTRUCTIONS 3.5.2 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 Control Box, plus additional functions and information not directly accessible through the standard hardware interface.

  • Page 32: Hand-Held Remote Control

    STILETTO AL HD OPERATING INSTRUCTIONS 3.5.3 Hand-Held Remote Control The optional Hand-Held Remote Control (HHRC): • Contains an SPDT (Mom-Off-Mom) toggle switch (UP/DOWN) protected by a switch guard and waterproof boot to extend and retract the mast • Uses three LED lights to backlight text to indicate the status of the system as follows: •...

  • Page 33: Accessory Options (Sold Separately)

    STILETTO AL HD OPERATING INSTRUCTIONS 3.5.4 Accessory Options (Sold Separately) This section describes accessory options available for the mast system. 3.5.4.1 D-TEC® ® The D-TEC Safety System (Figure 3-15) is a safety device which: • Mounts at the highest point of the mast/payload configuration •...

  • Page 34: Additional Accessory Options

    STILETTO AL HD OPERATING INSTRUCTIONS Specifications for the D-TEC are listed in Table 3-1. Table 3-1 D-TEC Specifications Functional Characteristics Operational Parameters Detection Simultaneous AC Voltage (Electric Field) and Electromagnetic and Electrostatic (Magnetic Field) Detection Minimum Voltage Detection 2.3 Kilovolts/Meter at 0° (Reduced with angle)
  • Page 35 STILETTO AL HD OPERATING INSTRUCTIONS Table 3-2 Additional Accessory Options (Continued) Accessory Description PositionIt™ Remotely pans and tilts a payload. P/N: 5061001 PI-150 with a payload capacity of 150 lb.-ft. (202 N-m). P/N: 5191201 PI-75 with a payload capacity of 75 lb.-ft. (101 N-m).
  • Page 36 STILETTO AL HD OPERATING INSTRUCTIONS PAGE 34 OF 114 TP-7121110000-00 OCTOBER 2024...

  • Page 37: Technical Data

    STILETTO AL HD OPERATING INSTRUCTIONS Technical Data 4-Meter Stiletto AL HD Models Extended Height (ft / m) (+50 / -50mm) (+2.0 / -2.0 13.1 / 4 Nested Height (in / m) (+2.0 / -5.0 mm) (+0.08 / -0.2 50.4 / 1.28...
  • Page 38 Maximum Tilt from Vertical assumes the rated payload. • Typical Payload Sail Area (CD = 1.5) for 4-meter Stiletto AL HD: 1.58 square meters (17 square feet) Consult factory for larger sail areas, as the payload and wind capacities may be reduced.

  • Page 39: Installation

    OPERATING INSTRUCTIONS Installation This section describes the physical and electrical installation of the Stiletto AL HD and provides the general procedures that must be followed to ensure a successful installation. Be sure to read and understand the entire installation procedure and the Safety Summary (Section 1) before beginning installation.

  • Page 40: Recommended Installation Tools

    STILETTO AL HD OPERATING INSTRUCTIONS • Cables will eventually need routed between components of the system as follows: • Customer power to the Control Box • The three meter motor cable and the three meter mast data cable will need routed between the Control Box and mast junction box •...

  • Page 41: Installation Hardware

    STILETTO AL HD OPERATING INSTRUCTIONS Installation Hardware Table 5-2 describes hardware that may be used during installation. Depending on the specific installation application, all hardware may not be used. Table 5-2 Installation Hardware Hardware* Supplied By Notes Support Bracket Assembly (Together) (6) 10.5x20.0x2.2 18-8...
  • Page 42 STILETTO AL HD OPERATING INSTRUCTIONS Table 5-2 Installation Hardware Hardware* Supplied By Notes Ground Straps 10-32 UNF-2B The Will-Burt Ships with mast system. Hardware Company Payload (To the Mast System) with (6) M8x1.25 – 6H ↧12 mm holes. When using...

  • Page 43: Installation Dimensions

    STILETTO AL HD OPERATING INSTRUCTIONS Installation Dimensions Dimensions provided are for reference only and are not intended for vehicle design purposes. Depending on the mast system and components being used, the exact design of components may vary. Masts with other heights, capacities, and finishes are available. For more information on additional mast sizes, capabilities, and finishes, see www.willburt.com.
  • Page 44 STILETTO AL HD OPERATING INSTRUCTIONS Top Down View Side View Bottom View Up Figure 5-2 Mast Installation Dimensions (Not to Scale) PAGE 42 OF 114 TP-7121110000-00 OCTOBER 2024...

  • Page 45: Support Bracket Assembly Dimensions

    STILETTO AL HD OPERATING INSTRUCTIONS 5.4.2 Support Bracket Assembly Dimensions Figure 5-3 Support Bracket Assembly Bolt Hole Pattern 5.4.3 Control Box Dimensions inch inch inch inch inch 12.6 101.5 5.75 190.4 Ø F inch inch inch inch inch 0.28 12.6 190.4...
  • Page 46 STILETTO AL HD OPERATING INSTRUCTIONS Figure 5-4 Control Box Installation Dimensions (Measurements in Inches) PAGE 44 OF 114 TP-7121110000-00 OCTOBER 2024...

  • Page 47: Emi Filter Dimensions (Optional Equipment)

    STILETTO AL HD OPERATING INSTRUCTIONS 5.4.4 EMI Filter Dimensions (Optional Equipment) Inch [mm] 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 48: Unpacking & Handling

    STILETTO AL HD OPERATING INSTRUCTIONS Unpacking & Handling 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 49: Secure The Support Bracket Assembly

    STILETTO AL HD OPERATING INSTRUCTIONS 11. Slowly lower the mast until the mast is on the mounting surface and the weight of the mast has settled. Stop lowering the mast once the mast weight has settled. 12. Ensure the mast is temporarily secured to prevent it from tipping over during the installation process.

  • Page 50: Secure The Base Of The Mast

    STILETTO AL HD OPERATING INSTRUCTIONS 5.6.0.2 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 51 STILETTO AL HD OPERATING INSTRUCTIONS 3. Attach one end of the ground strap to the mast at any of the ground stud locations. The M5 ground stud provided can be moved to any of the ground stud locations as needed. The Ground Stud locations are designated with the electrical ground label (Figure 5-6).

  • Page 52: Secure The Control Box

    STILETTO AL HD OPERATING INSTRUCTIONS 5.6.0.4 Secure the Control Box The Control Box may be installed outside or inside an enclosure such as the cab of a vehicle. To install the Control Box: 1. Use the Control Box as a template, drill six M6 (¼ inch) holes into the mounting structure.

  • Page 53: Electrically Install The Mast System

    Components J2 to J12 Figure 5-8 Stiletto AL HD Wiring (Not to Scale) 2. Plug the 10-pin mast data cable into bulkhead connector J5 on the Control Box and bulkhead connector J6 at the base of the mast. Screw both connectors in place so that the cable is secure.

  • Page 54: Connect Power To The Mast System

    STILETTO AL HD OPERATING INSTRUCTIONS 4. Depending on the Mast System configuration, a cable may be used with optional components including the Hand-Held Remote or D-TEC. If used, plug in the 8-pin data cable to bulkhead connector J3. Screw the connector in place so that the cable is secure.
  • Page 55 STILETTO AL HD OPERATING INSTRUCTIONS An Emergency Stop Switch Kit (Figure 5-9) is supplied with each mast. This kit includes a panel mounted push-pull E-Stop switch, and a legend plate. The emergency stop shall be installed in a position reachable by the operator when operating the mast with the mast controls. This Emergency Stop Switch kit must be used for CE compliance.

  • Page 56: Additional Accessory Installation

    STILETTO AL HD OPERATING INSTRUCTIONS Additional Accessory Installation Depending on the configuration of the mast system, optional components selected, or the installation environment, additional accessories such as PC Interface or positioners may need to be installed. Install any additional accessories as appropriate.

  • Page 57: Wiring Vehicle Interlock On Sensor

    OPERATING INSTRUCTIONS Wiring Vehicle Interlock on Sensor The Stiletto AL HD masts are designed to allow for integration into vehicle safety circuitry to eliminate the possibility of driving with the mast extended. Usage shall be used to comply with various safety standards such as NFPA-1901. Possible Vehicle Interlock systems include a customer-supplied flashing warning lamp in the cab, or wiring into the parking brake or transmission circuit.

  • Page 58: 5.11 Install Payload

    STILETTO AL HD OPERATING INSTRUCTIONS 5.11 Install Payload The exact installation procedures for payload will vary based on the customer-specific payload and any adapter 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 59: Operation

    STILETTO AL HD OPERATING INSTRUCTIONS Operation This section describes the operation of the system. Be sure to read and understand the entire operation procedure and the Safety Summary (Section 1) before beginning operation. Pre-Operation Check Before operating the system: • All operators read and understand the entire operation procedure.

  • Page 60: Operation Equipment

    STILETTO AL HD OPERATING INSTRUCTIONS Operation Equipment Table 6-1 lists recommended equipment for operation. Table 6-1 Recommended Installation Tools & Materials Tools and Materials Safety Glasses Safety Gloves Safety Shoes Hard Hat or Helmet Hearing Protection Nitrile or Vinyl Gloves Crank Handle Assembly (For manual operation only.)

  • Page 61: Extend The Mast With Up/Down Switch

    STILETTO AL HD OPERATING INSTRUCTIONS 6.4.2 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 6-1). 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 62: Retract The Mast With Up/Down Switch

    STILETTO AL HD OPERATING INSTRUCTIONS 6.4.3 Retract the Mast with UP/DOWN Switch To retract 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 down position (Figure 6-2). As long as the UP/DOWN Switch is held in the down position, the mast will retract and the display will show the appropriate intermediate extension height.

  • Page 63: Retract The Mast With Override Switch (Emergency Operation)

    STILETTO AL HD OPERATING INSTRUCTIONS 6.4.4 Retract the Mast with OVERRIDE Switch (Emergency Operation) The OVERRIDE Switch is used with the UP/DOWN Switch or the “Mast Down” button to ignore any errors returned by the Control Box in order to retract the mast. Use the OVERRIDE Switch only for emergency operation of the mast.

  • Page 64: Retract The Mast Using The "Mast Down" Button And The Override Switch

    STILETTO AL HD OPERATING INSTRUCTIONS 6.4.4.2 Retract the Mast Using the “Mast Down” button and the OVERRIDE Switch Note: Use extreme caution when using the OVERRIDE Switch at the fully nested area of mast deployment. Holding the UP/DOWN Switch beyond the limits of travel may result in equipment damage.

  • Page 65: Control Box Display Operation

    STILETTO AL HD OPERATING INSTRUCTIONS Control Box Display Operation This section explains how to use the Control Box Display. Using the Control Box display (Figure 6-5), the operator can perform an emergency stop and can access all functions of the mast.

  • Page 66: Emergency Stop (E-Stop)

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.2 Emergency Stop (E-Stop) If an emergency stop (E-Stop) (Figure 6-5) is required at any time, press the “E-Stop” button. This will halt motion and disable all operation. When the E-Stop is used, an orange notification appear informing the operator that the mast has been stopped (Figure 6-6).

  • Page 67: Prepare The System For Powered Operation

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.3 Prepare the System for Powered Operation To prepare the mast system for powered operation: • Ensure the mast system is stationary on level, stable ground. • Ensure enable input is closed (Section 5.6.0.6). • Perform the Pre-Operation Check (Section 6.1).
  • Page 68 STILETTO AL HD OPERATING INSTRUCTIONS All of the methods of extension can be accessed from the Home Screen (Figure 6-8). Auto Up® Presets “Mast Up” “Deploy To” Figure 6-8 Home Screen - Mast is Fully Nested If a command is available for use, the icon will be colored white. If a command is not available, the icon will be colored dark gray.

  • Page 69: Using The Auto Up® Feature

    STILETTO AL HD OPERATING INSTRUCTIONS Any of the auto sequences can be aborted by pushing any of the buttons or switches on the controller, HHRC, Control Box, or Control Box display at any point during the auto sequence. If the auto sequence is aborted, the mast will stop and wait for input from the controller, HHRC, Control Box, or Control Box display.

  • Page 70: Using The "Deploy To" Feature

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.4.3 Using the “Deploy To” Feature 1. To extend the mast, press the “Deploy To” button (Figure 6-8). The Deploy To - Enter Height Screen will appear (Figure 6-11). Reset Figure 6-11 Deploy To - Enter Height Screen 2.

  • Page 71: Using The Presets Feature

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.4.4 Using the Presets Feature 1. To extend the mast, press the Presets button (Figure 6-8). The Select Preset Screen will appear (Figure 6-12). Figure 6-12 Select Preset Screen 2. Using the arrows or the scroll wheel, select the desired Preset height then press the green check mark button.

  • Page 72: Lowering The Mast

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.5 Lowering the Mast The mast can be stowed by using: • Auto Stow® • “Mast Down” Button • “Deploy To” Feature • Presets Feature All of the above methods of retraction can be accessed from the Home Screen (Figure 6-13).
  • Page 73 STILETTO AL HD OPERATING INSTRUCTIONS If the retraction method is automated (Auto Stow® feature, “Deploy To” feature, and Presets feature), an Automated Motion Warning Screen will appear asking the user to check for obstructions before operating the mast (Figure 6-14). After ensuring the operation area is clear, press the green check mark button.

  • Page 74: Using The Auto Stow® Feature

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.5.1 Using the Auto Stow® Feature 1. To fully stow the mast, press the Auto Stow® button (Figure 6-13). 2. An Automated Motion Warning Screen will appear asking the user to check for obstructions before operating the mast (Figure 6-14). After ensuring the operation area is clear, press the green check mark button.

  • Page 75: Using The Presets Feature

    STILETTO AL HD OPERATING INSTRUCTIONS 6.5.5.4 Using the Presets Feature 1. To retract the mast, press the Presets button (Figure 6-13). The Select Preset Screen will appear (Figure 6-17). Figure 6-17 Select Preset Screen 2. Using the arrows or the scroll wheel, select the desired Preset height then press the green check mark button.

  • Page 76: Crank Handle Operation (Emergency Operation Without Power)

    STILETTO AL HD OPERATING INSTRUCTIONS Crank Handle Operation (Emergency Operation Without Power) This section describes 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 77 STILETTO AL HD OPERATING INSTRUCTIONS 4. Place the crank handle assembly onto the manual override. Press down on the manual override ride with the crank handle assembly so the manual override lowers. When the manual override is lowered, the lock is disengaged and the mast can be operated.
  • Page 78 STILETTO AL HD OPERATING INSTRUCTIONS PAGE 76 OF 114 TP-7121110000-00 OCTOBER 2024...

  • Page 79: Transportation

    STILETTO AL HD OPERATING INSTRUCTIONS 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 80: Shipping

    STILETTO AL HD OPERATING INSTRUCTIONS 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.

  • Page 81: Maintenance And Adjustments

    STILETTO AL HD OPERATING INSTRUCTIONS Maintenance and Adjustments This section describes the routine maintenance and adjustment procedures required to keep the system operational. Be sure to read and understand the entire operation procedure and the Safety Summary (Section 1) before beginning any maintenance or adjustment procedure.

  • Page 82: System Info Screen And Contact Us Screen

    STILETTO AL HD OPERATING INSTRUCTIONS System Info Screen and Contact Us Screen If information about the mast and the software is needed, the user can see that information by using the System Info Screen (Figure 8-1). This screen says the serial number, the software version, etc.

  • Page 83: Power Isolating Procedure

    STILETTO AL HD OPERATING INSTRUCTIONS Power Isolating Procedure 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. The J1 connector on the Control Box can be removed to isolate power to the mast and Control Box. Be sure source power is removed before removing the J1 connector.

  • Page 84: Periodic Inspections

    STILETTO AL HD OPERATING INSTRUCTIONS Periodic Inspections This section describes the systematic care and inspection of equipment to keep it in safe operating condition and to prevent breakdowns. If the system does not perform as required, see Section 10 for troubleshooting. If anything looks wrong and cannot be diagnosed and/or fixed, contact The Will-Burt Company.
  • Page 85 STILETTO AL HD OPERATING INSTRUCTIONS Table 8-2 Periodic Inspections (Continued) Frequency Inspection Action Weekly Mast Cables – Inspect Mast System Replace cables as required. cables. Look for cracked, frayed, or Tighten loose connections. If the broken insulation; bare wires; loose bulkhead connectors are unable to or broken connectors.

  • Page 86: Mast Damage

    STILETTO AL HD OPERATING INSTRUCTIONS Mast Damage If damage to the mast occurs, do not use the mast system and have it serviced before use. Servicing the mast system may require removal of the mast system. If the mast system is installed on a vehicle, consult the vehicle manual for specific installation details.

  • Page 87: Enter Settings Screen

    STILETTO AL HD OPERATING INSTRUCTIONS 8.8.1 Enter Settings Screen 1. To adjust the mast system, go to the Settings Screen (Figure 8-3). To go to the Settings Screen, select the gear icon on the bottom left of the screen. Figure 8-3 Select Settings Button Below is the Settings Screen (Figure 8-4).

  • Page 88: Set Above Ground Level Offset

    STILETTO AL HD OPERATING INSTRUCTIONS 8.8.2 Set Above Ground Level Offset The mast system can be programmed to offset the above ground level height. This feature can be used if the mast is on a vehicle/platform or in other situations where the mast above ground level.

  • Page 89: Set Preset Heights

    STILETTO AL HD OPERATING INSTRUCTIONS 8.8.3 Set Preset Heights The preset height feature allows the mast to automatically extend or retract to a height pre- programmed by the user. Four different preset heights can be programmed. The preset heights can be programmed or re-programmed during any time.
  • Page 90 STILETTO AL HD OPERATING INSTRUCTIONS To make the current height of the mast the preset height: Press the arrow button by preset parameter that says “SET TO CURRENT HEIGHT”. Press the green check mark button to confirm. To enter the height of the preset: Press the arrow button by preset parameter that says “ENTER HEIGHT”.

  • Page 91: Adjust Screen Brightness

    STILETTO AL HD OPERATING INSTRUCTIONS 8.8.4 Adjust Screen Brightness To change the screen brightness of the Control Box display screen: 1. Go to the Settings Screen (Section 8.8.1). Scroll through the setting options and select “Screen Brightness”. Below is the Brightness Screen (Figure 8-9).
  • Page 92 STILETTO AL HD OPERATING INSTRUCTIONS Auto Brightness: The Auto Brightness option will allow the Control Box display’s sensor to automatically select the brightness of the screen. Brightness Scale: The brightness scale allows the user to select the brightness of the display manually.

  • Page 93: Change Units Between Imperial And Metric

    STILETTO AL HD OPERATING INSTRUCTIONS 8.8.5 Change Units Between Imperial and Metric To change the units of the mast system between Imperial or Metric: 1. Go to the Settings Screen (Section 8.8.1). Scroll through the setting options and select “Change Units”. Below is the Change Units Screen (Figure 8-12).

  • Page 94: Long-Term Storage

    STILETTO AL HD OPERATING INSTRUCTIONS Long-Term Storage This section describes the best practice for long-term storage (longer than one month) of the Mast System. When putting the system into long-term storage, ensure the: • Mast is fully nested • Payload is removed •...

  • Page 95: Reference Information

    STILETTO AL HD OPERATING INSTRUCTIONS Reference Information This section describes reference information for your system including some optional equipment. Nycoil® (Optional) The Nycoil® Cable Conduit (Figure 9-1) is an optional external coiled hose used to house electrical wiring, camera and positioner cables.

  • Page 96: Guying

    STILETTO AL HD OPERATING INSTRUCTIONS Guying Stiletto AL HD 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 6.1).

  • Page 97: Extended Glossary Of Terms

    • Mast: refers to the mechanical telescoping mast. • Mast System: refers to the entire Stiletto AL HD mast system (telescoping mast, Control System, and additional accessories). • MOSFET: stands for metal-oxide semiconductor field-effect transistor.

  • Page 98: Mounting Position Terms

    STILETTO AL HD OPERATING INSTRUCTIONS • Top Tube: refers to the tube with the smallest diameter. When the mast is fully extended, this is the tube furthest from the mounting surface. • Ø: stands for diameter. 9.4.2 Mounting Position Terms For the purposes of this manual, regions of the mounting location are defined as follows: •...

  • Page 99: 10 Troubleshooting

    STILETTO AL HD OPERATING INSTRUCTIONS 10 Troubleshooting This section describes system troubleshooting information. Please contact The Will-Burt Company if these guides do not solve the issue. Be sure to read and understand the entire operation procedure and the Safety Summary (Section 1) before beginning any maintenance or troubleshooting procedure.
  • Page 100 STILETTO AL HD OPERATING INSTRUCTIONS If you need to access the home screen for any reason, press the red “X” button to dismiss the fault screen. Below is the home screen with a fault error notice (Figure 10-2). Figure 10-2 Home Screen with Fault Error Notice To get back to the fault screen, press the Settings button in the bottom left of the screen.

  • Page 101: Warnings

    STILETTO AL HD OPERATING INSTRUCTIONS 10.1.2 Warnings When a warning screen occurs, the mast can still be used and moved, but the operator should still fix the issue. Below is an example of a warning error (Figure 10-4). Figure 10-4 Example of a Warning Screen If you need to access the home screen, press the red “X”...
  • Page 102 STILETTO AL HD OPERATING INSTRUCTIONS To get back to the warning screen, press the Settings button in the bottom left of the screen. Scroll to where the warning alert is and press the green check mark button (Figure 10-6). Figure 10-6 Warning Alert in Settings List Select “RESOLVE”...

  • Page 103: 10.2 Troubleshooting Electrical

    STILETTO AL HD OPERATING INSTRUCTIONS 10.2 Troubleshooting Electrical This section includes a list of caution and warning notices and their potential causes. Caution notices do not stop motion or use, but let you know of potential issues. Warning (Fault) codes point out problems and usually inhibit operation to prevent potential damage.

  • Page 104: Warning Conditions

    STILETTO AL HD OPERATING INSTRUCTIONS Table 10-1 Caution Codes Caution Trigger System Latch Until Possible Causes Code Condition Response Lower Limit 0003 Motor internal • 5 OVERRIDE • Mast has been Utilization rate Switch Failed/ Switch overused. If has risen...
  • Page 105 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition E-Stop Pressed 00000002 E-Stop has • Twist E-Stop to • E-Stop has been been (ERR 00000002) neutral/reset pressed/ pressed position...
  • Page 106 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition Local Down Switch 00000010 Local Down • Local Down • Switch is being Switch Stuck Warning Switch is no held on...
  • Page 107 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition Encoder Warning 00000040 Encoder • Valid encoder • Encoder height data (ERR 00000040) signal detected requires changes not adjustment or...
  • Page 108 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition SDO Configuration 00000200 Error • 5 OVERRIDE • Sensor cable occurred in Error Switch from mast to setup SDO (ERR 00000200)
  • Page 109 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition Motor CAN bus 00001000 Motor CAN • 5 OVERRIDE • Cable from bus node is Error Switch motor to junction...
  • Page 110 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition Conflicting Up/ 00004000 Up and • One or both • Switch(es) Down Limit Down Limit Switch Switches is(are) require Switches are...
  • Page 111 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition Lower Limit Active 00010000 Lower Limit • Rescale system • Switch requires Switch (ERR 00010000): adjustment or activated recalibration - or -...
  • Page 112 STILETTO AL HD OPERATING INSTRUCTIONS Table 10-2 Warning (Fault) Codes Warning Trigger System Response Latch Until Possible Causes Code Condition Motor Faulted 00040000 Motor fault • 5 OVERRIDE • Motor has detected. Warning Switch detected an (ERR 00040000): activations internal error...

  • Page 113: 11 Appendix

    STILETTO AL HD OPERATING INSTRUCTIONS 11 Appendix 11.1 System Wiring Diagrams The system wiring diagrams are as follows: TP-7121110000-00 PAGE 111 OF 114 OCTOBER 2024...
  • Page 114 STILETTO AL HD OPERATING INSTRUCTIONS PAGE 112 OF 114 TP-7121110000-00 OCTOBER 2024...
  • Page 115 STILETTO AL HD OPERATING INSTRUCTIONS TP-7121110000-00 PAGE 113 OF 114 OCTOBER 2024...
  • Page 116 STILETTO AL HD OPERATING INSTRUCTIONS PAGE 114 OF 114 TP-7121110000-00 OCTOBER 2024...

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