Skytron AURORA LED Series User manual

REV 9/08
INSTALLATION INSTRUCTIONS
LED SERIES
SURGICAL LIGHTS

Distributed by:
SKYTRON
5085 Corporate Exchange Blvd. S.E.
Grand Rapids, MI 49512 [phone]
www.skytron.us
Manufactured by:
DKK Dai-Ichi Shomei Co., LTD
Tokyo, Japan

Page 1
WIRE CUTTERS
CRIMP PLIERS
DIGITAL LEVEL
PORTABLE LIFT, 750LB. CAPACITY
12" ADJUSTABLE WRENCH
SLOTTED HEAD SCREWDRIVER 1/4"
PUNCHSET 1/8" - 3/8"
Although current at the time of publication, SKYTRON'S policy of continuous development makes this
manual subject to change without notice.
TOOLS REQUIRED:
3/8" DRIVE RATCHET
ALLEN WRENCH SET-METRIC
(2) STEP LADDERS
3/4" DEEP SOCKET, 3/8" DRIVE
PHILLIPS HEAD SCREW DRIVER
UTILITY KNIFE
(2) 1/2" BOLT, 6" TO 8" LONG
PERMISSIBLE ENVIRONMENTAL CONDITIONS
DURING TRANSPORT AND STORAGE (IN ORIGINAL PACKAGING MATERIALS)
 •AMBIENTTEMPERATURE: 10°-60°C(14°-140°F)
 •RELATIVEAIRMOISTURE: 10%-85%,NOCONDENSATEBUILD-UP
 •AIRPRESSURE:500hPa-1060hPa(14in-Hg-31in-Hg)
DURING USE - FOR DRY LOCATIONS
 •AMBIENTTEMPERATURE: 15°-30°C(60°-85°F)
 •RELATIVEAIRMOISTURE: 30%-60%NONCONDENSING
 •AIRPRESSURE:700hPa-1060hPa(20.7in-Hg-31.3in-Hg)
WARNING
This equipment is intended for use by healthcare professionals only.This equipment may cause
radio interference or may disrupt the operation of nearby equipment. It may be necesssary
to take mitigation measures, such as re-orienting or relocating the lighthead or shielding the
location.
ATTENTION, CONSULT MANUAL FOR FURTHER INSTRUCTIONS.
INDICATES SPECIAL USER ATTENTION.
AC VOLTAGE
EQUIPMENT LABELS AND SPECIFICATIONS
FUSE TYPE 2 AMP, 250V, TIME LAG
2A
CLASS I, TYPE B EQUIPMENT- IPXO RATED.
CONTINUOUS OPERATION
TYPE B
EQUIPMENT

Page 2
ELECTRICAL REQUIREMENTS
This fixture requires that electrical connections are made by a licensed electrician in accordance with
state, local and national electrical codes using UL (Underwriters Laboratory) recognized materials.
Do not turn on main power to fixture until all lightheads are installed, connections are complete and
the fixture has been reviewed by a SKYTRON representative.
ELECTRICAL HAZARDS EXIST!
Excercise caution when working on this fixture, the installation of this fixture must be made only by
qualified and authorized personnel familiar with the essential knowledge and techniques.
CONNECTION MEANS
CAUTION
Connection of the fixture wires must be made using crimp connectors. Main terminal devices shall be
so located or shielded that, should a wire of a stranded conductor escape when the conductors are fit-
ted, there is no risk of accidental contact between live parts and accessible parts. Acceptable sheilding
methods include UL aproved shrink tubing and electrical tape.
NATIONAL ELECTRICAL CODE, NFPA & ANSI REQUIREMENTS
The installation of connecting cords between equipment parts shall meet the requirements of the Na-
tion Electrical Code, ANSI/NFPA70 as applicable.
BENDING REQUIREMENTS
Connection leads shall be constructed in such a manner that moveable leads in normal use are not
bent around a radius of less than five times the outer diameter of the lead concerned. Avoid conditions
employing severe bends to ensure the integrity of conductors.

Page 3
CONDUIT REQUIREMENTS
This fixture requires 2 dedicated conduit raceways at the wall control to separate the 120VAC supply
lines from the 30VDC supply lines to the lighting fixture. Failure to observe this requirement will allow
the migration of Electrical Magnetic Interference and will disrupt the operation of the lights.
Use of approved metal conduit shall be employed throughout the fixture's wiring circuit where appli-
cable.
PROTECTIVE MEANS
This fixture requires a properly circuit protected, dedicated, 120VAC, 15 amp circuit. An isolated
power supply circuit must be protected by a 15 amp, double pole, single throw circuit breaker.
Proper performance and safety of this fixture can only be achieved by an adequate grounding sys-
tem. Fixture ground must be a dedicated ground point ultimately bonded to the facilities grounding
system to prevent the migration of electrical interference generated by other devices.

Page 4
The procedures described in this manual will be
performed by representatives of the owner (staff or
contracted service), therefore it is the responsibility
of the owner to ensure that all safety precautions
are followed. Only qualified and trained individuals
should attempt the installation of this product.
The following precautionary instructions are used
in this manual.
WARNING
Indicates a possibility of personal in-
jury.
CAUTION
Indicates a possibility of damage to
equipment.
NOTE
Indicates important facts or helpful
hints.
Preinstallation Requirements
1. Appropriate metal conduit & wiring installed
from wall control mount to ceiling mounting struc-
ture. Flexible conduit to extend 18" below finished
ceiling.
2. 120VAC, 15amp dedicated power supply line in
separate conduit to be provided at wall control.
3. Painting and flooring must be complete prior to
fixture installation.
4. Optional Camera System Models require a 1"
metal conduit from mounting plate to control unit
J-box.
SPECIAL USER ATTENTION
WARNING
The mounting plate must be accurately
leveledwithin0.1°topreventlighthead
drift.
NOTE
Special Seismic calculations are avail-
able if applicable.
NOTE
•Themultiplearmassembliesareeasier
to handle during installation if the arms
are left taped and tied together.
•In some cases it may be necessary
to connect the electrical wires from the
wall control to the radial arm junction
box before the arm assembly can be
bolted to the mounting plate.
•Usetwo6"to8"boltstoholdxture
while connecting wiring.
NOTE
Radial Arm wires are tagged for proper
connection to the Wall Control (top arm
#1, next arm #2, bottom arm [triple arm
models] #3).
CAUTION
Connection of the fixture wires must
be made using crimp connectors. Main
terminal devices shall be so located or
shieldedthat,shoulda wireofa stranded
conductor escape when the condutors
are fitted, there is no risk of accidental
contact between live parts and ac-
cessible parts. Acceptable sheilding
methods include UL approved shrink
tubing and electrical tape.

Page 5
NOTE
•Roomplacementofthewallcontrol
will vary by application. Always follow
current standards from the NFPA and
NEC (National Electrical Code) for
proper compliance.
•Theselectionofanchoragefasteners
shall be determined by the engineer on
record and will vary by application.The
selected fasteners must not interfere
with wall control components.
NOTE
Seismic applications require the use of
approved fasteners. Calculations are
available upon request.
CAUTION
Avoid "hanging" the front face plate
assembly.
NOTE
Connection leads shall be constructed
in such a manner that moveable leads
in normal use are not bent around a
radius of less than five times the outer
diameter of the lead concerned. Avoid
conditions employing severe bends to
ensure the integrity of conductors.
NOTE
Determine correct placement for each
Balance Mechanism (BOM)/Vertical
Support Tube (VST) on the radial arm
assembly. The longest VST goes into
the top radial arm.
WARNING
Apply Blue Loc-Tite to all of the 6mm
mounting screws and use a 4mm allen
wrench to tighten the screws.
CAUTION
The 6mm mounting screws for attaching
the VST to the radial arm may be dif-
ferent lengths. Observe any color code
markings and make sure the proper
screws are installed in the proper holes
to avoid any damage to the electrical
components.
WARNING
DO NOT remove lighthead when
support arm is in down position;The
balance mechanism will be severely
damaged and may result in bodily
injury.
NOTE
•3/4" metal conduit and minimum
12AWG wire (3 wires per lighthead)
is required between Wall Control and
Fixture.
•Separatededicatedconduitrequiredfor
120VAC supply lines to wall control.
•Allwiringtobeinaccordancewithlocal,
state and national electrical codes.
SPECIAL USER ATTENTION

Page 6 MODEL IDENTIFICATION
LED7 LED7
LED5 LED5
LED5
MODEL IDENTIFICATION
MODEL LED75
1 - 30" Diameter Lighthead
1 - 24" Diameter Lighthead
MODEL LED755
1 - 30'' Diameter Lighthead
2 - 24" Diameter Lightheads
MODEL LED7
1 - 30" Diameter Lighthead
MODEL LED5
1 - 24" Diameter Lighthead
MODEL LED55
2 - 24" Diameter Lightheads
MODEL LED555
3 - 24" Diameter Lightheads

Page 7
TYPICAL INSTALLATION SEQUENCE /
COMPONENT IDENTIFICATION
1. Mounting Plate
2. Radial Arm Assembly(RAA)
3. Ceiling Cover
4. Vertical Support Tube(VST)
INSTALLATION NOTES
•TheSKYTRONSurgicalLightingFixtureisnor-
mally shipped in two to four crates, depending on
the model. A carton containing the Vertical Sup-
port Tubes, miscellaneous hardware, and various
instructional materials is packed separately.
•FollowtheInstallationInstructionsandutilizethe
Installation Check List to assure proper installa-
tion.
•Specialadapterplatesfor mounting SKYTRON
surgical lights on existing mounting structures are
available. Contact your SKYTRON representative
for special application details.
•Additionalmaterialsrequiredforproperinstallation
include Loc-Tite compound.
•Aurora Series lighting xtures require a wall
mounted control box. Single and Dual Lighthead
models 8" x 10", for Triple 10" x 13-1/2". 3/4" metal
conduit and minimum 12 AWG wire is required
between wall control and fixture.
•Contact SKYTRON representative for Seismic
calculations if applicable.
5. Balance Mechanism(BOM)
6. Lighthead
7. Sterilizable Positioning Handle
8. Wall Control
1
3
4
4
55
2
8
7
7
6
20,000 HOUR
INDICATOR
COLOR TEMPERATURE
INDICATOR
4,500K WHEN ILLUMINATED
MAIN POWER
2A, 250V
FastActing
2A, 250V
FastActing
012345
012345

Page 8
UNCRATING PROCEDURE
Open the top of the lighthead box and remove the
packing material,remove the sterilizablepositioning
handle and remove lighthead from the crate.
NOTE
Detailsmayvary depending uponmodel
and support structure fabrication.
ALL fixtures use METRIC fasteners.
INSTALLATION PROCEDURE
Specific seismic information is available for applica-
tions.Refer to seismic drawings.The lighting fixture
should be installed in the following sequence:
1. Mounting Plate
2. Radial Arm Assembly and Ceiling Cover
3. Vertical Support Tubes/ Balance Mechanisms
4. Lightheads
5. Wall Control
1. Mounting Plate
a. Check the strength and stability of the mount-
ing structure. It should be fabricated of steel and
welded or bolted to the structural ceiling. It should
be braced in a manner that will allow no twisting
or lateral motion. In standard installations a steel
stiffener plate should be used to connect the 3/4"
diameter "all-thread" support rods and to provide
an attachment base for the angle-iron sway bracing.
The 3/4" diameter support rods should be mounted
in a 9-1/2" square pattern and should extend 2-1/4"
below the finished ceiling. SeeMountingStructure
details in the back of this booklet.
b. Install the SKYTRON mounting plate on the
threaded rods between jam nuts. The plate should
normally be located 1-3/8" off the finished ceiling
(measured from the bottom of the plate) and ac-
curately leveled, within 0.1 degree, using a digital
level. Tighten the jam nuts securely. See figure
2.
Figure 1. Radial Arm Assembly
LIGHTHEADS
•Use extreme caution when removing
the contents from the crates to pre-
vent damage to the lights. Leave the
lightheads in their crates until ready to
install.
•Ifthelightheadmustbesetdownafter
it is removed from the crate, always lay
it on the foam shipping block. Do not
lay it on the front face.
UNCRATING
•Shouldanydamagetothexturebe
noted while uncrating,furtherunpacking
should be stopped and the container
with all the wrappings held for inspection.
The transportation company should be
notified immediately so an inspector
can be sent. Consult the Damaged
Shipment Claim Procedure sheet for
further details.
•Personnel uncrating SKYTRON sur-
gical lights should be aware that they
are delicate medical equipment and
special care in handling should prevail
throughout installation.
RADIAL ARM ASSEMBLY
•Whentheradialarmassemblyisre-
moved from the crate and set on the
floor prior to mounting it, be sure the
mounting flange is toward the floor. If
the arm assembly is set on the floor
upside down the hub cover may be
damaged. See figure 1.
MOUNTING
FLANGE
CORRECT
WRONG
HUB
COVER

Page 9
WARNING
The mounting plate must be accurately
leveledwithin0.1°topreventlighthead
drift.
NOTE
Specific seismic calculations are avail-
able if required.
2. Radial Arm Assembly and Ceiling Cover
NOTE
•Themultiplearmassembliesareeasier
to handle during installation if the arms
are left taped and tied together.
•In some cases it may be necessary
to connect the electrical wires from the
wall control to the radial arm junction
box before the arm assembly can be
bolted to the mounting plate.
•Usetwo6"to8"boltstoholdxture
while connecting wiring.
a. Install the Radial Arm Assembly(RAA) onto
the mounting plate using the bolts provided. Tighten
the mounting bolts securely.
NOTE
Radial Arm wires are tagged for proper
connection to the Wall Control (top arm
#1, next arm #2, bottom arm [triple arm
models] #3).
Figure 3. Radial Arm Installation
Figure 2. Mounting Plate Installation
b. Observe wire tags and color codes and con-
nect the electrical wires from the wall control to the
radial arm junction box wires.
CAUTION
Connection of the fixture wires must
be made using crimp connectors. Main
terminal devices shall be so located or
shieldedthat,shoulda wireofa stranded
conductor escape when the condutors
are fitted, there is no risk of accidental
contact between live parts and ac-
cessible parts. Acceptable sheilding
methods include UL approved shrink
tubing and electrical tape.
c. Install the ceiling cover and secure. See
figure 3.
FINISHED
CEILING
3/4"
SUPPORT ROD
SWAY
BRACING STIFFENER PLATE
JAM NUTS
MOUNTING PLATE
1-3/8"
FINISHED CEILING
RADIAL ARM
CEILING
COVER
MOUNTING
PLATE

Page 10
Figure 5. VST to RAA Installation
Figure 6.
Figure 4. Balance Mechanism
CAUTION
The 6mm mounting screws for attaching
the VST to the radial arm may be dif-
ferent lengths. Observe any color code
markings and make sure the proper
screws are installed in the proper holes
to avoid any damage to the electrical
components.
b. Observe the wire colors and connect the wires
from the radial arm to the corresponding BOM/VST
wires using crimp connectors. See figure 5.
4. Lightheads
Model LED7 Lighthead
Refer to Model Identification for correct lighthead
placement.
a. To make it easier to install the lighthead,
locate the support arm of the balance mechanism
so that it points inward toward the ceiling cover.
This will prevent the radial arm from moving when
installing the lighthead. See figure 6.
b. Remove the four (4) screws from the lighthead
support arm.
c. Install the lighthead mounting collar onto the
support arm and secure with the screws previously
removed. See figure 7.
VST
BOM
SCREW
RAA
VST
CRIMP
CONNECTORS
POINT SUPPORT ARM
TOWARD CENTER LINE
c. Insert the vertical support tube into the radial
arm receptacle. Observe any screw color codes,
apply Loc-Tite to screw threads, and secure the
BOM/VST assembly with the 6mm mounting screws.
Repeat procedure for any remaining BOM/VST
assemblies.
3. Vertical Support Tubes/Balance Mecha-
nism
NOTE
Determine correct placement for each
Balance Mechanism(BOM)/Vertical
Support Tube(VST) on the radial arm
assembly. The longest VST goes into
the top radial arm.
WARNING
Apply Blue Loc-Tite to all of the 6mm
mounting screws and use a 4mm allen
wrench to tighten the screws.
a. Install the VST on the BOM, apply Blue Loc-
Tite to screw threads and secureVST with the allen
screws provided. See figure 4.

Page 11
Figure 9. LED5 Lighthead Installation
d. Pull the lighthead down and remove the Above
Horizontal Limit Stops from the BOM. See figure
8.
WARNING
DO NOT remove lighthead when
support arm is in down position;The
balance mechanism will be severely
damaged and may result in bodily
injury.
d. Pull the lighthead down and remove the Above
Horizontal Limit Stops from the BOM. See figure
8.
WARNING
DO NOT remove lighthead when
support arm is in down position;The
balance mechanism will be severely
damaged and may result in bodily
injury.
Figure 8. Above Horizontal Limit Stops
Model LED5 Lighthead
a. To make it easier to install the lighthead,
locate the support arm of the balance mechanism
so that it points inward toward the ceiling cover.
This will prevent the radial arm from moving when
installing the lighthead. See figure 6.
b. Remove the four (4) screws from the lighthead
mounting stub.
c. Install the lighthead mounting stub into the
support arm and secure with the screws previously
removed. See figure 9.
Figure 7. Model LED7 Lighthead Installation
SUPPORT
ARM
MOUNTING
COLLAR
ABOVE HORIZONTAL
LIMIT STOP
SUPPORT
ARM
MOUNTING
STUB

Page 12
CAUTION
Aurora Lightheads operate on DC VOLTAGE. The PC boards are susceptible to Static
Charges even when not powered. Pay close attention to wiring diagrams, wire labeling and
color codes.White wires (neutral) to lightheads must remain separate and not touch any
other wire or metal parts. Incorrect wiring may result in incorrect polarity being supplied to
Lighthead. This WILL DAMAGE internal circuitry and components VOIDING WARRANTY.
5. Wall Control
NOTE
•3/4" metal conduit and minimum
12AWG wire (3 wires per lighthead)
is required between Wall Control and
Fixture.
•Separatededicatedconduitrequiredfor
120VAC supply lines to wall control.
•Allwiringtobeinaccordancewithlocal,
state and national electrical codes.
a. Remove the front panel assembly from the
wall control box for ease in wire connection. Re-
move the (4) retaining screws. Set the front panel
assembly aside.
b.Install the wall control box enclosure as desired
for the application (surface or recessed mount) as
shown in the wall control illustration. See figure
10.

Page 13
Figure 10.
20,000 HOUR
INDICATOR
COLOR TEMPERATURE
INDICATOR
4,500K WHEN ILLUMINATED
MAIN POWER
2A, 250V
Fast Acting
2A, 250V
Fast Acting
012345
012345
TO LIGHTHEAD #2
TO LIGHTHEAD #1
NEUTRAL
LINE
GROUND
120VAC
INPUT
FROM FACILITY
TO LIGHTHEAD #2
TO LIGHTHEAD #1
FIXTURE JUNCTION BOX
R
G
W
R
G
W
R
G
W
R
G
W
R
R
G
W
W
G
R
R
G
G
W
W
R
W
R
W
R
G
W
G
G
2 DEDICATED CONDUIT
RACEWAYS REQUIRED TO
SEPARATE 120VAC INPUT
SUPPLY LINES FROM
30VDC SUPPLY LINES TO
LIGHT FIXTURE

Page 14
NOTE
•Roomplacementofthewallcontrol
will vary by application. Always follow
current standards from the NFPA and
NEC (National Electrical Code) for
proper compliance.
•Theselectionofanchoragefasteners
shall be determined by the engineer on
record and will vary by application.The
selected fasteners must not interfere
with wall control components.
NOTE
Seismic applications require the use of
approved fasteners. Calculations are
available upon request.
c. Make electrical connections using approved
wire crimps. Observe wire markings and colors.
CAUTION
Connection of the fixture wires must
be made using crimp connectors. Main
terminal devices shall be so located or
shieldedthat,shoulda wireofa stranded
conductor escape when the conductors
are fitted, there is no risk of accidental
contact between live parts and ac-
cessible parts. Acceptable sheilding
methods include UL approved shrink
tubing and electrical tape.
d. Connect the electrical conductors from front
face plate assembly. Observe wire markings and
colors. Avoid undue stress on conductors and in-
ternal components.
CAUTION
Avoid "hanging" the front face plate
assembly.
e. Attach recess mount flange on recessed ap-
plications. See figure 11.
f. Attach the front panel assembly using the (4)
phillips screws originally removed.Use care to avoid
pinching conductors and creating excessive bends
in wiring.
NOTE
Connectionleads shallbeconstructed
in such a manner that moveable leads
in normal use are not bent around a
radius of less than five times the outer
diameter of the lead concerned. Avoid
conditions employing severe bends to
ensure the integrity of conductors.

Page 15
Figure 11.
ANCHOR (4)
D
E
JUNCTION
BOX
3"
DIMENSIONS
RECESS MOUNT FLANGE
OPTIONAL BACK-BOX INSTALLATION
SINGLE
OR
DUAL
11-3/4"W x 14"H
SIDE VIEW
FRONT
PANEL
BACK VIEW
8"
4"
10"
6-7/8"
7-5/8"
8-5/8"
11"
5-7/8"
13-3/4"W x 17-1/4"H
10"
4"
13-1/2"
6-3/8"
TRIPLE
A
B
C
D
E
F
SURFACE MOUNT
SCREW (4)RECESS MOUNT
FLANGE
ANCHOR (4)
"BACK-BOX" DIMENSIONS
SINGLE / DUAL
8-1/2"W x 11-5/8"H x 4"D
TRIPLE
10-1/2"W x 14-1/2"H x 4"D
CONDUIT
CONNECTOR
A
F
C
1"
3/4" CONDUIT
FINISHED WALL
CONTROL BOX WITH RECESS
MOUNT FLANGE INSTALLED
NOTE:
FRONT EDGE OF "BACK-BOX"
MUST BE FLUSH WITH FINISHED
WALL SURFACE
(2) GROMMETS
SCREW (4)
RECESS
MOUNT FLANGE
ANCHOR (4)
RECESSED MOUNT
FRONT
PANEL
RECESS
DEPTH
A
C
B
3"
20,000 HOUR
INDICATOR
COLOR TEMPERATURE
INDICATOR
4,500K WHEN ILLUMINATED
MAIN POWER
2A,250V
FastActing
2A,250V
FastActing
012345
012345
SCREW (4)
20,000 HOUR
INDICATOR
COLOR TEMPERATURE
INDICA
TOR
4,500K WHEN ILLUMINATED
MAIN POWER
2A,250V
FastActing
2A,250V
FastActing
012345
012345
20,000 HOUR
INDICATOR
COLOR TEMPERATURE
INDICA
TOR
4,500K WHEN ILLUMINATED
MAIN POWER
2A,250V
FastActing
2A,250V
FastActing
012345
012345
120VAC
30VDC

Page 16

Page 17
SIG (WHITE)
GND (GREEN)
+30V (RED)
SIG (WHITE)
GND (GREEN)
+30V (RED)
+30V
COLOR TEMPERATURE INDICATOR 4,500K WHEN ILLUMINATED
NO.1 DIMMER SWITCH
Wall Control Unit (For Dual Type)
MAIN
POWER
SWITCH
AC120V
POWER
SUPPLY
NO.2 DIMMER SWITCH
LEGEND
RAA VST SA L1-L6 A DCB-5 DCB-2
- Radial Arm Assembly - Vertical Support Tube - Support Arm - LED (White) - Amber (LED) - Crimp Connectors - a drive circuit board - a drive circuit board - Brush Block - Slip Ring
- 3/4” CONDUIT - 12AWG WIRING
(XHHW-2 OR THHN AS REQUIRED BY APPLICATION)
- (3) CONDUCTORS
MODEL LED75
IMPORTANT
120 VAC isolated power supply requires double
pole, single throw 15 amp (maximum) breaker.
FIXTURE MOUNTED JUNCTION BOX 4”Lx 4”Wx 2 1/4”D
DEDICATED
3/4” CONDUIT

Page 18