Will Burt Night Scan Chief Installation, Operation & Maintenance Manual

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Night Scan Chief

NIGHT SCAN CHIEF

INSTALLATION, OPERATION & MAINTENANCE MANUAL

The Will-Burt Company

169 S. Main Street

Orrville, OH 44667

www.willburt.com

Revision 1 i

Revision 1, December 2007

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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. The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of improper installation, improper storage, unauthorized service, alteration of products, neglect or abuse, or use of the product in a manner inconsistent with its design, accident, acts of God, or failure to properly maintain this product. This warranty does not extend to any component parts not manufactured by Manufacturer, however, Manufacturer's warranty herein shall not limit any warranties made by manufacturers of component parts which may extend to Buyer.

THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, AND NO REPRESENTATIONS, GUARANTEES OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING, BUT NOT LIMITED, TO A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) ARE MADE BY MANUFACTURER IN CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF MANUFACTURER.

Claims for defects in material and workmanship shall be made in writing to Manufacturer within thirty (30) days of the discovery of defect. Failure to provide notice as required hereby shall be conclusive evidence that the product was in conformity with the warranty, and the Manufacturer shall be released from any and all liability relating to the product. Manufacturer may either send a service representative or have the product returned to its factory at Buyer's expense for inspection. If judged by Manufacturer to be defective in material or workmanship, the product will be replaced or repaired at the option of Manufacturer, free from all charges except authorized transportation.

THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF MANUFACTURER WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL, OR BE RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.

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TABLE OF CONTENTS

0. SAFETY SUMMARY I

1. INTRODUCTION 1-1

1.1 Safety Precautions................................................................................................................................1-1

1.2 Introduction............................................................................................................................................1-1

1.3 Description.............................................................................................................................................1-1

1.4 Reference Data.....................................................................................................................................1-2

1.5 Technical Information............................................................................................................................1-2

INSTALLATION 2-1

2.1 Introduction............................................................................................................................................2-1

2.2 Tools and Materials Required for Installation........................................................................................2-1

2.3 Unpacking..............................................................................................................................................2-2

2.4 Attaching to vehicle...............................................................................................................................2-2

2.5 Connecting the Push/Pull Switch (Junction Box)..................................................................................2-4

2.6 Connecting the Remote Control(s)........................................................................................................2-4

2.7 Connecting the Interlock Contact (optional)..........................................................................................2-5

2.8 Connecting Interlock Input Contacts (optional).....................................................................................2-5

2.9 Installing the Warning Light...................................................................................................................2-6

2.10 MULTIPLEX SYSTEMS OPERATING AT 24 VOLTS........................................................................2-6

2.11 Pre-operational Check.........................................................................................................................2-6

3. OPERATING INSTRUCTIONS 3-1

3.1 Theory of Operation – Mechanical........................................................................................................3-2

3.2 Theory of Operation – Electrical............................................................................................................3-3

3.3 Push/Pull Switch – NFPA INSTALLATIONS.........................................................................................3-3

3.4 Push/Pull Switch – non-NFPA INSTALLATIONS..................................................................................3-4

3.5 Remote Controls (Hand held)................................................................................................................3-4

3.6 Raising the Mast....................................................................................................................................3-5

3.7 Aiming the Remote Control Positioner..................................................................................................3-5

3.8 Stowing the Mast...................................................................................................................................3-5

3.9 Emergency Stow (Loss of Power):........................................................................................................3-6

MAINTENANCE AND SERVICE INSTRUCTIONS 4-1

4.1 Introduction............................................................................................................................................4-1

4.2 Scheduled Maintenance........................................................................................................................4-1

4.3 Adjustments...........................................................................................................................................4-2

4.4 System Schematics...............................................................................................................................4-7

4.5 Troubleshooting Electrical...................................................................................................................4-10

4.6 Troubleshooting Mechanical ...............................................................................................................4-19

PARTS LIST 5-1

5.1 Part Lists................................................................................................................................................5-1

6. REVISIONS 6-1

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7. SOFTWARE REVISIONS 7-1

7.1 Introduction.........................................................................................................................................7-1

8. APPENDICES 8-2

LIST OF ILLUSTRATIONS

Figure 1-1 Night Scan Chief Base and Remote Control Positioner.............................................................. 1-1

Figure 1-2 Mast Loads..................................................................................................................................1-1

Figure 2-1 Lifting Point..................................................................................................................................2-2

Figure 2-2 Night Scan Base Mounting Hole Locations................................................................................. 2-3

Figure 2-3 Standard Junction Box ................................................................................................................ 2-3

Figure 2-4 Junction Mounting Hole Locations...............................................................................................2-4

Figure 2-5 Hand Held Receptacle Pins......................................................................................................... 2-5

Figure 2-6 Example of Warning Light Installation......................................................................................... 2-6

Figure 3-1 Actuator and Proximity Sensors..................................................................................................3-2

Figure 3-2 Photo Interrupter and Flag...........................................................................................................3-3

Figure 3-3 Cover and Screw Removal for Manual Stow (Night Scan Chief only) ........................................ 3-7

Figure 4-1 Proximity Switch Adjustment .......................................................................................................4-3

Figure 4-2 LED Location and Function.........................................................................................................4-3

Figure 4-3 Flag Settings................................................................................................................................4-5

Figure 4-4 DIP switch location: Chief base board.........................................................................................4-6

Figure 4-5 DIP switch location: Chief RCP board.........................................................................................4-6

Figure 4-6 NFPA Handheld Remote Wiring..................................................................................................4-7

Figure 4-7 Non-NFPA Hand Held Remote Wiring ........................................................................................4-7

Figure 4-8 Night Scan Chief Base Wiring.....................................................................................................4-8

Figure 4-9 Night Scan Chief Remote Control Positioner (RCP) Schematic.................................................4-9

Figure 5-1 Exploded View - Base Left Side..................................................................................................5-2

Figure 5-2 Base Right Side...........................................................................................................................5-3

Figure 5-3 Exploded View – Mast Pivot Assembly .......................................................................................5-3

Figure 5-4 Exploded View - Remote Control Positioner (RCP)....................................................................5-5

Table 1-1. Reference Data Night Scan Chief..................................................................................................1-2

Table 2-1. Tools and Materials Required for Installation................................................................................2-1

Table 2-2. Handheld Remote Control Connector Pin-out............................................................................... 2-5

Table 4-1. List of Base Board Faults............................................................................................................. 4-10

Table 4-2. List of Remote Control Positioner Board Faults .......................................................................... 4-14

Table 4-3. List of Remote Control Board Faults............................................................................................4-17

Table 4-4. List of Warning Codes .................................................................................................................4-18

Table 4-5. Mechanical Troubleshooting........................................................................................................4-19

Table 5-1. Night Scan Chief Base Assembly Parts List..................................................................................5-1

Table 5-2. Remote Control Positioner Assembly Parts List............................................................................5-4

Table 7-1. Software Revision Log...................................................................................................................7-1

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LIST OF TABLES

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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.

CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate

injury. It is also used to alert against unsafe practices.

GENERAL SAFETY PRECAUTIONS The following are general safety precautions that are not related to any specific procedures and therefore do

not appear elsewhere in this publication. These are recomm ended precautions that personnel must understand and apply during many phases of operation and maintenance.

Electrocution Hazard! Contact with high voltage will result in death or serious injury. Observe general

safety precautions for handling equipment using high voltage. Do not locate or operate mast near electrical lines, cables or other unwanted sources of electricity. Do not operate mast in lightning. Be certain electrical cables are undamaged and properly terminated. Always disconnect power before performing service, repair

or test operations.

Safety Instruction - Read Manual! Failure to follow operating instructions could result in death or serio us

injury. Read and understand the operator’s manual before using the mast.

Tip Over Hazard! Mast tip over could result in death or serious injury. Do not operate in high winds.

Operate on level ground only. Stand clear of mast and mast payload during operation. Be certain mast is

level and secure before and during installation, operation and maintenance.

Safety Instruction - Trained Personnel Only! Death or serious injury could result if proper inspection,

installation, operation and maintenance procedures are not observed. Installation, operation and

maintenance to be performed by trained and authorized personnel only. Proper eye protection should be

worn when servicing the mast.

Health and Safety Hazard! Solvent used to clean parts is potentially dangerous. Avoid inhalation of fumes

and also prolonged contact to skin.

Safety Instruction-Do not look at lights! Do not look directly into lights when they are illuminated.

Temporary impairment or permanent vision damage could occur.

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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.

Crush Hazard! Death or serious injury could result if mast fails suddenly. Do not stand directly beneath the

mast or its payload. Be certain payload is properly installed and secured.

Burst Hazard! Over pressurizing mast will trip safety valve and could result in death or se rious injury. Do not

exceed maximum operating pressure of 20 psi (138 kPa) for Standard Duty masts. Keep personnel clear of

safety valve exhaust direction.

Fire Hazard! Cleaning solvent, used for maintenance, is flammable and can be explosive resulting in death

or serious injury. Do not smoke. Use cleaning solvent in a well-ventilated area. Keep cleaning solvent away

from ignition sources. Always store cleaning solvent in the proper marked container.

Relocation Hazard! Relocating the mast during operation or after extension could result in death or serious

injury. Do not relocate the mast during operation or while extended. This applies especially to masts

mounted to vehicles. Operate the mast only if the vehicle is stationary and the vehicle engine is off.

Mast Extension Hazard! Extending mast into obstructions could result in death or serious injury and could

render the mast inoperable and partially extended. Before applying power and operating the mast, be certain

there is sufficient clearance above and to all sides of the expected location of the fully extended mast and

payload. Keep all persons clear of mast and mast extension. Do not lean directly over the mast.

Mounting Structure Hazard! Mounting mast into a structure unable to resist the forces generated from

customer-specific loading scenario could result in death or serio us injury and could damage the mast. Before

operation, be certain mounting structure is capable of resisting forces generate d from all loa ding and

environmental conditions, including, but not limited to, mast size and weight, payload size and weight, sail

size, wind speed, guy line arrangement, support bracket or roof line location and base plate assembly.

Electrocution Hazard! Do not touch live wires. Death or serious injury could result.

Safety Instruction – Operation! Make sure all power has been disconn ected prior performing maintenance.

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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.) The mast area is free of personnel and mechanical obstruction;

2.) All electrical cables are undamaged and properly terminated;

3.) The operator must have full view of the mast during use;

4.) Any transit tie-downs on the payload have been removed;

5.) The vehicle is not moving;

6.) The area above the mast is free of mechanical obstructions.

Safety Instruction-Operation! Lamps are extremely hot and should not come into contact with people or

combustible and/or explosive materials. Do not operate if breakage occurs or unit is knocked over.

Entanglement Hazard! Tangled cables can cause equipment damage. Ensure control cables are not

tangled and are free to pay out as mast is extended.

Safety Instruction – Installation! At all times while using pipe and hose during installation, recognize that:

1.) Pipe and hose should be routed, mounted and restrained to protect from damage;

2.) Do not use second hand piping for installation;

3.) Do not bend air pipe and hose at a radius less than specified by the manufacturer;

4.) Pipes should be marked to avoid hazards from incorrect connection;

5.) The exhaust should be fitted with a silencer and be directed away from personnel;

6.) When routing piping, install in such a way as to minimize torsion on the joints;

7.) Mounting air pipe and hose shall be accomplished only by the use of tools to prevent readily disconnecting air pipe and hose from mast.

Safety Instruction – Operation! Do not operate the Chief vertical RCP during an electrical storm.

Lifting Hazard! Manually lifting over 55 lb (25kg) 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.

Safety Instruction – Operation! All operators must read the Operation section of this manu al and be

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properly trained.

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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.

1.3 DESCRIPTION

The Night Scan Chief is a transportable lighting system consisting of a directionally adjustable group of lights attached to a self-erecting, extensible mast. Air pressure required to extend the mast is provided by a compressor unit mounted within the Night Scan Chief. The unit is designed for installation on any vehicle for the purpose of providing on the scene temporary lighting. Refer to Figure 1-1 for identification of the major components of the Night Scan Chief unit.

RIGHT SIDE LIGHT

MAST

LEFT COVER

BASE

BASE LOOK-UP LIGHT

RCP HOUSING

LEFT SIDE

LIGHT

RCP COVER

RCP SADDLE

ASSEMBLY

Figure 1-1 Night Scan Chief Base and Remote Control Positioner

BASE RIGHT COVER

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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. 140DC 300DC 1800 3000P 5400 6000

NS6 Stowed Height 10 in 10 in 10 in 10 in 10 in 10 in NS7.5 Stowed Height 10 in 10 in 10 in 10 in 10 in 10 in NS6 Ext. Height 6ft. 6ft. 6ft. 6ft. 6ft. 6ft. NS7.5 Ext. Height 7ft-6in 7ft-6in 7ft-6in 7ft-6in 7ft-6in 7ft-6in Total Unit Weight** 100 lb. 100 lb. 100 lb. 110 lb. 120 lb. 130 lb. Tube Diameter Range 3.5 to 2.5in 3.5 to 2.5in 3.5 to 2.5in 3.5 to 2.5in 3.5 to 2.5in 3.5 to 2.5in No. of Mast Sections 3 3 3 3 3 3 Mast Air Volume

(NS7.5) Max. Operating

Air Pressure Required DC Electrical

Power Supply Required Electrical

Supply for Lights

0.26 cu. ft. 0.26 cu. ft. 0.26 cu. ft. 0.26 cu. ft. 0.26 cu. ft. 0.26 cu. ft.

20 psi 20 psi 20 psi 20 psi 20 psi 20 psi 12V/20 amp

24V/10 amp 12V/12 amp

24V/6 amp

12V/20 amp 24V/10 amp

12V/25 amp 24V/13 amp

12V/20 amp 24V/10 amp

220V/10 amp

12V/20 amp 24V/10 amp

220V/15 amp

12V/20 amp 24V/10 amp

220V/25 amp

12V/20 amp 24V/10 amp

220V/30 amp

*Maximum dimension is the largest dimension on all specified models. **Weight given is approximate for 7.5-foot models

1.5 TECHNICAL INFORMATION

Power Requirements

The DC power for the Chief is supplied through direct connection to the base circuit board. The DC power is internally protected with a 20 amp auto-resetting circuit breaker. The Chief will operate from either 12 or 24 volt DC power with no customer changes necessary. The electronic system has built in reverse polarity protection. For optimum performance, a minimum of 11 volts is required at the Chief base. Long runs of cable can introduce power loss For long runs, it may be necessary to add an intermediate junction box in the DC cable so that DC power can be applied closer to the Chief.

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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.

35# 200# 200#575# 575#

Figure 1-2 Mast Loads

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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. Only a properly trained and qualified certified electrician should

perform electric installations and service.

Lifting Hazard! Manually lifting over 55 lb (25kg) 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.

2.1 INTRODUCTION

The Chief has been designed to provide for ease of installation. This section of the manual provides the procedures that must be followed to insure a successful installation. Be sure to read and understan d the entire installation procedure before you begin.

2.2 TOOLS AND MATERIALS REQUIRED FOR INSTALLATION

Table 2-1 provides a list of tools and materials required to install and test the Night Scan Chief.

Wrenches Crimping tool or Solder set Screwdrivers Wire cutter/stripper ½ inch or M12 Mounting Hardware (6 each) Multimeter (to verify power is turned OFF) Torque wrench Clean Shop Rags Drill Hoist (minimum 250 lb capacity)

Table 2-1. Tools and Materials Required for Installation

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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 occurre d, notify carrier.

3. Be sure that all components are include d and that the requi red tools are readily available.

LIFTING POINT

Figure 2-1 Lifting Point

2.4 ATTACHING TO VEHICLE

If the Night Scan Chief is to be mounted in a well, be certain that adequate drainage is provided. A minimum of (4) drain holes (one per corner) at least one inch in diameter is recommended . While the unit has been designed to withstand adverse environmental conditions, it cannot be submerged.

The mounting holes provided on the unit are 9/16 inches in diameter. There are four holes in t he base plate and two holes in the RCP saddle. Studs or bolts (not provided) shall be located on the vehicle in accordance with Figure 2-2. It is important that the surface be flat such that the saddle and base plate are in the same plane. The areas to which the unit is mounted must be reinforced to withstand loading as shown in Figure 1-2. Attach and torque all hardware as appropriate for its material and size. It may be advantageous to attach the four (4) mounting bolts in the base plate, complete the wiring as outlined in the following sections and raise the unit before attaching the saddle bolts. Be certain that the saddle bolts are located in accordance with Figure 2-2 and that the saddle is centered with respect to the RCP. Adjust the location if necessary.

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33.0

SADDLE MOUNTING

HOLES (

n.56" SEE NOTE)

BASE MOUNTING HOLES (

n.56" SEE NOTE)

4.8

2.4

5.5

40 1/8" (6FT. MAST)

46 1/8" (7.5FT. MAST)

11.0

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. The installer must take necessary precautions to seal the lid and the knockouts if installation in a wet location is unavoidable. The junction box also serves as a location to which DC power is routed by the installer for the unit. It may be flush or surface mounted. Hardware for mounting is not supplied.

KNOCK-

OUT

JUNCTION BOX

ENCLOSURE

COR D GRIP F OR

DC \ CONTROL CABLE

TO NIGHT SCAN

HOLES PROVIDED FOR OPTIONAL FLUSH MOUNTING

HHRC CONNECTOR

PUSH PULL

SWITCH

Figure 2-3 Standard Junction Box

Flush Mounting

For a flush mount installation, four #8 screws, nuts and lock washers must be provided by the installer. The screw length should be 3 ½ inches plus the panel thickness. Remove the junction box cover and make the necessary cable connections (see schematics in section 4.4). Place the jun ction box behind the panel and guide the screws through the panel, junction box cover and junction box. Secure on back side using lock washers and nuts.

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Surface mounting

For a surface mount installation, four #8 screws, nuts and lock washers mu st be provide d by the install er. The screw length should be ¾ inch plus the panel thickness. Remove the junction box cover and mou nt unit through the counter bored holes in the junction box. Secure on the back side using lo ck washers and nuts. Make the necessary cable connections (see schematics in section 4.4) and replace cover.

5.75"

MOUNTING HOLES

" SEE NOTE)

(Ø.19

2.60"

Figure 2-4 Junction Mounting Hole Locations

2.5 CONNECTING THE PUSH/PULL SWITCH (JUNCTION BOX)

While a two switch implementation of this circuit can be realized, the use of a Push/Pull switch is highly preferred. One switch available for non-NFPA installations is a Square-D 9001K R9RH13. For NFPA compliant installations, Square-D part number 9001SKR8RH25 should be u sed. Other ma nufacturers of Industrial Control Pilot Devices should have equivalent switches. This switch is available as part of a prewired kit (part # 913316 for NFPA or part #4204201 for non-NFPA installations) from Will-Burt. Refer to the schematics in section 4.4 for wiring detail.

2.6 CONNECTING THE REMOTE CONTROL(S)

Hand Held Remote Control (HHRC) In the event that the accessory kit (part # 913316 or 4204201) is not used, a suitable connector mu st be

supplied by the customer to mate with the connector of the handheld remote control (HH RC ). The co nnector on the HHRC is an ITT Cannon CA3106E14S-2P-B-F80-A232. Please refer to Table 2-2 and Figure 4-7 for wiring schematic.

Pin B of the HHRC should connect to pin A of the DC Power/input connector. Pin C of the HHRC should connect to pin B of the DC Power/input connector. Pin A of the HHRC should connect to pin C of the DC Power/input connector. Pin D of the HHRC should connect to pin D of the DC Power/input connector.

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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. This relay output is from a bi-stable (latching) relay whose contacts close when the unit has completely stowed. This type of scenario gives the best failsafe condition in the event of a broken wire. Its state is not affected by whether or not there is power to the mast. This isolated contact is capable of carrying up to 2 amperes and is available on pins J4-8 and 9. Please refer to the schematics in section 4.4. Its usage is at the discretio n of the integrator. It can be used in conjunction with a customer-supplied relay to drive a flashing warning light. (refer to Figure 2-6)

2.8 CONNECTING INTERLOCK INPUT CONTACTS (OPTIONAL )

Some customers may require preventing operation of the Chief unless other conditions are first met. An example might be having the parking brake set. This can be accomplished by inserting an isolated contact in series with the stop circuit of the Push/Pull switch. Inserting these contacts between the violet wire connected to pin J4-6 base circuit board and the KA-1 contact of the Push/Pull switch breaks continuity and thus will immediately stop operation of the Chief and prevent further operation until continuity is restored through the contacts. Please refer to the schematics in section 4.4.

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Night Scan Chief

2.9 INSTALLING THE WARNING LIGHT

As required by NFPA regulations, a red flashing or rotating light, located in the driving compartm ent, must b e 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. See the wiring schematics in section 4.4. A customer supplied flashing relay and lamp may then be installed in the driving compartment such that the driver can see the lamp. One example using a Bosch relay is shown below.

WARNING

LIGHT

TO BATTERY

( - )

87A

TO BATTERY

( + )

BOSCH RELAY

0 332 209 151

OR EQUAL

PIN- J4-8 PIN- J4-9

Figure 2-6 Example of Warning Light Installation

2.10 MULTIPLEX SYSTEMS OPERATING AT 24 VOLTS

When operating at 24 volts, the Night Scan Chief “chops” the voltage sent to the 12 vdc motors is the system. As a result of this starting and stopping, voltage might be fed back through the power wires and into the power supply. In some instances, this may lead to unexpected behavior in a multiplex system. In order to mitigate this back feeding of voltage, an 820uF capacitor (Will Burt Part Number 204001) can be placed across the positive and negative input terminals (TB3-5 and TB3-6) on the base circuit board. Please refer to wiring schematic Figure 4-8. Note the direction of the capacitor for installation.

2.11 PRE-OPERATIONAL CHECK

Before beginning installation, make certain that the area is free

of overhead power lines and other unwanted sources of

electricity. Follow OSHA safety regulations when working near

energized power lines. Be sure to allow sufficient clearance on

all sides of mast to allow for side sway.

For outdoor use only. Do not use in areas that have been

classified as hazardous as defined in Article 500 of the

Do not use in the presence of flammable gases or liquids

such as paint, gasoline or solvents. Do not use in areas of

limited ventilation or where high ambient temperatures are

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National Electric Code.

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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 po wer 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.

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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. Do not use in areas of

limited ventilation or where high ambient temperatures are

present. Contact with combustible materials can cause

ignition resulting in fire or explosion.

Before operating, make certain that the area is free of

overhead power lines and other unwanted sources of

electricity. Be sure to allow sufficient clearance on all sides

of mast to allow for side sway.

Do not move vehicle until mast has been securely stowed.

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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 driv ing of the actuator. The sensor also notifies the operator through the Remote Control(s) that certain RCP function s are available. The compressor assembly included in the base will receive pow er and pre s surize the mast when the up button is depressed. If, at any time, power to the unit is lost, the exhaust valve opens, exhausting all air from the mast.

As the mast is nested, the base control looks for indication from a magnetic switch that the mast has fully retracted and may be safely restored to its fully nested (horizontal) position. If the “double click” unattended stow sequence was not used, the RCP will begin the autostow sequ ence to insure that the RCP is properly positioned for engagement with the saddle. If the autostow “double click” sequence was used, the RCP will have properly positioned itself as the mast descended prior to horizontal nesting into the saddle.

PROXIMITY SWITCHES

ACTUATOR

Figure 3-1 Actuator and Proximity Sensors

RCP

The RCP provides pan and tilt functions upon command from the Remote Control(s). DC powered gear motors turn the shafts until an opaque flag in the assembly reaches a photo interrupter. At this time, the LED on the Remote Control(s) for that direction of travel will go out, indicating that a limit has been reached in that direction.

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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 R CP, 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. In an NFPA compliant installation, a completely stowed Night Scan Chief draws zero current and cannot be extended or operated until the initiate circuit is engaged. Included in this initialization circuit is an input for a safety interlock. This can be used for an emergency stop, or other interlock function such as a “Park/Neutral” switch from the vehicle transmission. Relay contacts inserted in the violet wire coming from pin J4-6 of the base circuit board function to inhibit operation of the Chief (See schematics in section 4.4)

Additionally, a bi-stable (latching) contact closure is provided that indicates that the mast is properly stowed. It will close when the mast is properly stowed. If the mast is not stowed, the contact will be open. Even if the emergency stop feature is used prior to the mast completely stowing, the contact will still remain open. If the Night Scan has been stopped using the emergency stop button or by some other interruption of power, the initiate circuit will need to be activated again in order to continue operation.

When stowing the mast to horizontal position, the control monitors the current of the actuator. When the mast lowers, trips the Mast Nested limit switch, and comes up against the mechanical re sistance of the saddle; it senses it, considers itself stowed, and shuts itself down. This ensures a certain amount of preload on the RCP saddle.

If at any time during the operation of the mast an unexpected control situation occurs, the mast will stop any movement and a fault

message will be displayed on the Remote Control(s) display. Clearing the fault is accomplished by pushing the Push/Pull switch or momentarily interrupting power in some other way. Then the control may be re-initiated and operated again.

3.3 PUSH/PULL SWITCH – NFPA INSTALLATIONS

All operation of a completely stowed mast must be preceded by proper initialization. The initiate switch must be momentarily closed to power-up the Night Scan. When the Will-Burt Accessory Kit is used, the Push/Pull switch is located on the junction box. It is used to perform two functions. First, it can be used to “initiate” the

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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. Even with this, the Remote Control(s) would have to be subsequently pushed to get any action. In the unlikely event that the initiate switch were engaged, the Night Scan will power itself down if no Remote Control action occurs within thirty seconds. The “Push” portion of the Push/Pull switch functions as an Emergency Stop. If it is pushed, the mast will immediately be disconnected from power and stop.

the mast to vent.

It should be noted that prematurely disconnecting power in this way will immediately cause

Other interlock contacts could be inserted into this circuit to provide additional safety. The control also monitors the initiate input, and if it sees that this input is present for a prolonged period of time; the control will stop the mast and appropriate error code will be displayed (Err, 1.09). This is a preventative measure to ensure the initiate input is not hot-wired. Once the mast has been initiated, the Remote Control must then be used to begin raising the mast within thirty seconds or the control will shut itself down. If the mast has been initiated and raised any amount, the control will remain powered until the mast is fully stowed, the emergency stop function is used, or the power is somehow otherwise interrupted.

3.4 PUSH/PULL SWITCH – NON-NFPA INSTALLATIONS

All operation of a completely stowed mast must be preceded by proper initialization. The initiate switch must be closed to power-up the Night Scan. When the Will-Burt Accessory Kit is used, the Push/Pull switch is located on the junction box. It is used to perform two functions. First, it can be used to “initiate” the control by pulling the switch operator. Secondly, it functions as an emergency stop when the switch operator is pushed all the way in. When using Will-Burt’s accessory kit push/pull switch, accidental initiating is extremely unlikely since it would require pulling the switch button. The “Push” portion of the Push/Pull switch functions as an Emergency Stop. If it is pushed, the mast will immediately be disconnected from power and stop.

be noted that prematurely disconnecting power in this way will immediately cause the mast to vent.

It should

Other interlock contacts could be inserted into this circuit to provide additional safety.

3.5 REMOTE CONTROLS (HAND HELD)

Wired Hand Held Remote Control

• The Remote Control accepts switch activations from the operator and translates them into

serial commands for transmission to the base control board via the RS-485 link. If the operator engages a switch, the Remote Control will appropriately send commands repeatedly as long as the operator continues to engage that switch. The Base control will pass along appropriate serial commands to the RCP in response to the Remote Control(s). Additionally, variou s states of the system will be passed to the Remote Control so that button status LEDs can give proper indication of the state of the Night Scan. An example of this is that the LED next to the “Mast Down” button will not be lit unless it is appropriate to lower the mast. Upon first beginning to raise the mast, it will be noted that the “Mast Down” button does not become active until a certain amount of movement has been accomplished. This is to ensure that there is enough downward travel available for proper stowing of the mast. If the button status LED for a particular button is not lit, that button will not function. Another reason for a button status LED not being lit could be an actuator reaching the extent of its travel (or limit switch).

• Two special functions are implemented in software whereby the operator can initiate an

unattended lowering and stowing of the mast, or an unattended partial raising of the mast. The Autostow is accomplished by two rapid sequential activations of the “Mast Down” 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 Up” button or any other button on the Remote Control(s). The

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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. The Auto-Up function is not available on the non-NFPA Chief.

Wireless Held Remote Control

• The wireless remote control accepts switch activations from the operator and transmits to the base

control board. If the operator engages a switch, the Remote Control will appropriately send commands repeatedly as long as the operator continues to engage that switch. The Base control will pass along appropriate serial commands to the RCP in response t o the Remote Control(s). Feedback in the form of LED’s is not available with the wireless remote control.

3.6 RAISING THE MAST

Operation of the mast using the Remote Control(s) is fairly intuitive. A typical operational sequence could be as follows:

• Pull the Push/Pull Initiate button.

• Press and hold the “Mast Up” button on the Remote Control(s) until the mast has fully

extended.

• Press the desired Pan and Tilt buttons until the lights are facing appropriately.

• Press the Light and Aux light buttons momentarily to turn the desired lights on and off.

• Press the “Mast Down” button until the mast has completely stowed.

Note: In the Night Scan Chief, during the process of raising the mast, the mast will first be inclined to a

position perpendicular to its mounting surface by an actuator. Once the control senses it is in this position, air pressure will be applied to the tube sections to raise the mast further into the air. Lowering the mast is in reverse order. Air is vented from the tube sections reducing its height. Then the actuator declines the mast until it is finally stowed.

Auto-up Function (wired handheld remote control only)

The “Auto-up” function can be initiated by giving two quick successive depressions of the “Mast Up” button (within ½ second). The mast will then raise to the 90° position and automatically turn on both banks of lights. This automatic sequence can be aborted by pushing any of the buttons on the Remote Control(s) at any point during the Auto-up sequence. The mast will not extend up by itself, but will await further operator input from the Remote Control(s).

3.7 AIMING THE REMOTE CONTROL POSITIONER

The positioner can be “aimed” by utilizing the pan and tilt buttons located on the Remote Control(s). The Pan Left and Pan Right buttons allow horizontal movement, while there are independent Tilt Up and Tilt Down functions for vertical adjustment of each side of the RCP.

3.8 STOWING THE MAST

There are two methods of stowing the mast. The normal method involves pressing and holding the “Mast Down” button until the mast is fully stowed and the control shuts itself off. A second method, available on

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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. Once this has been satisfied, the control will shut itself off on NFPA compliant installations. For non-NFPA installations, it will be necessary to manually shut off power by pushing the Push/Pull switch on the junction box. If by chance there is no increase in current and the actuator shuts off because of its internal limit switch, a fault message will be displayed.

Once the control is shut off, the Night Scan is totally disconnected from power, and the “Mast Stowed” safety interlock contact closes signaling it is safe to move the vehicle.

Be sure that no buttons are

illuminated on the remote after you believe it is stowed. Illuminated buttons indicate that the unit

stowed. After making certain that the unit is properly stowed in the saddle, unplug the remote

is not

control and stow it where it will not be damaged in transport. Unplugging the remote will remove any possibility that the Chief could become active and extend unexpectedly.

3.9 EMERGENCY STOW (LOSS OF POWER):

Make sure all power has been disconnected from the Night

Scan prior to manually lowering mast.

Make sure lights have cooled completely before manually

panning or tilting the RCP.

In the event of power loss or an unrecoverable error condition, the Night Scan Chief will automatically exhaust all air and nest. However, the mast will NOT return to its fully stowed, horizontal position. This must be accomplished manually. It is required that two people perform this operation as the mast is very heavy and can cause severe injury or death if not done with extreme caution. It may be necessary to manually pan the RCP so that when it is manually nested, the lights do not make contact with the mounting surface or the saddle. To manually pan the unit, firmly grasp the RCP by the horizontal shafts

slowly rotate to a point perpendicular to the length of the base. Additionally, it may be necessary to

and manually tilt the lights to prevent damage when stowing the mast. Tilt the lights by grasping the top and bottom of the light bar and

slowly rotating the lights such that they face down when fully stowed.

Support the mast before removing shoulder screw! Once

removed, the mast and light assembly is free to fall.

Remove the right side base cover (opposite look up light). Secure the mast in an upright position to prevent it from falling freely. Remove the knurled shaft from the bottom of the actuator. CAREFULLY lower the mast down into the saddle. Secure the mast in this nested position before moving the vehicle.

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Night Scan Chief

COVER SCREWS

RIGHT SIDE COVER

KNURLED

PIN & E-CLIP

Figure 3-3 Cover and Screw Removal for Manual Stow (Night Scan Chief only)

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Night Scan Chief

CHAPTER 4

MAINTENANCE AND SERVICE INSTRUCTIONS

4.1 INTRODUCTION

This section of the manual describes routine maintenance procedures and covers gen eral service information. Refer to Chapter 5 for exploded views of the Night Scan Chief and the accompanying Table s with item descriptions and part numbers, which may be used for ordering replacement parts.

4.2 SCHEDULED MAINTENANCE

Cleaning and Lubrication - Mast

Will-Burt pneumatic telescoping masts should be cleaned and lubricated o n a regular basis to insure smooth operation and to prolong useful life. This maintenance should be perform ed typically about once a month depending upon local environmental conditions and frequency of use. Signs that cleaning and lubrication are needed can be:

• A noticeable gritty film on the exterior surfaces of the mast sections

• Erratic extension or retraction of the mast

• Noisy operation of the mast

• Sticking of one or more mast sections when mast is extending or retracting

A pneumatic telescoping mast is a pressure vessel.

Caution must be exercised to stay clear when the mast

is being extended. Do not lean directly over the mast.

Proper eye protection should be worn when working on

the mast.

PROCEDURE:

1. One person operating hand held remote control should slowly pressurize the mast just enoug h to extend the top mast section. Another person may need to hold down the larger mast section collars to assure the proper sequence of extension. Release “Mast Up” button as soon as the mast section is up.

2. Wipe down the extended mast section u s ing a non-abrasive cleanser or solvent such as lacquer thinner. Do not allow the cleaning fluid or solvent to run down inside the collar.

3. Repeat steps 2 and 3 for the next larger mast section .

4. Inject approximately 1/2 oz. of TMD Mast Lubricant* or a lightweight machine oil into the wee p hole (drain) of the exposed mast section. The weep holes are located app roximately 10 inches below the collar on each tube except the top one.

5. Repeat steps 2, 3 and 5 for each of the remaining mast sections.

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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.

NOTE: Do not lubricate the exterior of the mast, as this will cause it to attract dust and contaminants from the air.

* TMD Mast Lubricant is specifically formulated for cold weather use, but is suitable for year around use. Regular winter maintenance and the frequent use of TMD Mast Lubricant should signifi cantly reduce the potential for mast freeze ups.

Cleaning Night Scan Base and Remote Control Positioner (RCP)

Make sure lights are completely cool before attempting to

clean.

The exterior of the RCP and Night Scan base should be wiped down periodically to remove dirt and road grime using a soft cloth or sponge and a mild solution of soapy water. The lenses of the lights should be cleaned using standard glass cleaner and a soft towel.

4.3 ADJUSTMENTS

Adjusting the 90º Proximity Switch

The proximity switch (sensor) is intended to stop the actuator when the mast is at 90 degrees when being raised. It senses the magnet that is threaded into the clevis and signals the base circuit board to cut power when the actuator is in the correct position. In the event that this switch needs adjusted (i.e. after replacing the actuator) to stop the mast at 90 degrees, the following procedure must be followed. Use Figure 4-1 as an aid to identify the components.

1. Make certain that the Chief is level.

2. Remove the right hand base cover (opposite the loo k up light)

3. Loosen the upper jam nut to lower the switch approximately 1/8”.

4. Raise the mast to 90 degrees. Verify that the mast is plumb using a level or check to see that it is square to the sheet metal side plate on the base.

5. Raise the switch until it senses the actuat or. This will be indicated by 1) an audible “click” of the exhaust valve closing, 2) lights on the hand held will change state, indicating that RCP functions are available and 3) the LED on the base circuit board will change from green to yellow.

6. Secure the switch in position using the upper and lower jam nuts.

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7. Cycle the mast several times, checking that the mast is plumb each time. Adjust the switch if necessary.

8. Replace cover.

GAP

PROX SWITCH

MAST

MAGNET

UPPER

LOWER JAM NUT

JAM NUT

Figure 4-1 Proximity Switch Adjustment

90°

PROX SWITCH

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Figure 4-2 LED Location and Function

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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.

by verifying that the collars are stacked with no gaps between them.

It is important that the mast has properly nested

If the collars are not properly stacked see Table 4-5 for further instructions. If the switch is found to require adjustment, it will most commonly need to be moved upward (toward the RCP) on the mast. The magnet is located at the lower end and side of the top tube. It is not visible outside the mast.

The following procedure must be followed to adjust the magnetic switch.

1. Loosen the band clamp securing the swi t ch to the base tube. Move the switch up approximately 1/8”

and tighten band clamp.

2. Initiate the mast, if necessary, and press the down button the hand held remote. If the mast does not

nest, repeat the adjustment until it does. A small piece of steel or iron filings may be used to help locate the magnet.

3. If repeated attempts do not succeed, hold a magnet u p to the switch and press the do wn button. If

the mast begins to nest, continue repeating the adjustment until the switch has sensed the magnet.

4. If the mast will not nest when a magnet is held to the switch, ch eck the wiring to the circuit board for

loose or disconnected wires. See schematics in section 4.4. If the wiring is intact, replace the magnetic switch.

Resetting the RCP Home Position

The Chief unit is shipped with the lights in home position. Home position is established by setting small flags in the RCP that engage photo interrupters on the RCP board. It orients the lights such that the light bars are parallel to the axis of the mast and are facing downward when nested. On all models, the RCP shafts should contact the saddle simultaneously during nesting when correctly set. It should be noted that having the RCP covers off could cause improper RCP operation when outdoors. This procedure should be performed indoors. To set the home position, the following procedure must be obse rved.

DISCONNECT ALL AC POWER TO THE CHIEF!

2. Initiate the mast and raise it to the 90-degree position. The hand held remote should show both left

and right tilt up functions are available and the pan left function is available.

3. Remove the RCP covers to access the flags.

4. Refer to Figure 4-3 for reference. The flags are attached to the timing rings on the horizontal and

vertical shaft gears.

5. Once the set screws are loose, pan and tilt the unit to the correct ho me position. Be careful that the

flags do not come into contact when panning and tilting, they may become bent.

6. It is important that the flags engage the correct photo interrupter when setting the home position, see

Figure 4-3. Turn the timing ring on the right horizontal shaft such that it rotates down toward the upper photo interrupter. As you approach the interrupter, watch the wired hand held remote. As soon as the tilt down LED goes out, stop rotating the ring and tighten the set screw. To set the pan home position, turn the timing ring counterclockwise (looking from above the RCP) until the pan right LED goes out. Tighten the adjustment screw to secure the ring.

7. Pan and tilt the unit until the second set screw in each ring is accessible and tighten.

8. Stow the mast, watching for the lights to be oriented as de scribe d in the beginning of this section.

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9. Initiate and raise the mast to 90 degrees. Repla ce the RCP cover.

+++

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.

To set the operational mode for the Base board, locate the DIP switch S2 (see Figure 4-4) and set the DIP switch as follows:

• Position 1 - DO NOT CLOSE

• Position 2 - Close if the system is a non-NFPA compliant installation

• Position 3 - Close if the system does not have an RCP

• Position 4 - DO NOT CLOSE

• Position 5 - DO NOT CLOSE

• Position 6 - DO NOT CLOSE

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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.

• Position 3 – DO NOT CLOSE

• Position 4 – DO NOT CLOSE

+++

Figure 4-5 DIP switch location: Chief RCP board

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4.4 SYSTEM SCHEMATICS

A system schematic is given in order to aid in electrical troubleshooting as outlined in the following section.

BLU

BRN

RED BLK

GRY

VIO

GRN

BLK

WHT

BLK

RED

TB3

TO HHRC

BATTERY (+) 10 GA BATTERY (-) 10 GA

TO CUSTOMER

VEHICLE INTERLOCK

(2 AMP. MAX. LOAD)

CLOSED CIRCUIT

WHEN STOWED

SEE SECTION 2.12

KA-3 KA-5

20 GA TWISTED PAIRS

RED

BLK

WHT

BLK

RED

BLK

GRN

GRY

BRN

BLU

VIO

18 GA

(init) (kill)

(com)

4032504 16 FT CABLE 4032505 30 FT CABLE 4032506 50 FT CABLE

18 GA

20 GA TWISTED PAIRS

Figure 4-6 NFPA Handheld Remote Wiring

TO HHRC

BATTERY (+) 10 GA BATTERY (-) 10 GA

REMOVE G-H JUMPER IF

PARKING BRAKE INTERLOCK

IS USED. CLOSED WHEN

BRAKE "ON"

TO CUSTOMER

VEHICLE INTERLOCK

(2 AMP. MAX. LOAD)

CLOSED CIRCUIT

WHEN STOWED

KA-1

(SHOWN IN PULLED POSITION)

20 GA TWISTED PAIRS

RED

BLK

WHT

BLK

RED

BLK

GRN

GRY

BRN

BLU

VIO

18 GA

(init) (kill)

(com)

4032504 16 FT CABLE 4032505 30 FT CABLE 4032506 50 FT CABLE

Figure 4-7 Non-NFPA Hand Held Remote Wiring

18 GA

20 GA TWISTED PAIRS

RED BLK

BLU BRN GRY

VIO

GRN

BLK

WHT

BLK

RED

TB3

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SUPPLIED

CUSTOMER

LEFT LIGHT POWER

|3|

BLU

BLK

TO RCP

BRN

MAST @ 0

|4|

INTERNAL COIL CABLE

BLK

RED

BLU

WHT

BLK

BRN

MAST@90

|5|

GND

RIGHT LIGHT POWER

GND

|6|

ANTENNA

|9|

|10|

YEL/GRN

TB2

TB1

|7|

|8|

BLK

RED

WHT

APPLICATIONS

MAST DOWN

VIO

BLU

BRN

GRY

GRN

MAST

BASE

WITH NO J-BOX

BRAKE "ON"

CLOSED WHEN

REMOVE JUMPER

IF PARKING BRAKE

INTERLOCK IS USED.

|14|

BLK

RED

WHT

18 GA

20 GA TWISTED PAIRS

4032504 16 FT CABLE

4032505 30 FT CABLE

4032506 50 FT CABLE

10 GA

|13|

|12|

|11|

LOOK-UP LIGHT

WHT/RED

DOWN

VALVE

(OPT)

BEEPER

TB3

BLK

RED

BLK 1

WHT 2

BLK 2

WHT 1

WHT/BLK

4206101 CABLE

BRN

BLU

ORG

BLK

INCLINATION MOTO R

AIR COMPRESSOR

SHIELD

Figure 4-8 Night Scan Chief Base Wiring

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BOX

JUNCTION

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Night Scan Chief

STROBE

|13|

|12|

|11|

|14|

TB1

POINTERS @ HOM E POSITION

18GA RED

18GA BLK

PAN

|8|

|7|

|10|

|9|

YEL/GRN

18GA RED

18GA BLK

|5|

|6|

|3|

|4|

YEL/GRN

OPTIONAL

TILT

TO MAST

RED

WHT

GRN/YEL

WHT

RED

LIGHTS

TO RIGHT

|8|

|7|

|10|

|9|

YEL/GRN

RED

BLK

LIGHTS

TO LEFT

RCP

|5|

|6|

|3|

|4|

YEL/GRN

BLK

RED

DC LIGHTS AC LIGHTS

LIGHTS

TO RIGHT

LIGHTS

TO LEFT

Figure 4-9 Night Scan Chief Remote Control Positioner (RCP) Schematic

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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. For long runs, it may be necessary to add an intermediate junction box in the DC cabl e so that DC power can be applied closer to the Chief.

Fault Codes

Fault codes are presented on the LED alphanumeric display on the wireless remote control. Whe n faults occur, all operation ceases. Faults may only be cleared by killing power to the Chief. This may be accomplished by momentarily pushing in the Push/Pull switch and then re-initializing. Additionally, the fault code is also flashed by a red status LED located on the Base board. For instance, if the fault code were 3,07, then the LED would flash three times, pause, flash seven times, pause longer, and the repeat the flash sequence. During normal operation, the LED should flash a slow steady on/off pattern. The codes are as follows:

4.5.1.1 Base Board

The Base board is located in the base of the mast and is assigned unit number one (1 ). The Base board may generate the messages of Table 4-1:

Table 4-1. List of Base Board Faults

Message Meaning Root Issue Potential Causes

Err 1,01 Mast Down

Magnetic Switch Wiring Error

The Mast Down Magnetic Switch appears to have its complimentary outputs wired backwards This switch is located on the side of the mast.

This check is only made at power-up when the mast thinks it is nested. The wires on pins 5 and 6 of J3 may need to be swapped. The magnetic switch not being energized could also cause it. Place a magnet close to the switch to check before changing wiring.

Err 1,03 Excessive

actuator current draw during nesting

The current drawn by the actuator has exceeded a level of current greater that that required for proper nesting

Either a rigid object is in the way of the mast as its nesting, or the Mast Nested Proximity Switch is not being activated as the mast approaches the saddle. Check for foreign objects in the

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mast path, and confirm that the proximity switch is being properly activated.

Err 1,07 Unrecoverable

Communication Error

The Base board has not sent out communications recently

Err 1,08 Software Fault Internally detected

error

Err 1,09 Initiate

Pushbutton

The Initiate input has been closed for too long.

Err 1,10 EEPROM Life More than 20,000

writes have been made to a particular EPROM location

Err 1,11 Saddle Location The internal linear

actuator limit switch has opened before preload occurred

Indicates a software problem. Notify WillBurt

Wiring Short in the DC cable or incorrect DIP switch setting (S2)

Will only occur when the mast has had in excess of 20,000 cycles which is unlikely to happen. Replace the base board.

The saddle is too low with respect to the Chief base. Shim the saddle up as needed. Refer to section 2.4 for flatness requirement.

Err 1,12

Actuator 90

Proximity Switch Disagreement

The proximity switch sensing the mast actuator at 90

° has

conflicting complementary outputs.

There may be a wiring problem, or a defective proximity switch. Check the voltages at J3 pins 1 and 3 with respect to pin 2. These two voltages should be opposite of each other as the proximity switch is activated and inactivated. The voltages should be close to battery voltage or close to ground. If they are not, replace the actuator 90

proximity switch. Refer to system

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schematics in section 4.4

Err 1,13 Mast Nested

Proximity Switch Disagreement

Err 1,14 Mast Down

Magnetic Switch Disagreement

The proximity switch sensing the mast actuator at almost nested position has conflicting complementary outputs.

The magnetic switch sensing the mast is lowered (referring to tube set) 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. The voltages should be close to battery voltage or close to ground. If they are not, replace the actuator almost nested proximity switch. Refer to system schematics in section 4.4

There may be a wiring problem, or a defective proximity switch. Check the voltages at J3 pins 5 and 7 with respect to pin 6. These two voltages should be opposite of each other as the magnetic switch is activated and inactivated. The voltages should be close to battery voltage or close to ground. If they are not, replace the Mast Down switch. Refer to system schematics in section 4.4

Err 1,15

Actuator 90 Proximity Switch Wiring Error

Revision 1 4-12

The proximity switch sensing the mast actuator at 90

appears to have its complimentary

This check is only made at power-up when the mast thinks it is nested. The wires on pins 1

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Err 1,16 Mast Nested

Proximity Switch Wiring Error

outputs wired backwards

The proximity switch sensing the mast actuator at almost nested position appears to have its complimentary 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 4.4

This check is only made at power-up when the mast thinks it is nested. The black and brown wires on the proximity switch 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 4.4

Revision 1 4-13

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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. List of Remote Control Positioner Board Faults

Message Meaning Root Issue Potential Causes

Err 2,01 Pan Limit

Overlap

Both pan photosensors are blocked simultaneously

Err 2,02 Tilt Stuck The state of the tilt

photosensor has not changed even though the motor has been told to move for some period of time

Err 2,04 Pan Stuck The state of the

pan photosensors have not changed even though the motor has been told to move for some period of time

Foreign material in one of the photosensors or faulty photosensor. Check to make sure there is no foreign material in the photosensors. Clean with a soft cloth. If this does not get rid of the fault, replace RCP board

Something is preventing movement of tilt mechanism or the motor is defective. Check to see if voltage is being applied to the tilt motor. If it is, replace the gearmotor. Otherwise, the problem is in the photosensor on the RCP board. Replace RCP board

Something is preventing movement of pan mechanism or the motor is defective. Check to see if voltage is being applied to the pan motor. If it is, replace the gearmotor. Otherwise, the problem is in the photosensor on the RCP board. Replace RCP board

Revision 1 4-14

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Err 2,07 Unrecoverable

Communicatio n Error

The RCP board has not sent out communications recently

Err 2,08 Software Fault Internally detected

error

Err 2,09 Tilt Up Limit The tilt down

photosensor was made before the up photosensor indicating wrap around or the up photosensor is linear or defective

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) Indicates a software

problem. Notify Will-Burt Check to make sure the

tilt flag is not located in between the two photosensors. If it is, slowly move the left light bank 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. If the flag is not in between, replace the RCP board

Err 2,10 Tilt Down Limit The tilt up

photosensor was made before the down photosensor indicating wrap around or the down photosensor is linear or defective

Check to make sure the tilt flag is not located in between the two photosensors. If it is, slowly move the left light bank 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. If the flag is not in between, replace the RCP board

Revision 1 4-15

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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

Err 2,14 Pan Left Limit The right pan

photosensor was made before the left photosensor indicating wrap around or the left 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. If the flag is not in between, replace the RCP board

Err 2,15 Tilt Limit

Overlap

Both tilt photosensors appear to be blocked simultaneously

Revision 1 4-16

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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. List of Remote Control Board Faults

Message Meaning Root Issue Potential Causes

Err 3,07 Unrecoverable

Communicatio n Error

The Remote Control board has not received communications from the base board recently

Err 3,08 Software Fault Internally detected

error

Bad or improper connection in communications link, or Remote Control is not properly powered. Check continuity of the data lines from the DC power cable connector to the Remote Control connector. Refer to system schematics in section 4.4. Check to make sure that the base board software is 2.6 or newer. Refer to section 0 on how to check software revision level. Also check that the shield in the junction box has a good electrical connection all the way to the frame rail.

Indicates a software problem. Notify WillBurt

Revision 1 4-17

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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. At that point, normal operation continues. The codes are as follows:

Table 4-4. List of Warning Codes

Message Meaning Root Issue Potential Causes

WRN 1,04

Lookup Light The output driving

the Lookup light does not seem to have a light hooked to it. (The measured current is too low.)

Burned out bulb. Broken wire.

Revision 1 4-18

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4.6 TROUBLESHOOTING MECHANICAL

Table 4-5. Mechanical Troubleshooting

Symptom Root Issue Troubleshooting Sequence

Mast sticking during extension or retraction

Mast leaks down when extended

Erratic or noisy when raising to 90 degrees

RCP continually pans or tilts

Pan or tilt motor will not respond with no errors displayed on Remote Control(s)

Mast fails to fully nest in saddle and disconnects power

Mast is dirty and/or requires lubrication.

1) Clean and lubricate mast.

2) If condition continues, mast requires overhaul.

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. If the valve or compressor assembly is leaking at a fitting, remove the fitting, clean and reinstall using thread tape or sealant. Replace a faulty valve or compressor.

Bent or worn actuator or pivot

Replace damaged component

shaft

Bent flag in RCP 1) Remove RCP cover straighten or replace

flag.

2) Make sure wiring is not wound tight. Reset home position

Broken or loose motor wire lead or faulty motor

Binding of actuator, software fault or control erroneously sensed an increase in current

1) Reconnect wire lead

2) Replace motor.

1) Check that base board has software version 2.6 or later. See section 0 for verifying revision. Contact Will-Burt if update is required.

Mast will not begin to lower from 90

Mast tube sections do not fully collapse

position

Mast will not begin to lower from 90

Magnetic switch band clamped to mast is not made

position

Revision 1 4-19

2) See Table 4-1, Table 4-2 and Table 4-3 for software fault codes.

3) Check actuator for binding. Replace actuator if binding.

1) Extend and retract mast.

2) Check tube sections for damage.

3) Internal coil cord may be binding, contact Will-Burt.

1) Magnetic switch is may be out of adjustment. Loosen clamp and slide switch up and down the mast until contact is established.

2) Check wiring

3) Replace defective magnetic switch.

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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, 7.5 ft 4142202 7 Left Side Plate 4122702 8 Right Side Plate 4122802 9 Interface Panel 4122902

10 Look Up Light Assembly 913422 11 Mast Magnetic Switch Assembly 915519 12 Tube, Wireway 4123502 13 Knurled Shaft 4159201 14 Mast Stop 4121602 15 Rubber Pad 4123301 16 Proximity Sensor Mounting Bracket 4123001 17 Actuator Pivot Block 4138901 18 Actuator Shaft 4123401 19 Beeper Alarm 223002 20 Alarm Bracket 4204301 21 Strain Relief 4022403 22 Finish Plug 3781

Air Fitting, Swivel 4200102 24 25 26 27

Revision 1 5-1

Proximity Switch 216004

Stud Magnet 216005

Clevis 4120901

Key 4120801

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28 29 30 31 32

33 N/A N/A N/A N/A N/A N/A N/A N/A N/A

Shim Washer 4122601 External Retaining Ring 3401 Spacer 4121301 Internal Retaining Ring 3783 Pivot Block 4121001 Sleeve Bearing 4120401 Base Cover Left 4143002 Base Cover Right 4141002

Handheld Remote Control 4183601

14 15

Figure 5-1 Exploded View - Base Left Side

Revision 1 5-2

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1624

Figure 5-2 Base Right Side

MAST BOTTOM

Revision 1 5-3

Figure 5-3 Exploded View – Mast Pivot Assembly

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Table 5-2. Remote Control Positioner Assembly Parts List

Mark No. Description Part Number

1 Remote Control Positioner Frame 4124102 2 Circuit Board, RCP 4118401 3 Pan Bearing Housing 4124302 4 Tilt Coupling 4124801 5 Horizontal Bearing 913435 6 Bearing Retainer 4124202 7 Pan Bearing Spacer 4124401 8 Pan Gear 4124901

9 Pan Flag 4125201 10 Card Guide 913881 11 Terminal Bracket 4125401 12 Shim Washer 4203701 13 Key 4120802 14 Terminal Block 215001 15 Snap Ring 3401 16 Motor Assembly 4205001 17 Pan Bearing 3868 18 Flat Washer 3872

19 Snap Ring 4208001 20 O-Ring, PTFE 3398 21 Tilt Flag 4125101 22 Flag Mounting Ring 4125301

Revision 1 5-4

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620

15 12

Figure 5-4 Exploded View - Remote Control Positioner (RCP)

Revision 1 5-5

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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.

Revision 1 6-1

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CHAPTER 7

SOFTWARE REVISIONS

7.1 INTRODUCTION

There are several circuit boards in the Chief system. Each has its own mi croco ntroller 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 4.3, board 2 (the RCP board) has revision 4.2, and board 3 (a Remote Control board) has revision 4.2. To date, all software revisions are backward compatible, and require no hardware changes.

Table 7-1. Software Revision Log

Board

Base 1 4.3 Initial Release to production None RCP 2 4.2 Initial Release to production None HHRC 3 4.2 Initial Release to production None Base 1 4.4 Fix transceiver enable timing to prevent

HHRC 3 4.4 Fix transceiver enable timing to prevent

Base 1 4.5 Fix to SPI timing to prevent intermittent

Board

No.

Revision Comments Compatibility Issues

None

intermittent power up timing problem

None

intermittent power up timing problem

None

analog input read failures

Revision 1 7-1

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CHAPTER 8

APPENDICES

Revision 1 8-2

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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: Cas Number:

Not Applicable (N/A) N/A Chemical Family:

Industrial Metalworking Compound Emergency Telephone Number: Revision Date:

440-543-9845 (Etna) 5/3/00 HMIS RATING: H= 1 F= 1 R= 0 PP= C

SECTION B: HAZARDOUS INGREDIENTS

This Product does not contain any SARA Section 313 reportable compounds.

This product does not contain any carcinogens as defined by OSGA, NTP and IARC at greater

than 0.1%.

SECTION C: PHYSICAL & CHEMICAL CHARACTERISTICS

Boiling Point: Specific Gravity: Vapor Pressure: Unknown 0.9 Unknown

% Volatile (Vol.): Vapor Density (Air=1): Evap. Rate (N-BA=1): Unknown Unknown >1

Solubility in Water: Ph (N/A): Reactivity in Water: Nil N/A Nil

Appearance: Odor: Blue Liquid Petroleum Odor

Flash Point: Flammable Limits (In Air % by Vol.): Auto Ignition: >350°F (Upper) Unknown (Lower) Unknown Unknown

Extinguisher Media & Special Fire Fighting Procedures: Use water, fog, foam dry chemical or CO2. Do not use a direct stream of water. Product may float and can be re-ignited on the surface of the water. Do not enter confined fire space without proper protective equipment including a NIOSH approved self-contained breathing apparatu s. Cool exposed surfaces.

Unusual Fire and Explosion Hazards: None

FORM No. ENG- 330 - 95 – 03 7/7/00

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SECTION D: PHYSICAL HAZARDS

Stability: Conditions to Avoid: Stable 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. CO

and other organic compounds may be formed

upon combustion.

Hazardous Polymerization:

Will not occur

Conditions to Avoid:

STRONG OXIDANTS – HEAT – SPARK AND OPEN FLAMES

SECTION E: HEALTH HAZARDS

Signs and Symptom of Exposure:

Skin: Prolonged and repeated skin contact may cause irritation or skin disorders such

as dermatitis or oil acne. Wash thoroughly with soap and water prior to using

toilet facilities, eating, drinking or smoking. Eyes: Contact with eyes may cause temporary irritation. Inhalation: The inhalation of vapors (generated at high temperatures only) or oil mist may

cause a mild irritation of the mucous membrane of the upper respiratory tract. Ingestion: Considered no more than slightly toxic if swallowed.

Medical Conditions Generally Aggravated by Exposure:

Pre-existing skin and respiratory disorders may be aggravated by exposure.

Oral LD50: Dermal LD50: Inhalation LD50: N/E N/E N/E

OSHA PEL/TWA OSHA PEL/CEILING ACGIh TLV/TWA ACGh TLV/STEL 5mg/M3 N/E 5mg/M3 10mg/M3

FORM No. ENG- 330 - 95 – 03 7/7/00

Acute Toxicity Data:

Occupational Exposure Limits:

Chronic Health Data:

None

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SECTION F: EMERGENCY AND FIRST AID PROCEDURES

Skin contact: Remove contaminated clothing and wash with soap and water. If irritation occurs

get medical attention. Eye contact: Flush with water for 15 minutes. If irritation occurs get medical attention. Ingestion: 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. Mechanical (general): As required to prevent exceeding recommended exposure limits. Protective gloves: Use chemically resistant gloves to avoid prolonged skin contact. Eye Protection: Use safety glasses or goggles to prevent eye contact. Respiratory Protection: As needed to prevent overexposure to mist or fumes. Use NIOSH

approved chemical mist and organic vapor respirators.

Other protective clothing or equipment: Use chemically resistant apron as needed.

SECTION H: ENVIRONMENTAL PROTECTION / SPILL AND LEAK PROCEDURES

Spill or Leak: Recover free product. Add sand, earth or other suitable absorbent to spill area.

Minimize worker contact. Keep from sewers or waterways by diking or

impounding. Advise authorities if product enters waterways or extensive land

areas. Dispose of recovered material and residue in compliance with all federal,

state, and local regulations. Waste Disposal: Dispose of all waste products in accordance with all applicable federal, state and

local regulations. Handling and Storage Precautions: Keep container closed when not in use. Do not store

near heat, open flame or strong oxidants.

SECTION I: TRANSPORTATION REQUIREMENTS

DOT Shipping Regulations:

Consider this product to be non-hazardous. No special labeling required by DOT.

SECTION J: OTHER REGULATORY CONTROLS

The ingredients of this product are on the TSCA Inventory.

The information contained herein is based on the data available to us and is believed to be correct. The Will-Burt Company does not warrant or guarantee their accuracy or reliability and The Will-Burt Company shall not be liable for any loss or damage arising out of the use thereof. The information and recommendations are offered for the user’s consideration and examination and it is the user’s responsibility to satisfy itself that they are suitable and complete for its particular use.

FORM No. ENG- 330 - 95 – 03 7/7/00

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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. / NAME / DESCRIPTION:

___________________________________________________________________________ PRODUCT SERIAL No. : ________________DATE OF PURCHASE: ___________________ DEALER NAME (WHERE PURCHASED):

_________________________________________________________________________ INSTALLER NAME:

_________________________________________________________________________ WHERE DID YOU HEAR ABOUT THIS PRODUCT?

_________________________________________________________________ WHY DID YOU PURCHASE THIS PRODUCT?

______________________________________________________________________ WAS THE PRICE OF THIS PRODUCT COMPETITIVE? YES __________ NO __________ WOULD YOU PURCHASE THIS PRODUCT AGAIN? YES __________ NO__________ WOULD YOU RECOMMEND THE PURCHASE OF THIS PRODUCT TO YOUR FRIENDS OR

THEIR ASSOCIATES? YES __________ NO__________ DOES THE PRODUCT SATISFY YOUR NEEDS / REQUIREMENTS? IF NO, EXPLAIN:

_____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________

DO YOU BELIEVE ANY FEATURE COULD BE IMPROVED TO ENHANCE THE PERFORMANCE OF THE PRODUCT? IF YES, EXPLAIN: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________

PLEASE CONTINUE ON REVERSE SIDE.

FORM No. ENG- 330 - 95 – 03 7/7/00

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ARE SATISFIED WITH THE APPEARANCE OF THE PRODUCT? YES _______NO_________ IF NO EXPLAIN : _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________

RATE THE INSTALLATION / OPERATION / SERVICE INSTRUCTIONS. GOOD ____ FAIR ____ POOR_____

DO YOU HAVE ANY SUGGESTIONS FOR IMPROVING THE INSTALLATION / OPERATION / SERVICE INSTRUCTIONS? IF YES, EXPLAIN: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________

ADDITIONAL COMMENTS: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________

ALL SUGGESTIONS PRESENTED TO WILL-BURT COMPANY ON THIS FORM RELATED TO THE WILLBURT COMPANY PROPRIETARY PRODUCT LINES WILL BE REVIEWED. HOWEVER, THE EVALUATION OF ANY PARTICULAR SUGGESTION NEITHER IMPLIES NOR GUARANTEES IMPLEMENTATION OF THE SUGGESTED CHANGE. ALL REVISIONS, MODIFICATIONS, AND / OR IMPROVEMENTS MADE TO THE WILL-BURT PROPRIETARY PRODUCTS AS A RESULT OF SUGGESTIONS MADE ON THIS SHALL BE THE SOLE AND EXCLUSIVE PROPERTY OF THE WILLBURT COMPANY, AND NO COMPENSATION OR CONSIDERATION OF ANY KIND WILL BE PAID FOR SUCH RECOMMENDATIONS. ______________________________________________________________________________________

DO NOT WRITE IN THE SPACE BELOW - RESERVED FOR FACTORY USE ONLY. _____________________________________________________________________________ __________________________________

______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ _______________________________________________________________

________________________________________________

____________________ _____________________________________________________________________________ _____________

______________________________________________________________________________________ _____________________________________________________________________________________ ______________________________________________________________________________________ _____________________________________

__________________________________________

______________________________________________________________________________________ ______________________________________________________________________________________

_______________________________________________________________________

____________________________________________

_______________________________________

FORM No. ENG- 330 - 95 – 03 7/7/00

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