MAVIG GD60D012 User manual

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Assembly Instructions -Ceiling
Substructure
GD60D012
GD60D022
GD60D032

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Dear Customer,
Thank you for choosing a MAVIG suspension system or one of its components. Please
read this document carefully and ensure that you observe all instructions, warnings and
information. Please do not hesitate to contact us if you have any questions or comments
related to our products.
Contact details
The contact details for the MAVIG branch in your region can be found at the end of these
instructions.
Disclaimers
Every effort has been made to ensure that the contents of this manual do not contain any
errors or omissions. Nevertheless, MAVIG assumes no liability with regard to the contents
of this document and specifically disclaims any implied warranties.
Amendments
MAVIG products are subject to continuous development. MAVIG reserves the right to
make changes to the manual, packaging, equipment or technical specifications without
prior notification.
Translations
The original document is in English. The English version remains the definitive version.
Copyright and trademarks
All rights reserved. These instructions are protected by copyright. All other trademarks
referred to in this manual are the property of the manufacturer in question.

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Contents
1Symbols and Definitions ................................................................................................ 4
2Components and Scope of Delivery ............................................................................. 5
2.1.Tools Required ........................................................................................................... 8
2.2.Intended Use: .............................................................................................................. 9
3Installation..................................................................................................................... 10
3.1.Secure Ceiling Anchorage ....................................................................................... 11
3.2.Fastening the Ceiling Plate ...................................................................................... 12
3.3.Option to Fixate a Connection Plate ....................................................................... 13
3.4.Installation of the Middle and Interface Plates ...................................................... 14
3.4.1GD60D012 .......................................................................................................... 15
3.4.2GD60D022 .......................................................................................................... 16
3.4.3GD60D032 .......................................................................................................... 18
3.5.Fastening of an Assembly Aid ................................................................................ 20
4Safe Disposal ................................................................................................................ 2 0
5Technical Data .............................................................................................................. 21

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This manual describes the installation of the ceiling substructure for support arm
systems GD50, GD60D (and subtypes) and GD78.
1
SYMBOLS AND DEFINITIONS
WARNING
This indicates that the information is a warning. Warnings refer to
conditions which could result in injury or the death of the patient
or user. Read and make sure you understand all warnings
before installing the system.
CAUTION
This indicates that the information is provided as a precautionary
measure. Precautionary measures refer to circumstances which
could result in damage to the device or impair its proper
functioning. You must read and understand the precautions
before installing the system.
NOTE: This provides advice on the use of the system/device and other
useful information.
Wear protective shoes with steel toe cap.
Wear a hard hat.
Wear working gloves.

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2
COMPONENTS AND SCOPE OF DELIVERY
The ceiling substructure is available in three different length variations (see Fig. 1).
MAVIG purchase numbers:
Short variation: GD60D012
Medium variation: GD60D022
Long variation: GD60D032
GD60D032(max.79kg): GD60D022(max.59kg): GD60D012(max.41kg):
Fig. 1

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Fig. 2
1. Ceiling
2. Ceiling Plate - weight approx. 23kg (Fig. 3)
3. Middle Frame (only GD60D022 and GD60D032)
6x DIN 975 M16 class 8.8 threaded rods;
Length for GD60D032: 1000mm; Length for GD60D022: 495mm
6x tubes (only GD60D032) outer-Ø 55mm, inner-Ø 51mm, Length: 940mm
12x DIN 9021 washers (only GD60D032)
18x ISO4032 M16 class 8 hexagon nuts
4. Middle Plate - weight approx. 12.5kg (Fig. 4)
5. False Ceiling
6. Interface Plate – weight approx. 15 kg (Fig. 5)
6x DIN 975 M16 class 8.8 threaded rods; Length: 195 mm
24x ISO4032 M16 class 8 hexagon nuts (18x for GD60D012)
7. Anchor point as assembling aid for e.g. monitors
1x DIN 580 M12 eye bolt
1x DIN9021-13x37x3 washer
8. Anchor points for optional Connection Plate
2x ISO4032 M16 class 8 hexagon nuts
9. Connection Plate

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Ceiling plate
Fig. 3
Middle plate
Fig. 4

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Interface plate
Fig. 5
2.1.
TOOLS REQUIRED
- Torque wrench for 200 Nm (±3%) with socket and open-end wrench (SW 24 mm)
- Metal saw
- Vice with protective braces (e.g. Aluminum)
- Measuring tape
- Spirit level (accuracy: 1mm/m) – digital spirit level strongly recommended
- Paint Seal
- Loctite 270

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2.2.
INTENDED USE:
This installation instruction applies to the installation of the ceiling substructure.
Reliable Combination
The individual components of the ceiling substructure are compatible and reliable. Any
other assembly method or the use of parts that have not been supplied by the
manufacturer or authorised representatives of the manufacturer is strictly prohibited as
this could seriously compromise the safety of the structure.
Authorised Attachments
The ceiling substructure is only authorised for use with MAVIG products. For this purpose,
the interface plate of the ceiling substructure is fitted with six M16 threads deployed in a
bolt circle of Ø270 mm (see Fig. 5).
Specified Use
The ceiling substructure serves as the bridging element between the solid ceiling and the
false ceiling for ceiling mounted medical devices supported by suspension arms in the
operating theatre, intensive care, and general medical rooms.
The length of the substructure can be adapted to a specific needed length.
The ceiling substructure is designed to withstand long-term service.
The ceiling substructure must not be used in rooms in which flammable mixtures
consisting of anesthetic agents in combination with air, oxygen, or nitrous oxide could be
used.
The maximum payload is 399kg.
The maximum moment is 4444Nm.
Transport and Storage
The following storage conditions are valid for up to 15 weeks:
Temperature: -20°C to +70°C
Relative humidity: 10% to 95%
Air pressure: 70kPa to 106kPa
After 15 weeks, the ambient conditions recommended for use shall apply for storage.
Ambient conditions
The following ambient conditions are recommended for the use of the support arm
system:
Temperatures: +10°C to +40°C
Relative humidity: 20% bis 75%
Air pressure: 70 kPa bis 106kPa

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3
INSTALLATION
The installation of the ceiling substructure should be done by two people.
CAUTION: Risk of injury!
Individual assembly parts are very heavy!
Always involve at least 2 people in the mounting work.
Use lifting and supporting devices as defined in this manual!
CAUTION: Risk of injury!
Many installation steps are done above the head.
Use suitable safety equipment to protect yourself from falling parts!
CAUTION: Risk of injury!
Sharp edges may be exposed during the assembly of components.
Work with caution! If applicable, wear protective gloves!
Assembly of the systems: As pointed out by MAVIG in these assembly instructions,
the ceiling must be checked for sufficient stability by a structural engineer before
assembly and the assembly must occur under the guidance of the respective
construction supervision!
If these instructions are ignored, MAVIG will not assume any warranty for damages of
any kind!
The determination of the individual fastening elements and their respective tightening
torques for mounting on ceiling and wall is the sole responsibility of the respective
structural engineer.

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3.1.
SECURE CEILING ANCHORAGE
In all cases a civil or structural engineer must be consulted to make sure that the ceiling
is capable of safely carrying the loads shown in Fig.6:
The screws used to attach the system to the ceiling are not part of the system.
The substructure shall be fastened to the ceiling with following specifications:
o The maximum axial load per bolt will not exceed 7210N.
o The maximum Shear load per bolt will not exceed 957N.
o The maximum pullout force shall be calculated in accordance with local
building codes and it is part of structural analysis done by customer.
Fig. 6

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3.2.
FASTENING THE CEILING PLATE
NOTE:
The diameter of the opening in the false ceiling should be not
wider than 620mm.
Otherwise, the opening will not be covered with the GD60 ceiling
covers. For dimensions, see below.
Fig. 7
Fix the ceiling plate to the ceiling utilizing the six holes with diameter 17mm at 360mm x
451mm.
The ceiling plate can be fastened to the ceiling using six suitable screws. These screws
must be dimensioned according to the conditions of the ceiling and provided by the
customer.
Make sure that the plate is sitting flush to the ceiling in order to ensure optimum load
distribution.
This can be checked by use of a spirit level (accuracy: 1mm/m).
We recommend to use a digital spirit level.
Fig. 8

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3.3.
OPTION TO FIXATE A CONNECTION PLATE
If following installations need to fixate a connection plate of the GD60D above the
interface plate, use the dimensions given below to calculate the thread length:
In chapter 3.4.1(page 15):
Set 140mm as minimum value of “c”
Install 2 additional hexagon nuts on the 2 neighboring threaded rods, where
the connection plate needs to be fixated (red arrows below).
The additional nuts don’t need to be tightenend.
Fig. 9
In chapters 3.4.2 (page 16) and 3.4.3 (page 18):
The value of “a” has to be 155mm.
Install 2 additional hexagon nuts on the 2 neighboring threaded rods, where
the connection plate needs to be fixated (red arrows below) between the middle
and interface plate.
The additional nuts don’t need to be tightenend.
Fig. 10

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3.4.
INSTALLATION OF THE MIDDLE AND INTERFACE
PLATES
Fig. 11
NOTE:
In this manual we assume, that the lower face of the interface
plate has to be flush with the lower face of the false ceiling.
If this is not the case for your actual installation, adapt the
provided dimension and calculations in the following chapters
accordingly.
WARNING: falling parts / injury / death!
After tightening every threaded rod has to protrude min. 5mm
from the nut!
CAUTION: damage to equipment
Make sure that the length of the threaded rods are not too long!
The threaded rods may protrude max. 36mm from below the nut
of the interface plate (see Fig. 11).
NOTE:
Every M16 hexagon nut, including the ceiling plate securing
nuts, must be tightened with 200 Nm (±3%) torque and secured
with Loctite 270!
After tightening, mark every nut with seal paint from the nut to
the plate.
NOTE:
During installation, use a spirit level (accuracy: 1mm/m) to make
sure that the middle plate and interface plate are horizontally
aligned.

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3.4.1 GD60D012
NOTE: Use this configuration only, if the distance between the concrete
and lower face of the false ceiling is 75mm – 175mm.
Calculating the length (L1) of the threaded rods:
c=distance from concrete ceiling to lower face of false ceiling; must be measured!
Cut L1 to c+20mm / Tolerance: +10mm/-0mm
Fig. 12
Cut each of the M16 threaded rods (1) to the length L1 at one end only.
Deburr to remove the sharp edges at the cut ends of the threaded rods.
After deburring, no visible chamfer should be present.
Make sure that all threads are not damaged or dirty.
Screw hexagon nuts (2) ca. 50mm onto both ends of each threaded rod (1).
Apply Loctite 270 to the uncut ends of the threaded rods.
Screw the uncut ends of the threaded rods fully into the ceiling plate (3)
Secure each threaded rod with the preassembled hexagon nut to the ceiling
plate.
Make sure there’s still enough Loctite 270 on the rods for the nuts.
Fig. 13
Apply Loctite 270 to the lower ends of the threaded rods.
Push the interface plate (4) up to the required height on the threaded rods and
secure from beneath with hexagon nuts (5).
Adjust the height and level alignment of the interface plate.
Tighten the hexagon nuts to the interface plate from above and below.
NOTE:
Every M16 hexagon nut, including the ceiling plate securing
nuts, must be tightened with 200 Nm (±3%) torque and secured
with Loctite 270!
After tightening, mark every nut with seal paint from the nut to
the plate.
NOTE: During installation, use a spirit level (accuracy: 1mm/m) to make
sure that the interface plate is horizontally aligned.

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3.4.2 GD60D022
NOTE:
Use this configuration only, if the distance between the concrete
and lower face of the false ceiling is 175mm – 610mm.
If the measured value for c is more than 210mm, then only the
long threaded rods need to be cut.
Calculating the length of the threaded rods (L1) & (L2):
a: min. 145mm – max.155mm
b: min. 35mm – max.435mm
c=distance from concrete ceiling to lower face of false ceiling; must be measured!
IF c= 175mm up to 210mm:
Cut L1 to 95mm / Tolerance: +10mm/-0mm
Cut L2 to c-15mm / Tolerance: +10mm/-0mm; (final length L2 will be from 160mm to
195mm)
IF c= 210mm up to 610mm:
Cut L1 = c-115mm / Tolerance: +10mm/-0mm; (final length L1 will be from 95mm to
495mm)
L2= 195mm (don’t cut!)
Fig. 14

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Install the middle plate:
Cut each of the long M16 threaded rods (3) to the length L1 at one end only.
Burr max. 2mm the cut ends of the threaded rods.
Make sure that all threads are not damaged or dirty.
Screw hexagon nuts (2) ca. 5cm onto both ends of each threaded rod (3).
Apply Loctite 270 to the uncut ends of the threaded rods.
Screw the uncut ends of the threaded rods fully into the ceiling plate (1)
Secure each threaded rod with the preassembled hexagon nut to the ceiling
plate.
Make sure there’s still enough Loctite 270 on the rods for the nuts.
Apply Loctite 270 to the lower ends of the threaded rods.
Push the middle plate (4) up to the required height on the threaded rods and
secure from beneath with hexagon nuts (2).
Adjust the height and level alignment of the middle plate.
Tighten the hexagon nuts to the middle plate from above and below
Install the interface plate:
If needed, cut each of the short M16 threaded rods (5) to the length L2 at one
end only.
Burr max. 2mm the cut ends of the threaded rods.
Make sure that all threads are not damaged or dirty.
Screw hexagon nuts (2) ca. 5cm onto both ends of each threaded rod.
Apply Loctite 270 to both ends of the threaded rods.
Insert the threaded rods to the middle plate (4) and tighten them from above
and below with a hexagon nut (2).
Push the interface plate (6) up to the required height on the threaded rods and
secure from beneath with hexagon nuts (2)
Adjust the height and level alignment of the interface plate
Tighten the hexagon nuts to the interface plate from above and below.
NOTE:
Every M16 hexagon nut, including the ceiling plate securing nuts,
must be tightened with 200 Nm (±3%) torque and secured with
Loctite 270!
After tightening, mark each nut with seal paint from the nut to the
plate.
Also mark each tube with seal paint from its end to the ceiling
plate and the middle plate
NOTE:
During installation, use a spirit level (accuracy: 1mm/m) to make
sure that the middle plate and interface plate are horizontally
aligned.

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3.4.3 GD60D032
NOTE: Use this configuration only, if the distance between the concrete
and lower face of the false ceiling is 610mm – 1115mm.
Calculating the length of the threaded rod (L1) and the tube (b):
a: min. 145mm – max.155mm
b: distance between ceiling plate and middle plate = length of the tube
c=distance from concrete ceiling to lower face of false ceiling; must be measured!
Cut L1 to c – 115mm / Tolerance: +10mm/-0mm
Cut b to c – 175mm / Tolerance: ±1mm / ±0,5°
Fig. 15

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Install the middle plate:
Cut the tubes (5) to the length b at one end only. DON’T burr the tubes!
Cut each of the long M16 threaded rods (4) to the length L1 at one end only.
Burr max. 2mm the cut ends of the threaded rods.
Make sure that all threads are not damaged or dirty.
Screw hexagon nuts (3 / 9) ca. 5cm onto both ends of each threaded rod.
Place a washer (2) on top of each nut at the uncut ends of the threaded rods.
Apply Loctite 270 to the uncut ends of the threaded rods.
Screw the uncut ends of the threaded rods fully into the ceiling plate (1)
Secure each threaded rod with the preassembled hexagon nut to the ceiling
plate.
Make sure there’s still enough Loctite 270 on the rods for the nuts.
Make sure there’s a washer between every nut and the ceiling plate.
Apply Loctite 270 to the lower ends of the threaded rods.
Place one tube (5) and a washer (2) (6x) and the middle plate (6) on the
threaded rods (4) and secure each with a hexagon nut (3) from below.
Make sure there’s still enough Loctite 270 on the rods for the nuts.
Make sure there’s a washer inside every tube resting on the middle plate.
The hexagon nuts (9) are used to secure the washers (2) in a position near
the middle plate. They can’t be tightened.
Make sure that even after tightening there will be min. 5mm space
between the lower washers and the nuts (9)!
Tighten the hexagon nuts (3) to the middle plate from below.
Install the interface plate:
Make sure that all short M16 threaded rods (7) are not damaged or dirty.
Screw hexagon nuts (3) ca. 5cm onto both ends of each threaded rod.
Apply Loctite 270 to both ends of the threaded rods.
Insert the threaded rods to the middle plate (6) and tighten them from above
and below with a hexagon nut (3).
Push the interface plate (8) up to the required height on the threaded rods and
secure from beneath with hexagon nuts (2)
Adjust the height and level alignment of the interface plate
Tighten the hexagon nuts to the interface plate from above and below.
NOTE:
Every M16 hexagon nut, including the ceiling plate securing nuts,
must be tightened with 200 Nm (±3%) torque and secured with
Loctite 270!
After tightening, mark each nut with seal paint from the nut to the
plate.
Also mark each tube with seal paint from its end to the ceiling
plate and the middle plate
NOTE:
During installation, use a spirit level (accuracy: 1mm/m) to make
sure that the middle plate and interface plate are horizontally
aligned.

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3.5.
FASTENING OF AN ASSEMBLY AID
MAVIG supplies an eye bolt that can be fastened to the ceiling plate.
It will be used as an anchor point for lifting e.g. monitors and the GD60D- suspension
system.
Apply Loctite 270 to the bolt.
Screw the eye bolt with the washer to one of the four M12 threads in the ceiling
plate.
Tighten the bolt with the force of your hand only.
4.
SAFE DISPOSAL
The system/device must be disposed of in accordance with the nationally applicable
provisions at an appropriate recycling facility for electrical and electronic equipment. You
may also return the system/device to MAVIG for disposal. If you have any questions,
RoHS Conformity:
The support arm system meets the requirements of Directive 2011/65/EU, RohS
(Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic
Equipment) established for device group 9.
WARNING: falling parts / injury / death!
DON’T apply torque with a tool to the eye bolt!
Tighten the bolt with the force of your hand only.
This manual suits for next models
2
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