MDT Castle 2420 User manual
SERVICE
MANUAL
~
Moe
、
Castle®
2420
Field
Hospital
Surgical
Light
MDT
Diagnostic
Company
Castle
Facility
1777
E.
Henrietta
Road
PO.
Box
23077
Rochester,
New
York
14692
K
q
πι
Technology
for
Life
o
nu
Pai
PA
SERVICE
MANUAL
30840
(8/8/84)
Rey.
A
(2/20/85)
Text
Revision,
Add
Disconnect
Rev.
B
(1/15/87)
Letter
of
DPSC-RPDC-N90
D.
Angelucci/X5767:
Solicitation
No.
DLA120-86-R-1245;
Evaluation
of
CMM
(DEPMEDS
AT-05)
and
(DEPMEDS
AT-06)
Rev.
C
(9/28/87)
Text/Graphics
Revised:
Commercial
Pack
&
Mounting
Plate
with
Integral
Sus-
pension
Tube
Assembly
FOR
COMPLETE
MANUAL
ADD:
Installation
Instructions
30976
Operator's
Manual
30839
Parts
Catalog
30977
IMPORTANT
SPECIAL
SAFETY
SIGNS
AND
INSTRUCTIONS
ARE
USED
IN
THIS
MANUAL.
READ
THEM
CAREFULLY
BEFORE
USING
THE
LIGHT.
IT
IS
THE
RESPONSIBILITY
OF
THE
USER
TO
FOLLOW
ALL
RECOMMENDATIONS.
“Warning”
notes
alert
the
user
to
the
possibility
of
personal
injury.
CAUTION!
“Caution”
notes
alert
the
user
to
the
possibility
of
damage
to
the
equipment.
NOTE}
“Notes”
alert
the
user
to
pertinent
facts
and
conditions.
This
manual
contains
proprietary
information
of
the
Castle
note
>
Company,
Rochester,
N.Y.
Permission
is
hereby
granted
to
make
copies
in
part
or
in
whole
of
the
manual
for
education
and
training
purposes.
“CASTLE
is
a
registered
trademark
of
the
Castle
Company,
Rochester,
New
York.
ii
30840
30840
TABLE
OF
CONTENTS
SECTION
1.
DESCRIPTION
Light
Model
........
2420
Surgical
Light
Optical
System
.....
Pattern
and
Nominal
Illumination
Intensity
Control
........
Special
Tools
Required
SERVICE
INSTALLATION
CHECK
2420
Mechanical Adjustments
Angular
Lighthead
Drift
Lighthead
Rotational
Drift
Support
Arm
Vertical
Drift
Support
Arm
Horizontal
Drift
Extension
Arm
Horizontal
Drift
.
Light
Performance
Check
Optical
Safety
Check
..
Check
ON/OFF
Switch
Optical
Performance
Checl
Intensity
Control
Check
.
WIRING
DIAGRAM
Field
Hospital
Ceiling
Model
Wiring
Diagram
................................
.
PREVENTIVE
MAINTENANCE
Cleaning
Exterior
Surfaces
Cleaning
Interior
Surfaces
.
Replacement
Lamps
Replacing
Lamps
Replacing
Heat
Filter
..
.
TROUBLE
ANALYSIS
Wiring
Diagram
Trouble
Analysis
Guide
-
Electrical
and
Optical
Trouble
Analysis
Guide
-
Mechanical
.
REPAIR
Removing
Lighthead
Cover
Replacing
ON/OFF
Switch
...
Removing
Lighthead/Yoke
Assembly
Replacing
Lamp
Contact
.........
Replacing
Reflector
Lamp
Focus
.......
120V
Intensity
Control
.
Removing
Support
Arm
Replacing
Gas
Spring
.....
Wiring
Extension/Support
Arms
Removing
Extension
Arm
..
Installing
Extension
Arm
Mounting
Plate/Support
Tube
.
APPENDIX
Appendix
A:
Salient
Characteristics
Appendix
B:
List
of
Supplied
Equipment
.
Appendix
C:
List
of
Required
Equipment
..
Appendix
D:
Periodic
Maintenance
Adjustments
and
Procedures
Appendix
E:
Storage
Instructions
DATE:
9/87
REPLACES:
1/87
PAGE
60
63
603
63
69
그
ㅇ
0000
여
어 어 휴
유에
À
iii
LIST
OF
ILLUSTRATIONS
ILLUSTRATION
PAGE
Trouble
Analysis
Guide
-
Mechanical
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
10
Figure
11
Figure
12
Figure
13
Figure
14
Figure
15
Figure
16
Figure
17
Figure
18
Figure
19
Figure
20
Figure
21
Figure
22
Figure
23
Figure
24
Figure
25
Figure
26
Figure
27
oo
の
om
ょ
oN
一
Main
Components
and
Functional
Description
2420
Field
Hospital
and
Surgical
Light
.
-
Intensity
Control
.............
ee
-
Rotational
and
Angular
Movements
-
Light
Pivot
Adjustment
-
Yoke
Pivot
Adjustment
-
Vertical
Adjustment
.....
-
Support
Arm
Friction
Adjustment
-
Plumb
Suspension
Tube
..............
-
Extension
Arm
Frictional
Adjustment
..
-
Field
Hospital
Ceiling
Model
Wiring
Diagram
-
Lowering
Lens
Cover
..
-
Replacement
Lamp
..
-
Removing
Heat
Filter
-
Replacing
Heat
Filter
..
-
Removing
Lighthead
Cover
-
ON/OFF
Switch
Orientation
-
Lighthead
Connections
.......
-
Removing
Lighthead/Yoke
.
-
Lamp
Contact
Wiring
....
-
Dislodging
Retaining
Ring
...
-
Replacing
Reflector
-
Reflector
Orientation
-
Lamp
Focus
........
-
120V
Intensity
Control
.
-
Removing
Support
Arm
-
Replacing
Gas
Cylinder
-
Extension/Support
Arm
Wiring
. >
=
RemovingiEXens
ON
Ano
Sai
2e
creer
ice
eines
naaa
нее
TABLES
TABLE
PAGE
Trouble
Analysis
Guide
-
Electrical
and
Optical
.
11
12
DATE:
9/87
30840
REPLACES:
1/87
(3)
JUNCTION
BOX
(1)
WING
NUT
(4)
QUICK
DISCONNECT
|
(2)
MOUNTING
PLATE
|
(5)
SUSPENSION
TUBE
(7)
EXTENSION
ARM
(8)
SUPPORT
ARM
(6)
DUAL
ADAPTER
(9)
YOKE
k
A
T
(8)
SUPPORT
ARM
(7)
EXTENSION
ARM
(9)
YOKE
(10)
LIGHTHEAD
(10)
LIGHTHEAD
(1)
WING
NUTS
-
Secure
mounting
plateto
ceiling
studs.
(
2)
MOUNTING
PLATE
=
Ceiling
mount
for
light.
(
3)
JUNCTION
BOX
-
Power
connection
to
light.
(4)
QUICK
DISCONNECT
E
Field
connection
to
light.
(
5)
SUSPENSION
TUBE
-
Provides
single
point
suspension
from
ceiling.
(
6)
DUAL
ADAPTER
=
Mechanical
connection
for
extension
arms.
(7)
EXTENSION
ARM
-
Provides
horizontal
rotation
for
lightheads.
(
8)
SUPPORT
ARM
-
Provides
horizontal
rotation
and
vertical
adjustment
for
lightheads.
(
9)
YOKE
=
Angular
rotation
for
lightheads.
(10)
LIGHTHEAD
ni
Light
source
enclosure.
MAIN
COMPONENTS
AND
FUNCTIONAL
DESCRIPTION
30840
DATE:
9/87
v
REPLACES:
1/87
vi
PAGE
ADDED:
1/87
30840
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
1.
General
Description
LIGHT
MODEL
>
bs
2420
Field
Hospital
Surgical
Light
30840
DATE:
9/87
1
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
1.
General
Description
2420
SURGICAL
LIGHT
The
lighthead
and
arm
assemblies
are
attached
to
extension
arms
which
are
suspended
from
the
ceiling
by
means
of
a
single
suspension
tube
and
mounting
plate
assembly.
The
suspension
tube
ends
of
the
extension
arms
rotate
250°,
the
light-
head
ends
290°.
The
intensity
control
interconnect-
ing
line
is
connected
to
the
lighthead
cable
by
a
twist-lock
connector
on
the
mounting
plate.
Light-
head
wire
connections
are
located
at
the
suspen-
sion
tube
pivot
and
the
lighthead
swivel.
OPTICAL
SYSTEM
e
Lamp-150
Watt
Quartz
Halogen,
Double
Contact
Bayonet
Base,
Castle
Part
No.
49455
e
Blue-Green
color
correcting
heat
filter
between
lamp
and
reflector.
®
Dichroic
coated
reflector
to
further
color
correct
and
cool
the
light
beam.
®
Frosted
plastic
lens
for
controlled
diffusion.
PATTERN
AND
NOMINAL
ILLUMINATION
Light
measurements
are
made
36
inches
below
the
outer
edge
of
the
frosted
lens.
®
4000
footcandles
nominal
at
120V.
e
5-1/2
to
7
inch
diameter
light
pattern.
©
26
to
60
inch
depth
of
field.
INTENSITY
CONTROL
This
control
for
the
ceiling
model
is
remote
and
wall
mounted,
either
surface
or
recessed.
The
cus-
tomer
provides
an
ON/OFF
toggle
switch.
Rotating
the
control
knob
clockwise
turns
the
circuit
ON
and
increases
the
intensity
from
0
to
HIGH.
<>
Dal
Figure
1.
INTENSITY
CONTROL
SPECIAL
TOOLS
REQUIRED
e
Allen
Wrenches
e
External
Retaining
Ring
Pliers
Proto
Pliers
385
Tru-arc
Pliers
Model
1340
Utica
Pliers
U8400
or
equivalent
DATE:
9/87
30840
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
2.
Service
Installation
Check
A-
Lighthead
Angular
Drift
B
-
Lighthead
Rotational
Drift
C-
Support
Arm
Vertical
Drift
D-
Support
Arm
Horizontal
Drift
E
-
Extension
Arm
Horizontal
Drift
El
MOUNTING
PLATE
SUSPENSION
EXTENSION
À
TUBE
ARM
Bo
as
EZ
B
285
;
e
A
È
本
290°
AN
EXTENSION
SUPPORT
SUPPORT
ARM
A
ARM
A
Figure
2.
ROTATIONAL
AND
ANGULAR
MOVEMENTS
Double
Ceiling
Model
30840
3
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
2.
Service
Installation
Check
After
installation
is
completed,
service
personnel
should
make
mechanical
adjust-
ments,
and
electrical
performance
tests
before
the
equipment
is
operated.
These
adjustments
and
tests
are
outlined
in
this
Section.
note
>
2420
MECHANICAL
ADJUSTMENTS
These
instructions
include
all
the
adjustments
provided
to
correct
drift
in
the
2420
Light.
Refer
to
Figure
2
for
light
components,
location
of
the
indi-
vidual
adjustments,
and
angular
limitations.
Detailed
instructions
for
removing
and
replac-
ing
some
covers,
such
as
the
lighthead
cover,
are
located
in
the
Repair
Section.
Each
movement
is
divided
into
check
and
adjustment
steps.
Always
do
the
check
first.
If
the
particular
movement
does
not
meet
the
require-
ments
of
the
check,
then
proceed
with
the
adjust-
ment
steps.
Adjustments
A
thru C
should
not
be
required
on
newly
installed
equipment.
Make
the
adjustment
only
if
there
is
a
definite
rotation
drift.
There
should
be free
movement
of
the
arm
but
no
drift.
note
>
Angular
Lighthead
Drift
-
Figure
3
Adjustment
A
Correct
lighthead
drift
in
the
angular
plane
by
increasing
tension
on
the
yoke
pivot
spring
washer.
Check
1.
Rotate
the
lighthead
up
and
down
aboutits
axis.
2.
Lighthead
movement
should
stop
when
the
integral
handle
is
released
at
any
point
in
the
vertical
travel.
YOKE
FLAT
WASHER
PIN
INSERT
BUSHING
SPRING
LOCKNUT
WASHER
Figure
3.
LIGHT
PIVOT
ADJUSTMENT
Adjustment
3.
Remove
the
lighthead
cover.
Adjustment
is
made
on
the
right
hand
pivot.
4.
Tighten
locknut
until
angular
drift
is
just
eliminated.
5.
Again check
for
angular
drift.
6.
Replace
cover.
Lighthead
Rotational
Drift
-
Figure
4
Adjustment
B
Disconnect
or
turn
OFF
power
source
to
the
light
before
any
maintenance
to
avoid
hazardous
electrical
contact.
Allow
a
15
minute
cool-off
period
to
avoid
touching
hot
lighthead
parts.
Correct
lighthead
drift
in
the
rotational
plane
by
increasing
tension
on
the
yoke
mounting
spring
washer.
Check
1.
Rotate
lighthead
around
the
axis
of
the
support
arm.
2.
Lighthead
movement
should
stop
when
the
integral
handle
is
released
at
any
point
in
the
©
yoke
rotation.
Adjustment
1.
Remove
the
lighthead
switch
cover.
2.
Break
loctite
and
loosen
lighthead
set
screw.
SWITCH
COVER
SET
SCREW
Figure
4.
YOKE
PIVOT
ADJUSTMENT
3.
Break
loctite
and back
off
yoke
pin
about
1/8
inch
using
an
open
end
wrench.
4.
Tighten
yoke
pin
until
rotational
drift
is
eliminated.
5.
Apply
loctite
and
tighten
lighthead
set
screw
Check
again
for
rotational
drift.
@
Replace
switch
cover.
30840
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
2.
Service
Installation
Check
Support Arm
Vertical
Drift
-
Figure
5
Adjustment
C
Correct
lighthead
drift
in
the
vertical
plane
by
increasing
tension
on
the
support
pivot
spring
washers.
Check
1.
Move
the
support
arm
up
and
down
using
the
integral
handles.
2.
Lighthead
movement
should
stop
when
the
handle
is
released
at
any
point
in
vertical
travel.
Adjustment
3.
Tighten
friction
adjustment
screws
equally
until
vertical
drift
is
eliminated,
FRICTION
ADJUSTMENT
SCREWS
SUPPORT
ARM
Figure
5.
VERTICAL
ADJUSTMENT
Support
Arm
Horizontal
Drift
-
Figure
6
Adjustment
D
Correct
support
arm
drift
in
the
horizontal
plane
by
increasing
friction
on
the
bearing
post.
FRICTION
ADJUSTMENT
EXTENSION
ARM
SUPPORT
ARM
Figure
6.
SUPPORT
ARM
FRICTION
ADJUSTMENT
WING
NUT
Check
1.
Check
Adjustment
E
before
making
this
ad-
justment.
2.
Rotate
the
support
arm
about
the
extension
arm.
3.
(Check
for drift
at
several
locations
through
290°.
Adjustment
4.
Tighten
friction
adjustment
set
screw
until
horizontal
drift
is
eliminated
at
all
locations
through
290°
travel.
|
Extension
Arm
Horizontal
Drift
-
Figures
7
&
8
Adjustments
E1
and
E2
Double
lighthead
models
have
both
note
>
extension
arm
pivots
at
a
yoke
which
in
turn
is
connected
to
a
single
suspension
tube.
Adjustments
for
each
extension
arm
are
the
same
as
for
a
single
lighthead
model.
Correct
extension
arm
drift
in
the
horizontal
plane
by
plumbing
the
suspension
arm
and
adjust-
ing
the
tripod
(E1)
and
by
increasing
on
the
bearing
post
(E2).
Check
1.
Rotate
the
extension
arm
about
the
suspension
tube.
2.
Check
for
drift
at
several
locations
through
250°.
3.
If
the
extension
arm
usually
drifts
to
the
same
location
of
the
250°
travel,
make
adjustments
E1
and
E2.
4.
If
the
extension
arm
drifts
in
either
direction
at
any
location,
proceed
to
adjustment
E2.
Adjustment
E1
5.
Plumb
the
suspension
tube
by
adjustment
of
the
mounting
plate
wing
nuts.
STRUCTURAL
CEILING
7
FLAT
WASHER
MOUNTING
LOCKWASHER
PLATE
MOUNTING
STUD
Figure
7.
PLUMB
SUSPENSION
TUBE
30840
DATE:
9/87
5
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
2.
Service
Installation
Check
6.
Raise
mounting
plate
ring
in
direction
exten-
sion
arm
drifts
toward.
Lower
opposite
side
of
ring
if
necessary.
7.
Check
again
for
E1
type
drift.
8.
Tighten
all
leveling
nuts.
Adjustment
E2
9.
Tighten
friction
adjustment
set
screw
until
horizontal
drift
is
eliminated
at
all
locations
of
travel.
FRICTION
ADJUSTMENT
Figure
8.
EXTENSION
ARM
FRICTION
ADJUSTMENT
LIGHT
PERFORMANCE
CHECK
Performance
checks
are
required
to
insure
cor-
rect
and
safe
operation
of
the
light.
These
checks
and
any
necessary
adjustments
should
be
done
by
Castle
Division
Service
personnel.
Refer
to
the
Repair
Section
of
this
manual
for
any
service
corrections.
Optical
Safety
Check
1.
Remove
lens
cover.
2.
Ensurethatshipping
material
has
been
removed
from
around
blue-green
heat
filter.
3.
Check
that
heat
filter
is
in
place
and
that
three
spring
wires
are
in
place.
4.
Replace
lens
cover.
Check
ON/OFF
Switch
Check
Move
lighthead
through
maximum
travel
at
both
pivots
using
integral
handles.
Observe
that
the
light
does
not
flicker
or
go
out.
Check
for
positive
action
of
the
switch.
Service
Correction
1.
Ensure
that
all
lighthead
wires
are
firmly
at-
tached
to
flat
terminals
and
that
terminals
are
secure.
2.
Replace
ON/OFF
switch
if
required.
Optical
Performance
Check
The
light
should
have
a5-1/2
to7
inch
diameter
light
pattern
at
36
inches
below
the
outer
edge
of
the
lens
cover.
The
illumination
should
be
3000
to
5500
footcandles
at
120V,
measured
at
the
center
of
the
pattern.
Intensity
Control
Check
1.
Turn
intensity
control
to
a
middle
position.
Snap
intensity
control
toggle
switch
to
ON.
Snap
lighthead
switch
to
ON.
The
lamp
should
light.
4.
Rotate
intensity
control
counterclockwise.
The
light
should
dim.
5.
Rotate
the
intensity
control
clockwise
through
its
maximum
travel.
Light
intensity
should
vary
smoothly
without
falter
or
rough
spots.
DATE:
9/87
30840
REPLACES:
2/85
©
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
3.
Wiring
Diagram
umes
=
INI
1
i
=
1
DPST
SWITCH
E
1
1
SE
|
BY
CUSTOMER
oi
o
INTENSITY
|
115V-
M
i.
πι
|
oiro
|
°
115/230V
115/230V-115V
|
with
|
1
3/15A
|
TRANSFORMER
LI
1
ON/OFF
|
ー
ト
SWITCH
—
N
o
n2 N6
HD
|
и
1 1
トーーーーーー
-|
pes]
|
=
a
=
=
==
INTENSITY
CONTROL
|
[p
im
Е
=
|
Son
cb
Ре
pí
|
HOT
E
вонь
に
i
1
BLACK
1
ーー
1
| 1
1
1 i
DI
[ke
__Neuraatl
|
eue
|
| |
4
WHITE
n
|
!
|
GREEN
|
tha
|
т
|
GROUNDİ
|
YELLOW
|
Al
|
GREEN
| |
こ
T Τ Τ
1
İT
т T
I
T Ť
Tal
ESI
=]
es
Čs
i
-
Е
TWIST-LOCK
MOUNTING
SUSPENSION
EXTENSION
YOKE
PIVOT
CONNECTOR
PLATE
PIVOT
ARM
a
Fra
BLACK
ρα
it
|
et
POL
U
opeře:
sl
DM
it
t +
pot
ot
fell
|
|
Green
|
I
+
+
+
t
P
+
Loui
+
SUSPENSION
EXTENSION
YOKE
PIVOT
PIVOT
ARM
Figure
9.
FIELD
HOSPITAL
CEILING
MODEL
WIRING
DIAGRAM
30840
DATE:
9/87
REPLACES:
1/87
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
3.
Wiring
Schematic
|
|
TRANSFORMER
RED
=
a
120V
230V
VOLTAGE
SELECTOR
SWITCH
I
I
103°C
2404
THERMAL
CUTOUT
230v
220V
|
120V
BLU
Re
|
I
I
178
1
2 3
4 5
6
L
N
L
N
TRANSFORMER
WIRING
SCHEMATIC
8
DATE:
1/87
30840
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
4,
Preventive
Maintenance
Disconnect
or
turn
OFF
power
source
to
the
light
before
any
maintenance
to
avoid
hazardous
electrical
contact.
Allow
a
15
minute
cool-off
period
to
avoid
touching
hot
lighthead
parts.
CLEANING
EXTERIOR
SURFACES
Use
mild
cleaning
agents
that
will
not
damage
painted,
plated
or
plastic
surfaces.
CLEANING
INTERIOR
SURFACES
The
lens
cover,
blue-green
heat
filter
and
dichroic
reflector
should
be
handled
with
extreme
care
to
avoid
damage
to
their
optical
surfaces.
CAUTION!
1.
Loosen
thumbscrews
and
lower
the
lens
cover.
The
cover
will
be
suspended
by
a
retaining
strap.
RETAINING
STRAP
THUMBSCREWS
coves
Figure
10.
LOWERING
LENS
COVER
2.
Gently
clean
the
inside
of
the
reflector
with
cot-
ton
dampened
with
distilled
or
deionized
water.
The
cotton
will
conform
to
the
contour
of
the
reflector.
Clean
in
direction
of
flutes.
Wipe
dry
with
a
fresh
piece
of
cotton.
Do
not
use
acid
solutions,
including
chior-
inated
cleaners.
Do
not
use any
scrub-
bing
or
abrasive
action
to
avoid
damage
to
the
reflector.
CAUTION
The
water
should
be
deionized
or
distilled.
3.
Clean
the
outside
of
the
blue-green
heat
filter
in
the
same
manner.
4.
Gently
clean
both
surfaces
of
the
lens
cover
with
cotton
dampened
with
distilled
or
deion-
ized
water,
wipe
dry
with
fresh
cotton.
5.
Replace
the
lens
cover.
The
blue-green
heat
filter
and
lens
cover
must
be
in
place
to
prevent
ultraviolet
and
infrared
rays
from
reaching
the
patient
or
operator.
REPLACEMENT
LAMPS
150
Watt,
Quartz
Halogen,
Double
Contact
Bayonet
Base,
Castle
Part
No.
49455
150W
CASTLE
COMPANY
PART
NO.
49455
Figure
11.
REPLACEMENT
LAMP
REPLACING
LAMPS
Disconnect
or
turn
OFF
power
source
to
the
light
or
intensity
control
before
any
maintenance
to
avoid
hazardous
electri-
cal
contact.
Allow
a
15
minute
cool-off
period
to
avoid
touching
hot
lighthead
parts.
1.
Disconnect
or
turn
OFF
power
source.
2.
Loosen
lens
cover
thumbscrews.
The
lens
cover
will
hang
from
a
retaining
strap.
3.
Rotate
the
lighthead
to
face
the
operator
at
a
little
above
eye
level.
WIRE
S
>
BAFFLE
WIRES
Figure
12.
REMOVING
HEAT
FILTER
30840
DATE:
9/87
9
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
4.
Preventive
Maintenance
Hold
the
baffle
firmly
and
unhook
the
three
spring
wires.
Remove
the
heat
filter/baffle
assembly.
Avoid
touching
the
blue-green
glass.
Press
down
and
turn
the
lamp
counterclock-
wise
to
remove,
CAUTION
Read
handling
note printed
on
wrapper
of
new
lamp.
Skin
oils
will
damage
and
shorten
life
of
the
lamp.
If
accidentally
touched,
wipe
lamp
with
alcohol
or
distilled
water.
Hold
new
lamp
by
wrapper
and
insert
in
socket.
Press
down
and
turn
clockwise
to
insert.
Clean
both
surfaces
of
the
blue-green
heat
filter
with
cotton
dampened
with
deionized
or
dis-
tilled
water.
Replace
filter/baffle
assembly
in
upper
recessed
area.
Attach
spring
wires
and
lens
cover.
The
blue-green
heat
filter
and
lens
cover
must
be
in
place
to
prevent
ultraviolet
and
infrared
rays
from
reaching
the
patient
or
operator.
REPLACING
HEAT
FILTER
Disconnect
or
turn
OFF
power
source
to
the
light
or
intensity
control
before
any
maintenance
to
avoid
hazardous
electri-
cal
contact.
Allow
a
15
minute
cool-off
1.
period
to
avoid
touching
hot
lighthead
parts.
Disconnect
or
turn
OFF
power
source.
2.
Remove
lens
cover
and
unhook
the
three
heat
filter
spring
wires.
3.
Remove
the
filter/baffle
assembly
for
bench
work.
4.
Remove
the
filter
clips
and replace
filter.
мот
>
The
heat
filter
is
cone
shaped.
The
larger
diameter
positions
into
the
baffle
assem-
bly.
5.
Replace
the
filter
clips.
Tighten
screws
until
clips
are
snug.
Do
not
overtighten.
BAFFLE
FILTER
CLIP
Figure
13.
REPLACING
HEAT
FILTER
6.
Clean
both
surfaces
of
the
heat
filter
with
cotton
dampened
with
distilled
or
deionized
water.
7.
Replace
heat
filter
assembly,
spring
wires
and
lens
cover.
Nore
>
Ensure
that
the
heat
filter
is
positioned
in
the
upper
recessed
area.
The
blue-green
heat
filter
and
the
lens
cover
must
be
in
place
to
prevent
unfil-
tered
rays
from
reaching
the
operator
or
patient.
10
DATE:
9/87
REPLACES:
2/85
30840
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
5.
Trouble
Analysis
WIRING
DIAGRAM
The
Wiring
Diagram
is
located
in
Section
3
of
this
manual.
Use
this
diagram
in
conjunction
with
the
Trouble
Analysis Guides.
Several
of
these
checks
are
made
with
the
power
ON.
Only
trained
service
per-
sonnel
should
make
these
tests.
TROUBLE
ANALYSIS
GUIDE
-
ELECTRICAL
AND
OPTICAL
TROUBLE
PROBABLE
CAUSE
REMEDY
ON/OFF
Switch
ON,
|
No
power
to
light.
Check
power
cord
or
power
source.
Light
out.
Lamp
out.
Replace
lamp.
Defective
wiring.
Check
wiring
at:
1.
Lighthead.
2.
Lighthead
connection
box.
3.
Extension
arm
connection
or
support
post
disconnect.
4.
Mounting
plate
junction
box.
Correct
defective
wiring.
Defective
transformer.
1.
Check
transformer
connections.
2.
Replace
transformer.
Low
Light
Intensity.
|
Dirty
lens
or
reflectors.
Clean
or
replace.
Refer
to
Section
4
for
suggested
procedure.
Damaged
reflectors
or
lens.
Replace
defective
part.
Lamp
defective.
Replace
lamp.
Power
input
low.
Check
for
full
120V
or
220V
supply.
Loose
wire
connections,
frayed
or
broken
wires.
Intermittant
illumi-
nation
when
pivot-
Check
wiring
for
continuity.
ing
arms.
9
Defective
lamp.
Replace
lamp.
Defective
intensity
controller.
Irregular intensity
in-
crease
to
light
equip-
Repair
or
replace.
ped
with
optional
in-
tensity
control.
Defective
interconnecting
wiring.
Check
each
line
for
continuity
between
intensity
control
and
mounting
plate
junction
box.
30840
DATE:
9/87
11
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
5.
Trouble
Analysis
TROUBLE
ANALYSIS
GUIDE
-
MECHANICAL
TROUBLE
PROBABLE
CAUSE
REMEDY
Lighthead
drifts
in
angular
plane.
Yoke
pivot
out
of
adjust-
ment.
Adjust
tension
on
yoke
pivot
spring
washer.
Adjustment
A.
Lighthead
drifts
in
rotational
plane.
Yoke
mounting
pivot
out
of
adjustment.
Adjust
tension
on
yoke
mounting
spring
washer.
Adjustment
B.
Vertical
drift
in
sup-
port
arm.
Support
arm
pivot
out
of
adjustment.
Adjust
tension
on
support
arm
washers.
Adjustment
C.
Horizontal
drift
in
support
arm.
Support
arm
friction
plug
loose
on
bearing
post.
Adjust
friction
on
support
arm
bearing
post.
Adjustment
D.
Horizontal
drift
in
ex-
Suspension
tube
not
Adjust
mounting
plate
leveling
nuts.
tension
arm.
plumb.
Adjustment
E1.
Extension
arm
friction
plug
|
Adjust
friction
on
extension
arm
bearing
post.
loose
on
bearing
post.
Adjustment
E2.
12
DATE:
8/87
30840
REPLACES:
2/85
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
Disconnect
or
turn
OFF
power
source
to
the
light
before
any
maintenance
or
ser-
vice
work
to
avoid
hazardous
electrical
contact.
Allow
a
15
minute
cool-off
period
to
avoid
touching
hot
lighthead
parts.
On
ceiling
models,
power
must
be
turned
OFF
to
the
intensity
control.
After
any
service
work,
the
blue-green
heat
filter
and
the
lens
cover
must
be
re-installed
in
place
to
prevent
ultra-
violet
and
infrared
rays
from
reaching
the
patient
or
operator.
REMOVING
LIGHTHEAD
COVER
Loosen
four
screws
and
remove
the
lighthead
cover
from
the
lighthead
housing.
To
replace
cover,
rotate
housing
away
from
yoke.
COVER
SCREW
HOUSING
Figure
14.
REMOVING
LIGHTHEAD
COVER
REPLACING
ON/OFF
SWITCH
1.
Observe
the
switch
orientation.
OFF
is
toward
the
left
on
the
nameplate.
2.
Remove
switch
cover.
Disconnect
and
prevent
ends
of
blue
and
brown
wires
from
retracting
into
the
arm
or
yoke.
6.
Repair
5
/
SWITCH
o
HOUSING
SWITCH
COVER
OFF
OR
TERMINAL
SIDE
OF
SWITCH
Figure
15.
ON/OFF
SWITCH
ORIENTATION
FROM
SUPPORT
ARM
|
BREL
GRAY
P
GU
—
«Bes
NOTE:
WIRE
COLORS
ARE
BLACK
AND
WHITE
ON
SOME
LIGHTS.
Figure
16.
LIGHTHEAD
CONNECTIONS
3.
Press
down
on
terminal
surface
of
switch
to
remove
from
housing.
4.
Install
new
switch
in
housing
with
terminals
and
OFF
indication
toward
left.
5.
Rewire
switch
and
check
for
correct
operation.
Replace
switch
cover.
30840
DATE:
9/87
13
REPLACES:
1/87
2420
FIELD
HOSPITAL
SURGICAL
LIGHT
6.
Repair
REMOVING
LIGHTHEAD/YOKE
ASSEMBLY
Disconnect
or
turn
OFF power
to
the
light
or
intensity
control
to
avoid
hazardous
electrical
contact.
CAUTION)
1.
Remove
the
lighthead
switch
cover.
Secure
wires
from
lighthead
and
from
Support
arm
to
avoid
wire
ends
slipping
into
castings.
2.
Disconnect
ground
line
wire
nut.
3.
Disconnect
hot
and
neutral
wires
from
ON/OFF
switch.
4.
Break
loctite
and
loosen
lighthead setscrew.
The
support
arm
will
spring
upward
when
lighthead
is
removed.
Secure
arm
to
pre-
CAUTION
vent
pivot
movement.
10.
11.
12.
Refer
to
Adjustment
B
in
Section
2
to
correct
any
lighthead
rotational
drift.
Crimp
on
new
flat
terminals
to
support
arm
wires
(Part
No.
65199).
Connect
line
(black)
and
neutral
(white)
wires
to
ON/OFF
Switch.
Refer
to
Figure
16.
Connect
hot
and
neutral
wires
(blue
and
brown)
to
ON/OFF
switch.
Refer
to
Figure
16.
Connect
ground wires.
Wrap
wire
nut
with
tape.
Check
lighthead
for
correct
operation
and
rotation.
REPLACING
LAMP
CONTACT
Disconnect
or
turn
OFF
power
to
the
light
or
intensity
control
to
avoid
hazardous
electrical
contact.
Use Repair
Package
67501
for
this
Procedure.
Package
consists
of
the
contact
with
wiring,
retain-
ing
ring,
two
flag
terminals
and
sleeving.
de
Remove
lens,
heat
filter,
back cover
and
switch
plate.
=
Su
2.
Disconnect
ground
wire
from
heat
dissipation
en
N
plate.
Se
3.
Remove
cable
clamp
from
heat
dissipation
SWITCH
plate.
4.
Disconnect
lighthead
wires
from
ON/OFF
tog-
gle
switch. Cut
flag
terminals
from
wires.
5.
Lift
gasket
from
yoke
to
expose
contact
wires.
Lift
wires
from
yoke.
SEGMENT
6.
Remove
three
plate
mounting
screws
and
guide
heat
plate
along
the
sleeve.
Do
not
move
or
adjust
focus
screws
at
this
time.
CONTACT
PLATE
MOUNTING
WIRES
SCREW
Figure
17.
REMOVING
LIGHTHEAD/YOKE
SE
5.
Remove
yoke
pin
and
stop
segment.
Separate
yoxe
GROUND
lighthead
from
support
arm.
‘SCREW
6.
Cut
flag
terminals
from
yoke
wires.
g9
KW
GASTON
Stop
segment
must
be
in
place
to
prevent
i i
FOCUS
over
rotation
of
yoke
and
lighthead.
W
Pilot
CLEARANCE
HOLE
E
7.
Replace
lighthead
in
reverse
order
ot
removal.
DESA
Refer
to
Figure
17
for
placement
of
spring
PLATE
washer.
Apply
Loctite
#222
and
tighten
yoke
pin
until
rotational
drift
is
eliminated.
Figure
18.
LAMP
CONTACT
WIRING
14
DATE:
9/87
30840
REPLACES:
2/85
Table of contents
