Night Scan Chief NIGHT SCAN CHIEF INSTALLATION, OPERATION & MAINTENANCE MANUAL The Will-Burt Company 169 S. Main Street Orrville, OH 44667 www.willburt.
Night Scan Chief WARRANTY The Manufacturer warrants its products to be free from defects in material and workmanship for a period of one year from the date of shipment from the factory.
Night Scan Chief TABLE OF CONTENTS 0. SAFETY SUMMARY 1. INTRODUCTION I 1-1 1.1 Safety Precautions ................................................................................................................................1-1 1.2 Introduction............................................................................................................................................1-1 1.3 Description.......................................................................................................
Night Scan Chief 7. SOFTWARE REVISIONS 7-1 7.1 Introduction ......................................................................................................................................... 7-1 8.
Night Scan Chief SAFETY SUMMARY SIGNAL WORD DEFINITION Per the ANSI Z535.4 standard, the following signal words and definitions are used to indicate hazardous situations: DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
Night Scan Chief SPECIFIC SAFETY PRECAUTIONS The following are safety precautions that are related to specific procedures and therefore appear elsewhere in this publication for emphasis. These are recommended precautions that personnel must understand and apply during specific phases of installation, operation and maintenance. Safety Instruction-Operation! For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code.
Night Scan Chief Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric installations and service. When relamping an installed fixture, make sure all power to fixture is off and that the fixture is cool Safety Instruction – Operation! At all times prior to mast operation, insure that: 1.) 2.) 3.) 4.) 5.) 6.
Night Scan Chief CHAPTER 1 INTRODUCTION 1.1 SAFETY PRECAUTIONS Refer to the Safety Summary for precautions to be observed while operating or servicing this equipment. 1.2 INTRODUCTION This manual covers the installation, operation, troubleshooting and maintenance instructions for the Night Scan Chief. The manual should be reviewed in its entirety. Contact the Will-Burt factory with any questions before performing any procedures outlined in this manual. 1.
Night Scan Chief 1.4 REFERENCE DATA The reference data for the Chief given in Table 1-1 is not inclusive of all models. Please refer to product literature or www.willburt.com for additional information including length, width and height information. Table 1-1. Reference Data Night Scan Chief Model No. NS6 Stowed Height NS7.5 Stowed Height NS6 Ext. Height NS7.5 Ext. Height Total Unit Weight** Tube Diameter Range No. of Mast Sections Mast Air Volume (NS7.5) Max.
Night Scan Chief Mast Loads It is important that the mast be securely mounted to a sturdy platform, which will not overturn during operational loading of the mast. Figure 1-2 provides loading information for the mast, which can be expected during operation. All values given are in lbs.
Night Scan Chief CHAPTER 2 INSTALLATION Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric installations and service. Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing.
Night Scan Chief 2.3 UNPACKING Unpack the Night Scan Chief as follows: 1. Carefully open and remove all parts from shipping container. o Lift the unit from the shipping container by the base tube (see Figure 2-1). o Do not lift the Night Scan by the lights or RCP. 2. Inspect for any shipping damage. If damage has occurred, notify carrier. 3. Be sure that all components are included and that the required tools are readily available. LIFTING POINT Figure 2-1 Lifting Point 2.
Night Scan Chief 33.0 SADDLE MOUNTING HOLES (n.56" SEE NOTE) BASE MOUNTING HOLES (n.56" SEE NOTE) 11.0 4.8 2.4 5.5 40 1/8" (6FT. MAST) 46 1/8" (7.5FT. MAST) Figure 2-2 Night Scan Base Mounting Hole Locations Junction Box Installation The junction box serves as an interface between the Hand Held Remote Control and the Night Scan Base. It is not used in installations where only the Panel Mount Remote Control is used. The junction box is not rated for installation in wet locations.
Night Scan Chief Surface mounting For a surface mount installation, four #8 screws, nuts and lock washers must be provided by the installer. The screw length should be ¾ inch plus the panel thickness. Remove the junction box cover and mount unit through the counter bored holes in the junction box. Secure on the back side using lock washers and nuts. Make the necessary cable connections (see schematics in section 4.4) and replace cover. 5.75" MOUNTING HOLES (Ø.19" SEE NOTE) 2.
Night Scan Chief Table 2-2. Handheld Remote Control Connector Pin-out HHRC Pin Pin Function To Pin of DC Power Connector Recommended Wire Ga. A + Signal C 20 B + Power A 20 C - Power B 20 D - Signal D 20 Figure 2-5 Hand Held Receptacle Pins 2.7 CONNECTING THE INTERLOCK CONTACT (OPTIONAL) The Chief provides an interlock relay contact output to enhance integration into vehicle safety circuitry.
Night Scan Chief 2.9 INSTALLING THE WARNING LIGHT As required by NFPA regulations, a red flashing or rotating light, located in the driving compartment, must be automatically illuminated whenever the vehicle parking brake is not fully engaged and the light tower is extended. The warning light is wired into the system via the interlock contact described above. A customer provided, normally closed pilot relay should be installed on pins J4-8 and 9 of the base circuit board.
Night Scan Chief present. Contact with combustible materials can cause ignition resulting in fire or explosion. Before operating the Chief, be sure that there are no overhead obstructions and that there are no power lines within 20 feet of the mast. Visually inspect the unit for any damage. If damage is apparent, do not use the mast. Have it serviced prior to use. Check for any objects which might obstruct motion of the mast or cause binding. Remove any material that may hinder mast function.
Night Scan Chief CHAPTER 3 OPERATING INSTRUCTIONS All operators must read the Operation section of this manual and be properly trained. Keep personnel clear of mast while during operation. For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code. Do not use in the presence of flammable gases or liquids such as paint, gasoline or solvents.
Night Scan Chief 3.1 THEORY OF OPERATION – MECHANICAL Night Scan Chief – Mast The Night Scan Chief operates using a DC powered actuator to drive the mast from nest to 90 degrees. When at 90 degrees, a magnetic sensor detects the actuator position and prevents further driving of the actuator. The sensor also notifies the operator through the Remote Control(s) that certain RCP functions are available.
Night Scan Chief PHOTO INTERUPTER FLAG Figure 3-2 Photo Interrupter and Flag 3.2 THEORY OF OPERATION – ELECTRICAL The Chief control is based on a distributed intelligence control structure. Each main section of the Chief has a circuit board with an embedded micro controller. These sections are: the Base, the RCP, and the Remote Control(s). These boards “talk” to each other over a multi-drop RS-485 serial communications link. Another key component of the control is an initialization circuit.
Night Scan Chief control by pulling the switch operator. This is a momentary function, and the switch will return itself to a neutral position on its own. Secondly, it functions as an emergency stop when the switch operator is pushed all the way in. This is also a momentary function, and the switch will return itself to a neutral position on its own. When using Will-Burt’s accessory kit push/pull switch, accidental initiating is extremely unlikely since it would require pulling the switch button.
Night Scan Chief Auto-Up function is accomplished by two rapid sequential activations of the “Mast Up” button within a half second period of time. This automatic unattended sequence can be aborted at any time by a single activation of the “Mast Down” button or any other button on the Remote Control(s). The Auto-Up function will only bring the Chief from the horizontal stowed position up to the 90º position and turn the lights on. It will not raise the mast any further vertically on its own.
Night Scan Chief the hardwired remote control) involves giving two quick successive depressions of the “Mast Down” button (within ½ second). This will initiate an unattended complete stowing of the mast. This Auto-stow mode can be interrupted and canceled at any time by pressing any of the buttons on the Remote Control. Note: To ensure proper seating of the RCP in Night Scan Chief saddle, the control watches for an increase of current from the actuator.
Night Scan Chief COVER SCREWS RIGHT SIDE COVER KNURLED PIN PIN & E-CLIP Figure 3-3 Revision 1 Cover and Screw Removal for Manual Stow (Night Scan Chief only) 3-7
Night Scan Chief CHAPTER 4 MAINTENANCE AND SERVICE INSTRUCTIONS 4.1 INTRODUCTION This section of the manual describes routine maintenance procedures and covers general service information. Refer to Chapter 5 for exploded views of the Night Scan Chief and the accompanying Tables with item descriptions and part numbers, which may be used for ordering replacement parts. 4.
Night Scan Chief 6. Exhaust the mast completely. Allow several minutes for the lubricant to settle and spread around the wear ring and seal at the bottom of each mast section. Keep hands clear of the descending collars while the mast is being lowered to avoid pinching. 7. Extend the mast again one section at a time in the same sequence (smallest to largest). Wipe off any excess lubricant which flows out of the weep holes.
Night Scan Chief 7. Cycle the mast several times, checking that the mast is plumb each time. Adjust the switch if necessary. 8. Replace cover.
Night Scan Chief Adjusting the Magnetic Switch The Magnetic Switch is located on the mast base tube. In the Night Scan Chief, the magnetic switch senses a magnet located in the top tube and serves to indicate that the mast has exhausted all air and that it is safe to nest into the saddle. If the switch is out of adjustment, it will prevent the mast from nesting to the saddle from the 90 degree position.
Night Scan Chief 9. Initiate and raise the mast to 90 degrees. Replace the RCP cover. + + + + J4 POINTERS @ HOME POSITION + + + + Figure 4-3 Flag Settings DIP switch setting Chief base boards require that the DIP switch be set appropriately to determine operational mode. RCP boards require that the DIP switch be set appropriately to determine operational mode. This takes the place of setting the operational mode through software by changing a variable.
Night Scan Chief S2 Figure 4-4 DIP switch location: Chief base board To set the operational mode for the RCP board, locate the DIP switch S1 (see Figure 4-5) and set the DIP switch as follows: • Position 1 - Close to cause the RCP to self stow if there is an error. • Position 2 – DO NOT CLOSE.
Night Scan Chief 4.4 SYSTEM SCHEMATICS A system schematic is given in order to aid in electrical troubleshooting as outlined in the following section. BLU BRN GRY 20 GA TWISTED PAIRS J1 TO HHRC BATTERY (+) 10 GA BATTERY (-) 10 GA TO CUSTOMER VEHICLE INTERLOCK (2 AMP. MAX. LOAD) CLOSED CIRCUIT WHEN STOWED SEE SECTION 2.
Revision 1 O JUNCTION BOX Figure 4-8 10 GA WHT/BLK |11| |12| |13| |14| RED BLK WHT BLK GRN VIO SHIELD BLK RED AIR COMPRESSOR + BLK 2 WHT 2 BLK 1 4206101 CABLE BLU ORG WHT 1 J5 TB3 J4 BRN BLK M M BLU BRN GRY LOOK-UP LIGHT INCLINATION MOTOR _ + WHT/RED DOWN VALVE BEEPER (OPT) 18 GA 20 GA TWISTED PAIRS 4032504 16 FT CABLE 4032505 30 FT CABLE 4032506 50 FT CABLE BASE MAST J5 TB3 J4 REMOVE JUMPER IF PARKING BRAKE INTERLOCK IS USED.
Figure 4-9 Revision 1 RED BLK |3| |4| |5| RCP RED WHT |3| |4| |5| |6| YEL/GRN GRN/YEL TO LEFT LIGHTS YEL/GRN POINTERS @ HOME POSITION J4 + |6| YEL/GRN GRN/YEL |10| |9| YEL/GRN WHT 18GA RED + |10| TO RIGHT LIGHTS |8| 18GA BLK + |9| RED |7| PAN + BLK |8| |7| AC LIGHTS + TO LEFT LIGHTS TO RIGHT LIGHTS RED DC LIGHTS S1 TB1 J1 |11| |12| |13| |14| J1 TO MAST TILT 18GA BLK 18GA RED OPTIONAL STROBE Night Scan Chief + + + Night Scan Chief Remote Control
Night Scan Chief 4.5 TROUBLESHOOTING ELECTRICAL Operating Environment One of the most common causes of improper operation is trying to operate outside of the stated system requirements. (See section Table 1-1for DC power requirements). A good method of checking the voltage at the Chief is to connect a voltmeter to the wires in the junction box powering the Remote Control(s) (pins B and C of J1 (see schematics in section 4.4). This will give a good indication of power loss across the DC cabling.
Night Scan Chief mast path, and confirm that the proximity switch is being properly activated. Revision 1 Err 1,07 Unrecoverable Communication Error The Base board has not sent out communications recently Indicates a software problem. Notify WillBurt Err 1,08 Software Fault Internally detected error Indicates a software problem. Notify WillBurt Err 1,09 Initiate Pushbutton The Initiate input has Wiring Short in the been closed for too DC cable or long.
Night Scan Chief schematics in section 4.4 Revision 1 Err 1,13 Mast Nested Proximity Switch Disagreement The proximity switch sensing the mast actuator at almost nested position has conflicting complementary outputs. There may be a wiring problem, or a defective proximity switch. Check the voltages at black and white wires with respect to the blue wire. These two voltages should be opposite of each other as the proximity switch is activated and inactivated.
Night Scan Chief Err 1,16 Revision 1 Mast Nested Proximity Switch Wiring Error outputs wired backwards and 3 of J3 may need to be swapped. The proximity switch not being energized could also cause it. Place a magnet close to the switch to check before changing wiring. Refer to system schematics in section 4.
Night Scan Chief 4.5.1.2 RCP Board The remote control positioner (RCP) board is located in the positioner at the top of the mast and is assigned unit number two (2). It should be noted that having the RCP covers off can cause improper RCP operation, especially outdoors. The RCP board may generate the messages of Table 4-2: Table 4-2.
Night Scan Chief Revision 1 Err 2,07 Unrecoverable The RCP board Communicatio has not sent out n Error communications recently Bad connection in communications link, or RCP is not powered or is inadequately powered. Make sure the power at the RCP board is at least 10.5 volts. Check continuity of the internal coiled cable between the base board and the RCP board (see system schematics in section 4.4) Err 2,08 Software Fault Internally detected error Indicates a software problem.
Night Scan Chief Revision 1 Err 2,13 Pan Right Limit The left pan photosensor was made before the right photosensor indicating wrap around or the right photosensor is linear or defective Check to make sure the pan flag is not located in between the two photosensors. If it is, slowly move the RCP head by hand (with power off) until it is in the proper position. Readjustment of the flag may be necessary to set the proper home position.
Night Scan Chief 4.5.1.3 Remote Control(s) Board The handheld remote control board is located in the handheld unit and is assigned unit number three (3). The Remote Control board may generate the messages of Table 4-3: Table 4-3.
Night Scan Chief Warning Codes Warning codes are presented on the LED eight-digit alphanumeric display. The codes are a combination of numbers that identify both the general location of the warning, and the type of warning. The first of two numbers is a single digit number indicating which board. The second number is a two-digit number indicating the warning. Warning codes differ from Fault codes in that they do not require clearing. If the condition causing the warning goes away, so does the warning.
Night Scan Chief 4.6 TROUBLESHOOTING MECHANICAL Table 4-5. Mechanical Troubleshooting Symptom Mast sticking during extension or retraction Root Issue Troubleshooting Sequence Mast is dirty and/or requires lubrication. 1) Clean and lubricate mast. Air leak in mast or valve/compressor assembly. Use a soapy water solution to pinpoint the leak. If the mast is leaking, it will require new seals.
Night Scan Chief CHAPTER 5 PARTS LIST 5.1 PART LISTS Table 5-1. Night Scan Chief Base Assembly Parts List Mark No. Description Part Number 1 Base Plate 4121702 2 Base Circuit Board 4118301 3 Saddle Assembly 4122201 4 Compressor Assembly 4141101 5 Actuator 4136302 6 Mast Assembly, 6 ft 4142204 Mast Assembly, 7.
Night Scan Chief 28 Shim Washer 4122601 29 External Retaining Ring 30 Spacer 31 Internal Retaining Ring 32 Pivot Block 4121001 33 Sleeve Bearing 4120401 N/A Base Cover Left 4143002 N/A Base Cover Right 4141002 Handheld Remote Control 4183601 3401 4121301 3783 N/A N/A N/A N/A N/A N/A N/A 11 6 7 8 1 22 3 9 2 10 14 12 15 21 19 20 Figure 5-1 Revision 1 Exploded View - Base Left Side 5-2
Night Scan Chief 4 13 17 5 23 18 24 16 Figure 5-2 Base Right Side 25 MAST BOTTOM 32 32 31 33 28 31 30 33 28 27 26 Figure 5-3 Revision 1 28 29 Exploded View – Mast Pivot Assembly 5-3
Night Scan Chief Table 5-2. Remote Control Positioner Assembly Parts List Mark No.
Night Scan Chief 16 2 13 21 8 6 20 6 5 4 20 5 15 22 12 26 1 14 10 13 9 11 18 8 19 7 17 16 3 17 Figure 5-4 Revision 1 Exploded View - Remote Control Positioner (RCP) 5-5
Night Scan Chief CHAPTER 6 REVISIONS Revision 0, October 2007: Initial Release. Revision 1, December 2007: Update base schematic Figure 4-8 to correct inclination motor wiring and add capacitor. Add 2.10 to address capacitor use in 24 vdc multiplex installations.
Night Scan Chief CHAPTER 7 SOFTWARE REVISIONS 7.1 INTRODUCTION There are several circuit boards in the Chief system. Each has its own microcontroller with associated software. A person may “query” the software revisions by simultaneously holding down both Remote Control tilt buttons (up, down). The revision levels can then be viewed as they scroll across the alphanumeric display. A typical display might be “1:4.3 2:4.2 3:4.2”. This would indicate that board 1 (the base board) has revision 4.
Night Scan Chief CHAPTER 8 APPENDICES Revision 1 8-2
MATERIAL SAFETY DATA SHEET The Will-Burt Company Orrville, Ohio 330-682-7015 SECTION A: IDENTIFICATION AND EMERGENCY INFORMATION Product Name: Mast Lubrication 900600 Chemical Name: Not Applicable (N/A) Cas Number: N/A Chemical Family: Industrial Metalworking Compound Emergency Telephone Number: 440-543-9845 (Etna) HMIS RATING: H= 1 F= 1 Revision Date: 5/3/00 R= 0 PP= C SECTION B: HAZARDOUS INGREDIENTS This Product does not contain any SARA Section 313 reportable compounds.
SECTION D: PHYSICAL HAZARDS Stability: Stable Conditions to Avoid: Strong Oxidants Incompatibility: Strong Oxidants Decomposition Products: Highly dependent on combustion conditions. Mixture of air-borne solid, liquid and gases evolve upon pyrolysis or combustion of this product. CO2 and other organic compounds may be formed upon combustion.
SECTION F: EMERGENCY AND FIRST AID PROCEDURES Skin contact: Eye contact: Ingestion: Remove contaminated clothing and wash with soap and water. If irritation occurs get medical attention. Flush with water for 15 minutes. If irritation occurs get medical attention. Do not induce vomiting. Get medical attention. SECTION G: SPECIAL PROTECTION / SPILL AND LEAK PROCEDURES Ventilation: Local exhaust – required only to capture vapor, mist or fumes.
WILL-BURT PRODUCT REGISTRATION AND EVALUATION RETURN WITHIN 90 DAYS FROM DATE OF PURCHASE PLEASE COMPLETE THIS FORM AND RETURN TO WILL-BURT USING THE PREPAID SELFADDRESSED ENVELOPE WHICH HAS BEEN PROVIDED. THANK YOU FOR YOUR ASSISTANCE. CUSTOMER NAME: _____________________________________DATE: _______________ ADDRESS: __________________________________________________________________________ CITY / STATE / ZIP: ________________________PHONE No. : _______________________ PRODUCT MODEL No.
ARE SATISFIED WITH THE APPEARANCE OF THE PRODUCT? YES _______NO_________ IF NO EXPLAIN : _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ RATE THE INSTALLATION / OPERATION / SERVICE INSTRUCTIONS.
