Figure 38: Primary projector controls
ZAPCAM MODULE
The ZapCam Module includes three components referred to as the Briefing & Non-Motion Rooms, Queuing Line, and Simulator. Each is discussed in detail in the following sections.
COMPONENT NAME – BRIEFING & NON-MOTION ROOMS
Description
A two-room, modular, roofed structure primarily for the viewing of a "briefing" video (DVD) in preparation for the ZapCam ride. This briefing instructs visitors about all of the medical techniques highlighted in Zap! Surgery. Also, visitors can view the video (DVD) of the actual ZapCam ride without boarding the simulator (non-motion experience -- viewable in either the briefing room or smaller non-motion room, depending upon group size).
Primary Components
The primary operational components include:
Table 1 provides details about the above-listed primary, as well as support components.
Consumables / Spare Parts
Consumables consist only of air filters for electronic components. Available spare parts are listed in Table 2.
Special Instructions
Daily start up and shut down of all electronic components is automatic (controlled by general gallery circuit breakers), except that certain steps are required to prolong the life of the briefing room’s LCD projector and lamp as follows.
Daily projector start-up: After main power is turned on, depress the large "on/standby" key (Fig. 38) on the projector top (or using the remote control). This will turn on the lamp. Wait until the image brightens/clears to assure the image quality is good and focused.
Figure 38: Primary projector controls
Should a "replace lamp" message appear in the morning after turning on the projector, depress the menu button (Fig. 38) twice on the projector top (or remote) to clear this message for the day. It is not necessary to immediately replace the lamp at this time. However, monitor the projected image quality. If quality deteriorates significantly, replace the lamp from Zap spares per procedures in the supplemental manufacturer’s LCD projector manual (making sure that the lamp is set on "low" in the "install setting" menu).
Daily projector shutdown: BEFORE turning off exhibit power, depress the "on/standby" key twice on top of the projector (or on the remote) to turn the lamp off and allow it to cool before the fan shuts off. Allow the lamp to cool for at least a few minutes before gallery main power is shut off.
General Maintenance
Maintenance involves exhibit operating component ventilation/air filtering, lighting, and general cleaning. Table 3 is provided to guide what maintenance should be performed and at what frequency. It also should be used to record that the prescribed maintenance has been completed.
Troubleshooting
Refer to Cryosurgery – Fast Freeze troubleshooting section regarding problems such as:
Description
An integral system of safety barriers / informational panels positioned around the ZapCam simulator, coupled with a system of moveable stanchions to direct visitors into the ZapCam Briefing Room.
Primary Components
The primary operational components include:
Table 1 details the primary and associated components.
Consumables / Spare Parts
No consumables are associated with this exhibit piece/group. Available spare parts are listed in Table 2.
General Maintenance
Maintenance involves exhibit lighting, ventilation/air filtering, and general cleaning. Table 3 lists maintenance steps and frequency. It also should be used to record that maintenance was completed.
Special Instructions
The exit gate must always be latched during operation of the ZapCam simulator to prevent visitors from accessing the area without proper accompaniment and getting injured.
Troubleshooting
Exit gate sagging/hitting text panel: First check to see if the text panel(s) were simply knocked out of alignment. Push back into proper position as appropriate.
If the springs on the gate hinges have been weakened, it may also be necessary to increase the spring tension to realign the gate. Insert the spring tightening tool (provided in the Zap toolbox) into the right-most, side hole on the top of each spring body (Fig. 39). Pull the tool clockwise as far as possible. While keeping tension on the spring, carefully remove the small nearby stop pin (silver colored), and reinsert it in another hole (moving counterclockwise). Release tension on the tool and repeat this procedure on the same spring/other springs until the gate no longer sags.
Figure 39: Tightening spring tension
TensaBarrier® tape end will not attach to adjacent stanchion clip: Pull the tape completely out of the tape holder until it reaches the stop point. Usually the tape has been twisted 180° in the holder and the mount clip is upside down. Straighten the tape and allow it to be pulled back into the holder. It should then attach to the adjacent stanchion without difficulty.
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Description
A hydraulic / electric-powered, 12 to 15 passenger vehicle ("ZapCam") that visitors ride after viewing the introductory briefing about surgical techniques featured in Zap! Surgery. Visitors are told that they will board the ZapCam, it will be miniaturized, and they will observe surgery in progress from inside a patient’s body.
The operator can hear the visitors during the entire ride and detect problems through a microphone mounted in the front of the simulator that is connected to a small speaker on the control console. The operator also can see the riders via an infrared camera at the front of the simulator cabin, hooked to a monitor at the control console. Visitors can stop the ride using either of two emergency buttons mounted on the side doors. The operator also can stop the ride at any time by depressing either the "Emer Stop" or "Syst Reset" buttons on the control console.
Primary Components
The primary operational components include:
Table 1 provides details about the primary and associated components.
Consumables / Spare Parts
No consumables are associated with the simulator and associated pieces. Available spare parts are listed in Table 2.
Special Instructions
A floor loading analysis (assuming a vehicle filled with adult visitors) indicates a short-term, worst-case bearing load of 6,013 pounds is exerted on the left rear floor pad during simulator operation. The bearing load on this same pad in the static and level condition is 2,920 pounds. Therefore, floors in facilities renting this exhibit must be capable of supporting/distributing such loads with adequate safety margin. Moving the vehicle, once set in place , can only be done by a Carnegie Science Center staff member.
Only properly trained, responsible individuals at least 18 years old should be allowed to operate this exhibit. A written operating procedure (included as Attachment 3 herein) should be provided in a binder on the side of the control console. All operators must have thoroughly read this procedure and completed hands-on training with a qualified mentor before being allowed to operate the simulator alone.
Operators must always stay within arms reach of the control console when the simulator is running and give their undivided attention to the control panel and simulator’s movements. Customer interaction is strongly discouraged for this operator while the simulator is running.
Daily and weekly pre-operation system checks by facility technicians must be performed to assure safe operation. A checklist (Table 4 herein) should be kept in a binder on the side of the control console, or in another appropriate area, as a guide (and routine sign-off sheet) for technicians.
General Maintenance
Maintenance steps involve ventilation/air filtration, lubrication and cleaning of hydraulic/mechanical systems, lighting, and general cleaning. A very important step to assure good, continued simulator operation, involves cleaning the shafts of the linear feedback potentiometers (the three small diameter cylinders mounted parallel to each of the main operating hydraulic cylinders) at least several times per week with no-flash spray cleaner. Table 3 lists specific maintenance items to be completed and their frequency. Table 3 also should be used to record completion of the maintenance items.
Troubleshooting
No motion, sound or video when ride is started (or during ride): Depress the "Syst Reset" button on the control console. Wait for the simulator to sit down on the chassis, and then open the simulator door and inform riders that you will be restarting the ride. Close the door, confirm that the "Ride Ready" light is on, and push "Ride Start". Watch/listen for proper operation.
If pushing "Syst Reset" does not resolve the problem, push "Syst Reset" again to stop movement, and open the door to inform riders that you will need to completely reboot the system. Leave the door open and turn off the key on the control console. However, do not turn off the projector (do not depress "Proj" button). Wait about 10 seconds, turn the key back on, wait until the console lights stop flashing, push "Pump Start", and wait for the "Ride Ready" light to come on. Inform riders that you will try again and close the door. Start the ride as usual.
If there is continued difficulty with the projector, it may be necessary to reset the projector controller. This may be accomplished by first depressing the "Proj" button and allowing the projector to cool, completely shutting off the main 3-phase circuit breaker, waiting a few minutes, and powering back up.
No apparent power to simulator or console: On occasion, a complete loss of power to the simulator and console may be experienced which doesn’t obviously coincide with loss of facility lighting / power. This can be attributable to fluctuations in the main power feed (brownout, etc.) that causes the simulator circuitry to automatically shut itself down temporarily for protection. If such a condition occurs, turn the control console key off and wait for several minutes. Then turn the key back on to see if power has been restored. If start up appears normal, run the simulator without passengers to confirm that the system is o.k.
Main power fluctuations may also cause the 3-phase circuit breaker reserved for the simulator to kick off. If so, reset it and test the simulator (watching carefully for any other signs of electrical problems).
When a power problem as described above occurs, the controller of the simulator’s projector may need to be reset. Follow the reset procedure in the above section.
If there is a complete lack of response (no console lights, etc.) when the control console key is turned on, but the projector cooling fan can be heard running inside the simulator cabin, a fuse is likely blown. Open up the electrical panel on the front of the simulator frame and check the fuse in the location labeled F1. Turn off the main 3-phase power to the simulator before replacing this fuse (250 volt, BUSS MDL ½ amp).
There is power to the control console, but the program does not boot ("Ride Ready" button does not light and laser disc player is not getting power): Open the electrical panel on the front of the simulator frame. Check the center of three fuses located in the right fuse block (looking toward the rear of the simulator). Turn off the main 3-phase power to the simulator before replacing this fuse (250 volt, BUSS MDL-1.25 amp).
Simulator motion does not stop when a door is opened: If a console light indicates a door is open and the motion does not automatically stop, operators should immediately depress "Syst Reset" or "Emer Stop" to discontinue motion and bring the platform down.
Each door has a safety interlock switch at the upper front of the door opening (Fig. 40). This switch should not allow simulator movement unless the door is closed. If the switch is suspected to be faulty, try bending the spring clip outward on the switch slightly to make certain that the spring portion firmly hits the screw mounted on the front edge of the door. Run the simulator and open the door to confirm proper switch response. If necessary, replace the switch from Zap spares.
Figure 40: Interlock switch location
Figure 41: Console lamp replacement
Control console button not lit: If a miniature lamp needs to be replaced on the console, pry the colored button lens up/off carefully by pinching the lens top and bottom and then pulling upward on the lens. Pull up on the small metal clip visible just under the button (Fig. 41), which will dislodge the lamp. Replace the lamp from Zap spares, push the assembly back into the socket, and replace the button lens. Check for proper operation.
Note that a single lamp is used for each button, except there are two lamps under the "L-DR / R-DR" button to indicate either a left or right door is open, respectively. Also, dual lamps power the "I-LOC / TEMP" and "SYNC-1 / SYNC-2" buttons. Lamp operation should be watched during morning power up.
The "Proj" button is lit by a LED, rather than a miniature lamp. The entire button would need to be replaced if this button does not light.
Doors fall too easily: Confirm that the operators are pushing both sides of the door up firmly until the rollers on both sides latch into the top notches of the tracks. If the door rollers don’t seat in both notches, the door can drop unexpectedly.
If a door still falls too easily, the gas springs (2 per door) may need to be replaced. This procedure requires a second person to hold the door up at the center fold while the gas springs are removed and replaced by another person.
To replace the old assemblies, remove the small retaining clips on the end of each gas spring and then dislodge the unit (pop the ends off of the ball sockets connected to the simulator doorways). Place a small amount of lithium grease in the ball socket of the new gas spring from Zap spares and first snap the lower end of the spring into place (with the rod down). It will then be necessary to compress (push hard downward) the cylinder while attempting to snap the top socket into place. Replace the retaining clips to finish the procedure.
Doors don’t operate smoothly: When the nylon rollers (one in each door track) become worn, proper tension is lost in the door tracks, and the doors may bind or jerk during up or down operation. Replace the rollers to improve door operation by first removing the front door latch strike plate (Fig, 42). It is not necessary to remove both the front and rear strike plate. Lower the door about half way until the front nylon roller comes out of the strike plate opening. Push the entire bottom door panel slightly forward until the rear nylon roller disengages from the rear track. The entire lower door panel will then swing free from both tracks. Slip the old rollers off of the studs (Fig. 43), lightly spray the stud tips with silicone lubricant, and put new rollers on from Zap spares. Push the rollers back into both door tracks (the rear track first), raise the door completely, and replace the strike plate.
Figure 42: Door strike plate
Figure 43: Roller replacement
Ventilation fans not running: Open the simulator’s front, bottom access panel (containing the large air filters). Then, open the gray colored electric panel on the right side of the cavity (looking toward the rear of the simulator). Check all fuses in this panel. There are eight identical fuses [250 volt, BUSS MDL-3 (3 amp)] for the four fans [four fuses (one per fan) for the low speed, and four (one per fan) for the high speed]. These fuses tend to burn out as an entire set of four (high speed or low speed set). Prior to replacing the fuses, turn off the main 3-phase power to the simulator.