TABLE OF CONTENTS
Carolina High Mast offers a complete, safe and dependable high mast lighting system for illuminating large outdoor areas such as:
Highways Railroad Yards Interchanges Freight Yards Prison Yards Ports Commercial Parking Lots Shopping Centers Industrial Plants Toll Plazas Coal mines and Yards Airports Power Plants Parks and Sports Yards
Critical to any high mast system is the service hoist and pole. Carolina High Mast manufactures a safe, reliable service hoist that lowers the fixtures for relamping and maintenance, and safely returns the units for operation.
SYSTEM CHOICES AVAILABLE FROM CHM
C A R O L I N A H II G H M AASSTT NA H GH M
TOP LATCH TOP LATCH The Standard Top Latch Lowering Device Includes:
Three-position stainless steel type 316 latching cams. Three spring-loaded stainless steel centering arms. Stainless steel hoist cables. Stainless steel hardware. Pre-wired aluminum distribution box. Copper-free aluminum cover secured with stainless steel hardware. Hot-dipped galvanized headframe, luminaire ring and fixture mounting tenons per ASTM -123. Square D circuit breaker mounted in an aluminum enclosure. Twist-lock weather-tight power connector set. Internal winch system for use with portable power unit assembly (internal motorized winch and mobile drive system optional.) Luminaire ring lowers to within four feet of pole base for servicing luminaires and other electrical equipment. Luminaire ring accommodates up to 12 high mast fixtures, up to 16 floodlight fixtures, mounted symmetrically around the ring.
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Data in this publication subject to change without notice.
T O P L AT C H ( S u g g e s t e d S p e c i f i c a t i o n s )
HEADFRAME ASSEMBLY
The headframe assembly shall consist of a 1/4" thick minimum top plate, with sheave support plates fabricated from a minimum 11 gauge steel sheet. The sheave support plates shall be welded to the headframe base plate. All steel plates shall be laser cut for accuracy. The complete headframe assembly shall be hot-dipped galvanized per ASTM A-123 after fabrication. Hoist cables shall operate over corrosion-resistant 5-inch diameter aluminum steel sheaves. The entire cable groove surface shall be machined to eliminate any rough surface on which the cable shall ride. The main power cord shall be supported by a minimum of two 6-inch nonconductive thermoplastic polymer power cord sheaves grooved to provide for a nonabrasive smooth operation. A two-piece threaded male and female thermoplastic polymer insulating bushing assembly shall be installed on the headframe opening to prevent wear on the power cord as it travels up and down the pole. All sheaves shall have sintered bronze oilite bearings and run on a stainless steel axle secured with self-locking stainless steel hardware. Keeper bars shall be positioned at both ends of the sheave assemblies to keep the cord in its track during pole erection and during normal operation. The top latching assembly shall contain three (3) symmetrically located, extremely stout, precision-cast matching stainless steel latch pins and enclosed cam mechanisms to assure corrosion-resistant, trouble-free operation for years to come. All moving latch parts are bolted to the ring for servicing from the ground. The complete two-part latch pin and cam assembly shall be made of stainless steel (type 316) material. There shall be no moving latch parts or springs attached to the headframe assembly. All motion required to achieve latching or unlatching shall be internal to the latch cam. This will help prevent shock and vibration damage to the lamps and luminaires, as well as prevent the formation of ice buildup on the latching mechanism. Latching occurs by the alternate raising and lowering of the luminaire ring. When
latching of the ring occurs, no horizontal movement of the fixtures (which can cause fixture damage) is permitted. When in the latch position the space between the headframe and the luminaire ring shall be no more than six inches. The use of Z type top latching system is not an acceptable alternate to the stainless steel latch cam. All hardware is corrosion-resistant stainless steel. The headframe assembly shall have a copper-free, spun aluminum cover, retained on its 360-degree perimeter by stainless steel hardware. The dome assembly shall provide a weather-tight seal against the elements for the headframe roller assemblies. The headframe shall bolt directly to the high mast pole. The headframe base plate and pole top plate shall have four 9/16" x 3" slotted holes to accommodate 1/2" type 18-8 stainless steel hardware.
MIL-W83420C. These special cables are specifically designed for lowering device applications and virtually make twistings a thing of the past. Swivel bearings may be used in the transition assembly but they shall not take the place of the antirotational cable. A transition assembly shall be supplied to attach the winch cable to the three hoist cables and the main power cord. The three hoist cables shall pass up through the pole shaft, over the headframe hoist cable sheaves, to the luminaire ring, where they travel through the stainless steel latch pin, stainless steel guides and compression spring assembly and terminate with a collet-type strand-vise device.
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Data in this publication subject to change without notice.
HEADFRAME ASSEMBLY
The headframe assembly shall consist of a 1/4" thick minimum top plate, with sheave support plates fabricated from a minimum 11-gauge steel sheet. The sheave support plates shall be welded to the headframe base plate. All steel plates shall be laser-cut for accuracy. The complete headframe assembly shall be hot-dipped galvanized per ASTM A-123 after fabrication. Hoist cables shall operate over corrosion-resistant 5-inch diameter aluminum steel sheaves. The entire cable groove surface shall be machined to eliminate any rough surface on which the cable shall ride. The main power cord shall be supported by a minimum of two 6-inch non-conductive thermoplastic polymer power cord sheaves grooved to provide for a nonabrasive smooth operation. A two-piece threaded male and female thermoplastic polymer insulated bushing assembly shall be installed on the headframe opening to prevent wear on the power cord as it travels up and down the pole. All sheaves shall have sintered bronze oilite bearings and run on a stainless steel axle secured with self-locking stainless steel hardware. Keeper bars shall be positioned at both ends of the sheave assemblies to keep the cord in its track during pole erection and during normal operation. On the underside of the headframe shall mount three cast aluminum guide sockets. The socket opening shall be tapered cone-shaped for locking and aligning the stainless steel locking pin mounted on the luminaire ring up against the headframe. The stainless steel locking pin shall insert a minimum of 4-1/2" into the cast aluminum guide socket. When in the latch position, the space between the headframe and the luminaire ring shall be no more than four inches when in the latched position. All hardware is corrosion-resistant stainless steel. The headframe assembly shall have a copper-free, spun aluminum cover, retained on its 360-degree perimeter by a stainless steel hardware. The dome
assembly shall provide an airtight seal against the elements for the headframes roller assemblies. The headframe shall bolt directly to the high mast pole. The headframe base plate and pole top plate shall have four 9/16" x 3" slotted holes on a 10 3/4" arc to accommodate 1/2" type 18-8 stainless steel hardware.
The three hoist cables shall pass up through the pole shaft, over the headframe sheaves, to the luminaire ring, where they travel through guides and a compression spring and terminate with a collet-type device. A safety mechanism shall be located in the base of the pole and consist of a stainless steel safety cable and hook to act as a backup to the winch cable assembly in maintaining the tension on the transition assembly. The safety cable shall be secured to the foundation or anchor bolts and not attached to the pole structure.
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Data in this publication subject to change without notice.
PORTABLE POWER UNIT ASSEMBLY (MODEL #C408GXXX) MOBILE PLATFORM SYSTEM (MODEL #C508GXXX)
The portable power unit shall incorporate the drive motor, torque limiter, drive shaft and electrical controls. The torque limiter is factory set to provide safe reliable operation. A twenty-five-footlong cord on the remote electrical control box provides for remote operation of the portable power unit. The drive motor is a heavy duty 120-volt reversing electric drill. The portable power unit shall be provided with a weatherproof, portable, enclosed stepdown transformer to operate the 120-volt power unit.
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Data in this publication subject to change without notice.
NOTES:
1. Unit is trailerable, eliminating loading and unloading hassles. 2. Fully adjustable arm allows operation of lowering device from uneven ground. 3. For retrofit situations, unit can operate lowering device through a single 5 x 8 hand hole. 4. Above 120 volts the voltage transformer is integral. 5. Tongue may be tilted for storage. 6. All adjustment pins are safety clipped. 7. 25-foot cord makes remote operation easy. 8. All winches wound with 1/4-inch diameter stainless steel anti-rotational cable. This cable is specifically manufactured for lowering device applications.
ATTACH SAFETY CABLE WHEN NOT IN USE. ALSO USE TO SECURE CABLE ASM, WHEN SAFETY CABLE IS NOT REQUIRED.
The mobile cart drive allows one maintenance person to operate the service platform, lowering the fixtures to ground level for service.
REMOTE SWITCH and 25 FT (7.6M cord STEPDOWN TRANSFORMER STORAGE BOX for REMOTE SWITCH and CORD 72,000 in. (1829 mm) ADJUSTABLE HITCH FOR 2,000 in. (51mm) BALL
DRIVE MOTOR TORQUE LIMITER TRACKING PULLEY CIRCUIT BREAKER BOX 14,000 in. (368mm) SAFETY CABLE WINCH ADJUSTABLE HEAD attached to handhole by two j-bolts 105,000 IN. (2,667MM)
TONGUE TILTS UP FOR STORAGE 13,000 in. (330MM) WHEELS FOR EASY TRANSPORT
BOTH DRIVE AND WINCH ARE EXTERNAL TO THE POLE, MOUNTED TO A MOBILE CART.
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Data in this publication subject to change without notice.
NOTE:
This is for 347 and 480 volt system only. For 208, 240 and 277 volt systems, see Internal Motor as shown on page 9.
When used with Top Latch When used with Bottom Latch When used with Top Latch Mobile Platform System
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Data in this publication subject to change without notice.
INTERNAL MOTOR
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Data in this publication subject to change without notice.
OPTIONS
NOTE:
*Maximum number of luminaires is 12 regardless of arm arrangement (A) Ring-with-fixture dimension (for clearance planning) Six-fixture orientation: Arm+21 inches (533mm); Diameter=99 inches (2,515mm) Twelve-fixture orientation: Tee Arm=32 inches (762mm); Diameter=119 inches (2,972mm)
ARM ORIENTATION
ARM DEGREES
120
90
72
60
FEATURES
Arms are constructed of two-inch (51mm) round steel pipe (2 3/8-inch/60mm OD) Hot-dipped galvanized after fabrication Arms will be equally spaced around ring Counterweight is used to balance loaded arms
HOW TO ORDER
When ordering service hoist, specify quantity of luminaires per ring. (Appropriate number of arms shall be bolted to the ring.)
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Data in this publication subject to change without notice.
FLOODLIGHT MOUNTING AND AIMING 3-ARM, 3-12 FLOODLIGHTS ARM ARRANGEMENT 3-ARM, 3-12 ARM ARRANGEMENT
OPTIONS ARM ORIENTATION ARM DEGREES NUMBER ARMS NUMBER FLOODLIGHTS PER POLE PER POLE
NOTE:
*Maximum number of floodlights is 12 regardless of arm arrangement (A) Ring-with-fixture dimension (for clearance planning) Sixteen-fixture orientation: Arm=54 inches (1,372mm); Diameter=142 inches (3,607mm)
120
312
90
416*
72
510
60
612
FEATURES
Arms are constructed of two-inch (51mm) square steel pipe (2 3/8 inch/60mm OD), 27 or 54 inches (686 or 1,372mm) long Hot-dipped galvanized after fabrication Arms will be equally spaced around ring Counterweight is used to balance loaded arms when necessary.
HOW TO ORDER
When ordering service hoist, specify quantity of floodlights per ring. (Appropriate number of arms shall be bolted to the ring.)
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Data in this publication subject to change without notice.
C A R O L I N A
I G H
M A S T
Carolina High Mast offers a complete, safe and dependable high mast lighting system for illuminating large outdoor areas such as:
Highways Railroad Yards Interchanges Freight Yards Prison Yards Ports Commercial Parking Lots Shopping Centers Industrial Plants Toll Plazas Coal mines and Yards Airports Power Plants Parks and Sports Yards
THE STANDARD TOP-LATCH SYSTEM FOR IN EXCESS OF 12 FIXTURES INCLUDES: Three (3) symmetrically located stainless steel type 316 latching cams. Two (2) galvanized steel stabilizing pins. Three (3) spring-loaded stainless steel centering arms for stabilized raising and lowering. 1/4 " galvanized steel hoist cables. Stainless steel is optional. Stainless steel hardware. Copper-free aluminum cover secured with stainless steel hardware. Hot dipped galvanized headframe assembly per ASTM A-123. Circuit breakers mounted in an aluminum enclosure. Twist-lock weather-tight power connector set. Mobile cart drive system. (Portable power units and internal motorized systems are available. Contact the factory for more information on these drive systems.) Mobile crossarm platform which lowers to within five (5) feet of pole base for servicing fixtures and other electrical equipment. Hot-dipped galvanized steel pole, per ASTM A-123.
Mobile Platform System with Top-Latching Crossarm Service Platform for 13 to 21 fixtures (shown with Mobile Cart Drive Assembly)
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Data in this publication subject to change without notice.
shall be mounted on the underside of the headframe assembly. The 1-3/4" socket opening shall be tapered cone shaped for locking and aligning the 1-1/2" x 10" min. galvanized steel locking pin mounted on the mobile crossarm platform up against the headframe. The galvanized steel locking pin shall insert a minimum of six (6) inches into the cast aluminum guide socket. This will provide both stabilization of the platform and prevent horizontal movement of the crossarm platform when in its latched position. The minimum height of the aluminum guide socket is four (4) inches. When in the latched position, the space between the headframe and the mobile crossarm platform shall be no more than six (6) inches when in the locked position. The use of Z type top latching system is not an acceptable alternative to the stainless steel latch cam. All hardware shall be corrosionresistant stainless steel. The headframe assembly shall have a copper-free, spun aluminum cover, retained on its 360 degree perimeter by a stainless steel hardware. The dome and clamp band assembly shall provide a weather-tight seal against the elements for the top plate roller assemblies.
permit testing of the sportslighting fixtures while the service platform is in the lowered position. On the underside of the service platform shall mount a quantity of three (3) roller-contact, spring-loaded stainless steel centering arms with polymer rollers to balance and center the ring and to prevent shock to the lamps from impact of the service platform with the pole. The arms shall be fabricated from highstrength stainless steel. Highly visible six-inch (6") minimum retroreflective position indicator flags shall be provided for easy day or night operation. The three (3) hoist cables shall be galvanized steel-wound anti-rotational aircraft cord, 1/4 inch diameter manufactured to meet MIL-W83420C. These special cables are specifically designed for lowering device applications and virtually make twistings a thing of the past. Swivel bearings may be used in the transition assembly but they shall not take the place of the anti-rotational cable. A transition assembly shall be supplied to attach the winch cable from the mobile cart drive unit to the three (3) hoist cables and the main power cord. The three (3) hoist cables shall pass up through the pole shaft, over the top plate hoist cable sheaves, to the service platform, where they travel through the stainless steel latch pin, stainless steel guides, and compressions spring assembly. They terminate with a collet-type strand-vise device. A safety mechanism shall be located in the base of the pole and consist of a stainless steel safety cable and hook to act as a backup and to maintain the tension on the transition assembly.
Mobile Platform System with Top-Latching Crossarm Service Platform for 2 to 12 fixtures (shown with Mobile Cart Drive Assembly)
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Data in this publication subject to change without notice.
Mobile Platform System with Top-Latching Crossarm Service Platform for 13 to 21 fixtures (shown with Mobile Cart Drive Assembly)
Mobile Platform System with Top-Latching Crossarm Service Platform for 2 to12 fixtures (shown with Mobile Cart Drive Assembly)
LATCH SERVICE PLATFORM TOP LATCHING SERVICE PLATFORM STAINLESS STEEL STABILIZING SPRING MAIN POWER CORDS 3 LIFT CORDS TRANSITION YOKE (galvanized) CONNECTOR SET WINCH CABLE CIRCUIT BREAKER (mounted in aluminum enclosure)
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Data in this publication subject to change without notice.
8 floodlights (typical) 2 rows of 4 fixtures each 19-21 floodlights (typical) 3 rows of 7 fixtures each
4 floodlights (typical)
3 floodlights (typical)
2 floodlights (typical)
NEIGHBORHOOD SYSTEMS
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Data in this publication subject to change without notice.
45 CONE COVER
NUT AND WASHER (625 STAINLESS STEEL) BELOW BUSHING BOLT (500 Brass or Stainless Steel)
CABLE CONNECTOR (No. 14) FOR BOLT SET SCREW (No. 90M) FOR CABLE CONNECTOR
BONDING (No. 551M) SECURE TO 2 in. (51mm) CAP SCREW AND LOCK WASHER (Brass or Stainless Steel) 19
The high mast pole shall consist of two or more round or multisided tapered sections. The pole shaft section shall be fabricated from high-strength, low-alloy steel plate conforming to ASTM standards, with a minimum yield strength of 55,000 psi. These shaft sections shall telescope into each other to match the overall desired height of the pole. The overlap telescoping joint shall have a minimum slip distance equal to 1 1/2 times in inside diameter of the female section. The sections shall be pre-fitted and matched, marked at the factory. All sections shall maintain a uniform taper from top to bottom. There shall be a maximum of one longitudinal weld in the tapered sections of the shaft. The longitudinal seams shall have at least 60% penetration, except in the areas where the shaft section telescopes over another. In the overlapping areas, the weld penetrate shall be 100%. No transverse butt welds may be used in fabricating the shafts. The finished poles shall be hotdipped galvanized per ASTM A-123 after
fabrication, weathering steel per ASTM A-588 or powder-coat finish, with the color to be determined at the time of release. The base plate shall be fabricated from structural quality hot-rolled carbon steel plate that meets or exceeds ASTM standards with a minimum yield strength of 36,000 psi. The base plate shall telescope the pole shaft and is circumference-welded top and bottom. The base plate shall have slotted holes for 1/2" variation in the anchor bolt setting. A reinforced handhole(s), having an appropriate 10" x 30" opening shall be located 15" up from the base. A handhole cover, attaching hardware, and grounding provision hardware are included with each handhole frame. Anchor bolts are fabricated from a commercial quality hot-rolled carbon steel bar that meets or exceeds a minimum yield strength of 55,000 psi. Properly sized anchor bolts will be provided with two hex nuts and two flat washers per bolt.
All welding shall be of the highest quality and performed by American Welding Society certified welders and conforming to the latest revision of the American Welding Society specification AWS D1.1 Section 8. All welds shall be done by either the shielded metal-arc, gas-shielded flux core, gas metal-arc or submerged-arc process.
P L A T E
A N C H O R
B O L T
80 MPH
EPA ft.2
WT. LBS.
90 MPH
EPA ft.2
WT. LBS.
100 MPH
EPA ft.2
BOLT
CIR(INCHES)
DIA
INCHES
LENGTH HOOK
INCHES INCHES
NO.
REQUIRED
75.0 51.2 61.6 35.8 44.1 52.6 34.2 43.1 50.8 32.8 41.3 48.7 42.3 69.4 99.7 29.8 50.6 80.4
1900 1280 1540 895 1103 1325 855 1078 1270 820 1033 1218 1056 1735 2493 745 1265 2010
58.8 39.3 47.2 27.5 33.4 40.4 26.4 32.8 39.1 25.2 31.4 37.2 30.3 54.4 71.2 22.8 39.1 57.0
1463 983 1180 658 834 1010 680 820 978 630 785 930 758 1360 1780 570 978 1425
46.0 31.1 36.1 21.4 25.9 31.6 20.5 25.3 30.7 17.9 24.2 29.2 20.3 41.8 50.9 15.2 30.7 39.5
1150 778 903 535 648 790 513 633 768 440 605 730 508 1045 1273 378 768 988
24X22 24X22 25X23 24X22 25X23 25X25 26X24 27X27 27X27 28X26 29X29 29X29 29X29 30X30 34X34 29X29 30X30 34X34
1.25 1.25 1.25 1.25 1.25 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
20 20 21 20 21 22 22 23 23 24 25 25 26 26 30 26 26 30
1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54
6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00
6 6 6 6 6 8 6 8 8 6 8 8 8 12 16 8 12 16
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Data in this publication subject to change without notice.
HIGH MAST POLE POLE TOP AND BASE, SUPPORT PLATE AND POLE ELEVATION
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Data in this publication subject to change without notice.
SERVICE HOIST
Each service hoist consists of bracket arms, pre-wired ring headframe, cover, hoist winch cables, and a winch. The ring can accept up to 12 High Mast Luminaires, up to 24 Floodlights or up to 24 Sportslights.
NOTE: **Requires portable drive unit C408GXXX or optional mobile drive motor.
HMS
PRODUCT ID XXX
HMS= High Mast System
TL
ID
100
G
POLE FINISH X
G=Galvanized P=Prime Painted W=Weathering Steel X=Supplied By Others
080
10
-X-X-X
OPTIONS -X-X-X
See Options Table
A=ASHTO 02=2 13=13 F=Flood 03=3 14=14 H=High Mast N=NonASHTO (Standard) 04=4 15=15 S=Sports Floodlights 05=5 16=16 R=Roadway 06=6 17=17 X=Mixed 07=7 18=18 (Specify) 08=8 19=19 09=9 20=20 10=10 21=21 11=11 22=22 12=12 23=23 24=24
MD=Mobile Drive Motor 080=80 090=90 100=100 110=110 120=120 130=130 140=140 150=150
NOTE:
*Meters; 18, 21, 24, 27, 30, 34, 37, 40, 43, 46
**Complies with specifications published in 1994 edition Standard Specification for Structural Supports for Highway Signs, Luminaires and Traffic Signals published by the American Association of the State Highways and Transportation Officials (AASHTO). MAXIMUM OF 12 HIGH MAST FIXTURES PER RING.
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ELECTRICAL SYSTEMS AVAILABLE TWO AND THREE CIRCUIT SYSTEMS ARE AVAILABLE. POLE BASE
A* B C D E F G H J K L M N P R S T W X
VOLTAGE
120 120/240 208 208 240 120/240 240/480 277 277/480 480 480 220 347 347/600 220 240 240/415 220/380 Other Special
PHASING
Single Three Single Three Single Single Single Single Three Single Three Single Single Three Single Single Three Three
DESCRIPTION
Hoist Cable Winch Cable Winch Cable Hoist Sheaves 4=1/4-inch Stainless Steel S4=1/4-inch Stainless Steel S5=5/16-inch Stainless Steel S=Stainless Steel
Winch Support Drum Cable Guard PE Control X Lowering Device Not Fixtures (Specify) Night/Shift Circuit X (Specific) Lightning Arrestor on Ring Lightning Rod Single Aircraft Warning Light Double Aircraft Warning Light Double Aircraft Warning Light with Transfer Relay
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Data in this publication subject to change without notice.
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Data in this publication subject to change without notice.