Figure 9: Hinged side access panel
Figure 10: Connector cover
ENDOSCOPE MODULE
The Endoscopes Module includes eight components. The eight components share four center kiosks. The components are paired on the center kiosks as follows:
Each of the components is discussed in detail in the following sections.
Description
An orange table base with a large, primarily clear colored acrylic cube containing a three-level maze. Visitors move a small rubber block from top ("in") to bottom ("out") through the levels of the maze by inserting their choice of five tools/"endoscopes" through holes in the sides of the maze cube.
Primary Components
The primary exhibit components (no electronics) include:
Refer to Table 1 for more detail about primary and associated components.
Consumables / Spare Parts
An air filter is the primary consumable item for this exhibit. In addition to the rubber block, the five tools/"endoscopes" that must be replaced if found missing or broken include:
Spare parts provided for each exhibit rental are listed in Table 2.
Special Instructions
None
General Maintenance
Maintenance involves exhibit ventilation/air filtering, lighting, and general cleaning.
The maze/cube will become scuffed by the tools and require routine cleaning. Use hinged access panels on the four sides of the maze cube fastened with standard cabinet locks to remove any foreign objects and to access for cleaning.
Routine cleaning to remove the tool markings should be performed using Plexiglas cleaner, soft cloths, and "elbow grease". Additional cleaning may require buffing compound.
Table 3 should be followed for specific maintenance steps and frequency. Also use the table to record that maintenance was done as prescribed.
Troubleshooting
Acrylic glue may be required to occasionally glue small internal maze wall sections back into place. First clean the surfaces thoroughly where adhesive will be needed. Set the loose section into its correct position and then utilize a syringe to carefully and slowly inject glue into the space between surfaces to be bonded. Wipe any excess glue away immediately with a clean, soft cloth. Supplies to complete these steps are provided in the Zap tools box.
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COMPONENT NAME – FIBER OPTIC FUN
Description
An orange table base with an upper clear acrylic box displaying two types of flexible optical fibers. Large diameter architectural fibers are displayed that are partly shielded and emit light along their entire length (powered by light generators with constantly changing colors). In contrast, small diameter end-emitting fibers (that are completely shielded and allow light to exit only at their tips) are incorporated to form shapes at the ends of the tips familiar to visitors. Visitors use six buttons to turn on white light sources that feed these fibers and illuminate the design/shape. The colors of the shapes can be changed by the visitors when six colored wheels (positioned in line between the white light sources and the beginning tips of the end-emitting cables) are rotated.
Primary Components
The primary operational components include:
Consumables / Spare Parts
Air filters are the only consumable items associated with this exhibit. Spare parts provided are listed in Table 2.
Special Instructions
It is important to make sure that the ventilation fans always work that cool the bottom chamber housing the optical fiber illuminators.
General Maintenance
Maintenance involves exhibit ventilation/air filtering, lighting, and general cleaning. Table 3 should be followed for a listing of specific maintenance items and their frequencies. It also should be used to record completion of maintenance items.
Troubleshooting
Button(s) not working when pushed (halogen lights don’t respond and button doesn’t blink): Check the button switch associated with the subject bank of lights. Small, hinged access panels (Fig. 9) can be opened (just below the color wheels) to access the underside of the buttons. Visually/manually check for obvious wiring/shorting problems. Two wires operate each button electric switch. They are connected to the lower two of the three sideways-facing switch prongs. The two downward-facing prongs power the lamp. Check to see if the connections are loose, broken or frayed on the switch prongs. Replace or repair the terminated ends or wire as appropriate (replacement connectors and wire are provided in the Zap tool kit). Also check that the wire connectors are not touching (metal against metal) another switch prong (these connections can inadvertently be bent easily when pushing the lamp holder into the button base, causing a short of the switch operation).
Figure 9: Hinged side access panel
Figure 10: Connector cover
If the wires are all properly connected, next check the button and switch for proper operation. With the switch still installed, depress the button and listen carefully for a definite click sound from the switch. If a click is not heard, make certain that the lamp holder and integral switch are pushed firmly into the button base. If they are seated properly but still don’t work (no click), remove the lamp holder and switch and depress the small red button on the switch itself. If the switch works, attempt to properly seat the lamp holder and switch again in the button base. The proper seating procedure is to first push slightly inward, then rock the entire assembly to the right until a click is heard, and lastly rock the assembly to the left until another click is heard. If a proper seat cannot be achieved, replace the entire button body from Zap spares. Or if the switch itself is bad, replace it with a spare from Zap spares.
If the button itself appears to be functioning, but the halogen lights still are not responding, turn off the exhibit power momentarily (wait a minute to restore power) to see if the controller just needs reset. If this procedure does not rectify the problem, it is possible that the button wire connections may have come loose on the controller wiring block. Carefully trace backward and check the connection of the appropriate leads from the button, under the access cover located on the cabinet connection between the activity table and central kiosk (Fig. 10).
Button(s) not lit: If an individual button lamp appears to be out, access the underside of the button by opening the appropriate small hinged access panel (you may also be able to access through the front access door). First check that the two wires powering the lamp (the wires on the two prongs facing directly downward from the lamp holder) are firmly connected to both the lamp holder prongs and to the power source (located under the access cover on the cabinet connecting section between the central kiosk and activity table). If the wiring seems intact, carefully pull the lamp socket and integral button switch out of the button base, replace the lamp from Zap spares (note lamp markings carefully to obtain proper bulb), and reinstall firmly.
If all six buttons are not lit, check (and replace if needed) the power transformer fuse(s).
Architectural optical fiber bank not lit: First check that power is supplied to the applicable illuminator. Subsequently check the illuminator’s internal lamp. Replace the illuminator itself or lamp from Zap spares as needed. Handle new lamps with gloves or a clean cloth to prevent leaving oily residue on the lamp that will cause the lamp to burn out quickly. Additional instructions are included in the supplemental manufacturer’s manual entitled "Lumenyte Powerhouse™ Metal Halide 150 watt Illuminator Operating Manual".
Quartz halogen lamp(s) not lit: If an individual halogen projector lamp does not light when a button is depressed (but the button blinks), open the appropriate small side access panel and replace the lamp from Zap spares. If lamp replacement does not correct the problem, check that wiring and connections between the lamp and power source are secure.
If a group of lamps are not lit, open the access cover located on the cabinet connecting section between the activity table and the central kiosk using a round barrel key. Check the six fuses (each 250-volt, BUSS ABC 10) which are exposed adjacent/parallel to each other (Fig. 11). Replace as necessary from Zap spares. If replacement fuses blow repeatedly, the transformer likely is defective.
Figure 11: Lamp fuses
Halogen lights won’t turn off: If a button switch works (the button blinks when pushed, and stops blinking when pushed again), but the associated halogen lights won’t turn off, open the access panel on the cabinet connector section between the central kiosk and the activity table. Turn the activity table power off using the power strip switch, wait about 10 seconds, and restore the power. This will reset the controller and hopefully correct the problem.
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Description
An orange colored table base with a trapezoidal-shaped, clear acrylic, upper box. Visitors are challenged to manipulate two large aluminum grabbers/claws ("endoscopic tools") to move and stack ten gray, hard rubber cubes contained within the box.
Primary Components
The primary operational components (no electronics) include:
Table 1 provides additional details about the primary and support components for this exhibit.
Consumables / Spare Parts
An air filter on the front access panel is the only consumable item associated with this exhibit. Available spare parts are listed in Table 2.
Special Instructions
To minimize damage to the claw tips (which often are banged by visitors into the other claw and the box walls), make sure to limit the inside reach of each claw. Adjust the reach so that the claw tip cannot contact the bottom edge of the opposite sloping orange box wall. This is accomplished by adjusting the slip collar on the aluminum rod at the outside end of the gimbal.
Daily visual checks of the claw tips integrity is recommended.
General Maintenance
Maintenance is simple and involves air filter changes, upkeep of the mechanical grippers, and general cleaning (inside and outside the box enclosure). Maintenance steps are more frequent than most other Zap exhibits. Table 3 lists specific maintenance items and their frequency. This form should also be used to document completion of maintenance.
Troubleshooting
Claw tip protective pads need to be replaced: Open box lid with round barrel key to access the claw ends. Remove hex head screws and nylon lock nuts on the applicable black protective pad that needs to be replaced. Replace the pad and screws/nuts from Zap spares. Note "A" and "B" markings on the pad when obtaining the proper replacement pad from Zap spares.
See the Special Instructions section above about preventing/minimizing protective tip damage.
Claw does not clamp down on rubber block sufficiently: With box lid open, remove the black protective claw tip on the widest claw section only. Then remove seven hex head screws from one side of the claw to allow it to be split in half longitudinally (Fig. 12). Do not remove the four hex head screws on the other side of the claw. To adjust/tighten the claw mechanism, pull out the steel dowel pin that allows the "thumb" to pivot, then rotate the thumb to tighten the turnbuckle mechanism. Check to see if the claw will satisfactorily clamp on the blocks before reassembling the claw. Make certain that all nylon bushings are in place upon reassembly.
Figure 12: Disassembled claw
Claw "thumb" needs to be replaced: Expose "thumb" by disassembling as in the above section. Remove small cotter pin to allow thumb to be removed from steel dowel pin that connects it to the turnbuckle. Obtain new thumb and nylon bushings from Zap spares for installation. Check clamping action/tightness before reassembling the claw.
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Description
Two large aluminum grabbers/claws ("endoscopic tools") are utilized by visitors at this activity table to feed colored rods through a hole/ring in a metal plate. Visitors view and control all of their actions (which occur in a completely closed chamber) via images captured by a closed-circuit camera and projected to a large screen monitor (thereby simulating surgical techniques with endoscopes under conditions of remote monitoring).
Primary Components
The primary operational components include:
Table 1 provides details about primary and support components.
Consumables / Spare Parts
No consumables other than air filters are associated with this activity. Available spare parts are listed in Table 2.
Special Instructions
To minimize damage to the claw tips (which often are banged by visitors into the other claw and the box walls), make sure to limit the inside reach of each claw. Adjust the reach so that the claw tip cannot contact the bottom edge of the far sloping inside box wall. This is accomplished by adjusting the slip collar on the aluminum rod at the outside end of the gimbal.
General Maintenance
Maintenance is simple and involves air filter changes, upkeep of the mechanical grippers, and general cleaning (inside and outside the box enclosure). Maintenance steps are more frequent than most other Zap exhibits. Table 3 lists specific maintenance items and their frequency. This form should also be used to document completion of maintenance.
Troubleshooting
Claw does not clamp down on rods sufficiently: With box lid open, remove nine hex head screws from one side of the claw to allow it to be split in half longitudinally. Do not remove three hex head screws on the other side of the claw. To adjust/tighten the claw mechanism, pull out the steel dowel pin that allows the "thumb" to pivot, then rotate the thumb to tighten the turnbuckle mechanism. Check to see if the claw will satisfactorily clamp on the blocks before reassembling the claw. Make certain that all nylon bushings are in place upon reassembly.
Claw "thumb" needs to be replaced: Expose "thumb" by disassembling as in the above section. Remove small cotter pin to allow thumb to be removed from steel dowel pin that connects it to the turnbuckle. Obtain new thumb and nylon bushings from Zap spares for installation. Check clamping action/tightness before reassembling the claw.
No video image: First check that there is main power available to the camera power pack/adapter and confirm that the unit is securely plugged in. Also, check to see that the video cord from the camera has not been broken and the video jack connection on the plasma monitor is good. To check the jack connection on the monitor, open the central kiosk front cover (loosen the single bottom hex head screw and lift upward). Prop the cover up carefully or have a helper hold the cover. On the right side of the monitor, loosen two thumbscrews to open the right cover and check the video jack (fourth jack from the bottom). If the above measures do not correct the problem, try installing a new camera and/or power pack from Zap spares.
Back to topCOMPONENT NAME – PICTURE PERFECT
Description
This activity teaches visitors about improvements in image resolution (for endoscopes) using several different sets of optical fibers. The activity table consists of an orange-framed light box containing an image (the word "Zap") mounted on a slide that visitors can move to three positions. Light is projected through the word and then through three different bundles of end-emitting fibers depending on where the visitor places the slide mechanism (Fig. 13). The projected image can be seen at the end of the optical fiber bundles, and the image is vastly improved when projected through the bundle with the greatest quantity of fibers.
Visitors control the above-described slider and an orange "start" button that initiates an Electronic Presenter instruction video (DVD) clip.
Primary Components
The primary operational components include:
Table 1 provides further details about the primary and support components.
Consumables / Spare Parts
No consumables other than air filters are associated with this exhibit. Spare parts provided are listed in Table 2.
Special Instructions
Do not remove the activity table from the central kiosk without someone supporting the table weight or the custom support bracket being attached. Otherwise, the activity table will tip downward and may cause injury or damage.
General Maintenance
Maintenance is simple and involves only ventilation/air filtration, lighting, and general cleaning. Table 3 lists specific maintenance steps and their recommended frequency. The form also should be used to record that maintenance has been completed.
Troubleshooting
Slimlite fluorescent light fixture(s) in table top not lit: Open tabletop using round barrel key for locks on both sides of table. Check that main electrical cord connection is good and that electrical circuit connecting clips between fixtures are pushed in firmly to make good contact. Otherwise, remove the clear lamp cover(s) and try a new bulb(s) from Zap spares.
If a new bulb does not correct the problem and the fixture appears to be faulty, obtain a replacement fixture from Zap spares. To replace the fixture, first pull off the electrical circuit connecting clip(s). Then, carefully dislodge the fixture from the mount clips. Clip the new fixture onto the mounts and reconnect power.
Other problems: Refer to Cryosurgery – Fast Freeze troubleshooting section regarding operating problems such as:
COMPONENT NAME – REAL STORIES / REAL SURGERY
Description
An orange-framed activity table where visitors choose from various labeled buttons to view video (DVD) segments on actual endoscopic procedures. The visitors control this activity using four extra large orange buttons (one each per video video segment), plus one stop button.
Primary Components
The primary operational components include:
Table 1 provides further details about the primary and appurtenant components.
Consumables / Spare Parts
Air filters are the only consumable items associated with this activity. Spare parts available are listed in Table 2.
Special Instructions
None
General Maintenance
Maintenance is easy and involves exhibit ventilation/air filtering, lighting, and general cleaning. Follow Table 3 for specific maintenance items and their frequency. Also use the form to record that maintenance was completed.
Troubleshooting
Refer to Cryosurgery – Fast Freeze troubleshooting section regarding problems such as:
Description
An orange activity table with the profile of an upper human torso (head, throat and lungs) constructed from various colored acrylic. The visitor uses a tethered orange and white wand/"endoscopic tool" containing a magnet at the end to retrieve an object from the lung of the simulated patient.
Primary Components
The primary operational components (no electronics) include:
Table 1 gives further details about the primary and support components.
Consumables / Spare Parts
The only consumable items associated with this activity are an air filter on the central kiosk and the metallic object that visitors sometimes take with them or that gets lost. Spare parts provided are listed in Table 2.
Special Instructions
A short tether must be maintained on the "endoscopic tool" which is just long enough to allow easy use, but not too long to prompt unwanted use of the tool by visitors (as a "sword", etc.).
General Maintenance
General maintenance is simple and relates to exhibit ventilation/air filtering, lighting, and general cleaning.
Table 3 lists specific maintenance steps and their frequency. Use Table 3 to record that maintenance is completed as recommended.
Troubleshooting
Foreign object in "patient’s" lung: Visitors often stuff foreign objects into the "patient’s" throat / lung. Therefore, disassembly and cleaning may need to be done fairly frequently. This is accomplished easily by removing four hex head screws on either side of the acrylic torso and lowering the hinged side. To avoid stripping, dip screws in a small amount of liquid soap if they become difficult to place back into the acrylic during reassembly.
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Description
An orange framed, angled-top activity table where visitors run a custom computer program and perform virtual surgery with a "high-frequency scalpel" to eliminate problems in an abdomen. Externally, the table has a scalpel handle and a "start" button that visitors control. The start button initiates a short instructional video. Also, prior to and during the virtual operation, the "attending physician" gives assistance/guidance.
Primary Components
The primary operational components include:
Table 1 provides further details about the above primary and other support components.
Consumables / Spare Parts
Consumables include only air filters related to this activity. Spare parts provided are listed in Table 2.
Special Instructions
Daily start-up procedure: See the necessary procedure in the Special Instructions section for Cryosurgery – Cool Surgery
Daily shut down procedure: See the necessary procedure in the Special Instructions section for Cryosurgery – Cool Surgery
General Maintenance
Maintenance items are simple and deal with exhibit ventilation/air filtering, lighting, and general cleaning. Table 3 should be followed for specific maintenance items and their frequency. It also serves as a form to record that maintenance was completed.
Troubleshooting
"Scalpel" receiver/sensor not working: Open the front and rear access doors of the activity table using a round barrel key. The receiver / sensor is mounted on the inside end of the "scalpel" rod that feeds in and out of the rotating gimbal. Check to see that the sensor cable is securely plugged into the rear of the positioning system electronics unit, that the transmitter box is plugged securely into the front of the electronics unit, that the connections between the electronics unit and computer are tight, and that the electronics unit ready light is lit steady (a steady light indicates both that the positioning system is powered and not detecting an error). If all these conditions seem fine, change the sensor as described below using a Zap spare. However, change the positioning system power pack if a ready light is not displayed on the electronics unit (and main power is first confirmed available to the power pack plug).
To install a replacement power pack, plug it first into the back of the electronics unit, switch to STDBY on the front of the electronics unit, plug the power pack into the AC power source, and then switch back to FLY on the front of the electronics unit.
If the sensor seems faulty, first power the exhibit down (as described in the Special Instructions section above) and try a new sensor from Zap spares (without permanently installing it onto the end of the scalpel). To do this, unplug the old sensor cable from the rear of the positioning system electronics unit and plug in the replacement sensor. Power the exhibit back up (see Special Instructions section above), stretch the test sensor cable out so that the sensor end is located near the old sensor and move it around as you would the scalpel to do virtual surgery. If the test sensor works, power down the exhibit again and proceed as below to completely replace the sensor.
To complete sensor replacement, first remove the sensor mounting plate from the plastic bearing at the inside end of the scalpel arm. Loosen the single bolt/nut that keeps the mounting plate snug around the bearing, and then pull the plate with the sensor off of the bearing. Once the sensor is more accessible, cut the cable ties holding the old sensor to the scalpel arm mounting plate and pull the sensor and cable completely out. Note that the sensor also is held in place on the mounting plate with double-sided tape (Fig.14-16). Install the new sensor from Zap spares, making sure that just enough cable is loose to permit the scalpel to move around without pulling the cable too tight or catching it on nearby items. Restart the exhibit and close/lock all access doors.
Figure 14: Cabinet interior
If the above steps have not resolved the problem, replace the positioning system electronics unit from Zap spares (power down the exhibit first before disconnecting and reconnecting).
Other problems: Refer to Cryosurgery – Cool Surgery (troubleshooting section) regarding problems such as: