Giraffe Spot PT Lite Phototherapy System Operation, Maintenance and Service Manual Rev 105

User Responsibility This Product will perform in conformity with the description thereof contained in this operating manual and accompanying labels and/or inserts, when assembled, operated, maintained and repaired in accordance with the instructions provided. This Product must be checked periodically. A defective Product should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, Ohmeda Medical recommends that a telephone or written request for service advice be made to the nearest Ohmeda Medical Regional Service Center. This Product or any of its parts should not be repaired other than in accordance with written instructions provided by Ohmeda Medical and by Ohmeda Medical trained personnel. The Product must not be altered without the prior written approval of Ohmeda Medical’s Quality Assurance Department. The user of this Product shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, improper repair, damage, or alteration by anyone other than Ohmeda Medical. w U.S Federal law restricts this device to sale by or on the order of a licensed medical practitioner.

CAUTION

0086

Ohmeda Medical has declared that this product conforms with the European Council Directive 93/42/EEC Medical Device Directive when it is used in accordance with the instructions provided in the Operation and Maintenance Manual.

This symbol indicates that the waste of electrical and electronic equipment must not be disposed as an unsorted municipal waste and must be collected separately. Please contact an authorized representative of the manufacturer for information concerning the decommissioning of your equipment.

Table of Contents General Information Intended use...1-1 The Light Box...1-1 The Light Pipe...1-1 Controls, Indicators and Connections...1-2

Set Up and Checkout Mounting the unit...2-1 Pre-Use Checkout Procedure...2-1

Operation Basic Operating Procedure...3-1

Maintaining the unit Repair Policy...4-1 Maintenance schedule...4-1 Cleaning...4-2 Cleaning or replacing the fan filter...4-2 Factors that affect bulb life...4-2 Replacing the bulb...4-3 Accessories...4-4

Service Functional Description...5-1 Troubleshooting...5-2 Service Procedures...5-3 Illustrated Parts...5-5 Labels...5-9 Wiring Diagrams...5-11

Appendix Specifications... A-1

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iii

Definitions

w

Next to each warning or caution, we have placed an “attention, read accompanying documents” symbol to alert you to the presence of these important statements. When the attention symbol appears in front of the text that is printed on the system itself, it means that the text is elaborated upon in the operation manual. WARNING: A Warning statement is used when the possibility of injury exists. CAUTION: A Caution statement is used when the possibility of damage to the equipment exists. High voltage, electrical shock hazard. Hot surface, do not touch.

~

Indicates alternating current.

m

Indicates IEC Type B equipment. European Union Representative Hour meter On/Off

I/O

Cover infant’s eyes during phototherapy Internal fan not operating - unit overheated Blinking hourglass in display indicates hour meter is running. Note: A Note provides additional information to clarify a point in the text.

WARNING

w Do not use the Giraffe Spot PT Lite Phototherapy System in the presence of flammable anesthetics or gases which can support combustion; a possible explosion hazard exists under these conditions.

CAUTION

w Servicing of this product in accordance with the service manual should never be undertaken without the proper tools, test equipment and the most recent revision of the service manual which is clearly and thoroughly understood.

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General Information Intended Use The Ohmeda Medical Giraffe® Spot PT LiteTM Phototherapy System provides light for the treatment of indirect hyperbilirubinemia in term and premature infants in a hospital setting, administered by trained, professional medical staff, on the order of a licensed medical practitioner.

The Light Box A metal halide bulb provides the light source. A fan cools the bulb and extends bulb life. CI.38.007

Located on the front of the unit, a rocker switch turns power on and off. Located near the switch, a non-resettable hour meter shows how long the unit has been operated. Next to the hour meter, a green LED indicator lights when the unit is on, while a red LED indicator lights when the fan fails to operate correctly or the unit overheats. Underneath, on the base of the unit are the IEC power receptacle, two resettable circuit breakers, ground stud and the fan filter retainer. A mounting bracket on the back of the unit allows the unit to be positioned and secured in the dovetail slot of an accessory rail. Tightening two socket head mounting screws holds the unit in position.

The Light Pipe The light intensity delivered to the patient varies directly with the distance of the lens head from the mattress. You change the intensity and spot size by manually adjusting this distance. The flexible light pipe allows the lens to be positioned anywhere you wish; the light pipe bends to a new position and then holds the lens in place. The flexible light pipe transmits the light from the lamp to the lens, where it can be directed at the patient.

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General Information Controls, Indicators and Connections

2

CI.38.003

1

3

4 10

5 6

7

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

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CI.38.004

12

FRONT 8

Lens head Light pipe Light box Air exhaust Switch Hour meter Power indicator Air flow failure indicator Power cord receptacle Circuit breakers Air intake/fan filter retainer Ground stud

11

9 BOTTOM

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Set Up and Checkout CAUTION w

To avoid damage to equipment, install bulb before powering unit.

Mounting the unit WARNING w

To avoid patient injury, it is strongly recom1 mended never to mount the unit while a patient occupies the bed.

1. Using the T-handle hex key provided with the unit, loosen the two mounting screws on the side of the mounting bracket. 2. Position the light box on the accessory dovetail rail. 3. Secure the unit in place by tightening the two mounting screws with the T-handle hex key.

2

To mount the unit on the roll stand, follow the instructions provided with the stand.

Pre-use Check Out Procedure 1. Examine the power cord, light pipe, and light box for obvious signs of damage. 3 CI.38.013

2. Check that the light box is securely attached to the accessory dovetail rail. 3. Move the light pipe to verify that it moves freely and stays in position. 4. Connect the power cord to an appropriate power source. 5. Select “|” on the switch to turn the power on. The power LED indicator will light.

1. Mounting bracket 2. Mounting screws 3. Dovetail rail

Note: Immediately after turning the unit on, it takes several seconds for the light to be emitted from the lens head. If the light does not come on, switch off the unit, wait approximately a minute and switch it back on. 6. Position the lens head so that the spot is on the center of the bed. It is recommended that the Giraffe Spot PT Lite be checked with the Ohmeda Medical BiliBlanket® Light Meter II for desired therapeutic intensity before use with each patient.

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Set Up and Checkout Notes:

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Operation WARNINGS w To avoid overheating the patient, do not operate the lamp at a distance less than 38cm from the patient. w Prolonged exposure to any phototherapy light may cause eye damage. Infants should wear eye protection during therapy. Care should also be taken to protect the eyes of infants adjacent to the treatment area. w Exposure to any phototherapy device for prolonged periods may cause side effects in some caregivers and visitors. w The bilirubin levels of infants receiving phototherapy should be regularly measured. w All phototherapy methods have possible risks including, but not limited to apnea, bronze baby syndrome, cellular DNA disruption, diarrhea, hyperpigmentation-reddening, patent ductus arteriosus, riboflavin-calcium and other deficiencies, skin blistering, skin irritation and thrombocytopenia. Monitor the baby closely for signs of these conditions during phototherapy. w Bilirubin photoisomers may cause toxic effects. w Porphyrins are the by-products of the photochemical break down of the bilirubin molecule. In some cases, exposure of porphyrins to phototherapy may result in a localized reddening of the infant’s skin. Therefore, skin assessment is indicated with all types of phototherapy. w Light can adversely affect drugs and other infusion liquids. When using intravenous delivery systems during phototherapy, shield any tubing with an appropriate material. Do not store drugs or infusion liquids directly in the light path. w When using the Giraffe Spot PT LiteTM Phototherapy System with a radiant warmer, make sure the lens head is not directly in the path of the radiant heat rays, since this will block heat to the infant and may damage the lens head. w Phototherapy light can affect the temperature in thermoregulation devices (incubator, radiant warmers or heated mattresses) and may raise the patient’s body temperature. Always monitor the infant’s temperature to avoid temperature fluctuations during phototherapy. w The radiant energy from phototherapy lights can increase an infant’s insensible water loss. Take appropriate measures to maintain the patient’s fluid balance while administering phototherapy. w It is recommended to use the incubator or warmer in skin controlled (servo) mode. Always monitor the infant’s temperature to avoid temperature fluctuations during phototherapy. w Using reflective foils to increase the efficacy of phototherapy may cause hazardous patient body temperatures.

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Operation CAUTION

w Do not touch the lens. Residual hand oils can greatly decrease the output of the light.

CAUTION

w To avoid the device overheating, do not block any of the vents on the light box and do not operate the Giraffe Spot PT Lite Phototherapy System if the cooling fan is not working.

It is recommended that the Giraffe Spot PT Lite be checked with the Ohmeda Medical BiliBlanket® Light Meter for desired therapeutic intensity before use with each patient. 1. Connect the power cord to an appropriate power source.

Note: Immediately after turning the unit on, it takes several seconds for the light to be emitted from the lens head. If the light does not come on, switch off the unit, wait about one minute and switch it back on. 3. Rotate the base of the light pipe to aim the light in the desired direction. WARNING w To avoid overheating the patient, do not operate the lamp at a distance less than 38cm from the patient. 4. Raise or lower the lens head to achieve the desired therapeutic light intensity. Note: The Giraffe Spot PT Lite will not damage the clear hood of an Ohmeda Medical incubator, even if it is in direct contact with the hood. CAUTION

w Do not place opaque objects in the direct light path. Light energy can cause heating and damage to nontransparent materials.

WARNING w Oxygen enriched environments greatly reduce the temperature at which materials burn. Be extremely careful to remove all opaque materials from the immediate light path when using the light while administering oxygen. At a distance of 38cm from the patient, the spectral irradiance output measured with a BiliBlanket light meter should not be less than 30 µW · cm-2 · nm-1 in the center spot. The spot diameter should be at least 19cm.

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CI.38.007

2. Select “|” on the power switch to turn the power on.

Maintaining the Unit Repair Policy Warranty repair and service must be performed by an Ohmeda Medical Service Representative or at the Ohmeda Medical Service and Distribution Center. To contact an Ohmeda Medical Service Representative, call your Ohmeda Medical Service Office listed on the back cover of this manual. Do not use malfunctioning equipment. Make all necessary repairs or have the equipment repaired by an Ohmeda Medical Service Representative. Parts listed in the service manual for this product may be repaired or replaced by a competent, trained person who has experience in repairing devices of this nature. After repair, test the equipment to ascertain that it complies with the published specifications. Use only Ohmeda Medical service parts. CAUTION w

Detailed information for more extensive repairs is included in the service manual solely for the convenience of users having proper knowledge, tools and test equipment, and for service representatives trained by Ohmeda Medical.

Maintenance schedule Operator maintenance This schedule lists the minimum maintenance frequencies. Always follow hospital and local regulations for required maintenance frequencies. Weekly or After Each Patient Clean the Giraffe Spot PT Lite Phototherapy System. Disinfect the unit if required or after use with infectious patients. Quarterly Inspect the air filter and clean or replace as required. Note: This is the minimum inspection frequency. The filter must be cleaned or replaced whenever it appears dirty.

Service maintenance The unit should be maintained in accordance with the procedures detailed in the service manual. Service maintenance must be performed by a technically competent individual. This schedule lists the minimum maintenance frequencies. Always follow hospital and local regulations for required maintenance frequencies. As Required We recommend a maximum bulb replacement interval of 2500 hours. IEC standards recommend bulb replacement at 25% output reduction, which occurs at approximately 1400 hours of operation. However, sufficient spectral irradiance for effective phototherapy continues well after 25% reduction. Annually Perform the electrical safety tests, light intensity check and light pipe position retention check described in the service section.

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Maintaining the Unit Cleaning WARNING w

Never use flammable cleaning solutions to clean the Spot PT Lite.

Unplug the power cord and allow the unit to cool at least 10 minutes before cleaning. CAUTION w

It is recommended that the lens be cleaned with nonflammable optical cleaner and a lint-free soft cloth. If an alcohol solution is used, thoroughly dry the lens to make sure no residual cleaner remains.

Clean the outside of the light box and light pipe using a mild detergent solution. Aqueous solutions which are both hospital disinfectants and microbactericides may be used. Do not allow liquids to seep into the housing. Apply the cleaning solutions with a clean cloth or sponge. Always dry the parts with a clean damp soft cloth to avoid scratches and remove cleaner residue. Do not spray cleaner into the vents, since this will contaminate the bulb, optics and electronics.

CI.38.004

The following lists some cleaning solutions that may be used safely: Generic Formulation Maximum Concentration Level Hydrogen Peroxide 6% Iodophor Solution 0.27% ® Cavicide 100% spray (sprayed on a cloth - not directly on the equipment) Do not use bleach, Quaternary Ammonium or Glutaraldehyde to clean the Giraffe Spot PT Lite; they may damage the unit.

Cleaning or replacing the fan filter 1. Disconnect power to the unit. 2. Unsnap the filter retainer from the bottom of the fan. 3. Inspect filter (6600-0236-850). Clean by rinsing in water or replace if necessary. The filter retainer is keyed, with one tab smaller than the other 3, to aid in correctly aligning the retainer.

Factors that affect bulb life Duty Cycle Turning the unit on and off frequently will reduce bulb life. Vibration and mechanical shock Take care when moving the unit. Make sure it is mounted or located in a stable, vibration free place. Thermal stress Operating without the cooling fan running, operating with clogged filters and moving the unit before the bulb cools will reduce bulb life. Bulb contamination Residual hand oils on the surface of the bulb will cause it to degrade more rapidly and fail prematurely.

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Fan filter retainer

Maintaining the Unit Replacing the bulb It is recommended that the bulb be replaced after 2500* hours of use or if the light output is less than 30 µW · cm-2 · nm-1. WARNING w

To ensure the proper operation and light intensity, replace the bulb only with an Ohmeda Medical bulb (6600-0235-850). Use of other bulbs may harm the patient, will affect the performance of, and may result in damage to, the Giraffe Spot PT Lite Phototherapy System.

1. Turn off power and disconnect the power cord. Allow the lamp to cool at least 10 minutes. When the unit is connected to a power source, there is high voltage in the bulb assembly. Always disconnect the power cord when replacing the bulb.

CI.38.005

WARNING w

2. Using a 3mm T-handle hex key (6600-1246-400), remove the screw in the front of the unit, located in the center at the top of the cover. Remove the cover. 3. Grasp the bulb assembly by the electrical connector or the bulb’s ceramic base, and pull it free from the wire retainer that holds it in place. CAUTION w

Do not touch the center glass bulb, mirror, or the end of the light pipe with your fingers. Residual hand oil on the bulb may result in reduced lamp performance. If you touch the bulb during installation or if you see stains, it is recommended that you clean the bulb with a non-flammable optical cleaner and dry with a clean, soft cloth. If an alcohol solution is used, thoroughly dry the bulb to make sure no residual cleaner remains.

4. Disconnect the electrical connector and discard the bulb in accordance with local mercury disposal regulations. CAUTION w

To avoid damage to equipment, install bulb before powering unit.

CI.38.006

5. Connect the new bulb and slide it back into place. Orient the bulb so that “THIS SIDE UP” faces up. Be sure that the bulb seats completely in the groove in the metal housing. The mark on the top of the bulb should be at the 12:00 o’clock position. 6. Reinstall the cover and secure it with the screw. Make sure to align the pins on the bottom inside of the cover with the pivot slots on the housing. WARNING w

Never operate the unit without both covers installed. During servicing, never look directly at the lamp. Exposure exceeding even 15 minutes a day can cause eye damage. During troubleshooting proper eye protection should be worn.

CAUTION w

Do not store out-of-box units in conditions outside the normal operating environmental ranges.

*IEC standards recommend bulb replacement at 25% output reduction which occurs at approximately 1400 hours of operation. However, sufficient spectral irradiance for effective phototherapy continues well after 25% reduction.

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Maintaining the Unit Accessories Power cords    North America... 6600-0775-603    IEC Plug... 6600-0592-602    U.K... 6600-0574-603    C.E... 6600-0574-612    Australian... 6600-0574-613    Italian... 6600-0574-615 Bulb ... 6600-0235-850 Fan Filters (package of 12)... 6600-0236-850 T-handle Hex Key (fits cover and mounting bracket)... 6600-1246-400 Portable Roll Stand... 6600-0894-216

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WARNING: This service manual is available in English only. (EN)

• • •

If a customer’s service provider requires a language other than English, it is the customer’s responsibility to provide translation services. Do not attempt to service the equipment unless this service manual has been consulted and is understood. Failure to heed this warning may result in injury to the service provider, operator, or patient from electric shock, mechanical hazards, or other hazards.

Service Functional Description The Giraffe Spot Phototherapy Lite consists of three printed circuit assemblies (PCA), several peripheral components and an arc lamp. Power enters through an IEC320 receptacle line filter assembly. The line filter, along with a clampon ferrite bead that is located on the harness immediately after the line filter, provide filtering of both the phase and neutral lines for compliance with various agency approvals. The phase and neutral line then pass through circuit breakers for protection in the event of a device failure. After the circuit breaker, the phase and neutral are connected to the power switch. The output of the power switch is connected to the power supply PCA. The power supply is a universal input (90-264 VAC 50/60 Hz) switching power supply. The supply outputs +12VDC. This voltage is not adjustable. The output of the power supply is applied to the remaining two PCAs. The remaining two PCAs are the ballast and indicator board. These two boards work interactively to properly light and monitor the operation of the bulb. A description of the ignition and operation of the lamp follows below. The bulb in this product is an arc lamp. To light the lamp a high voltage must be applied across the anode and cathode of the lamp. Once the arc has occurred a low voltage but higher current will fully sustain the arc. The energy input into the lamp causes the chemicals inside the lamp to excite causing them to emit a high intensity light. The ballast converts the incoming 12 volts to kilovolt pulses. The ballast’s circuitry detects the presence of an arc and then outputs 52 volts to the bulb. If no arc is detected, the circuitry shuts down until power is cycled. The ballast takes in a remote on/off control signal that is sent from the indicator board and outputs a lamp status signal to the indicator board. The indicator board utilizes the on/off control line to turn off the lamp in the event of an over-temperature condition. A remote off-board thermostat is used to sense when an over-temperature condition occurs. The thermostat is normally closed and opens during an over-temperature condition. In normal operation, the thermostat is closed, the over-temperature LED is off and the ballast control signal is low (<0.5 volts), which turns the ballast on. In an over-temperature condition, the thermostat is open, and the over-temperature LED signal to the ballast control is high (>2.7 volts), which turns off the ballast. The lamp status signal from the ballast is converted to a 12 volt referenced signal to control the counting of the hour meter. If a fault is detected by the ballast, or if the ballast is turned off due to over-temperature conditions, the lamp status signal will go low, causing the hour meter to stop counting. A flashing hour glass on the display of the hour meter indicates that the hour meter is counting. When in the stop counting mode, the elapsed hours will be displayed, but the flashing hour glass will not occur. Due to the large current (approximately 5 amperes) required by the ballast, the ballast and the indicator board are connected in parallel to the power supply. The 12 volt supply for the hour meter and the two cooling fans is passed directly through the indicator board. In addition the indicator board contains a power indicator LED. When power is applied to the device regardless of the lamp status the power indicator will light, the fans will operate, and the hour meter display will light.

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Service Troubleshooting Symptom

Possible Problem

Bulb does not light after switch- Bulb is too hot for unit to ing unit off briefly and Over switch back on. temp light doesn’t light. Power light is lit.

Solution Allow bulb to cool at least one minute and reapply power. If you leave the unit on, the fan will assist in cooling the bulb.

Arcing sound heard. Bulb doesn’t light.

Bad connection.

Over temp light doesn’t light.

Bad power switch.

No arcing sound.

Bad circuit breaker. Bad line filter.

Check line voltage circuitry to power supply. Trace line voltage from line filter through circuit breakers and power switch to power supply. If line voltage is present going into any of these devices but not present on the output of the device, then replace that device. If line voltage is present at power supply, verify power supply output. 12 volts should be present at J2 pins 1 referenced to pin 4. If there is no output, replace power supply.

Tripped circuit breaker.

Reset breaker. If it trips again, disconnect power and troubleshoot for short.

Power light doesn’t light, and Over temp light is off or Blinking power light and Over temp light is off

Bad power supply or Shorted fan.

Replace power supply.

Bulb doesn’t light. Over temp light doesn’t light. Power light is lit, or Arcing sound heard but bulb does not light

Bad bulb.

Replace bulb.

Bad ballast.

Replace ballast*.

Bulb doesn’t light or bulb goes out every few minutes. Over temp light is lit or goes out when bulb lights Power light is lit.

Unit is in overheat mode due to dirty filter.

Check fan inlet filter. Clean or replace filter if dirty.

Bad main or ballast fan.

Verify that both fans are running. If a fan is not running, replace it. If the fans are running, they are running too slowly. Replace the main fan.

Bad thermostat.

Thermostat can be tested with an ohm meter. In normal operation the thermostat should be closed.

Replace fan.

*Due to the dangerous high voltage pulses and internal testing circuitry in the ballast, testing of the output is not recommended. Replacing the bulb is recommended to determine if the problem is with the bulb or the ballast.

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Service Symptom

Possible Problem

Solution

Bulb lights but power light doesn’t light. Over temp light doesn’t light.

Bad indicator board.

Replace indicator board.

Low light output

Wrong light meter

1. Use BiliBlanket Light Meter.

Bulb installed incorrectly

2. Re-seat bulb to correct alignment in bracket. Check that the mark at the top of the bulb is at 12:00 o’clock.

Bad bulb

3. Replace bulb.

Lens blocked

4. Clean lens.

Mirror installed incorrectly

5. Install mirror as described in “Replacing the bulb bracket, mirror and thermostat”.

Bad mirror

6. Replace mirror.

Bad ballast

7. Replace ballast*.

Bad light pipe

8. Replace light pipe.

Bad hour meter.

Verify that 12 volts is present on J3 pins 2 referenced to pin 4. If there is no voltage, check the power supply. If voltage is present replace hour meter.

Hour meter doesn’t display hours. Power light is lit.

Hour meter doesn’t count hours Bad hour meter when bulb is on. Light is lit. Bad indicator board Bad ballast

Verify that >11 volts is present on J3 pins 1 referenced to 4. If voltage is present replace hour meter. If voltage is less than 11 volts verify that voltage at J1 pin 4 referenced to pin 5 is >1.421 volts. If voltage is present replace indicator board. If voltage is not present, replace ballast*.

*Due to the dangerous high voltage pulses and internal testing circuitry in the ballast, testing of the output is not recommended. Replacing the bulb is recommended to determine if the problem is with the bulb or the ballast.

WARNING

w Shock hazard. The ballast emits high voltage pulses. Disconnect the unit from power source and use extreme care when servicing it. It is not recommended to measure the voltages at the lamp; this may damage equipment.

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Service Service Procedures Use Static Control Work Station to help ensure static charges are safely conducted to ground. Whenever this symbol appears beside a procedure, take static control precautions.

Light Intensity Check In order to ensure uniform light distribution and the performance of all the optical components, perform the following procedure. 1. Turn on the light and wait 5 minutes until the lamp stabilizes. 2. Focus the light so that the spot diameter is 20 cm (about 38 cm from the bed surface). 3. Using the Biliblanket Light Meter II, measure the light at the 5 points indicated on the diagram. The spectral irradiance output measured with a BiliBlanket light meter should not be less than 30 µW - cm-2 - nm-1 in the center spot. 4. Divide the lowest reading by the highest reading. If the lamp is functioning properly the result should be greater than 0.4.

Light Pipe Position Retention Check To determine if the light pipe has been damaged, move the light pipe to verify that it moves freely and stays in position in it’s normal operating positions. WARNINGS

w Never operate the unit without both covers installed. During servicing, never look directly at the lamp. Exposure exceeding even 15 minutes a day can cause eye damage. During troubleshooting proper eye protection should be worn. w Due to the high pressures inside the lamp improper cooling could cause the lamp to shatter. Both covers should be installed prior to applying power. During troubleshooting proper eye protection should be worn. w Change the bulb every 2500 hours (regardless of output). If this interval is exceeded the bulb may rupture with an audible pop, and shattered glass and toxic chemicals may escape from the light box. Dispose of the bulb in accordance with local toxic waste regulations. w When doing repairs that require removing the covers, always check the tightness of the two bolts that secure the mounting bracket to the unit.

CAUTION

w The design of this product utilizes both covers to provide proper cooling of the lamp and circuitry. Operation of the unit without the covers for a duration of more than 10 minutes can cause overheating of the lamp circuitry, which could damage the device.

Opening the Light Source Enclosure (See Figure 5-1) 1. Disconnect the unit power cord from the wall outlet or equipment that it is plugged into. 2. Using the 3mm T-handle hex key provided with the unit, remove the screw in the front of the unit, located in the center at the top of the front cover. Remove cover. 3. Use a 7mm nut driver or socket to loosen the nut that secures the sheet metal EMI housing cover. Slide the EMI housing cover up and out of the unit.

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Service Disassembling the light pipe (See Figure 5-2) w Do not touch the lens. Residual hand oils can greatly decrease the output of the light.

CAUTION

1. Remove the front cover and EMI housing cover. 2. To remove the light pipe, remove the retaining ring inside the bulb bracket, then remove the light pipe from unit. Save the Teflon washer, it will either stay in the bracket socket or remain on the light pipe. 3. To remove the lens head from the light pipe, first slide the sleeve up over the light pipe, then slide the retaining clip back over the pipe. This will expose the two mounting pins, which can be extracted by wiggling the lens head until they fall out. 4. To remove the external spring, grip the light pipe with one hand while pulling and rotating the external spring with the other (O-rings on the pipe create some resistance to removing the springs). Note: When installing a new lens head, be sure to orient it so that the diagram on the sides points at an angle away from the light. Important: Any time a repair requires that the EMI housing cover be removed, the Electrical Safety tests should be performed.

Replacing the Bulb Bracket, Mirror and Thermostat (See Figure 5-3 and 5-4)

Note: Retain original bulb packaging to store the bulb in while servicing the unit. 1. Remove the front cover, EMI housing cover, light pipe and bulb. 2. Use a 7mm wrench to remove the 3 nuts that secure the bracket. 3. To remove the mirror, use a small screwdriver to remove the 2 screws that hold it in position. To check the orientation of a replacement mirror, use an oil free non-maring stylus (for example a toothpick) to touch any point near the edge of the mirror. If the image touches the tip of the stylus, that is the bulb side of the mirror. If there is a small gap between the tip and the image, that is the side that faces away from the bulb bracket. The mirror retainer frame bends for spring tension. When installing a new mirror, make sure that bend faces the mirror. w Do not touch the center glass bulb, mirror or the box end of the light pipe with your fingers. Residual hand oils on the bulb may result in reduced lamp performance. If you touch the bulb during installation or if you see stains, it is recommended to clean the bulb with non-flammable optical cleaner and dry with a clean, soft cloth. If alcohol solution is used, thoroughly dry to make sure no residual cleaner remains.

CAUTION

4. To remove the thermostat, disconnect its connector from J4 on the LED board. 5. Cut the 2 cable ties that secure the thermostat to the cable tie holder and remove the thermostat. If you are replacing the thermostat, remember to order 2 new cable ties to hold it in position. 6. Remove the wire bulb retainer by removing the nut that secures it on the mounting stud. When replacing or reinstalling the bulb retainer, position it from 1.2 to 1.25cm (0.45 to 0.5 inches) from the bulb bracket to maintain adequate spring load on the bulb.

Replacing the Ballast (See Figure 5-3) WARNING

w Shock hazard. The ballast emits high voltage pulses. Disconnect the unit from power source and use extreme care when servicing it. It is not recommended to measure the voltages at the lamp: this may damage measuring equipment.

1. Disconnect all the wire harnesses coming from the ballast. 2. Disconnect the bulb connector from the bulb. 3. Cut the cable tie strain relief. Order a new cable tie (6600-0384-400) when you replace the ballast. 4. Using a 2mm hex key, remove the 4 M3 screws that secure the ballast and remove the ballast. 6600-0361-000 Revision 105

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