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CNG TY C PHN C KH IN L GIA

LU GIA MECHANNICAL ELECTRIC JOINT STOCK COMPANY

---------o0o--------

ASSEMBLY ERECTION Operation and

maintenance manualfor

lighting Masts

(3-point SUSPENSION system)

ADDRESS : 70-LUGIA STR.,HO CHI MINH, VIET NAM

LIGHTING & URBAN EQUIPMENT COMPANY.,LTD


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ASSEMBLY ERECTION OPERATION ANDMAINTENANCE MANUAL

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TABLE OF CONTENTS

No

.CONTENT Page

1 Part I - Introduction 6

2 Part II - Assembly 9

3 Part III - Hoisting wire ropes 11

4 Part IV - Assembly of fixed bracket & hoisting system 17

5 Part V - Erection 22

6 Part VI - Luminaire carriage assembly 25

7 Part VII - Luminaire carriage latching system 28

8 Part VIII - Luminaire and accessories 30

9 Part IX - Maintenance 34

10 Part X - Manufacturers information 35

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LUGIACOAPRON flood lighting MAS3-point suspention system

REMOTE pendant control

i?u khin cm tay

luminaires carriage ringDn ?n d i ng

FIXED SYSTEMDn c inh

C ABLE FOR LIFT UP AND DOWN D8C p nng h D8

J UNTION BOXHp u n i

Kim thu s? t

Thn c tmast body

transition plateTm chuyn

service doorCa ct

reduction gear

Hp gim tc ,

trc b nh v?t

C OV ER PROTEC TIONN?n chp

PO WER SUPPLY 6x4mm2 (ELECTRICA L, INFORMATION)C p Dp 6X4mm2 & c p thng tin

motor 1,1kw ng c 1.1KW

electrical boardBng in

5m

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Part I

1.1 - IntroductionThis manual has compiled to assist site management with the following:

Assembly, erection, operation and periodic maintenance of lighting masts

with winch operated raising and lowering equipment.

Before starting operation, users are recommended to carefully read the instruction.

Lighting masts floodlighting manufactured by HAPULICO is made based on the structure

of steel section with length suitable for transport and installation.

Sections of the Mast body and Utilities are manufactured by modern production line with

advanced technology.

Our engineers had made necessary calculation to gain the comprehensive capacity on mast

structure. A special computer program was used to achieve figures which match the height,

load and wind velocity of polygon section mast.

Strictly following content of working security is essential during the period of installation,

operation and maintenance.

Save time, make it easy to deal with the mast if instruction is closely followed.

The constant development and progress in design and manufacture of the company may

make some actual parts of the mast different from the one in supplied material. The

company holds the rights to modify our production without prior notice.

1.2 - Safety warningSafe working practices in assembly, erection and operation of the equipment should be

observed at all times.It is essential that the following procedures are followed when operating the equipment.

1. Mechanical and electricity works must be controlled by qualified and authorized person only.

2. Unauthorized and observation people must keep a safe distance from the mast.

3. During the work, do not stand right under:

- Flood light: including the fixed bracket and mobile luminaire carriage.

- Ground for conducting maintenance.

When work is in progress

The mast controller is at least 5m far from the mast.

4. Mast controllers and observation people must wear safety helmet.

5. Do not use the corrupted metal cable.

6. Pulling cable and installing equipment with glove.

7. Using lifeline is a must when being on the flood light.

8. Do not use over-limitation safety equipments.

9. Do not operate in strong wind condition.

10. Do not use the similar replacing equipments. Use the right-designed equipments

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Part II COLUMN ASSEMBLY2.1 PACKING, SITE REQUIREMENT AND UNLOADING

2.2 ASSEMBLY OF COLUMN SECTIONS

2.1 PACKING, SIT REQUIREMENT AND UNLODING

1. Column sections are co-axially packed inside each other for ease of handing in transport

2. The fixed bracket assembly and accessories are packet in separate containers.3. The winch is supplied mounted on its mounting bracket ready for bolting into the mast.4. The equipment required at site will be :

a. A mobile crane of sufficient capacity and lift height.

b. Suitable slings.c. A quantity of wedges and timber for packing, to suit the number of column section

d. Two pull lift devices with a minimum capacity of 4 tonnes

e. A crowbar, a sledge hammer...f. A quantity of rubber based grey paint or linseed oil to suit the number of joints.

g. A crew of 4 men are normally required to carry out the assembly and erection, in

addition to the crane crew.

5. Unload the column sections onto the packing on the ground in order of assembly and in lineso that the center of gravity will be adjaccent to the column foundation when assembled,

making due allowance for the joint overlap. This will minimise crane handling when erecting

the column (Figure 2.1).

c t C a thao t c

K hung mng ct

C c o n c tCG

(Figure 2.1)

(Figure 2.1).

2.2 ASSEMBLY OF COLUMN SECTIONS

1. Arrange the base section onto the packing with the access opening on the top and levelled so

that the axis of the column section will be horizontal. The height of the packing must be

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compatible with the base plate and the fixed bracket dimentions so that both will be clear of

the ground when assembled.2. Make sure that the base plate is wedge to prevent rotation.

3. Check that the packing under the arranged sections is a minimum of 300mm clear of the end

of the slip joint length ( L ) (Figure 2.2) to allow for column during assembly.

(figure 2.2)

4. Lubrication for the slip joints is provided by rubber based paint or linseed oil applied to the

column sections to be joined as follows (Figure 2.3)a. The external suface of the lower column section is coated for approximatetely 75% of

the slip joint length from the end of the section.The minimum length of the slip joint is

marked on the male section of the column joint, with red coloured paint.

b. The internal surface of the upper column section is coated for approximately 75% of theslip joint length leaving the first 25 % of slip joint length clear.

ct 300

L

L

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0.75L0.25L 0.25L 0.75L

Chiu di mi ghp khi lp = L

(Figure 2.3)

5. To facilitate, the internal surface can be coated while the section is resting on the packing,

prior to slinging to the required assembly height.

6. Do not use oil or grease for assembly lubrication as this may lead to a detrimental appearance

if runs or drips are formed.

7. Sling the section for assembly at its centre of gravity and engage the sections, making surethat the centre line of the column is correctly aligned in the horizontal and vertical planes.

8. While installing the pull winchs into 2 sides of the column under the close supervision pullwinch will move unanimously to ensure column sections to be fitted synchronously according

to the column axis.(figure 2.4)

(Figure 2.4)

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9. During operation perform step. 8 the external surface of the slip joint can be hammered

using a wooden block and a sledge hammer, to assist in achieving a good joint. Do nothammer directly on the galvanised surface. The length of the slip joint L according to

design.

10. Misalignment of the sections for any reason may lead to jamming, which will prevent goodtelescoping of the joint any may be difficult to rectify.

11. Compare of theoretical slip joint length with the actual slip joint length, and if necessary

continue to apply pressure as describel in 9 above until at least the minimum nominateddimension is obtained.

12. Continue assembly process of column step. 3. Always check straight level of the column

sections.

13. When the final section of the column is in plate, the packing must be arrange so that there isat least 1300mm to enable fitting of the fixed bracket at a later stage.

Part III HOISTING WIRE ROPES3.1 WIRE ROPES

3.2 CORRECT PROCEDURES3.1 WIRE ROPES

1. Hoisting wire ropes are stainless steel supplied by LUGIACO

2. Do not substitute any other construction of wire ropes.3. Minimum breaking strain:

a. 4259 kg for 8mm diameter.

b. 6680 kg for 12mm diameter.

3.2 CORRECT PROCEDURES FOR MAKING UP SUSPENSION WIRE ROPES

1. Disconnect the cable as illustrated in pictures 3.1 and 3.2.

2. If cable is wrongly disconnected, it will be tied or twisted. Though the cable surface is

strained but in fact, its inner structure was mixed.

3. If that tied/twisted positions are strained, then at the position, length and quality of cable

will be reduced, life expectance and safety of cable will seriously lessen.4. Do not straighten the tied or twisted section. Replacement of new one is essential in the

case.

5. Types of

twisted

section.

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a) Picture 3.3 & 3.4: Twisted on the left or right due to wrong disconnection.

b) Picture 3.5 & 3.6: Illustration of the right and left twisted (the usage of this is

absolutely forbidden, it is obligatory to replace with the new one).

c) Picture 3.7 & 3.8: Illustration of straightening the right/left twisted (the usage of this is

absolutely forbidden, it is obligatory to replace with the new one).

6. The fastening clams must be put in position. U-fastening clams must closely touch the wire

and be located from the first position (picture 3.9).

Picture 3.9

7. Wrongly cliping (3.10) will affect the strength of the wire, to repair this, it is essential to

make the fastening clams in series (3.11).

Picture 3.10

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Picture 3.11

8. The number of fastening clams are required as in the following table:

Cable radius (mm) 8 12

Number of fastening clams

(nos) 0303

Distance to the center (mm) 45 60

Part IV ASSEMBLY OF FIXED BRACKET AND HOISTING SYSTEM

4.1 ASSEMBLY OF HOISTING WIRE ROPES TO THE TRANSMISSION SET

4.2 ASSEMBLY OF TRANSMISSION SET

4.3 ELECTRICAL POWER CABLE ASSEMBLY

4.4 POSITIONING THE TRANSMISSION SET

4.5 ASSEMBLY OF FIXED BRACKET

4.1 WIRE ROPES

- Prepare the 3 hoisting wire ropes to the same length and mark (refer figure 4.1)

im nh du

Lc

(Figure 4.1)

Lc : Length of wire rope

Length of wire rope in the following table

Mast size Mast 25 m Mast 30 m Mast 35 m Mast 40 m

Lc (mm) 24500 29500 34400 38900

4.2 ASSEMBLY OF TRANSMISSION SET

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1. Feed the pull through rope into the mast through the door opening and attach the other end to

the base plate (Figure 4.2).

(Figure 4.2)

2. Tie the other end of the rope to the transmission set (Possitioning (1) Figure 4.3)

3. Tie 3 hanging rope to the transmission set (Possitioning (2) Figure 4.3) place a wooden block

in the column (3) (Figure 4.4) to protect the hanging rope and power cable

(Figure 4.3)

(Figure 4.4)

4. Lay the cables out perfectly straight to avoid any kinks and attach. Pull the transmission set

into column.

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5. If it is not possible to lay the cables out straight thay may be coiled as shown in (Figure 4.5)

(Figure 4.5)

Note : In order to avoid faulty in the assembly process it requires to distinguish electric cable and

hanging cable with a colour plaster, each kind with one colour

Ensure to assemble according to right direction of electric cable and hanging cable from

transmission set to puly (Figure 4.6)

A

B

3

5

(Figure 4.6)

Include :

A : Puly hanging rope

B : Puly electric cable

3 : Hanging rope

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5 : Electric cable

4.3 ELECTRICAL POWER CABLE ASSEMBLY

1. One, two or three power cables may be supplied subject to the power required for the

luminaires.

2. Identify each power cable using coloured adhesive tape.

3. Each power cable (5) is placed facing a hoisting wire rope (3) (Figure 6)

4. Fasten the electric cable in to the tranmission set with clamp plates (4). Note electric cable (5)must be let unstraight until the hanging cable is straight.

5. Leave a distance of 2m metre between the transmission set and cable end (Figure 4.7)

2000mm

45

3

(Figure 4.7)

4.4 POSITIONING THE TRANSMISSION SET

1. When the wire ropes and power cables are correctly aligned, pull the transmission set through

the mast until the 2m above the top of the door opening.

2. Wire ropes and electrical cables must project outside the top of the mast, for it to pass through

the fixed bracket when fitted.

Note :1. Bolt to fit winch bracket and machine is M16 (Page 27)

2. Mechenical transmission system includes machine, cable drum and chain transmission set were

assembled and adjusted at the bottom of column (Figure 4.8).

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transition plateTm chuyn

serv ice doo rCa c t

reduction gear

Hp gim tc,trc b nh v?t

motor 1,1kwng c 1.1KW

electrical boardBng in

(Figure 4.8)

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4.5 ASSEMBLY OF FIXED BRACKET

1. Assemble the fixed bracket to the stub using M16 bolts (Refer page 27)

2. Remove the fixed bracket cover (Figure 4.9).

3. Pass the hanging rope (to raise fixed bracket with crane) with position one among three age of

fixed bracket according to vertical (Figure 4.9)

(Figure 4.9

4. Feed (about 2m) hanging cable and electrical cable through fixed bracket.

5. Slide fixed bracket to the top of mast (Figure 4.10)

(Figure 4.10)

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6. Pass the wire ropes and electrical cable above pulies (Figure 4.11) (Note : Separate hanging

ropes and electrical cable with cable dividing set in the fixed bracket and dont let the cable

attach).

(Figure 4.11)

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7. Pull hanging rope and electrical cable to the bottom of base plate and bind together (Note :

Dont let the cable be twisted)

Part V ERECTION

5.1 COLUMN FOUNDATIONS

5.2 PROCEDURE FOR ERECTION

5.3 BOLT TORQUE TABLE

5.1 COLUMN FOUNDATIONS

1. The column foundation, supplied by others, must be designed by competent civil engineers to

suit the soil conditions at the location of the column.

2. Before pouring concrete for the foundation it is recommended that templates be used to

ensure thats the bolts will be correctly centred and vertical. The protruding portion of the

bolts should be coated with grease and protected by a cap.

5.2 PROCEDURE FOR ERECTION

1. Thread nuts over all the anchor bolts so that they will be under the column base plate and

clear of the top of the concrete by approximately 15-20mm.

2. Adjust two pairs of nuts diametrically opposite at 90 degrees so that thay are 15-20mm higher

than the remainder and level with each other. These four nuts will provide a means of

obtaining vertical alignment by adjustment (Figure 5.1)

160

15-20

15-20

(Figure 5.1)

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3. The fifting point will be several metres further up the column than the centre of gravity. At

the lifting point a suiteble sling is applied from which two Pull-lift or similar divices, one

each side of the column, are arranged with the lower end anchored at the base plate. These

Pull-Lift devices are tensioned to avoid a possible seperation of slip joint, and to prevent

the sling from slipping up the column (Figure 5.2)

4. Before lifting the column, mark the base plate and foundation to ensure that the fixed bracket

assembly and lighting array are correctly aligned.

5. If necessary, rotate the column on the packing prior to lifting to facilitate the alignment.

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(Figure 5.2)6. When the column is located over the bolts, fit washers and nuts to the anchor bolts. Adjust the

4 nuts on the underside of the base plate which are apaced at 90 degrees and are 15-20mm

above the others, using the weight of the column to facilitate its vertical adjustment

7. When the column is vertically aligned tighten all the nuts under the base plate and the

corresponding nuts above. Apply lock nuts to all bolts. Keep the mast suppended on the crane

until this operation is completed. Tension the nuts as specified on the bolt torque table Page

27.

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8. Fill the space under the base plate with grout and protect exposed parts of the anchor bolts

with bitumen or by other suitable means (Figure 5.3)

(Figure 5.3)5.3 BOLT TORQUE TABLE

RECOMMENDED BOLT TORQUE FOR LUGIACO MASTS

Lc xit ai c

tham kho trang 27

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FOUNDATION ANCHOR

BOLTS

BOLTS FOR COLUMN AND ACCESSORIES

SIZE

(mm)CLASS

NUT TORQUE

(Nm)

SIZE

(mm)CLASS

TORQUE

(Nm)

CLAS

S

TORQUE

(Nm)

M30 4.6 495 M10 5.8 30 8.8 45

M36 4.6 865 M12 5.8 50 8.8 80M42 4.6 1380 M16 5.8 125 8.8 190

M48 4.6 2065 M20 5.8 245 8.8 375

M56 4.6 3335 M24 5.8 420 8.8 640

M64 4.6 5035

NOTE:

Foundation anchor bolts are class 4.6

If high tensile steel foundation bolts are used special anchoring and tensioning techniques must

be follower and specialised. Foundation engineering design is required

Hexagon head bolt class identification is marked on the head of the bolt.

Never use bolts of a class lower than specified.

When tensioning bolts and nuts, apply the torque wrench to the nut and hold the bolt head with a

spanner to prevent the bolt turning.

Part VI LUMINAIRE CARRIAGE ASSEMBLE

6.1 PREPARE

6.2 LUMINAIRE CARRIAGE ASSEMBLE

6.1 PREPARE

1. Fit the 3 luminaire carriage support arms into mast body.

2. Installation operation floor above of bracket 0,6m

6.2 LUMINAIRE CARRIAGE ASSEMBLE

1. Parts of luminaire carriage

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- Luminaire carriage

- Fixed frame

- Support for obstruction lighting

- Support for flood light

- Junction box

- Located frame

- Latch grove

2. Parts of luminaire carriage installation together (refer figure 6.1)

5

8

1

2 6

34

7

(Figure 6.1)

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(Figure 6.1)

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3. Hanging cable installation refer (Figure 6.2)

(Figure 6.2)

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4. Remove luminaire carriage with hand and check refer (Figure 6.3)

(Figure 6.3)

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Part VII LATCHING OF THE LUMINAIRE CARRIAGE

7.1 POSSITION OF THE LATCH

7.2 CLOSED AND OPEN STATUS OF THE LATCH

7.1 POSSITION OF THE LATCH

1. Latching of the luminaire carriage include 3 latchs arrange refer (Figure 7.1).

1

2

(Figure 7.1)

2. Latch (1) may be spun round pin (2) (Figure 7.2)

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1 2

(Figure 7.2)

7.2 STATUS OF THE LATCH

Status of the latch:

1. Closed status: the flood light reaches the mast top, the latch (1) is fixed to the supporter (3)

on the fixed bracket (Figure 7.3)

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1

3

(Figure 7.3)

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2.Open status: starting the lowering; the latch (1) leaves the supporter (3) and moves down

(Figure 7.4)

(Figure 7.4)

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(Figure 8.2)

The Figure 8.2 describle the operation of the switch. The process ends when the pin (1)

contact to the process switch (2).

Part IX- MAINTENANCE

9.1 12 - MONTH MAINTENANCE

9.2 24 - MONTH MAINTENANCE

9.3 REPLACEMENT OF HANGING CABLE

9.4 REPLACEMENT OF ELECTRIC CABLE

9.5 REPLACEMENT OF THE PULLING SLING

9.1 12-month maintenance.1.Shut down the electric source.

2.Check all the bolts, nuts; tighten the transmission set to see if they are already loosen or

corroded.

3.Check lubricant level in service outlet box. Fill in or replace if necessary.

Hanging and pulling cable.

4.Thoroughly check the outstanding conditions of the pulling sling all the way long from the

winch pulley to the distribution unit.

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5.Check all the links between the distribution unit and the sling to see if they are already loosen or

malfunctioned.

6.Check the fastening clams of the electric cables to see if the electric cables already wear

some abrasion and fasten the bolts if necessary.

Equipments inside the Mast

7.Check the plugs and the electric wires to see if they are crooked and broken.

8.Check the connection points of the main panel.

9.Check the earthing wire

10. Connect the motor to the main and lower the lighting frame.

11. All the lights and the switch boxes must be check to detect any possible leakage of the rain

water (this is a crucial requirement).

12. Clean all the pane of the lights and the reflecting surfaces if necessary. It is forbiddance to use

the materials or substances possibly causing scratches to the glass panes of the lights.

13. Disconnect the light bulb and check the holder.

14. Check the electric cable for the damages relating to the ultraviolet rays or other physical

reasons.

15. Check the connection in the connection boxes and at the intermediate connection point.

16. Check the liner around the electric cable.

17. Check the bolts and nuts of the flanges to detect the loosening and fasten if necessary.

18. Check the working condition of the hanging lock.

19. Test the lams.

20. Hoist the lighting frame.

21. Socket the plugs.

Anchor bolts at the foot of the mast.

22. Check the fastening of the nuts.

Note:

23. Take note and report all problems.

9.2 24-month maintenance .

1.check and carry out the maintenance regime for 12-moth period and do some more

subworks as follow:

2.Lower the lighting frame on to the supporters and disassemble it.

3.Unscrew the nuts and bolts connecting the flanges to detect any crook if having.

4.Check the washers for any abrasion, replace with the new one if necessary.

5.Check the outer surface of the electric cable for any abrasion. If so, replace the cables with thenew one.

6.Check the shape of the lighting frame.

9.3 Replacement of the hanging cable .

1.Prepare 1 section of the same sort of sling of which the length is 1m longer than the masts

height.

2.Make the loop at each end.

3.Lower the lighting frame onto the supporters.

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4.Disconnect the hanging cable from the lighting frame.

5.Cut the old sling at the at the position right above the hanging position.

6.Plait or joint one end of new sling to the just-cut end of the old section.

7.Lower the distribution unit until the end of new section could go inside the mast from the top

hole. Pay attention to keep the other end of new section from not sliding through the top

hole of the mast.

8.Disconnect the new sling and the old one, make the new loop and fasten the new sling to the

distribution unit.

9.Connect the other end the new sling to the lighting frame. Check the working processes of the

lighting frame (it is a must to keep the electric cable from not being tensile).

10. Reset the limit for the traveling of the lighting frame.

Picture 9.1

9.4 Replacement of electric cable

1.Prepare 1 section of the same kind of the old electric cable with 2m longer than the old one.

2.Lower the lighting frame onto the supporters.

3.Disconnect the electric cable from the connection boxes on the lighting frame. Tap one end of

the new cable to the connection box on the lighting frame. The other end will be jointed to

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the end of the old cable in order to get it slide into the mast through the top hole. The link

should be firm enough to be able to pull the new cable up into the mast through the top

hole.

4.Hoist the lighting frame to the working position, disassemble the old cable from the fastening

clams.

5.Manually pull the new cable all the way inside the mast and fasten it to the distribution unit by

using the fastening clams (remember that the electric cable is not supposed to bear

any weight of the lighting frame)6.Remove the old cable and tap the new one of the main panel

Picture 9.2

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9.5 Replacement of the pulling sling on the pulley winch

1.Disconnect the old sling from the distribution unit.

2.Unroll the old sling from the pulley (keep on pushing the Down button on control unit).

3.Get 1 section of the new sling with the same length as the old one.

4.Connect the one end of the new sling to the pulley. Keep on pushing the Up button to roll the

sling around the pulley.

5.Make the loop at the other end of new sling then connect it to the distribution unit.

6.Make the necessary adjustment and reset the traveling process of the lighting frame.

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