EMA-LED GmbH
Ottostraße 3
63785 Obernburg Germany
MOUNTING PREPARATION INSTRUCTION
EMALED SURGICAL LIGHTS
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
Table of Contents
1 Preface 3
2 General Instructions 4
3 Minimum Height of Room Required to Mount the Lights 5
4 Mounting Requirements 6
4.1 Safety Measures 6
4.2 Load Parameters 6
5 Variations of ceiling mounting 7
5.1 Ceiling Mounting Requirements 7
5.2 Mounting by means of a Counterplate 8
5.3 Mounting by means of Forcing Anchors 9
6 Electric Engineering Requirements 10
6.1 Cabling Requirements 10
7 Annex 13
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
1 Preface
This Manual describes ceiling mounting and connection to the power supply system of
stationary surgical lights EMALED 500/500, EMALED 500/300, EMALED 500,
EMALED 560/560, EMALED 560/300, EMALED 560.
The preparation measures are required in order to meet all customers’ demands to EMALED
lights.
EMALED lights are designed for lighting the operation field during surgery, diagnostic
examinations in surgery rooms and other rooms in clinics and outpatient units.
The surgical lights are designed for continuous operation.
Design of the lights is subject to changes with the purpose to enhance their performance.
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
2 General Instructions
2.1 The steps required to mount the lights on the ceiling and to connect them to the power
supply described below form general recommendations. Optional methods that can be
used for mounting EMALED surgical lights are described below in this Manual.
2.2 The lights cannot be mounted on the ceiling unless approved by the person responsible
for construction and assembly works.
2.3 EMALED lights should be assembled and mounted in accordance with Assembly
Manual 540.000.000 МА.
2.4 EMALED lights are not designed for operation in rooms where there is danger of
explosion.
2.5 The lights should be operated in the room with the ambient temperature between 10 and
35 С and the maximum relative humidity 80%.
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
3 Minimum Room Height for Ceiling Mounting of the Lights
3.1 The height from the lower edge of the light hinge to the upper plane of the floor should be
approximately 2 m.
3.2 The room height difference is compensated by the length of the extension
pipe.
3.3 When ordering the lights, please specify the exact room height from the upper edge of the
floor to the structural ceiling.
3.4 Table 1 shows minimum room heights for different mounting options with the light
height 2 m.
Table 1 – Minimum Room Height (Walk through height 2 m)
Minimum room
Light type
height, mm
Single, EMALED 560 & 500 2390
Double, EMALED 560/300 &
2500
500/300
Double, EMALED 560/560 &
2500
500/500
If the room height is less than that shown in Table 1, the walk through height is decreased by
a corresponding value.
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
4 Mounting Requirements
4.1 Safety Measures
4.1.1 Before the assembly of the light, calculate the static strength of the ceiling.
4.1.2 The static strength of the ceiling should be sufficient to endure effectively the load
created by the light.
4.1.3 Comply with the regional construction standards currently in force.
4.1.4 Perform engineering calculations for the ceilings and the load distribution in the
ceiling.
4.1.5 A statics expert should calculate, verify and confirm the load-bearing capacity by
completing the Report on the Load-Bearing Capacity of the Ceiling and on
Secure Mounting of the Light before the assembly of the light.
4.2 Load Parameters
For load calculation data see Table 2. Take into account the regional security ratios.
Table 2 – Load Parameters for Ceiling Mounting
Bending Vertical gravity
Light type
moment, Nm force, N
Single, EMALED 560 &
440 450
500
Double, EMALED 560/300
660 700
& 500/300
Double, EMALED 560/560
842 800
& 500/500
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
5 Variations of ceiling mounting
5.1 Ceiling Mounting Requirements
5.1.1 Using the counterplate and the М12×460 threaded through pins (included in the scope
of supply of the lights) is the most reliable and the most widely used method of
ceiling disk or ceiling plate mounting on the ferroconcrete ceiling. In this case the
ferroconcrete ceiling structure should conform to all construction standards.
5.1.2 When using high load-bearing capacity anchoring or with other types of ceilings, it is
the customer’s responsibility to perform the static strength calculations and to
perform the works required for ceiling disk (plate) mounting.
5.1.3 Please inform the statics expert in case the concrete reinforcement is damaged during
holing as this may lead to the change and redistribution of static load in the ceiling.
5.1.4 The lights are mounted by means of a ceiling disk (EMA 100.01.01.000)
For your information
The ceiling disk is designed for attachment by means of 4 pins on the 350 mm diameter at the
mounting point of the previously installed EMA light. In this case the statics expert should check the
strength and static load of the whole structure and make a conclusion on its suitability.
Picture 2 – Ceiling disk
160
270
350
OM_3.05_02_01 380 valid from: 26.10.2012
420
EMA-LED GmbH Preparation to Installation
5.2 Mounting by means of Counterplate
5.2.1 Please take into consideration the following aspects:
The Safety Measures are specified in section 3.1 above.
The length of the pins should be adequate for subsequent complete shielding of the
counterplate from impact noises with seamless floor or insulation.
5.2.2 Sequence of operations:
1) Mark and drill holes with the diameter of 16 mm for the ceiling disk (position 1)
according to Picture 2.
2) Screw the hex nuts with the spacing washers (position 2) on the pins (position 3)
with M12 thread, 2 nuts (a nut and a lock-nut) on each. Tighten the nuts to one
another, applying force.
3) Place the counterplate (position 4) on the structural ceiling (position 5) and insert the
prepared pins with nuts into the holes in the counterplate and the ceiling.
4) Screw on the ceiling disk and the counterplate with the 6 (М12) nuts and the
washers, tighten the nuts with the torque 60 Nm; place an additional nut on each pin
and tighten them, applying the same force.
5) The ceiling disk should be attached to the structural ceiling without any
clearances.
Picture 4 – Mounting by means of a counterplate
1-ceiling disk or ceiling plate 5-structural ceiling
2,6-spacer washers and hex nuts 7-power supply wires
3- М12×460 pin 8-impact noise insulation
4- counterplate 9-seamless floor
Picture 4 – Tightening with a counter plate
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
Note!
Please inform the statics expert in case the concrete reinforcement is damaged during
holing as this may lead to the change and redistribution of static load in the ceiling.
5.3 Mounting on the ceiling by means of forcing anchor
When it is impossible to mount the light using the counterplate as described in the above
sections, you can use forcing anchors under certain conditions that need verification in each
specific case.
The following provisions are in force in the Federal Republic of Germany. In other countries
please comply with the relevant national guidelines and regulations.
It is the manufacturer’s responsibility to present the permits to use forcing anchors for
mounting.
Pos. 1 Forcing anchor Pos. 4 Hex nut
Pos. 2 Ceiling anchor plate Pos. 5 Ferroconcrete (structural) ceiling
Pos. 3 Safety washer
Use only the forcing anchors that can be used for mounting in the tension zone in accordance
with the permit issued by Berlin Construction Equipment Institute!
The permit specifies precise data on design and mounting by means of the forcing anchors,
the permitted loads and the general conditions in terms of construction engineering.
A “Specific Case Permit” issued by a relevant regional construction supervision agency is
required to mount the ceiling anchor plate by means of forcing anchors.
Note!
Please inform the statics expert in case the concrete reinforcement is damaged during holing as
this may lead to the change and redistribution of static load in the ceiling.
Ceiling anchor plates for EMALED surgical light mounting should be secured by means of
the following forcing anchors.
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
Ceiling anchor plate
Reference circle Ø (mm) Mounting hole Ø (mm) HILTI forcing anchor
380 12 HAST-R M12x145/50
These forcing anchors can be used under the following standard conditions:
Concrete strength grade >= В 25
Structural ceiling thickness >= 15 cm
Distance to the edge of the next hole in the ceiling min. 15 cm
Please comply with the manufacturer’s instructions and information when securing the
forcing anchors.
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
6 Electric Engineering Requirements
6.1 Cabling Requirements
Cabling should in principle be done in compliance with the European Standard IEC
60364-710 and the national standards currently in force.
Calculations, laying and checking of the cables are at the customers care and should be
performed by skilled professionals.
The switch unit and the safety devices should in principle be mounted by the customer!
The section of the connecting wires between the safety devices and the transformers should
be minimum 1,5 mm2.
The wires should be laid along the centre of the ceiling anchor plate.
The length of the output leads should be 500 mm or more.
The section of the potential compensation wire should be minimum 4 mm2.
The stranded wires should have terminals for strand termination.
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
If you have any questions regarding this Manual or if you need assistance in designing,
please contact our main factory.
EMA-LED GmbH
Ottostraße 3
63785 Obernburg
Germany
Tel. : +49 6022 206 811
Fax : +49 6022 208 754
Е-mail : info@emaled.de
or our authorized service company
Medizintechnischer Service Jens Clos
Grabenstrasse 55
56130 Bad Ems
Germany
Tel. : +49 2603-5049460
Fax: +49 2603-5049459
Е-mail : j.clos@emaled.de
OM_3.05_02_01 valid from: 26.10.2012
EMA-LED GmbH Preparation to Installation
Report on Ceiling Load-Bearing Capacity
and Reliable Mounting of the Light
Note!
The light can only be mounted upon presentation of this Permit!
Medical facility ___________________________________________________________
(Name and address of medical facility)
__________________________________________________________________________
____
__________________________________________________________________________
____
Surgery room
_________________________________________________________________
Type of light
EMALED 500/500
EMALED 500
Type of ceiling mounting
by means of counterplate
by means of forcing anchors
other method
Conclusion
This certifies that the structural ceiling and the mounting structure are reliable and have
sufficient load-bearing capacity to mount the said light.
Expert Construction Engineer _________________________________________________
(title) (signature) (last name)
_____________________________
(date) Seal
(Construction
supervision agency)
OM_3.05_02_01 valid from: 26.10.2012
