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: [phone]

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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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
5.1 REMOVAL OF BLUE 80 LAMPHEADS AND MAQUET POWER SUPPLY ...............................................................	29
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
7.2 INSPECTION BY THE OPERATOR .................................................................................................................	33
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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SECTION 9. TROUBLESHOOTING THE POWER SUPPLY .........................................................................	39
SECTION 10.0: PARTS LISTING ...................................................................................................................	41
10.2 BLUE 80 LIGHTHEAD PARTS ....................................................................................................................	42
10.3 ISO SHELTER MOUNTING KIT ..................................................................................................................	43
10.4 POWER SUPPLY......................................................................................................................................	56
10.5 REUSABLE SHIPPING CONTAINER. ...........................................................................................................	62
FIGURES
FIGURE 1: POWER BREAKER.................................................................................................................................	4
FIGURE 2: JUNCTION BOX .....................................................................................................................................	4
FIGURE 3: EXISTING LIGHT SYSTEM ......................................................................................................................	5
FIGURE 4: REMOVING WIRES FROM LIGHT SYSTEM ................................................................................................	6
FIGURE 5: REMOVING TRANSPORTATION CEILING PADS .........................................................................................	7
FIGURE 6: REMOVE DIMMER SWITCH.....................................................................................................................	7
FIGURE 7: INSTALLATION OF VELCRO STRAPS........................................................................................................	8
FIGURE 8: POWER SUPPLY BRACKET INSTALLATION...............................................................................................	9
FIGURE 9: DRILLING TEMPLATE ...........................................................................................................................	10
FIGURE 10: POWER SUPPLY MOUNTING BRACKET ...............................................................................................	10
FIGURE 11: BOLT/BRACKET POSITIONING ............................................................................................................	10
FIGURE 12: CEILING FLANGE AND PLATE .............................................................................................................	11
FIGURE 13: CEILING FLANGE AND PLATE .............................................................................................................	12
FIGURE 14: MAIN ARM INSTALLATION ..................................................................................................................	13
FIGURE 15: CONDUIT INSTALLATION ....................................................................................................................	14
FIGURE 16: RETAINING RING ASSEMBLY..............................................................................................................	15
FIGURE 17: RETAINING CLAMPS, HOOD ASSEMBLY ..............................................................................................	15
FIGURE 18: ASSEMBLED HOOD ASSEMBLY ..........................................................................................................	15
FIGURE 19: LOW VOLTAGE AC CONNECTIONS.....................................................................................................	16
FIGURE 20: AC OUT CABLE ROUTE....................................................................................................................	16
FIGURE 21: HIGH VOLTAGE AC WIRE/PLUG ........................................................................................................	17
FIGURE 22: SPRING ARM TO MAIN ARM INSTALL ..................................................................................................	18
FIGURE 23: INSERTING MALE LIGHT PLUG ...........................................................................................................	19
FIGURE 24: BLUEMMSA CONTAINER LABEL ......................................................................................................	20
FIGURE 25: BLUE 80 LIGHT CONTAINER INVENTORY ............................................................................................	21
FIGURE 26: LAMPHEAD INSTALLATION .................................................................................................................	22
FIGURE 27: SPRING ARM CONNECTION ...............................................................................................................	23
FIGURE 28: SECURING LAMPHEAD ......................................................................................................................	23
FIGURE 29: RETAINING RING/PROTECTIVE COVER ...............................................................................................	24
FIGURE 30: MILITARY POWER SUPPLY ................................................................................................................	25
FIGURE 31: PRIMARY/SECONDARY TAPS .............................................................................................................	26
FIGURE 32: BLUE 80 BULB ACCESS PANEL..........................................................................................................	27
FIGURE 33: BLUE 80 VOLTAGE MEASUREMENT....................................................................................................	28
FIGURE 34: VELCRO STRAP, P/N HAN40475......................................................................................................	29
FIGURE 35: SPRING ARM STRAPPING POSITION ....................................................................................................	30
FIGURE 36: CEILING MOUNTED VELCRO STRAP, P/N HAN40468.........................................................................	30
FIGURE 37: BLUE 80 LAMPHEAD .........................................................................................................................	31
FIGURE 38: LAMPHEAD ALIGNMENT.....................................................................................................................	31
FIGURE 39: BLUE 80/80 POWER SUPPLY ............................................................................................................	32
FIGURE 40: WEIGHT BALANCER ..........................................................................................................................	36
FIGURE 41: BLUE 80 LIGHTHEAD BRAKE SCREW ...................................................................................................	36
FIGURE 42: SPRING ARM BRAKE ADJUSTMENT......................................................................................................	37
FIGURE 43: BLUE 80 LIGHTHEAD BRAKE ADJUST ..................................................................................................	37
FIGURE 44: LIGHT BULB REPLACEMENT PROCEDURE ............................................................................................	38

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FIGURE 45: SCHEMATIC, WIRING, POWER SUPPLY, MILITARY...............................................................................	40
FIGURE 46: FLANGE AND SUSPENSION ................................................................................................................	41
FIGURE 47: SPRING ARMS AND LIGHTHEADS .......................................................................................................	41
FIGURE 48: BLUE 80 LIGHT COMPONENTS...........................................................................................................	42
FIGURE 49: HAN40457 ASSEMBLY, CONDUIT, ½” EMT, 28.5” LONG ...................................................................	44
FIGURE 50: HAN40460 ASSY, RING, ANCHOR PLATE,.........................................................................................45
FIGURE 51: HAN40464 TOGGLE, SPRING WING..................................................................................................	46
FIGURE 52: HAN40465 ROUND HEAD SCREW, ZP..............................................................................................	47
FIGURE 53: HAN40466 PLATE, HOLDING, VELCRO .............................................................................................	48
FIGURE 54: HAN40467 TEMPLATE, MOUNTING, TRANSFORMER BOX, ARMY ........................................................	49
FIGURE 55: HAN40468 STRAP, VELCRO, 2” .......................................................................................................	50
FIGURE 56: HAN40475 COVER, TRANSPORT, ARM .............................................................................................	51
FIGURE 57: HAN40482 CONNECTOR, TURN LOCK, FEMALE, 20 AMP..................................................................	52
FIGURE 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
FIGURE 61: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 1 OF 6..........................................................	56
FIGURE 62: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 2 OF 6..........................................................	57
FIGURE 63: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 3 OF 6..........................................................	58
FIGURE 64: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 4 OF 6..........................................................	59
FIGURE 65: HAN40489 ASSEMBLY, POWER SUPPLY, ARMY, SHEET 5 OF 6..........................................................	60
FIGURE 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	HAN40489	Assembly, Power supply, Army (1)
Yes	No	5605-3036	Bulb: B80 21.5v 130w (2)
Yes	No	5605-0756	Handle: Plastic, 200 series (3)
Yes	No	5605-0756	Handle: Plastic, 200 series (3)
Yes	No	HAN40457	Blue 80/80 Field Light, Installation/Operators Manual (1)
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)

Table 1: Part Inventory Checklist

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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.

1.1Blue 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	Multiple taps, 19.5 volts to 27.5 volts
		with 120 VAC input.
	Output Current Per Transformer	5.5 amps at 21.4VAC

	Suspension System	Blue 80/80 Suspension
	Main Arm lengths	39” (1000mm) upper arm, (33”)
		850mm lower arm
	Weight of main arm system	40 lbs.
	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-STD- 810, 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

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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.

2.1Disconnect power at main breaker panel

2.1.1Turn 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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After removing the ceiling pad, reinstall the bolt and washer into the existing threaded hole in the ceiling.

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.

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

3.2.1Taking 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

3.2.2Take 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

3.2.3Take (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

3.2.4It 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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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	Figure 12: Ceiling Flange and Plate	(3) Mounting Bolts
	Bracket		and Washers

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.

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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. See Figure 14.

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.

(1) Nut	Figure 14: Main Arm Installation	(1) Nut
(1) flat washer		(1) lock washer
per stud above		(1) flat washer
ceiling flange		per stud below
		ceiling 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.

				Conduit
Existing						Figure 15: Conduit Installation	Conduit			Conduit
				compression
green wire				fitting						mounting
							Ceiling cover			flange
	Main arm cable						grommet
	taped to green
	wire

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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual

HAN40527, Rev A, 21 April, 2006

3.7Ceiling Cover Installation

3.7.1Around 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.

Figure 17: Retaining Clamps, Hood Assembly

3.7.3Place 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 18: Assembled Hood Assembly

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Blue 80/80 Field Light, Installation, Operators, Service and Parts Manual

HAN40527, Rev A, 21 April, 2006

3.8Low Voltage AC Wire Run from Power Supply to Light Connection

3.8.1Place 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

3.8.2Push 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" cable

Compression fitting

Figure 20: AC OUT Cable Route

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