Doc Level

Technical Reference Manual

Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
Reference ID TRM-PM-01 Classification Confidential

TECHNICAL REFERENCE MANUAL

PNEUMATIC MAST ASSEMBLY

Page 1 of 10
 Doc Level
Technical Reference Manual
Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
Reference ID TRM-PM-01 Classification Confidential

Table of Contents
1. INTRODUCTION ................................................................................................................................................. 3
1.1. General ....................................................................................................................................................3
1.2. Purpose and Scope of Manual.............................................................................................................3
1.3. Organization of Manual ........................................................................................................................3
1.4. Specifications ..........................................................................................................................................3
1.4.1. General .............................................................................................................................................. 3
1.4.2. Air Pump ............................................................................................................................................ 3
1.4.3. Air Circuit ........................................................................................................................................... 4
1.4.4. Safety Valve ...................................................................................................................................... 4
1.4.5. Pressure Sensor .................................................................................................................................. 4
1.4.6. Solenoid Valve .................................................................................................................................. 4
1.4.7. Control Box ........................................................................................................................................ 4
2. EQUIPMENT DESCRIPTION ................................................................................................................................ 4
2.1. Pneumatic Mast .....................................................................................................................................5
2.2. Controls and Indicators .........................................................................................................................5
2.3. System Operating Pressure ....................................................................................................................6
2.4. Schematic Diagram ...............................................................................................................................6
3. INSTALLATION INSTRUCTIONS ........................................................................................................................... 7
3.1. Notes ........................................................................................................................................................7
3.2. Installation Configuration ......................................................................................................................7
4. Operation .......................................................................................................................................................... 7
4.1. Preparatory Work....................................................................................................................................7
4.2. Precautions .............................................................................................................................................8
4.3. Extending the Mast ................................................................................................................................8
4.4. Retracking the Mast ...............................................................................................................................8
5. MAINTENANCE AND CARE .............................................................................................................................. 9
5.1. General ....................................................................................................................................................9
5.2. Standard & Special Tools and Test Measuring and Diagnostic Equipment ....................................9
5.3. Spares and Repair Parts .........................................................................................................................9
5.4. Periodic Maintenance ...........................................................................................................................9
5.5. Troubleshooting Guide ..........................................................................................................................9
5.5.1. Abnormal Extension of Mast ......................................................................................................... 10
5.5.2. Abnormal Retraction of Mast ....................................................................................................... 10

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 Doc Level
Technical Reference Manual
Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
Reference ID TRM-PM-01 Classification Confidential

1. INTRODUCTION

1.1. General
A mast is a long pole or spar rising from the keel or deck of a ship and supporting the yards,
booms, and rigging. The pneumatic mast is a mechanical device that uses compressed air for
rising and retracting several of the mast cylinder sleeve pistons. The pneumatic mast is
characterized as having small volume, light weight that can be easily transported, installed,
and used. It can be mounted on ground, vehicle, and ship with wide application areas such
as communication, mobile wireless base station, monitoring, military, and other fields. Made
from high-strength aluminum alloy, it is suitable for noiseless and stable operations for heavy
loads. The mast can be designed and manufactured to meet the customers requirement of
verity of loads and heights.

1.2. Purpose and Scope of Manual

This manual enumerates various features, characteristics, and operation of pneumatic mast.
The content of this manual is intended to be used by maintenance and Quality Assurance
personnel for inspection and maintenance of pneumatic mast.

1.3. Organization of Manual

Content of this manual is organized in sections containing relevant information about the
pneumatic mast assembly. Section 1 is general introduction to the assembly followed by
section 2 containing equipment description. The third section contain the troubleshooting
guide and the last section give the operational instructions.
Numbered lists or table indicate priority and listed items require sequential steps such as
assembly or disassembly instructions where steps are to be followed sequentially. Bulleted list
does not indicate priority are generally used to enumerate characteristics or properties of the
item.

1.4. Specifications

1.4.1. General
Table 1. Specifications of Mast Assembly
Initial height ho 2,550 mm
Maximum height hmax 15,650 mm
Number of sections 10
Minimum pipe diameter dmin 109 mm
Maximum pipe diameter dmax 285 mm
Weight 177 Kg
Maximum top load 100 Kg
Horizontal pull at the top 60 Kg
Working Pressure 0.3 MPa
Environment temperature -30C ~ +60°
Voltage AC 220V
Current 10 A

1.4.2. Air Pump

• Model: 2660 CHI44-487

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PNEUMATIC MAST ASSEMBLY Revision No 0
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• Working Voltage: 220 VAC

• Airflow rate: 0. 0.140 m3 per minute
• Working pressure: 3 kg/cm2
• Weight: 2 kg

1.4.3. Air Circuit

• Input pipe diameter: 3/8 inch
• Output pipe diameter: 3/8 inch
• Number of Ports: 6

1.4.4. Safety Valve

• Model: AXD2.111-0.5
• Operating pressure limit: 0.4 MPa / 4 kg/cm2

1.4.5. Pressure Sensor

• Model: QPM11-NC
• Upper limit: 0.3 MPa / 3 kg/cm2
• Lower limit: 0.25 MPa / 2.5 kg/cm2

1.4.6. Solenoid Valve

• Model: UW-15
• Bore Diameter: 1/2 inch
• Working Voltage: DC 24 V
• Current: 0.5 A

1.4.7. Control Box

• Dimensions: 400 x 280 x 490 (L x W x H) mm
• Ingress Protection (IP) Code: IP43

2. EQUIPMENT DESCRIPTION
The pneumatic mast assembly consists of mast, air supply system and the control system. The
system is shown in Figure 1.

Figure 1. The Pneumatic Mast Assembly

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Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
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2.1. Pneumatic Mast

The pneumatic mast is made from high-strength aluminum alloy. Depending on the required
length, the mast is composed of various cylindrical pitch sleeve that move inside each other
while extending or retracting. Apart from cylindrical pitch sleeve, the mast is composed of
pitch sleeve, seal ring, stop collar, crash pad, damping ring, piston, guide ring, bolt, air tap,
foundation, etc.

Figure 2. Pneumatic Mast

2.2. Controls and Indicators

Controls and indicators are shown in Figure 3.

Power Switch Powers the control cabinet. It has the electric leakage
protection function
Power Indicator The indicator light will light up once the power is turned
ON
Pressure Gauge Display the pressure of the pneumatic mast assembly
Air pump Operation Switch Up : Extend the mast
Pause : Stop extension or retraction of mast
Down : Retract the mast
Air Pump Indicator The indicator light will light up once air pump turns ON. If it
does not light up, it means that the system pressure has
reached 0.25MPa ≤ P ≤ 0.3MPa
Safety valve The safety valve prevents the over pressurization of the
system beyond 0.4 mPa

Figure 3. Controls and indicators

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PNEUMATIC MAST ASSEMBLY Revision No 0
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2.3. System Operating Pressure

The pneumatic mast has assembly maintains the operating pressure (0.25MPa ≤ P ≤ 0.3MPa)
automatically. When the system pressure is lower than 0.25MPa/2.5 Kg/cm², the system will
automatically turn on the air pump to maintain the pressure. After attaining the pressure
of0.3MPa/3 Kg/cm², the air pump turns off automatically. During automatic operation, the air
pump should not be turn off to avoid permanent damage to the system.

2.4. Schematic Diagram

The mechanical schematic diagram of the system is shown in Figure 2. The control system
consists of air switch, contactor, relay, pressure switch, safety valve, vent valve, pressure
gauge, etc.

Figure 4. - Mechanical Schematic Diagram of Pneumatic Mast Assembly

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Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
Reference ID TRM-PM-01 Classification Confidential

Figure 5. Electrical Schematic Diagram of Pneumatic Mast Assembly

3. INSTALLATION INSTRUCTIONS

3.1. Notes
• Mast is not designed as a lift for persons, animals, and other dangerous goods.
• The mast be extended only in vertical position. Operation in inclined position is prohibited.
• The mast is not designed for operation under high voltage electric facilities. The safe
distance must be kept when it is used close to the high voltage electric facilities.
• During operation of mast, all electrical power be disconnected. The installation of
electrical equipment shall strictly follow the operating instruction and comply with the
safety standard.
• Always operate mast assembly through provided control box. It should not be operated
directly after bypassing the control box.
• The mast is not designed for as a lightning rod. The lightning arrester shall be installed at
certain height. For specific parameters, please consult the local professional department.

3.2. Installation Configuration

The pneumatic mast assembly can be installed in different configurations. For specific
configuration, respective installation manual be consulted.

4. Operation

4.1. Preparatory Work

• Prior to operation, ensure that the load is firmly installed on the mast.

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PNEUMATIC MAST ASSEMBLY Revision No 0
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• In case of anomaly, immediately stop extension and retraction operation and check the
cause of fault.
• The mast be extended only in vertical position. Operation in inclined position is prohibited.
• Ensure towlines are properly secured to the ground using anchor anchors firmly inserted
into ground. All towlines must be evenly tightened. Angle between ground and the top
towline must be around 45o.
• During operation of mast, all electrical power be disconnected. The operation of
electrical equipment should comply with the safety standard.
• The rainwater penetration into the mast body will not hinder the normal use of the mast.
However, discharge the trapped water during periodic maintenance. Removal of
trapped water must be ensured before winters as it will cause damage to the seals due to
freezing.
• Familiarization of the operation controls and extending/retracting operations of the mast.
• Ensure the control system is working normally.
• Inject lubricating oil into the oil filler hole of all cylindrical pitch sleeves.

4.2. Precautions
• Ensure that mast is fully retracted when the wind speed above 10 kmph or the face area
of the installed load exceeds 0.8 m².
• As the mast has no self-locking function, there should be certain pressure in the mast
when the towline is pulled. The pressure gage shall be observed when the towline is
pulled. It will be OK when the displayed pressure falls into the range of
0.25MPa≤P≤0.3MPa.
• During retraction operation, if the control switch is at “Down ” and the system pressure is
lower than 1.2 Kg/cm², the mast does not retract or it is found that certain cylindrical pitch
sleeve is clamped, put the control switch to the position “Pause ” and ensure that no
personnel is under the mast.
• Mast should never be retracted by pulling the air pipe as it may result in mechanical
damage or personal injury.
• When the last pitch retracts, ensure that personnel are cleared off the installed load to
avoid head injury.

4.3. Extending the Mast

1. Turn ON the power supply using Power Switch.
2. To extend the mast, turn the control switch to the position “Up ”, the mast will extend in
steps.
3. When the extension is completed, and air pump will stop.
4. Turn OFF the power supply using Power Switch.
5. Constantly observe the pressure on the gauge. If pump does not stop, and pressure
exceeds 0.35 MPa, manually stop the air pump and inspect the system.

4.4. Retracking the Mast

1. Loosen the towlines on different steel bars and check if the load is in the normal drawing
condition to ensure that the retraction operation can be started.
2. Turn ON the power supply using Power Switch.
3. To retract the mast, turn the control switch to the position “Down ”, the mast will retract
in steps.
4. When the extension is completed, and air pump will stop.

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 Doc Level
Technical Reference Manual
Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
Reference ID TRM-PM-01 Classification Confidential

5. Turn OFF the power supply using Power Switch.

6. Constantly observe the pressure on the gauge. If pump does not stop, and pressure
exceeds 0.35 MPa, manually stop the air pump and inspect the system.

5. MAINTENANCE AND CARE

5.1. General
This section gives the Maintenance Checks and Services (PMCS) required for Pneumatic Mast
Assembly at various maintenance echelons as per the Maintenance Chart.

5.2. Standard & Special Tools and Test Measuring and Diagnostic Equipment
Standard tool kit will be used during the routine maintenance.

5.3. Spares and Repair Parts

As per OEM spare parts list.

5.4. Periodic Maintenance

Periodic inspection and maintenance is to be carried out as per Table 2.
Table 2. Periodic Maintenance Chart
Before Quarterly Yearly
Item Inspection standard
use inspection inspection
Fixed hoop of mast ✓ ✓ ✓ No cracks or loose hoop
Foreign matters in the
No foreign matters in the electric
electric appliance ✓ ✓
appliance cabinet
cabinet
No noise, odor, abnormal
Running of air pump ✓ ✓ ✓
stoppages, etc
Intake pressure ✓ ✓ ✓ Pressure lesser than 0.4MPa.
Mast foundation ✓ ✓ ✓ No crack/ displacement
Manual control of Normal operation of manual
✓ ✓
mast extension/ retracting of mast
Lubricating oil Oiling through injection hole at
✓ ✓
injection the top of each section
Towline wear ✓ ✓ Check the wear
Clean irrespective of sand or
Mast cleaning ✓ ✓
dust

5.5. Troubleshooting Guide

In case of abnormal extension or retracting of mast, use respective troubleshooting guide
(paragraph 5.5.1 and 5.5.2).

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 Doc Level
Technical Reference Manual
Revision Date 1-Nov-2021
PNEUMATIC MAST ASSEMBLY Revision No 0
Reference ID TRM-PM-01 Classification Confidential

5.5.1. Abnormal Extension of Mast

Figure 6. Troubleshooting Guide - Abnormal Extension

5.5.2. Abnormal Retraction of Mast

Figure 7. Troubleshooting Guide - Abnormal Retraction

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