FRC FOCUS, NightMaster Manual
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Document Number:
XM-LGT1PM-R0A
GENERAL LIGHTING
LGT100 Rev0309
OPTIMUM
FOCUS
NIGHTMASTER
FIRE RESEARCH CORPORATION www.fireresearch.com
26 Southern Blvd., Nesconset, NY11767
TEL ( 631 ) 724-8888 FAX ( 631 ) 360-9727 TOLL FREE 1-800-645-0074
1
LGT100 Rev0309
CONTENTS
Table of Contents
CONTENTS ................................................................................................................ 2
INTRODUCTION ...................................................................................................... 4
Overview ................................................................................................................ 4
Features .................................................................................................................. 4
Specifications ......................................................................................................... 5
SAFETY SUMMARY ................................................................................................ 6
INSTALLATION INSTRUCTIONS .......................................................................... 8
Install Lamphead on Telescopic Pole .................................................................... 8
Install Recessed Mount Models 200, 230, 250 .................................................... 10
Install Aerial Mount Models 300 ......................................................................... 12
Install Top Mount Telescopic Pole Models 510, 512 ........................................... 14
Install Side Mount Telescopic Pole Models 530, 540, 542.................................. 16
Install Pedestal Mount Models 570, 580 ............................................................. 18
Install Quick Release Bracket Set for Tripod Models 600, 642, 656 ................. 20
Install Quick Release Bracket for Portable Model 700 ....................................... 22
Install Brow Mount Models 800, 850 .................................................................. 24
MAINTENANCE ..................................................................................................... 26
Bulb Replacement Optimum and Focus .............................................................. 26
Cleaning ............................................................................................................... 26
Bulb Replacement NightMaster........................................................................... 28
Bulb Replacement Triple Cluster ......................................................................... 28
NO-SCRATCH FOR MODEL 530 TELESCOPIC POLE ....................................... 30
Install No-Scratch Guide Collar and Guide Rail ................................................. 30
Install No-Scratch Rubber Bumpers (Focus Lamphead Only) ............................ 30
RAISED POLE WARNING SWITCH AND INDICATOR ..................................... 32
Overview .............................................................................................................. 32
Description ........................................................................................................... 33
Parts List .............................................................................................................. 34
2
LGT100 Rev0309
List of Tables
Table 1. Lamphead Guide .......................................................................................... 5
Table 2. Recessed Mount Dimensions .................................................................... 11
List of Figures
Figure 1. Assemble Lamphead and Telescopic Pole .................................................. 9
Figure 2. Install Recessed Mount ............................................................................ 11
Figure 3. Install Under Aerial Mount ....................................................................... 13
Figure 4. Install Top Mount Telescopic Pole ........................................................... 15
Figure 5. Install Side Mount Telescopic Pole .......................................................... 17
Figure 6. Install Pedestal Mount .............................................................................. 19
Figure 7. Install Tripod Quick Release Bracket Set ................................................. 21
Figure 8. Install Portable Light Quick Release Bracket .......................................... 23
Figure 9. Install Contour and Flat Brow Mounts ..................................................... 25
Figure 10. Bulb Replacement Optimum and Focus ................................................. 27
Figure 11. Bulb Replacement NightMaster ............................................................. 29
Figure 12. No-Scratch ............................................................................................. 31
Figure 13. Raised Pole Warning Switch Housing Locations ................................... 33
Figure 14. Raised Pole Warning Switch Parts List .................................................. 34
3
LGT100 Rev0309
INTRODUCTION
Overview
OPTIMUM Lampheads utilize a super-efficient design to offer a maximum transfer of light from bulb to scene. The newest addition to the FRC lighting series includes
HIR and HID bulb options not available on classic Focus lights.
FOCUS Low Profile Lampheads introduced the concept of re-directing light with
50 parabolic curved and aimed surfaces. The innovative design directs light where it is needed. The low profile of the classic FOCUS offers mounting options that many other lights cannot.
NIGHTMASTER Lampheads are affordable scene lights that have a proven track record on emergency apparatus. Simple, functional, and available in multiple styles and mounting configurations.
Features
EFFICIENCY The brightest and best designed lights in the industry. A unique reflector design transfers more light from the bulb to the scene.
NO WASTED LIGHT Focus 100% of the light directly where it is needed.
RELIABLE and PROVEN Manufactured from heavy duty, thick extruded aluminum for long life and many hours of dependable performance. Proven under actual emergency situations.
COMPACT Focus lights will not take up valuable space on your vehicle.
ATTRACTIVE Modern design and stylish look of all our lights enhances the appearance of emergency apparatus.
VERSATILE Choose from 70W to 1500W and from 12V to 240V capabilities.
MOUNTING CHOICES FRC lampheads can be mounted virtually anywhere as telescopic poles, portable, fixed, brow mounted, recessed, or under aerial.
OPTIONS Include multiple size mounting brackets, costum length poles, wire guard, on/off power switch, raised pole indicator,and no scratch for Focus.
SAFETY TWIST LOCK Easy to use and standard on all FRC telescopic poles, the locking mechanism has no metal to metal contact, it can not jam or be over tightened.
4
LGT100 Rev0309
Specifications
Note: All Optimum, Focus, and NightMaster lampheads are available seperately or as part of a lighting assembly.
Series
O=Optium
F=Focus
L=NightMaster
L
O, F, L
O, F, L
L
O, F
O, F, L
O, F
O
O, F, L
O, F, L
F
L
F
F
O, F
O, F
O
O
Lapmhead
Style
TC0
S30
S50
P50
S75
M10
S72
R90
M12
M15
H70
H15
E70
E15
D15
D30*
H30
DT0
Table 1. Lamphead Guide
Bulb Type
HID
HID
HID
HID
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
Quartz Halogen
HIR
Quartz Halogen
Quartz Halogen
Watts
300
300
500
500
750
1000
750
900
1000
1500
70
150
70
150
150
300
300
250
Volts
120
120
240
240
12
120
120
120
240
240
12
12
24
12
12
12
24
24
Amps
* Two 150 watt bulbs are installed.
RESTRICTION NOTES
12/24 VDC lampheads are not available on 600 and 700 type mounts.
240 VAC lampheads are not available on 700 type mounts.
LT series lampheads are not available on 200, 230, 250, 300, 800, and 850 type mounts.
.
FOCUS HID lamphead is only available on 800 and 850 type mounts.
25.0
2.5
4.2
4.2
6.3
8.3
3.1
3.75
4.2
6.25
6.0
12.5
3.0
6.25
12.5
25.0
12.5
20.0
5
LGT100 Rev0309
SAFETY SUMMARY
FRC lighting products are engineered and manufactured with safety in mind. It is critical that FRC scene lights are installed, maintained, and operated correctly. Read and understand all instructions before installing, performing maintenance, or operating.
All components, equipment, and installation procedures shall conform to NFPA
1901, Standard for Automotive Fire Apparatus and NFPA 70 National Electrical
Code .
The following safety precautions shall be observed while performing procedures in this manual.
General Safety Precautions
Ensure power is off prior to connecting or disconnecting wires and plugs or performing maintenance.
Scene lighting lampheads are designed for outdoor use and will be extremely hot when operating. Do not use in areas of limited ventilation.
Installation Safety Precautions
Ensure power is off prior to connecting wires or cable to the power source.
Connect only to the type of power source as indicated on the lamphead identification label.
Ensure an appropriate sized circuit protection device is installed (circuit breaker or fuse).
Use a minimum of 16 AWG wire to connect AC lights and 12 AWG to connect
DC lights.
FRC lights are intended for mounting to a noncombustible surface only. Do not install insulation within 76 mm (3 in) of any part of the light, lighting fixture, or its components.
Install approved rubber or plastic grommets or bushings where wires or cable will pass through a surface.
Ensure all wire connectors or terminals provide a positive mechanical and electrical connection.
Electrical connections not enclosed in a box must be covered with an insulation equivalent to that on the conductors.
Lampheads will be extremely hot when operating, do not mount such that personnel or equipment could inadvertently come in contact with the lamphead.
Recessed lights require a minimum of 3 inch clearance between wall insulation and the light housing.
6
LGT100 Rev0309
Operation Safety Precautions
Operate portable lighting products only from the type of power source indicated on the identification label.
During operation use the handle to move the light, the housing will be extremely hot.
Ensure that all lighting components are clear of obstructions when raising telescopic poles.
Ensure that telescopic poles are lowered and stowed before moving the vehicle.
Maintenance Safety Precautions
Ensure power is off prior to removing the front glass or opening covers.
Do not operate the light with the front glass removed or cover opened.
Ensure replacement bulbs have the same voltage and wattage.
When handling a new quartz halogen, HIR, or HID bulb avoid touching it except on the flat seal at either end.
Use a clean soft cloth to wipe the reflector clean if necessary, do not use liquid or aerosol cleaners.
7
LGT100 Rev0309
INSTALLATION INSTRUCTIONS
Install Lamphead on Telescopic Pole
Lampheads and telescopic poles are shipped apart and need to be assembled
Note: The 512 telescopic pole must be installed before the lamphead is attached if the small diameter hole is used. Refer to Install Models 510,
512 Top Mount Telescopic Poles.
1. Place the lamphead and the pole on a flat surface.
2. Connect the lamphead wires to the pole wires. (Refer to Figure 1.)
a. Ensure that 3/8 inch of bare conductor shows at the end of each wire.
b. Insert the wires in the butt connectors and crimp.
For DC lights:
Connect black to black, white to red.
For AC lights:
Connect black to black, white to white, silver braid to green.
3. Ensure the crimps are tight. (Test by lightly tugging on the wires.)
4. Loop the excess wire in a zig-zag fashion to take up the slack.
Note: Ensure that the wires are not caught and squeezed by the lip of the pole. If this happens the wire insulation may be cut and short the wires to the pole.
5. Slide the lamphead onto the pole tucking the wires into the pole.
6. Apply thread lock and tighten the set screws to secure the lamphead on the pole.
(A medium strength locking compound like Loctite blue is recommended.)
8
BLACK
WHITE
SILVER
BRAID
LGT100 Rev0309
For DC Powered Lights:
Connect black to black, white to red
For AC Powered Lights:
Connect black to black, white to white, silver braid to green.
BLACK
DC powered lights will only have two wires.
WHITE
GREEN
Green Wire
Optimum lamphead only.
Slide the lamphead assembly onto the pole.
Make sure that the wires are not caught and squeezed by the lip of the pole.
Dimension A should be less than 0.015"
(The thickness of a folded piece of paper).
If A is larger, a wire is probably caught.
Disassemble and check the for wire insulation damage. If there is no damage, reassemble.
Loop the excess wire in a zig-zag to take up the slack and tuck into the pole
.
A
Note: The 512 telescopic pole must be installed before the lamphead is attached if the small diameter hole is used. Refer to Install Models 510, 512 Top Mount
Telescopic Poles.
Apply thread lock and tighten the set screws.
Figure 1. Assemble Lamphead and Telescopic Pole
9
LGT100 Rev0309
Install Recessed Mount Models 200, 230, 250
1. Measure and mark mounting location for cutout.
2. Cut out mounting hole.
3. Place the light in position to check for fit and mark mounting screw locations.
4. Double check the clearance around and behind the light housing. Recessed lights require a minimum of 3 inch clearance between wall insulation and the light housing.
5. Drill mounting screw holes.
Note: Wires may need to be connected before installing the recessed light.
6. Ensure that approved strain relief for the wiring is installed.
7. Secure the housing with mounting screws.
Wiring
12/24 VDC
Connect the BLACK wire to GROUND.
Connect the RED (or WHITE) wire to POWER.
120/240 VAC
Connect the SILVER BRAID or GREEN wire to chassis GROUND.
Connect the WHITE wire to RETURN.
Connect the BLACK wire to POWER.
FCA200
OPA200, OPA230
OPA250
10
LGT100 Rev0309
Model
FCA200-
D15, H30, S30, S50, S72, S75
D30, M10, M12, M15
OPA200-
S30, S50, S72, S75
M10, M12, M15, R90
OPA230-
E15, E70, H15, H70
OPA250-
S30, S50, S72, S75
M10, M12, M15, R90
FCA200
H H
2
Table 2. Recessed Mount Dimensions
W D H W
2
W
W
2
11
17 1/2
11
17 1/2
10 3/16
11 3/16
16 9/16
2
2
2
2
3 1/4
4 1/8
3 1/4
D
5 5/8
5 5/8
5 5/8
5 5/8
4 3/4
7 1/2
7 1/2
1 3/4"
9 3/4
16 1/8
9 3/4
16 1/8
8 3/4
H
2
4 1/4
4 1/4
4 1/4
4 1/4
3 7/8
9 9/16
15
5 3/4
5 3/4
Note: W
2
and H
2
will be the cutout dimensions.
Hardware Recommendations
For 200 mounts:
10-32 SS
W
W
2
D 3 1/8"
OPA200
H H
2
OPA230
H H
2
OPA230 is the only recessed light available with HID bulb.
W
W
2
D 3 3/4"
Hardware Recommendations
For 230 mounts:
1/4-20 SS
W
W
2
OPA250
D 1 1/4"
Hardware Recommendations
For 250 mounts:
10-32 SS
H H
2
Figure 2. Install Recessed Mount
11
LGT100 Rev0309
Install Aerial Mount Models 300
Before mounting check the identification label on the lamphead for specific voltage and current requirements. Check that the length of the power cord is correct.
Note: Before drilling holes place the light in position to check for fit. Ensure that the lamphead will clear all obstructions.
1. Place the light in position.
2. Mark the mounting hole locations and through hole for the wiring. Use the lamphead and attached brackets as a template.
3. Drill mounting holes.
4. Secure the mounting bracket(s). Use 5/16-18 SS hardware.
5. Ensure that approved strain relief for the wiring is installed.
6. Adjust the lamphead angle by loosing the nuts at the bracket pivot point, set at desired position and tighten nuts.
Wiring
12/24 VDC
Connect the BLACK wire to GROUND.
Connect the RED (or WHITE) wire to POWER.
120/240 VAC
Connect the GREEN wire to chassis GROUND.
Connect the WHITE wire to RETURN.
Connect the BLACK wire to POWER.
FCA300
12
LGT100 Rev0309
Adjust the lamphead angle by loosing the nuts at the bracket pivot point.
Required Clearance
Aimed directly forward 4 inches
Aimed at 30° downward 6.5 inches
Aimed at 45° downward 6.75 inches
Aimed directly down 7.5 inches
Note: It is best to use the lamphead and attached brackets as a template to mark mounting holes.
Hardware Recommendations
For 300 mounts:
5/16-18 SS
Figure 3. Install Under Aerial Mount
13
LGT100 Rev0309
Install Top Mount Telescopic Pole Models 510, 512
When positioning a telescopic pole ensure that the lamphead will clear all obstructions and the twist lock will be accessible.
Note: The 512 telescopic pole should be installed before the lamphead is attached. Two set screws allow the flange to be removed and the pole will fit up through a 1 5/8" hole. To install a fully assembled 512 pole down through the roof, a 2 1/2" hole will be needed so the handle and twist lock will fit through.
1. Check the light position for fit and freedom of operation
2. Mark the footprint of the mounting flange.
3. Drill mounting holes.
Note: The 512 requires a bead of RTV or similar sealant be applied between the mounting surface and the bottom outer edge of the flange.
4. For 512 apply a bead of sealant around the bottom outer edge of the flange.
5. Secure the mounting flange. Use 1/4-20 SS hardware. Install a backing plate if necessary for a sturdy mounting.
6. Ensure that approved strain relief for the wiring is installed.
Wiring
12/24 VDC
Connect the BLACK wire to GROUND.
Connect the RED wire to POWER.
120/240 VAC
Connect the GREEN wire to chassis GROUND.
Connect the WHITE wire to RETURN.
Connect the BLACK wire to POWER.
14
510
Top Mount
Pull Up
512
Thru-The-Roof
Push Up
510
Top Mount
Flange
Diameter
3 1/4"
1 3/4"
Diameter
Cutout
LGT100 Rev0309
1 7/8"
Round or Square
Flange
Drawings may not be to scale.
DO NOT USE AS A TEMPLATE
512
Thru-The-Roof Mount
2 1/2"
Diameter
Cutout
1 5/8"
Diameter
Cutout
2 5/8"
Hardware Recommendations
For 510, 512 mounts:
1/4-20 SS
Apply a bead of sealant around the bottom outer edge of the flange.
Flange
Diameter
4"
Note: The 512 telescopic pole should be installed before the lamphead is attached. Two set screws allow the flange to be removed and the pole will fit up through a 1 5/8" hole. To install a fully assembled 512 pole down through the roof, a
2 1/2" hole will be needed so the handle and twist lock will fit through.
3"
Figure 4. Install Top Mount Telescopic Pole
15
LGT100 Rev0309
Install Side Mount Telescopic Pole Models 530, 540,
542
When positioning a telescopic pole ensure that the lamphead will clear all obstructions and the twist lock will be accessible.
1. Place the light in position to check for fit and freedom of operation.
2. Slide the brackets up or down into required position. The set screws may need to be loosened.
3. Tighten set screws.
4. Mark the footprint of the mounting bracket(s).
5. Drill mounting holes.
6. Secure the mounting bracket(s). Use 5/16-18 SS hardware. Install a backing plate if necessary for a sturdy mounting.
7. Ensure that approved strain relief for the wiring is installed.
Wiring
12/24 VDC
Connect the BLACK wire to GROUND.
Connect the RED wire to POWER.
120/240 VAC
Connect the GREEN wire to chassis GROUND.
Connect the WHITE wire to RETURN.
Connect the BLACK wire to POWER
Slide bracket up or down into required position and tighten set screws.
Typical Bracket
16
530
Side Mount
Push Up
540
Side Mount
Pull Up
542
Side Mount
Pull Up
LGT100 Rev0309
530, 540, 542
Side Mount Brackets
3"
2 1/8"
1 1/2"
3"
Side Mount Bracket Footprint
The footprint is the same for all side mount and steady rest brackets.
530, 540, 542
Flush Mount Brackets
Drawings may not be to scale.
DO NOT USE AS A TEMPLATE
Hardware Recommendations
For 530, 540, 542 mounts:
5/16-18 SS
3 13/16"
3"
1"
2"
Figure 5. Install Side Mount Telescopic Pole
17
LGT100 Rev0309
Install Pedestal Mount Models 570, 580
When positioning a pedestal mount light ensure that the lamphead will clear all obstructions.
1. Place the light in position to check for fit and freedom of operation.
2. Mark the footprint of the mounting flange/bracket.
3. Drill mounting holes.
4. Ensure that approved strain relief for the wiring is installed.
5. Secure the mounting flange/bracket. Use 5/16-18 or 1/4-20 SS hardware. Install a backing plate if necessary for a sturdy mounting.
Wiring
12/24 VDC
Connect the BLACK wire to GROUND.
Connect the RED (or WHITE) wire to POWER.
120/240 VAC
Connect the SILVER BRAID or GREEN wire to chassis GROUND.
Connect the WHITE wire to RETURN.
Connect the BLACK wire to POWER.
OPA570
18
FCA580
570
Pedestal Mount
Flange
Diameter 3
1/2"
LGT100 Rev0309
5/8"
Diameter
Cutout
580
Side Mount Brackets
2 7/8"
Drawings may not be to scale.
DO NOT USE AS A TEMPLATE
Hardware Recommendations
For 570, mounts:
1/4-20 SS
Hardware Recommendations
For 580, mounts:
5/16-18 SS
3"
2 1/8"
Side Mount Bracket Footprint
The footprint is the same for all side mount and steady rest brackets.
1 1/2"
3"
Figure 6. Install Pedestal Mount
19
LGT100 Rev0309
Install Quick Release Bracket Set for Tripod Models
600, 642, 656
The quick release mounting bracket set will hold an FRC tripod securely on the vehicle. The mounting bracket set consists of a lower base into which the bottom of the tripod legs rest, and an upper locking bracket, which has a quick release knob on the right side.
1. Place the tripod in position to check for fit.
Note: The mounting brackets are aligned left and not centered on each other.
2. Mark the mounting hole locations.
a. Align the left sides of the brackets and the left side mounting holes for the tripod to fit correctly.
b. The upper bracket is mounted with the pull knob to the right side.
c. Use the brackets as templates.
Helpful Hint: Mount the bottom bracket first. Attach the quick release bracket to the hole on the upper slide casting of the tripod. Rest the tripod legs in the base, and push the upper bracket in position flush to the mounting surface. Mark the top bracket hole locations.
3. Dill the mounting holes. The mounting brackets are predrilled for 1/4-20 hardware.
Note: Tripods with Focus lampheads require that 3/4" spacers be installed between the mounting surface and the brackets so the back of the lamphead will clear the mounting surface.
4. Install the mounting brackets (and spacers with Focus lamphead).
Quick Release Bracket Set
(Shown with Focus lamphead spacers.)
642
Tripod w/Focus
Lamphead
20
Tripods with
Focus lampheads use a 3/4" spacer under both mounting brackets.
LGT100 Rev0309
Align the left sides of the brackets and the left side mounting holes for the tripod to fit correctly.
The pull knob must be to the right side.
2"
Total distance from top to bottom of mount brackets:
43 1/2" for 600, 656
30 1/4" for 642
2"
9/16"
39 3/4" for 600, 656
26 1/2" for 642
3"
SIDE VIEW FRONT VIEW
Figure 7. Install Tripod Quick Release Bracket Set
21
LGT100 Rev0309
Install Quick Release Bracket for Portable Model 700
The quick release brackets will hold an FRC portable lamphead securely to the vehicle or a telescopic pole. Pull the quick release knob to install or remove the portable light.
703 Quick Release Bracket for Flat Surface Mounting
1. Place the 703 bracket in position to check for lamphead fit.
2. Mark the mounting hole locations. Use the bracket as template.
3. Dill the mounting holes. The mounting bracket is predrilled for 5/16 hardware.
4. Pull the quick release knob to install the portable light on the bracket.
705 Quick Release Bracket for Pole Mounting
Note: If the 705 quick release is to be retrofit onto an existing pole the lamphead to pole adapter P/N LT100 must be removed and replaced with the 705 adapter P/N X-LT214-705.
1. Place adapter on top of pole and tighten two set crews.
2. Place the 705 into the adapter and tighten the set screw.
3. Pull the quick release knob to install the portable light on the bracket.
Focus
FCA700
Optimum
OPA700
703 Quick Release Bracket for Flat Surface Mounting
705 Quick Release Bracket for Pole Mounting
22
NightMaster
LTA700
703
Quick Release Bracket for
Flat Surface Mountingt
2" 3 1/8"
LGT100 Rev0309
Hardware Recommendations
For 703 mounts:
5/16-18 SS
2 1/4" 3 3/8"
Drawings may not be to scale.
DO NOT USE AS A TEMPLATE
703
Quick
Release
705
Quick
Release
Base (lamphead not shown) shown on a telescopic pole with a
705 quick release bracket.
Base with Focus lamphead shown on a 703 quick release bracket.
705
Pole
Mount
Adapter
Note: For a retrofit the lamphead to pole adapter
P/N LT100 must be removed and replaced with the
705 adapter P/N X-LT214-705.
Figure 8. Install Portable Light Quick Release Bracket
23
LGT100 Rev0309
Install Brow Mount Models 800, 850
Before mounting check the identification label on the lamphead for specific voltage and current requirements. Check that the length of the power cord is correct.
Note: Before drilling holes place the light in position to check for fit. Ensure that the lamphead will clear all obstructions.
1. Place the light in position.
2. Mark the mounting hole locations and through hole for the wiring. Use the lamphead and attached brackets as a template.
3. Dill the mounting holes. The mounting brackets are predrilled for 1/4-20 or
5/16-18 hardware.
4. Place the four rubber washers in position at each mounting hole.
5. Secure the light.
6. Ensure that approved strain relief for the wiring is installed.
Wiring
12/24 VDC
Connect the BLACK wire to GROUND.
Connect the RED (or WHITE) wire to POWER.
120/240 VAC
Connect the GREEN wire to chassis GROUND.
Connect the WHITE wire to RETURN.
Connect the BLACK wire to POWER.
FCA850
Flat
Mount
OPA800
Contour
Mount
24
TYPICAL
INSTALLATION
FCA800
Contour
Mount
LGT100 Rev0309
OPA800
Note: It is best to use the lamphead and attached brackets as a template to mark mounting holes.
FCA850
Flat
Mount
Hardware Recommendations
For 800, 850 mounts:
1/4-20 or 5/16-18 SS
OPA850
Figure 9. Install Contour and Flat Brow Mounts
25
LGT100 Rev0309
MAINTENANCE
Bulb Replacement Optimum and Focus
1. Ensure power is OFF and the lamphead is cool to the touch prior to replacing the bulb.
2. Ensure the replacement bulb has the same voltage and wattage rating. (If there are two bulbs installed, each bulb will be half the listed wattage.)
3. Hold the glass in place while removing the bezels. Remove the four cap head screws and remove the bezels. Remove the glass.
Note: Optimum gasket is attached, the Focus gasket may come off.
4. Slide the bulb sideways into the spring contact and lift it out from the opposite side.
Note: When handling the new bulb avoid touching it except on the flat seal at either end. (Grease or oily fingerprints can cause damage the quartz bulb.)
If the bulb is accidently touched, gently wipe it clean with alcohol.
5. Check both lamp base contacts to be sure they are perfectly clean.
6. Push one end of the bulb into the spring contact until the other end can be placed into the opposite contact. Rotate the lamp back and forth about its axis to ensure adequate seating of contacts.
Caution: Do not operate the light with the front glass removed.
7. Insert the Focus gasket in the groove with the splice positioned down.
8. Hold the glass in position. Ensure the glass is inside the lip on all four sides.
9. Install the bezels and secure with the four screws.
Note: Bulb life is extended when the lamphead is mounted so the bulb is in a horizontal position.
Cleaning
High intensity lights may, over time, develop a powdery white film on the reflector.
If this happens remove the glass (see bulb replacement procedure) and gently wipe the refelctor clean with a soft cloth.
26
OPTIMUM
LAMPHEAD
Bulb
LGT100 Rev0309
Glass
Bezel Screw
FOCUS
LAMPHEAD
Housing
Lip
CAUTION
Position the glass inside the housing lip on all four sides. Failure to do so may result in racking the glass when the screws are tightened.
Glass
Housing
Lip
Gasket Bulb Glass
Bezel Screw
Splice in gasket should be down.
Figure 10. Bulb Replacement Optimum and Focus
27
LGT100 Rev0309
Bulb Replacement NightMaster
1. Ensure power is OFF and the lamphead is cool to the touch prior to replacing the bulb.
2. Ensure the replacement bulb has the same voltage and wattage rating.
3. Loosen the two screws on each side of the lamphead. Open the glass cover
(the gasket may also come off).
4. Slide the bulb sideways into the spring contact and lift it out from the opposite side.
Note: When handling the new bulb avoid touching it except on the flat seal at either end. (Grease or oily fingerprints can cause damage the quartz bulb.) If the bulb is accidently touched, gently wipe it clean with alcohol.
5. Check both lamp base contacts to be sure they are perfectly clean.
6. Push one end of the bulb into the spring contact until the other end can be placed into the opposite contact. Rotate the lamp back and forth about its axis to ensure adequate seating of contacts.
Caution: Do not operate the light with the front glass removed.
7. Ensure the gasket is in place. Close the glass cover and tighten the two screws.
Do not over tighten the screws.
Note: Bulb life is extended when the bulb is mounted in a horizontal position.
Bulb Replacement Triple Cluster
12 Volt, 100 Watt, PAR 46 Bulb
1. Ensure power is OFF and the lamphead is cool to the touch prior to replacing the bulb.
2. Ensure the replacement bulb has the same voltage and wattage rating.
3. Remove the three screws (newer installations have one screw) and the collar that hold the bulb in place.
4. Remove the three wires one at a time from the bulb and connect them to the same terminal on the new bulb.
5. Put the new bulb in position and set the collar in place.
6. Install and tighten the screw(s).
28
NIGHTMASTER
LAMPHEAD
Screw
Glass
Cover
Glass
Cover
Hinge
Smaller NightMaster lampheads will have two screws on the side.
Larger lampheads will have two screws on the top.
NIGHTMASTER
Triple Cluster
PAR 46 Bulb
Black
Wire
White
Wire
Red
Wire
Rear View of Bulb
Figure 11. Bulb Replacement NightMaster
29
LGT100 Rev0309
LGT100 Rev0309
NO-SCRATCH FOR MODEL 530 TELESCOPIC POLE
Install No-Scratch Guide Collar and Guide Rail
1. Install the telescopic pole according to instructions for side mouint telescopoic pole.
Note: It is recommended that the Steady Rest Bracket be installed with the
No-Scratch option.
2. Use the guide rail as a template and mark the mounting holes.
Note: The slot in the guide collar has to engage the guide rail when the pole is in the down position. The collar mounts on the handle of the pole, ensure the guide rail will be in the correct position before drilling mounting holes.
3. Drill holes and secure the guide rail.
4. Place the guide collar in position on the pole handle. Before tighting the two screws ensure that when the slot engages the rail the lamphead is in the correct position.
5. Tighten the screws.
Install No-Scratch Rubber Bumpers (Focus Lamphead
Only)
The rubber bumpers help prevent scratching and denting by eliminating any metalto-metal contact between the rear of the lamphead and the apparatus body surfaces when the pole is lowerd.
1. Place the rubber bumper in position on the bottom of the end cooling fin.
2. Using the bumper as a guide, drill a hole through the cooling fin with a number
30 bit.
3. Place the backing plate on the rivet and insert the rivet thru the bumper and mounting hole.
4. Secure the bumper with the rivet.
No-Scratch Guide Rail and Guide Collar for
530 Telescopic Poles
No-Scratch
Rubber Bumpers for Focus
Lampheads
Shown with a Steady
Rest Bracket Installed
30
LGT100 Rev0309
As the Pole is Raised the guide collar disengages from the guide rail and the lamphead is free to rotate 360°.
As the Pole is Lowered the guide collar engages the guide rail and prevents the pole from being lowered unless the lamphead is correctly aligned.
The rubber bumpers are available as an option for FOCUS lampheads only.
Pole Raised
Guide Collar
Disengaged
Pole Lowered
Guide Collar
Engaged
3"
2 1/8"
1 1/2"
3"
Steady
Rest
Bracket
Guide
Rail
530
Pole
Guide
Collar
2 "
1 5/16 "
Guide Rail
Footprint
Side Mount Bracket Footprint
The footprint is the same for all side mount and steady rest brackets.
The rail is approximately
8 1/4 inches long.
Figure 12. No-Scratch
31
LGT100 Rev0309
RAISED POLE WARNING SWITCH AND INDICATOR
Overview
The raised pole warning switch is a normally closed magnetic switch mounted on the outer pole. A magnet, mounted on the inside of the inner pole, keeps the switch contact open when the pole is in the down position (see Diagram 1).
When the light is raised the magnet moves with the inner pole away from the switch and the contact closes (see Diagram 2).
This completes the electrical circuit to turn on the raised pole warning indicator.
(Refer to the Wiring diagram.)
Telescopic
Pole
Switch
Housing
Telescopic
Pole
Switch
Housing
Magnet
Diagram 1. Pole Down; Magnet Holds
Switch Open
Magnet
Diagram 2. Pole Moves Up with Magnet;
Switch Closes
Wiring
The switch is shown with pole in the up position.
Switch
Ground
Indicator
+12 VDC
Ground and +12 VDC can be swapped as required for installation.
Three Types of Switch Housings
Side Mount Pull-Up Poles and
Thru-The-Roof Push-Up Poles
Top Mount
Pull-Up Poles
Side Mount
Push-Up Poles
The switch is housed within the mounting flange.
The switch is housed within a cylindrical clamp that is mounted on the outer pole with screws.
The switch is housed within a
PVC holder that is mounted in the bottom steady rest bracket.
32
LGT100 Rev0309
Description
Specifications
Switch
Contact Single Pole Single Throw (SPST)
Position Normally Closed (NC)
Current 0.25 AMPS
Power 3 WATTS
CAUTION: If the switch is to be used with a higher current application a relay must be provided to avoid switch failure.
Indicator
Type 1891
Voltage + 14 VDC
Current 0.25 AMPS
Switch Housing Locations
If the switch housing is removed during installation, care should be taken to remount the switch in the correct position. Raise and lower the pole and ensure that the switch opens and closes correctly.
Models 510
Top Mount
Pull-Up Poles
Models 512
Thru-The-Roof
Push-Up Poles
Models 530
Side Mount
Push-Up Poles
Models 540, 542
Side Mount
Pull-Up Pole
Figure 13. Raised Pole Warning Switch Housing Locations
33
LGT100 Rev0309
Parts List
Part Number Description
LT-S100 Kit, Raised Pole Warning, 510 Poles
1 . LT-S347SW . Switch Assembly, Top Flange, Magnetic, NC
. LT-S347C-SW . Switch Assembly, Top Flange C/E, Magnetic, NC
2 . LT-S337
3 . LT-SZL606
LT-S101
4 . LT-S336SW
2 . LT-S337
. Magnet, Inner Pole
. Indicator Assembly
Kit, Raised Pole Warning, 512, 540, 542 Poles
. Switch Assembly, Donut, Magnetic, NC
. Magnet, Inner Pole
3 . LT-SZL606
LT-S102
-LT-S102-B
-LT-S102-C
5 . LT-S304SW
-5 . LT-S305SW
. Indicator Assembly
Kit, Raised Pole Warning, 530 Poles
Kit, Raised Pole Warning, 530 Poles, 5" Bracket
Kit, Raised Pole Warning, 530 Poles, 7" Bracket
. Switch Assembly, Steady Rest,
. Switch Assembly, Steady Rest 5"
-5 . LT-S306SW
6 . . LT350C
. Switch Assembly, Steady Rest 7"
. . Switch Holder, PVC
7 . . LT-808-2000 . . Switch, Magnetic, NC
8 . LT-S318C . Magnet, Pole End w/Strain Relief
3 . LT-SZL606 . Indicator Assembly
1
2
3
8
5
4
6
7
Figure 14. Raised Pole Warning Switch Parts List
34
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35
LGT100 Rev0309
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