Note: This is a general instruction manual. The high-mast lighting ordered by your company is manufactured in accordance with the requirements specified in the contract between both parties, so there may be slight differences between the actual product and this manual.

1.Overview

Elevating high-mast lighting is widely applicable for large-area illumination in places such as wide roads, overpasses, squares, parking lots, car washes, ports, freight yards, train marshalling yards, and airport aprons.

2.Main Technical Parameters

Parameter Specification

Total Installation Height                        m

Diameter of Lamp Panel                       m

Lighting Power                               W

Power of Equipped Motor                  1.5 KW

Load-Bearing Capacity of Steel Wire Rope ＞5000 Kg

Lifting Speed                           ＜0.2 m/s

Total Weight                               Kg

3.Structure

The elevating high-mast lighting consists of a lamp panel (with lamps installed on it), a lamp pole, a lifting mechanism, and electrical devices.

3.1Lamp Panel

The lamp panel can be lifted and lowered for easy maintenance and overhaul. It is made of high-quality steel plates, and is equipped with lamps, light sources, ballasts, triggers, hook assemblies, and terminal blocks. The shape of the lamp panel is determined according to the user's requirements.

3.2Lamp Pole

The lamp pole is a one-time formed multi-prismatic conical pole, with a diagonal diameter of Ø280 at the upper end. The taper of each section is 1:69, and there are generally 3-4 sections, each with a length of 7-10 m. The steel pole is made of Q235 steel plates produced by Baosteel, which are rolled and formed, then welded into a uniformly reducing conical pole using the CO₂ gas shielded welding process, and finally inserted into an integral lamp pole without transverse welding. The inner and outer surfaces of the lamp pole are hot-dip galvanized, and the outer surface is sprayed with plastic.

An electrical door is opened at the bottom of the pole, inside which the lifting mechanism and electrical devices are installed. A door frame is welded at the edge of the electrical door to make up for the reduction in strength caused by opening the door on the pole body. The electrical door cover is equipped with a waterproof gasket to prevent rainwater from seeping in.

A pulley block, a travel switch, a hook device, a rain cover, and a lightning rod (integrated with the lamp pole) are fixed at the top of the pole.

3.3 Lifting Mechanism

The lifting mechanism is composed of a ZD-type motor, a coupling, a hoisting mechanism, etc. In case of power failure, the lamp panel can be immediately kept in any state. It is equipped with an emergency braking device to prevent the lamp panel from falling and a safety locking function for steel cable breakage, thus ensuring safety. The hoisting mechanism is composed of non-rotating galvanized steel wire ropes, a reel, a worm gear reducer, gears, an auxiliary steel wire pulley block and other parts, with safe and reliable operation and convenient operation.

3.3.1 Head

The head is fixed at the top of the pole body in the form of a set bolt. It is a load-bearing and guiding assembly composed of multiple pieces of sheet material distributed at 120 degrees, a pulley block, a stainless steel rotating shaft and other components. It is connected to the lamp panel through pulleys and stainless steel wire ropes. A fiberglass rain cover and a lightning rod are installed above the head, with a protection angle of 90 degrees for the lightning rod.

3.3.2 Lamp Panel

The lamp panel is composed of two semi-circular rings connected by a flange. There are three hanging feet distributed at 120 degrees on the periphery of the lamp panel. Nylon guide wheels and anti-collision rings are installed at the front ends of the hanging feet to guide the lamp panel to be correctly positioned when it is lifted or lowered. A number of lamp mounting plates can be welded on the periphery of the lamp panel for lamp installation.

3.3.3 Latching System

The latching system consists of two parts: one part is a latching box, which is fixedly installed on the side of the head. The latching box is a steel component and requires no maintenance; the other part is a suspension mechanism, which is composed of a hanging foot, a two-way spring, a pin shaft, etc. It is installed on the hanging foot of the lamp panel and can be lowered to the ground along with the lamp panel for easy inspection and maintenance. Coordinating with the lifting operation of the lamp panel, the latching system can smoothly complete the hooking and unhooking actions of the lamp panel. The attached signal flap mechanism can clearly show the action and status of the hook. The entire lamp panel is equipped with three sets of latching systems distributed at 120 degrees.

3.3.4 Hoisting System

The external power single hoisting system is composed of a worm reducer, a reel, a stainless steel wire rope, a rigging connector and a rope stopper. The worm reducer is fully enclosed, and its lubricating oil is sufficient for consumption during the entire service life of the high mast, requiring no maintenance. A locking device is installed on its input drive shaft for safety locking during non-working hours. A specially made rigging connector is used to connect the main steel cable of the hoist and the three auxiliary steel cables for hanging the lamp panel. The rope stopper can ensure that the stainless steel wire rope runs in the correct position and prevent friction damage. An overload reducer is provided to ensure that no overtop phenomenon occurs. The lifting speed of the lamp panel is 3.5 meters per minute. When the lamp needs to be maintained, only the small door at the bottom of the pole needs to be opened, and the lifting can be realized by remote control of the buttons. In case of power failure, a manual device can be used for lifting to facilitate maintenance.

3.3.5 Power Driver

The power driver is a two-way, single-speed electric driver, which can lift and lower, with light weight and simple operation. The driver is equipped with an over-torque protection device. When it runs overloaded, it slides to avoid excessive torque causing the breakage of the lifting cable, thus improving the lifting safety.

3.4 Power Supply Part

The power supply part is installed on the electrical board inside the door at the bottom of the lamp pole, including the lamp group power supply, the motor power supply and the control part. The lamp group power cable (i.e., the main cable) is connected to the four-terminal terminal block on the electrical board. The main cable is connected when the lamp is on and disconnected when lifting. The lamp power supply can be divided into three groups, and clock control or light control can be selected through switches S1-S3. A control box is equipped inside the pole.

3.5 Control System

3.5.1

The lifting system is equipped with a travel switch double protection circuit, and the motor control system has leakage protection and overheating protection functions.

3.5.2

The lamp control has two modes: computer timing control system and remote master control system:

(B1) The computer timing control realizes automatic control according to the set program;

(B2) The remote master control can select the control location for manual remote control operation according to the actual control requirements.

3.6 Lamps

3.6.1

The lamp body and lamp cover are made of die-cast aluminum alloy, and the surface is treated with electrostatic spraying, featuring a lightweight structure and corrosion resistance. The lamp housing has a corrosion resistance grade of Class II, an protection grade of IP65, and an anti-shock grade of Class I. It complies with the provisions of Safety Requirements and Tests for Luminaires (GB7000.1-7000.6).

3.6.2

The reflector is made of high-purity aluminum by pressing and forming, and treated with anodizing and electrochemical polishing, which has the characteristics of stable optical performance and high reflectivity.

3.6.3

The light-transmitting cover is made of curved high-strength tempered glass, which can withstand a high temperature of more than 200℃, with high light transmittance and impact resistance.

3.6.4

The reflector, the tempered glass cover and the lamp holder are bonded into one body with sealant to form an internal bulb replacement structure, which has good sealing performance. The sealing ring can withstand a high temperature of more than 250℃, and the sealing degree reaches IP66.

3.7

 Electrical Appliances

400W high-pressure sodium lamps produced by Shanghai Yaming are used, equipped with ballasts, triggers and capacitors.

4.Other Technical Instructions

4.1 The lamp panel can be lowered to the ground, and all maintenance and repair work can be completed on the ground.

4.2 A special fully enclosed worm gear reducer is selected, which does not require adding lubricating oil or maintenance during the entire service life. A locking device is provided on the worm power input shaft for locking during non-working hours. 

4.3 The unique design of the latching system is novel, with smooth hooking and unhooking, safe and reliable. A signal flap is attached to the latching mechanism to clearly show the action and state of the hook, facilitating operation and increasing safety. 

4.4 Remote control operation is adopted (a manual lifting system can be equipped at the same time), and personnel can operate in a safe area to ensure safety. 

4.5 Anchoring piles are provided on the inner wall of the pole, equipped with safety chains for double safety protection when the lamp panel is in the hooked state. 

5.Operation Methods 

5.1 Lifting and Automatic Hooking of the Lamp Panel

5.1.1 Check if the winch mechanism is normal. 

5.1.2 Insert the cable plug of the control handle into the corresponding socket on the electrical panel (four-core socket on the electrical panel). 

5.1.3 Turn the function changeover switch WK to the "Hooking" position. 

5.1.4 Press the "Lift" button AQ1, and the motor will lift until it touches the upper travel switch XK1, then stop automatically.

5.1.5 Press the "Lower" button AQ2 until the hook is automatically secured, then press the "Stop" button AQ3. If the steel cable is loose and the lamp panel is upright, it means it is properly hooked; otherwise, repeat steps (4)-(5) until it is properly hooked. 

5.1.6 After completion, remove the cable plug of the remote control handle from the electrical panel. 

5.2 Lowering and Automatic Unhooking of the Lamp Panel 

5.2.1 Remove the lamp group power cable (i.e., the main cable) from the electrical panel, and insert the cable plug of the remote control handle into its corresponding socket. 

5.2.2 Turn the function changeover switch WK to the "Unhooking" position. 

5.2.3 Press the "Lift" button AQ1, and the lamp panel will lift until it touches the travel switch XK2, then stop automatically. 

5.2.4 Press the "Lower" button AQ2, and the lamp panel will lower automatically and unhook. When it reaches the lower support, press AQ3 to stop. 

5.2.5 After completion, remove the cable plug of the remote control handle from the electrical panel. 

5.3 Lighting Operation 

5.3.1 Connect the lamp group power cable (i.e., the main cable) to the electrical panel. 

5.3.2 Select the appropriate control state: 

a.If S1, S2, and S3 are in the through state, all three groups of lamps should be on. 

b.If automatic timing control is used, the user can set the lighting and extinguishing times according to local needs. At this time, S1, S2, and S3 are in automatic control, and S3 is used to adjust the lighting groups. 

6. Maintenance and Inspection 

6.1 Maintenance of the Transmission Mechanism 

6.1.1 After the lamp panel is lowered to the lower support, maintenance can be carried out. First, remove oil stains, check if the steel wire rope has broken wires, rust, wear, etc., and if the steel wire rope joint is loose. 

6.1.2 Open the upper cover of the worm gear reducer and check if the worm gear teeth are worn and if the worm has axial movement. 

6.1.3 Check if gears, couplings, etc., are worn. 

6.1.4 Check if all fastener screws are loose. 

6.1.5 If the transmission lubricating oil (grease) is too dirty, it should be replaced. Ensure that there is sufficient lubricating oil in the worm gear box, and it is strictly prohibited to work with insufficient or no oil. 

6.1.6 Maintenance and inspection should be carried out once a quarter, focusing on inspection. Problems found should be solved in a timely manner. Severely worn or damaged parts should be replaced in a timely manner. 

6.2 Overhaul of the Transmission Mechanism 

6.2.1 Overhaul should be carried out once a year. Conduct a comprehensive inspection of the wear of worm gears, worms, gears, bearings, pulleys, shafts and other components, as well as the operation status of the motor. 

6.2.2 When there is wear on the meshing surfaces of the worm and worm gear, and the operating status of the motor.

6.2.3 Replace the steel wire rope if there are local broken wires (no more than 3), obvious wear or hard damage.

6.2.4 Replace the bearing if there are point contacts or severe cracks on the inner and outer rings of the bearing. 

6.2.5 If the fit clearance between the shaft and the drum, the shaft and the pulley, and the bearing seat is greater than 0.5, replace them as appropriate. 

6.2.6 Overhaul or replace the motor if it makes abnormal noises, excessive vibration, or has insulation damage or leakage. 

Lamp Inspection 

6.4 Check if the main cable and various electrical components have short circuits, external damage or other faults. 

7.For More Pictures and Style Options, Please Visit Our Company Website: www.senfalighting.com