Getinge Blue 8080 User manual
Blue 80/80 Field Light, Installation,
Operators, Service and Parts Manual.
HAN40527, Rev A
Getinge USA, Inc.
1777 East Henrietta Road
Rochester, NY 14623-3133 USA
Phone: (800) 950-991
BLUE 80/80 FIELD LIGHT, INSTALLATION, OPERATORS, SERVICE AND PARTS MANUAL
HAN40527, Rev A, 21 April, 2006
Related Publications: 56351056/B Hanaulux Blue 30/80 Operating Instructions
56321004A Hanaulux Blue 30/80 Spare Parts Lists
DESCRIPTION OF SYMBOLS & NOTES IN MANUAL
DANGER
“Danger” notes alert the user to the possibility of serious injury or death.
“Warning” notes alert the user to the possibility of personal injury.
“Caution” notes alert the user to the possibility of damage to the equipment.
“Notes” alert the user to pertinent facts and conditions.
This manual contains proprietary information of Getinge USA, Inc. It shall not be reproduced
in whole or in part without the written permission of Getinge USA, Inc.
is a registered trademark. Copyright 2006
by Getinge USA, Inc.
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
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Table of Contents
SECTION 1: GENERAL DESCRIPTION: .........................................................................................................2
1.1
BLUE 80 LAMPHEAD ....................................................................................................................................2
1.2 BLUE 80/80 POWER SUPPLY .......................................................................................................................2
1.3 BLUE 80/80 SUSPENSION SYSTEM............................................................................................................... 3
SECTION 2: REMOVAL OF EXISTING CASTLE 2420 LIGHT SYSTEM FROM ISO SHELTER...................4
2.1
DISCONNECT POWER AT MAIN BREAKER PANEL ............................................................................................. 4
2.2 REMOVE JUNCTION BOX, CONDUIT AND WIRING .............................................................................................4
2.3
REMOVE EXISTING LIGHT SYSTEM ................................................................................................................ 5
2.4 REMOVE WIRES FROM LIGHT SYSTEM ...........................................................................................................6
2.5 REMOVE TRANSPORTATION CEILING PADS ....................................................................................................6
2.6
REMOVE DIMMER SWITCH ............................................................................................................................7
SECTION 3: INSTALLATION OF LIGHT SUSPENSION, WIRING AND BRACKETS ...................................8
3.1
INSTALLATION OF CEILING MOUNTED TRANSPORTATION PLATES AND STRAPS ...............................................8
3.2.
POWER SUPPLY BRACKET .......................................................................................................................... 9
3.3 CEILING PLATE AND FLANGE...................................................................................................................... 11
3.4 CEILING FLANGE TO MAIN ARM INSTALLATION ............................................................................................12
3.5
MAIN ARM INSTALLATION...........................................................................................................................13
3.6 MAIN ARM WIRING AND CONDUIT INSTALLATION .........................................................................................14
3.7 CEILING COVER INSTALLATION................................................................................................................... 15
3.8
LOW VOLTAGE AC WIRE RUN FROM POWER SUPPLY TO LIGHT CONNECTION..............................................16
3.9 HIGH VOLTAGE AC WIRE FROM POWER SOURCE TO POWER SUPPLY .........................................................17
3.10
SPRING ARM TO MAIN ARM INSTALLATION ................................................................................................18
SECTION 4.0: INSTALLATION OF LAMPHEADS AND POWER SUPPLY: ................................................ 20
4.1
REMOVING COMPONENTS FROM SHIPPING CASE.........................................................................................20
4.2
LAMPHEAD INSTALLATION ..........................................................................................................................22
4.3 POWER SUPPLY INSTALLATION AND CONNECTION ......................................................................................25
4.4 SETTING POWER SUPPLY TAPS .................................................................................................................26
4.5
INITIAL SETTING OF POWER SUPPLY VOLTAGES ......................................................................................... 27
SECTION 5: SECURING BLUE 80 MAIN ARMS ...........................................................................................29
REMOVAL OF BLUE 80 LAMPHEADS AND MAQUET POWER SUPPLY ...............................................................29
5.1
5.2
SECURING MAIN ARM AND SPRING ARMS ..................................................................................................... 29
SECTION 6.0: OPERATION OF THE BLUE 80/80 LIGHT SYSTEM: ...........................................................31
6.1
SETTING UP LIGHT SOURCE .......................................................................................................................31
6.2
ENERGIZING THE POWER SUPPLY. ............................................................................................................. 32
SECTION 7.0: PREVENTIVE MAINTENANCE OF BLUE 80/80 LIGHT SYSTEM........................................33
INSPECTION BY THE OPERATOR .................................................................................................................33
7.2
7.3
CLEANING/DISINFECTION........................................................................................................................... 34
7.4 STERILIZING THE HANDLES ........................................................................................................................34
SECTION 8.0: CORRECTIVE MAINTENANCE..............................................................................................35
8.1
TROUBLESHOOTING PROCEDURES .............................................................................................................35
8.2 LIGHTHEAD REMOVAL PROCEDURES...........................................................................................................36
8.3
SPRING ARM TENSION ADJUSTMENT PROCEDURE ........................................................................................ 37
8.4
SETTING THE BRAKE PRESSURE OF THE BLUE 80 LIGHTHEAD ......................................................................37
8.5 REPLACEMENT OF BULBS...........................................................................................................................38
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
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SECTION 9. TROUBLESHOOTING THE POWER SUPPLY ......................................................................... 39
SECTION 10.0: PARTS LISTING ...................................................................................................................41
BLUE 80 LIGHTHEAD PARTS ....................................................................................................................42
10.2
10.3 ISO SHELTER MOUNTING KIT ..................................................................................................................43
10.4
POWER SUPPLY......................................................................................................................................56
10.5 REUSABLE SHIPPING CONTAINER. ...........................................................................................................62
F
IGURES
F
IGURE 1: POWER BREAKER.................................................................................................................................4
F
IGURE 2: JUNCTION BOX .....................................................................................................................................4
FIGURE 3: EXISTING LIGHT SYSTEM ...................................................................................................................... 5
FIGURE 4: REMOVING WIRES FROM LIGHT SYSTEM ................................................................................................ 6
F
IGURE 5: REMOVING TRANSPORTATION CEILING PADS .........................................................................................7
F
IGURE 6: REMOVE DIMMER SWITCH.....................................................................................................................7
FIGURE 7: INSTALLATION OF VELCRO STRAPS........................................................................................................ 8
F
IGURE 8: POWER SUPPLY BRACKET INSTALLATION............................................................................................... 9
FIGURE 9: DRILLING TEMPLATE ...........................................................................................................................10
FIGURE 10: POWER SUPPLY MOUNTING BRACKET ...............................................................................................10
F
IGURE 11: BOLT/BRACKET POSITIONING ............................................................................................................ 10
FIGURE 12: CEILING FLANGE AND PLATE .............................................................................................................11
F
IGURE 13: CEILING FLANGE AND PLATE .............................................................................................................12
FIGURE 14: MAIN ARM INSTALLATION ..................................................................................................................13
FIGURE 15: CONDUIT INSTALLATION ....................................................................................................................14
F
IGURE 16: RETAINING RING ASSEMBLY..............................................................................................................15
FIGURE 17: RETAINING CLAMPS, HOOD ASSEMBLY .............................................................................................. 15
FIGURE 18: ASSEMBLED HOOD ASSEMBLY ..........................................................................................................15
F
IGURE 19: LOW VOLTAGE AC CONNECTIONS ..................................................................................................... 16
FIGURE 20: AC OUT CABLE ROUTE.................................................................................................................... 16
FIGURE 21: HIGH VOLTAGE AC WIRE/PLUG ........................................................................................................ 17
F
IGURE 22: SPRING ARM TO MAIN ARM INSTALL ..................................................................................................18
FIGURE 23: INSERTING MALE LIGHT PLUG ...........................................................................................................19
FIGURE 24: BLUEMMSA CONTAINER LABEL ...................................................................................................... 20
F
IGURE 25: BLUE 80 LIGHT CONTAINER INVENTORY ............................................................................................ 21
FIGURE 26: LAMPHEAD INSTALLATION ................................................................................................................. 22
F
IGURE 27: SPRING ARM CONNECTION ...............................................................................................................23
F
IGURE 28: SECURING LAMPHEAD ...................................................................................................................... 23
F
IGURE 29: RETAINING RING/PROTECTIVE COVER...............................................................................................24
IGURE 30: MILITARY POWER SUPPLY ................................................................................................................25
F
F
IGURE 31: PRIMARY/SECONDARY TAPS .............................................................................................................26
F
IGURE 32: BLUE 80 BULB ACCESS PANEL..........................................................................................................27
FIGURE 33: BLUE 80 VOLTAGE MEASUREMENT....................................................................................................28
F
IGURE 34: VELCRO STRAP, P/N HAN40475...................................................................................................... 29
F
IGURE 35: SPRING ARM STRAPPING POSITION .................................................................................................... 30
F
IGURE 36: CEILING MOUNTED VELCRO STRAP, P/N HAN40468......................................................................... 30
FIGURE 37: BLUE 80 LAMPHEAD .........................................................................................................................31
F
IGURE 38: LAMPHEAD ALIGNMENT ..................................................................................................................... 31
F
IGURE 39: BLUE 80/80 POWER SUPPLY ............................................................................................................ 32
IGURE 40: WEIGHT BALANCER ..........................................................................................................................36
F
F
IGURE 41: BLUE 80 LIGHTHEAD BRAKE SCREW...................................................................................................36
F
IGURE 42: SPRING ARM BRAKE ADJUSTMENT...................................................................................................... 37
IGURE 43: BLUE 80 LIGHTHEAD BRAKE ADJUST .................................................................................................. 37
F
F
IGURE 44: LIGHT BULB REPLACEMENT PROCEDURE ............................................................................................38
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
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IGURE 45: SCHEMATIC, WIRING, POWER SUPPLY, MILITARY ............................................................................... 40
F
F
IGURE 46: FLANGE AND SUSPENSION ................................................................................................................41
FIGURE 47: SPRING ARMS AND LIGHTHEADS ....................................................................................................... 41
FIGURE 48: BLUE 80 LIGHT COMPONENTS........................................................................................................... 42
F
IGURE 49: HAN40457 ASSEMBLY, CONDUIT, ½” EMT, 28.5” LONG ...................................................................44
F
IGURE 50: HAN40460 ASSY, RING, ANCHOR PLATE,.........................................................................................45
FIGURE 51: HAN40464 TOGGLE, SPRING WING..................................................................................................46
F
IGURE 52: HAN40465 ROUND HEAD SCREW, ZP.............................................................................................. 47
FIGURE 53: HAN40466 PLATE, HOLDING, VELCRO ............................................................................................. 48
FIGURE 54: HAN40467 TEMPLATE, MOUNTING, TRANSFORMER BOX, ARMY ........................................................49
F
IGURE 55: HAN40468 STRAP, VELCRO, 2” .......................................................................................................50
FIGURE 56: HAN40475 COVER, TRANSPORT, ARM .............................................................................................51
FIGURE 57: HAN40482 CONNECTOR, TURN LOCK, FEMALE, 20 AMP .................................................................. 52
F
IGURE 58: HAN40487 ASSEMBLY, CABLE, AC OUT, EXTERNAL, ARMY ..............................................................53
FIGURE 59: HAN40541 BRACKET, MOUNTING, ELECTRICAL BOX, ARMY ..............................................................54
FIGURE 60: HAN40551 NUT, WIRE, TWIST LOCK, YELLOW..................................................................................55
F
IGURE 61: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 1 OF 6..........................................................56
F
IGURE 62: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 2 OF 6..........................................................57
FIGURE 63: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 3 OF 6..........................................................58
F
IGURE 64: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 4 OF 6..........................................................59
FIGURE 65: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 5 OF 6..........................................................60
F
IGURE 67: BLUEMMSA REUSABLE SHIPPING CONTAINER.................................................................................. 62
Tables
Table 1: Parts Inventory Checklist……………………………………………………………………………………1
Table 2: Blue 80/80 System Technical Data……………………….………………………….…………………….2
Table 3: Transformer Secondary Tap Voltages…………………………..…………………………….……….…26
Table 4: Preventive Maintenance Recommendation…………………………………………………………..…..32
Table 5: Mechanical/Optical Troubleshooting…………….……………………………….……………………..…34
Table 6: Power Supply Troubleshooting………………………………………………….……………….………...36
Table 7: Upper Level System Part numbers/components…………………………….……………….………..…40
Table 8: Blue 80 Part numbers/description…………………………………………….……………….…………...41
Table 9: ISO Mounting kit……………………………………………….……………….……………….…………...42
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The following is the suggested tool list for proper installation.
Tools Required for Installation of the Blue 80/80 Field Light
Item
Socket Set up to 1" socket
Flatblade Screwdriver #1 and #2
Phillips Screwdriver #2 and #3
Wire Cutters
Tape Measure
Open/Closed End Wrench set to 1"
Metric Allen Set
Electric Drill
9/16" Drill Bit
Digital Multimeter
The following is an inventory checklist of items for Blue80/80 Field Light System
Received Part Number Item Name
BLUE80/80CASE
SHIPPING CONTAINER
Yes No BLUE80/80 CASE Container, Reusable Shipping (1)
Yes No 5607-7852 Blue 80 Lightheads (2)
Yes No
Yes No
Yes No
Yes No
Yes No
ISO Mounting Kit
Yes No HAN40457 Assy, conduit, 1/2" emt (1)
Yes No HAN40460 Assy, ring, anchor plate (1)
Yes No HAN40464 Toggle, spring wing (4)
Yes No HAN40465 Screw, rh, .250-20, UNC-3A (4)
Yes No HAN40466 Plate, holding, velcro (2)
Yes No HAN40467 Template, mtg, xfmr box, army (1)
Yes No HAN40468-24 Strap, velcro, 2" x 24" (1)
Yes No HAN40468-40 Strap, velcro, 2" x 40" (1)
Yes No HAN40475 Cover, transport, arm (2)
Yes No HAN40482 Conn., Turn lock, female 20amp (1)
Yes No HAN40487 Assy, cable, ac out, external (1)
Yes No HAN40541 Brkt, mtg, elect box, army (2)
Yes No HAN40551 Nut, wire, twist, yellow (6)
Yes No X0216 Tape, electrical, black (1)
Yes No HAN40580 Bubble Level(1)
Suspension System
Yes No 569004905 Ceiling Flange (1)
Yes No 569004990 Suspension, Duo, Blue 80 (1)
Yes No 569004991 Spring Arm (2)
HAN40489 Assembly, Power supply, Army (1)
5605-3036 Bulb: B80 21.5v 130w (2)
5605-0756 Handle: Plastic, 200 series (3)
5605-0756 Handle: Plastic, 200 series (3)
HAN40457 Blue 80/80 Field Light, Installation/Operators Manual (1)
Table 1: Part Inventory Checklist
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HAN40527, Rev A, 21 April, 2006
Section 1: General Description:
The dual Blue 80 light system is designed for installation into a military ISO Shelter. It is a
light system that can be disassembled and assembled for rapid deployment of the shelter.
The main and spring arms are permanently secured to the shelter, and the lampheads and
power supply are removable for shipment.
1.1 Blue 80 Lamphead
• Multifunctional filter and reflector system with 1,500 facets and specially coated reflector
provides high precision, true-to color and neutral white light
• Illuminance at 80,000 lux
• Equipped with a two-stage interference filter for additional infra-red filtering
• Automatic back-up system from primary to secondary light source
• Integrated ON/OFF switch, easily accessible on the light head
• Sterilizable Handle
• Full rotation around the central axis with accurate positioning where required
Table 1 provides technical data on the Blue 80 lamphead and power supply.
1.2 Blue 80/80 Power Supply
The power supply was designed for installation into a portable military ISO shelter. Mobility of
this system was a major consideration, thus the Blue 80/80 power supply was designed to be
hung via a wall mounted bracket assembly, and electrically connected with simple quick
disconnects on both the AC input and the AC output lines.
The Blue 80/80-power supply has a matched pair of transformers. Each transformer supplies
power to one lamphead. The transformers step-down the incoming voltage (110VAC to 120VAC)
into multiple secondary voltages, ranging from 24.5VAC to 27.5VAC, to accommodate for
tolerances with incoming voltages and wiring resistance.
Power resistors are placed in series with both outputs to reduce the voltage sent to enable the
bulb to operate at its specified 21.4VAC.
An inline fuse assembly is mounted on the output of the transformer to protect both lightheads.
The fuse is rated at 9 amps, 32 volts. The circuit is protected on the primary side by SPDT 20amp breaker switches installed on the front panel. Both switches are labeled and switch the
incoming AC power to each light. The breakers have visible light indication, showing the
ON/OFF switch position.
The input AC voltage is fed into the housing with a female connector. It is mated with a turn lock
style, male connector. This turn style connector is embedded within the housing enclosure and
will mate up to the input connector. These connectors are a quarter locking twist design thus
ensuring positive connection when mated together.
The output AC low voltage connection utilizes a female plug connector. This, in turn, will mate
up to a matched male connector and will be terminated at a junction box for the cable run to the
ceiling mounted light system.
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1.3 Blue 80/80 Suspension System
The Blue 80/80-suspension system is made up of (3) section. The upper section is a (2) plate
system; a mounting plate that attaches directly to the ceiling of the shelter, and a suspension
plate that attaches to the mounting plate. The dual extension arm is secured to the suspension
plate, and the spring arms are secured to the main arm. Table 1 provides technical data on the
Blue 80-suspension system.
Lighting Data Blue 80 Lamphead
Illumination Ec at 39.5 in(1m) distance 80,000 lux
Light field diameter at 39.5 in (1M) distance 7 in (18cm)
Working distance 27.5 - 51 in (70-130cm)
Depth of working area with homogenous light field 23.75 in (60cm)
Depth of light exit 13.75 in (35cm)
Color temperature 4,300 Kelvin
Color rendering index Ra 93
Max. temperature increase in operation field 13 Degree C
Temperature increase at surgeon’s head 2 Degree C
Luminous efficiency 250lm/W
Total irradiance 320 W/m2
Power consumption Max 150W
Dimension of lighthead 19.5 x 14.5 z 8in (500x370x200mm)
Weight of lighthead 12lb (5.5kg
Electrical Data Blue 80/80 Power Supply
Weight of Box 61.5 lbs. (135.3 kg)
Input Voltage 110-120VAC, 60 Hz, 1 phase
Input Current Per Transformer 4.35 - 6.16 amps
Output Voltage
Output Current Per Transformer 5.5 amps at 21.4VAC
Suspension System Blue 80/80 Suspension
Main Arm lengths
Weight of main arm system
Spring Arms 25.4” (619.8mm)
Weight of spring arms 9 lbs. (4.1kg).
Ceiling plate dimensions 15.54” OD
Ceiling plate weights 32 lbs. (70.4kg)
Environmental storage
To meet the environmental conditions for storage and transportation specified in MIL-STD810, environmental test methods and engineering guidelines, the Blue 80/80 Power supply,
and Lamp heads must be packaged in the Getinge supplied shipping case, Pt#
Blu8080case, Hardigg Pt # dsi-80205-1100.
NOTE: Power supply model HAN40489 is only to be used in ISO shelter with Dual 80/80
systems, Part Number
Table 2: Blue 80/80 System Technical Data
Multiple taps, 19.5 volts to 27.5 volts
with 120 VAC input.
39” (1000mm) upper arm, (33”)
850mm lower arm
40 lbs.
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Section 2: Removal of existing Castle 2420 Light System from ISO Shelter
This section covers the removal of the existing Castle 2420 light systems from the ISO Shelter.
2.1 Disconnect power at main breaker panel
2.1.1 Turn off all power to the lights by turning off the appropriate breaker switches. The breaker
numbers to the lights are listed on the door, inside the breaker panel. See Figure 1.
Figure 1: Power Breaker
2.2 Remove junction box, conduit and wiring
Remove the junction box cover to access the wires and junction box mounting screws.
Depending on the method used to secure the wires, either twist the wire nuts off, or if
compression wire nuts were used, cut the wires from the wire nuts. After separating the wires,
remove the screws holding the junction box to the ceiling. Next, remove the screws securing
the junction box and conduit from the ceiling channel. Pull the wires through the conduit, but
do not remove them from the ceiling channel at this time. See Figure 2.
Figure 2: Junction Box
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2.3 Remove existing light system
Remove the light heads from the ceiling straps and lower the light heads as far as possible
DANGER
before removing the light system from the ceiling. While one person holds the light system, a
second person shall remove the three bolts securing the lights to the ceiling. Safely lower the
light system to the ground. This is a two-person procedure, and extreme caution should be
used to avoid having the light system drop or fall on someone. See Figure 3.
Straps
Figure 3: Existing Light System
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2.4 Remove wires from light system
Remove the strain relief on the far end of the ceiling wire channel located along the middle of
the ISO Shelter ceiling. Pull the cable out approximately 6 inches and cut the Green, White
and Black wires above the black cable insulation. It may be necessary to reach into the end of
the wire channel, and pull the wires out from the end of the wire channel in order to get them
to move freely. At this point do NOT remove the Green ground wire, as it will be used as a pull
wire to run the new wiring through the channel.
Remove the White and Black power wires by pulling one at a time through the opening in the
middle of the channel, or by pulling them out the open end of the channel. It may be necessary
to use needle nose pliers to remove the wires through the strain relief in the middle of the
channel, to get the wire connector through the strain relief, if this option is used. See Figure 4.
Cut wires
here after
removing
cable from
strain relief
Figure 4: Removing Wires from Light System
2.5 Remove transportation ceiling pads
Remove the two transportation-ceiling pads with straps that secure the light heads to the
ceiling. Replace the bolt and washer back into the ceiling after removing the straps, as they
will be used later to secure the new arm system transportation straps.
See Figure 5.
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Figure 5: Removing Transportation Ceiling Pads
2.6 Remove dimmer switch
Unscrew the front cover on the dimmer switch, and cut the three power wires to the cable on
the right hand side. Disconnect the strain relief from the main power feed cable, and pull the
cable out of the box. The strain relief will not be used, and can be discarded. The existing
cable will be used on the new light system. After removing the cable, unscrew the backing
plate from the wall. Remove the strain relief at the ceiling wire channel, and pull the cable and
wires out. The strain relief at the ceiling wire channel will be used later in Step 3.8. See
Figure 6.
After removing the ceiling
pad, reinstall the bolt and
washer into the existing
threaded hole in the ceiling.
The power cable
will be used with
the new light
Figure 6: Remove Dimmer Switch
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Section 3: Installation of Light Suspension, Wiring and Brackets
This section covers the installation of the Blue 80/80 light system transport system, the main
suspension, wiring, and power supply brackets into the ISO Shelter. This step is performed once
during initial installation of a system.
Before starting the installation, make sure the ISO Shelter is completely level, using the
leveling devices associated with the shelter. If the ISO shelter is not level prior to installation,
the light systems will not hang properly.
3.1 Installation of Ceiling Mounted Transportation Plates and Straps
Unscrew the bolts and washers from the ceiling that were used to secure the ceiling pads in
step 2.3. There are two different length straps, 24" and 40". Mount the 24" closest to the main
cable channel, and the 40" on the other side. If they are mounted with the 40" nearest the
main cable channel, it will have no effect on the operation of the tie down system. Take the
bolt and washer, and slide it through the bottom of the ceiling plate, which is the side without
the groove in it. There is a small hole in the Velcro, approximately 6" from the buckle. Slide the
Velcro strap onto the bolt, with the "fuzzy" loop side facing up, or away from the ceiling plate
surface. The strap will sit in the groove machined into the ceiling plate, and the "fuzzy" loop will
make contact with the ceiling. Secure the ceiling plate to the top of the shelter and tighten, with
the strap running parallel to the ISO shelter (door to door). There are (2) plates per light
system, (4) total. See Figure 7.
Door Door
Figure 7: Installation of Velcro Straps
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3.2. Power Supply Bracket
3.2.1 Taking a tape measures and a piece of tape, measure down from the ceiling 22 inches,
and from the end of the side wall 11 inches, and place the tape in this area. Go back
and mark and exact centerline location of 22 inches down and 11 inches across onto the
tape. This measurement will be either the top right or top left-hand hole for the drilling
template, depending on which light system is being installed. (right hand shown). See
Figure 8.
22"
11"
Figure 8: Power Supply Bracket Installation
3.2.2 Take the drill template and line up with the marked centerline on the top right or left
hand hole, (depending on which of the two light systems is being installed). Using tape
and a level, line up the template parallel to the floor, and tape the template to the wall.
After the template is installed, mark the four holes onto the wall, and remove the
template. Drill (4) small pilot holes approximately 1/8" to 1/4" in diameter, then finish
using a 5/8" drill bit. See Figure 9.
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Figure 9: Drilling Template
3.2.3 Take (2) .250-20 x 1 1/2" long threaded bolts, and insert through the Power Supply
Mounting Brackets, and screw on the spring nuts. See Figure 10.
Figure 10: Power Supply Mounting Bracket
3.2.4 It is necessary to leave a very minimum amount of threads securing the spring nut to
the bolt. Push the spring nuts into the holes, and push the bolt and bracket securely
against the wall to enable the spring clip to open. It may be necessary to tighten and
loosen the bolts a few times in order to get the spring clips to engage correctly. If a
spring clip comes loose from the bolt, the spring clip can be removed from the wall
with a pair of needle nose pliers or a similar tool. See Figure 11.
4 Bolts and
Spring Clips
Figure 11: Bolt/Bracket Positioning
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
acket
and Washers
HAN40527, Rev A, 21 April, 2006
3.3 Ceiling Plate and Flange
Mount the ceiling plate to the ceiling of the ISO shelter using the mounting hardware provided.
The ceiling plate must be aligned so the conduit-mounting bracket is facing the wiring channel.
It will line up directly to the threaded hole in the wiring channel from where the previous
conduit was removed in step 2.2. This is a two-person installation. See Figure 12.
Conduit Mounting
Br
Ceiling plate is heavy, and caution should be taken when installing. Two people
should install this plate, one securing it in position, while the other installs the
hardware.
Figure 12: Ceiling Flange and Plate
(3) Mounting Bolts
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3.4 Ceiling Flange to Main Arm Installation
Slide cable from Main Arm through the throat of the Ceiling Flange. Align the (4) holes, (2)
above and (2) below the circular plate of the ceiling flange, and slide over main arm tube.
Secure to the Main Arm tube with the (4) countersunk screws provided.
See Figure 13.
(2) Screws
below circular
plate
(2) Screws
above circular
plate, (not
shown)
Figure 13: Ceiling Flange and Plate
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HAN40527, Rev A, 21 April, 2006
3.5 Main Arm Installation
Before installing the Main Arm, The majority of the hardware on the ceiling plate must be
removed. All that should remain on the (6) studs of the ceiling plate, is (1) hex nut per stud, (6)
total. Screw these (6) nuts all the way flush to the plate. To aid in the installation of the Main
Arm, place (1) flat washer on each stud, and tape it to the ceiling plate. This will allow easier
installation of the Main Arm to the ceiling plate. The Main arm installation is a two person
operation, and the Main Arm must be aligned correctly before attaching any further mounting
hardware. There is a small notch machined out of the top of the Main Arm tube that must run
parallel to the conduit-mounting bracket. This notch is for the cable to sit in when the Main Arm
is tightened to the ceiling plate. Once the Main Arm is aligned with the notch, secure the Main
arm to the (6) studs using a flat washer, a lock washer and a hex nut on each stud. Slowly
tighten the lower nuts, but do not tighten them completely. Make sure the cable is still sitting in
the notched cutout while tightening the nuts. Once the upper tube of the Ceiling Flange is
almost touching the Ceiling Plate, take the small bubble level supplied with the installation kit,
and adjust the lower nuts until the Ceiling flange is sitting level on the studs. At this time,
tighten the upper nuts down onto the Ceiling Flange, checking afterwards to make sure the
Flange is still level.
NOTE: If Spring Arms are to be installed on Main Arm before mounting Main Arm to
ceiling flange, follow Steps 3.10.1 and 3.10.2 first, then install unit as shown above.
See Figure 14.
(1) Nut
(1) flat washer
per stud above
ceiling flange
Figure 14: Main Arm Installation
(1) Nut
(1) lock washer
(1) flat washer
per stud below
ceilin
flange
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
HAN40527, Rev A, 21 April, 2006
3.6 Main Arm Wiring and Conduit Installation
Take the small black grommet from the ceiling cover, and slide it over the conduit. Next, take
the power cable from the Main Arm and slide it through the cut end of the conduit, exiting the
end with the compression fitting. Take the end of the cable and tape it to the existing green
lead wire exiting the middle of the ceiling wiring channel from the old light system. Slowly pull
the green wire through the wiring channel at the far end of the channel. After the wire has
successfully been pulled through the end of the wiring channel, screw the conduit into the
existing threaded hole in the wiring channel and tighten. Next, secure the opposite end of the
conduit under the conduit-mounting flange located on the Ceiling Plate and tighten. See Figure
15.
Existing
green wire
Main arm cable
taped to green
wire
Conduit
compression
fitting
Figure 15: Conduit Installation
Conduit
Ceiling cover
grommet
Conduit
mounting
flange
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
HAN40527, Rev A, 21 April, 2006
3.7 Ceiling Cover Installation
3.7.1 Around the main axle, you must now mount the retaining brackets. This is done by
clamping the two brackets around the axle, screw side out. Tighten Screws. See Figure
16.
Figure 16: Retaining Ring Assembly
3.7.2 Place the clamps onto the hood assembly as shown in Figure 17.
3.7.3 Place both hood pieces around the main shaft, inserting the bottom of hood into the
groove from the small retaining ring. Ensure that rubber grommet around conduit fits
snugly inside of hood. Screw hood assembly to plate assembly. See Figure 18.
Figure 17: Retaining Clamps, Hood Assembly
Figure 18: Assembled Hood Assembly
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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual
cable
HAN40527, Rev A, 21 April, 2006
3.8 Low Voltage AC Wire Run from Power Supply to Light Connection
3.8.1 Place the existing strain relief black rubber grommet (from Step 2.6) and nut over the 6
wire, 5 foot long, "AC out" cable end, leaving approximately 12" to 16" of cable. Place the
cable through the side of the wiring channel and pull the wires through the open end of the
channel. Take the 6-wire cable from the light system, and match the 6 wires from the AC
out cable, and secure together using the wire twist nuts provided. After securing the wires
together with the wire nuts, take the black electrical tape supplied and wrap the wire nuts
and wires securely together. See Figure 19.
Figure 19: Low Voltage AC Connections
3.8.2 Push the taped wire/cable bundle into the open end of the wiring channel, slowly pulling
the "AC out" cable through the strain relief in the wire channel. After successfully placing
the taped ends of the cables back into the open end of the wiring channel, secure the
"AC out cable to the wiring channel with the strain relief grommet and nut. See Figure 20.
5' "AC OUT"
Compression
fitting
Figure 20: AC OUT Cable Route
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