Stryker Berchtold CHROMOPHARE Building instructions

CHROMOPHARE®
Surgical Lights, Single and Combination Lights
Service and Parts Manual

i
S
Table of Contents
1. Warnings and Cautions....................................................................................................................... 1
2. Product Symbols ................................................................................................................................. 2
3. ESD Procedure..................................................................................................................................... 3
3.1. Electrostatic Discharge ......................................................................................................................3
3.2. Electrostatic Dissipative Wrist-Straps...............................................................................................3
4. Comprehensive Tools.......................................................................................................................... 4
4.1. Required Tools.....................................................................................................................................4
4.2. Optional Tools .....................................................................................................................................4
5. System Architecture............................................................................................................................ 5
5.1. Model Plate .........................................................................................................................................5
5.2 CHROMOPHARE (Ceiling) ..................................................................................................................6
5.2.1 Single Light, Classic Cardanic Unit (A.C) .......................................................................................... 6
5.2.2 Light Combination, Classic Cardanic Unit (A.C)............................................................................. 6
5.2.3 Single Light, Flat Cardanic (N.C.) ....................................................................................................... 7
5.2.4 Light Combination, Flat Cardanic (N.C)........................................................................................... 7
5.2.5 Single Light, New Flat Cardanic (N.F.C) ............................................................................................ 8
5.2.6 Light Combination, New Flat Cardanic (N.F.C)............................................................................... 8
5.3 CHROMOPHARE E 520, E 550, E 558, F 528, F 628 (Wall) ...............................................................9
5.3.1 Single Light, Classic Cardanic (A.C)................................................................................................... 9
5.3.2 Single Light, Flat Cardanic (N.C) ........................................................................................................ 9
5.3.3 Single Light, New Flat Cardanic (N.F.C) .......................................................................................... 10
5.4. CHROMOPHARE E 520, E 550, E 558, F 528, F 628 (Mobile).........................................................11
5.4.1 E Series With Emergency Power ....................................................................................................... 11
5.4.2 E Series Without Emergency Power................................................................................................. 12
5.5 F Series (Mobile) ...............................................................................................................................13
5.6. Chromophare VPA Video/Power Arm ............................................................................................14
5.6.1 VPA Single (Stand-Alone) Mount ..................................................................................................... 14
5.6.2 VPA Video Power Arm/Light Combination .................................................................................... 14
5.6.3 VPA Video Power Arm/Light/Flat Panel Combinatio................................................................... 15
5.6.4 Shoulder Mount VPA Video Power Arm/Light/Light/Flat Panel/Shoulder.............................15
5.7. ChromoView Monitor Supports(Yoke) ..........................................................................................16
5.7.1 Single Monitor Support Arm............................................................................................................. 16
5.7.2 Dual Monitor Support Arm ............................................................................................................... 16
6. Unpacking/Packing........................................................................................................................... 17
6.1 Transport Inspection........................................................................................................................17
7. Suspension Maintenance.................................................................................................................. 19
7.1. Leveling Suspensions.......................................................................................................................19
7.2. Replacing the Ceiling Tube .............................................................................................................20
7.3 Replacing a Suspension for Lights and Light/Flat Panel Combination Suspensions ..............22
7.4. Replacing the Horizontal Arm on a Wall Single Light..................................................................24
7.5. Replacing a Spring Arm for Light Head or Flat Panel Support Arm (Ceiling Suspension)......25

ii
S
7.6. Replacing Spring Arm for Wall Mounted Single Light................................................................27
7.7. Replacing Spring Arm for VPA.........................................................................................................29
7.8. Replacing VPA POD ..........................................................................................................................29
7.9. Replacing the Light Head or Monitor Yoke ..................................................................................29
7.9.1 Classic Cardanic for Light Head or Monitor Yoke......................................................................... 30
7.9.2 Flat Cardanic......................................................................................................................................... 31
7.9.3 New Flat Cardanic (N.F.C) .................................................................................................................. 32
7.10. Adjusting Suspension Brakes for Lights, Flat Panels, and VPA....................................................35
7.10.1 Horizontal Arm Brakes........................................................................................................................35
7.10.2 Light/Flat Panel Spring Arm Brakes................................................................................................. 35
7.10.3 Cardanic Brakes on a Classic ............................................................................................................ 36
7.10.4 Cardanic Brakes on the Flat Cardanic ............................................................................................ 36
7.10.5 Cardanic Brakes on New Flat Cardanic.......................................................................................... 36
7.10.6 Light Head Brakes................................................................................................................................ 37
7.10.7 VPA Spring Arm Brakes....................................................................................................................... 37
7.11. Adjustments for Lights, Flat Panel, and VPA Suspensions...........................................................38
7.11.1 Spring Arm Height Adjustment for Lights and Flat Panel Spring Arms.................................. 38
7.11.2 Flat Cardanic Height Adjustment ................................................................................................... 38
7.11.3 Height Adjustment for NFC Spring Arms....................................................................................... 39
7.11.4 Counter Balancing the Spring Arm for Lights and Flat Panels .................................................39
7.11.5 VPA Spring Arm Up/Down Brakes.................................................................................................... 40
7.11.6 VPA Height Stop Detents.................................................................................................................... 41
7.12 Spring Arm Wire Harness Replacement for Lights .......................................................................41
7.13 Spring Arm Cover Replacement ....................................................................................................45
7.15 Dual Flat Panel Arm Maintenance..................................................................................................47
7.15.1 Dual Flat Panel Spring Arm Counterweight Adjustment........................................................... 47
7.16 Servicing Suspension Stop Rotation .............................................................................................51
7.16.1.1 Changing/Replacing Stop Location................................................................................................ 51
7.17 Horizontal Arm Maintenance .........................................................................................................53
7.17.1 Replacing Height Compensation Tube (HCT) on Horizontal Arm ........................................... 53
7.17.2 Replacing internal wiring on Horizontal Arm (light suspension only) ................................... 55
7.18 Replacing Suspension Bottom Cap (Jar Cover) ............................................................................57
7.19 Suspension Mounted EndoLite ......................................................................................................58
7.19.1 General Information ........................................................................................................................... 58
7.19.2 Endo Repair........................................................................................................................................... 61
7.20 Replacing the Slip Ring (Commutator) on an F Gen Light..........................................................62
8. Cardanics ........................................................................................................................................... 66
8.1 Cardanic Replacement.....................................................................................................................66
8.1.1 Cardanic Replacement for EXX0/EXX5 Light Heads (Halogen/HID)........................................66
8.1.2 Cardanic Replacement for EXX8 Light Heads (E LED) ................................................................. 68
8.1.3 Cardanic Replacement for FXX8 Light Heads (F-Gen) ................................................................ 71
8.1.4 F-Generation Cardanic Security Tool:............................................................................................. 71
9. Light Head Maintenance................................................................................................................... 82
9.1 Light Handles / Focus Mechanism ................................................................................................82
9.1.1 Light Handle Replacement................................................................................................................ 83
9.2 F 528/628 (F-Gen) Light Head Maintenance.................................................................................83
9.3 E558/668/778 (E LED) Light Head Maintenance ..........................................................................84

iii
S
9.3.1 Accessing the light head internals................................................................................................... 84
9.3.2 Lower Glass Replacement.................................................................................................................. 85
9.3.3 Frame/Frame Seal/Glass Seal Replacement ................................................................................. 85
9.3.4 Distribution Board............................................................................................................................... 87
9.3.5 LED Module replacement .................................................................................................................. 89
9.3.6 Light Head Reassembly (Refer to 9.3.1 for Illustrations).............................................................91
9.4 E550/650 (Halogen) and E655/805 (HID) Light Head Maintenance ..........................................92
9.4.1 Dome Removal and Replacement Exx0/Exx5............................................................................... 92
9.4.2 EndoLite ................................................................................................................................................ 93
9.4.3 Lower Glass Assembly......................................................................................................................... 94
9.4.4 Replacing the Filter Glass Assembly................................................................................................ 95
9.4.5 Circuit Boards ....................................................................................................................................... 98
9.4.6 Cuircuit Board Replacement............................................................................................................. 98
9.4.6.1 CPU Board...............................................................................................................................98
9.4.6.2 Camera Board (only with in-light option) ............................................................................99
9.4.6.3 Dimming Control Board (E550/650) .................................................................................. 100
9.4.6.4 EVG Board (E655/805)......................................................................................................... 100
9.5 Light Head Dome Cover Replacement for F528/F628.............................................................. 101
10. Control Panels ..............................................................................................................................104
10.1 Halogen and HID light controls (Exx5/Exx0).............................................................................. 104
10.2 LED Light controls - E LED and F-Generation (Exx8/Fxx8) ....................................................... 108
11. Power Supply Service Instructions...............................................................................................117
11.1 General Information...................................................................................................................... 117
11.2 SK Boxes.......................................................................................................................................... 119
11.3 Tube mounted power supplies.................................................................................................... 121
11.4 Camera distribution board........................................................................................................... 122
12. Preventative Maintenance............................................................................................................123
13. Contact Information .....................................................................................................................124

1
S
1. Warnings and Cautions
Please read this manual and follow its instructions carefully. The words WARNING, CAUTION, and Note carry
special meanings and should be carefully reviewed:
WARNING: The personal safety of the patient or user may be involved. Disregarding this
information could result in injury to the patient or user.
CAUTION: Special service procedures or precautions must be followed to avoid damaging the
instrument.
WARNING: A lightening bolt is intended to warn of the presence of hazardous voltages. Refer
all service to authorized personnel.
WARNING: Potential explosion hazzard.
WARNING: A yellow box with a hand within a triangle is intended to warn the user of the
presence of an electrostatic sensitive device. Follow ESD prevention procedures.
Note: Special information to make maintenance easier or important information more clear.
To avoid potential serious injury to the user or the patient or both and to avoid damage to this device, the
user must adhere to the following warnings and cautions.
• Do not add additional weight to the surgical lights.
• Do not place anything over the surgical lights.
• Do not look directly into the surgical light while powered on.
• Do not operate the surgical light if any component of the light (such as the glass) is damaged.
1. Stryker trained personnel are the only personnel authorized to install the equipment described in this
manual.
2. Attempt no repairs or adjustments, unless specically instructed to do so in this manual.
3. Disconnect the unit from the electric outlet before inspecting or servicing system components. Note that
more than one electrical supply may be used. Disconnect all power sources before inspecting.
4. The electrical installation of the operating room must comply with any applicable IEC, CEC, NEC
requirements as well as the local codes and pre-installation manual.
5. Do not use accessories or cables other than those provided or recommended. Such use may result in
increased electromagnetic emissions or decreased electromagnetic immunity of the equipment or
system. Use of components or accessories not recommended by Stryker/Berchtold may result in reduced
performance or system breakdown.
Note: Test Equipment after servicing.

2
S
2. Product Symbols
An exclamation mark within a triangle is intended to alert the user to the presence of
important operating and maintenance (service) instructions in the literature accompa-
nying the product.
A lightning bolt within a triangle indicates the presence of hazardous voltage. Refer all
service to authorized personnel.
Denotes oxygen explosion hazard.
Denotes usage tips and useful information.
Denotes compliance to European Community Directive 93-42-EEC.
Indicates hot surfaces.
Denotes compliance to UL 60601-1, CAN/CSA C22.2 No. 601.1, CAN/CSA C22.2 NO.
601.2XX
Denotes the date the equipment was manufactured.
Denotes the manufacturer of the device.
A yellow box with a hand within a triangle is intended to warn the user of the presence
of an electrostatic sensitive device. Follow ESD prevention procedures.
In accordance with European Community Directive 2002/96/EC on Waste Electrical and
Electronic Equipment, this symbol indicates that the product must not be disposed of
as unsorted municipal waste but should be collected separately.
Note: The device does not contain any hazardous materials.
Legal regulations may include specications regarding the disposal of this product.
Please contact Stryker/Berchtold to withdraw this device from service for discard.

3
S
3. ESD Procedure
3.1. Electrostatic Discharge
Static electricity is a stationary form of electrical charge. This charge is due to the transfer of electrons within
a body or from one body to another. The magnitude of the charge depends on the size, shape, composition
and electrical properties of the substance that make the bodies.
Once a body develops a static charge, it will look for a conductive surface to discharge. This is called
Electrostatic Discharge (ESD). This discharge is only felt when the charge is larger than 3500 volts, yet many
components are sensitive well below this level.
Potentially dangerous levels of ESD can generate from the following common manufacturing sources:
• Plastic (bags, containers, binders)
• Paper (procedures, DHRs, pick slips)
• CRT Monitors
• Clothing
Subassemblies and equipment that contain ESD sensitive devices (without adequate circuitry) are also ESD
sensitive.
Avoid sliding ESD sensitive components across other materials. Sliding materials together can create the
build up of an electrostatic charge.
3.2. Electrostatic Dissipative Wrist-Straps
Wrist-straps should be worn during the handling of ESD sensitive devices. The wrist-strap should contain an
internal 1Mohm resistor to protect the operator in the case of accidental high voltage being applied to the
workstation surface.

4
S
4. Comprehensive Tools
4.1. Required Tools
• Genie lift or equipment lift, SLC-12 or equivalent
• Torpedo level
• Metric allen set
• Wrench Set
• Small and large phillips head
• Small and Large at head screw driver
• Snap ring plier
• Torque Wrench
• Spreader Forceps
• Screw Removal Tools
• Digital Level
• Wire Strippers
• Soldering Iron
4.2. Optional Tools
• Porta band saw
• Large hand le
• 1/2 inch Drill/Driver
• Tape measure
• Drill bit set
• Hand tool pouch
• Adjustable wrench
• Roofer’s square
• Hammer

5
S
5. System Architecture
5.1. Model Plate
The Model Plate is located next to the suspension installation point on the housing of the Light Head or the
VPA Pod.
1. Version Number
2. Model Number
3. Year of Manufacture (A=1993, B=1994, etc.)
4. Sequential Numbering
5. CE Mark
6. Symbol for Camera Preparation (optional)
7. Health Industry Bar Code

6
S
5.2 CHROMOPHARE (Ceiling)
The following sections apply to models E 520, E 550, E 558, E 650, E 655, E 668, E 778, E 800, E 805, F 528, F 628.
Note: Suspension in use applies to both E and F series Lights.
5.2.1 Single Light, Classic Cardanic Unit (A.C)
1. Ceiling Cover 5. Vertical Gimbal Joint 9. Panel Frame
2. Ceiling Tube Ø 125 mm 6. Horizontal Gimbal Joint 10. Light-Output Surface (Facing)
3. Horizontal Arm 7. Light Head Hood Support 11. Handle Assembly
4. Spring Arm 8. Rail 12. Control Unit
5.2.2 Light Combination, Classic Cardanic Unit (A.C)
1. Ceiling Cover 6. Vertical Gimbal Joint 11. Light-Output Surface (Facing)
2. Ceiling Tube Ø 125 mm 7. Horizontal Gimbal Joint 12. Handle Assembly
3. Horizontal Arm 8. Light Head Hood Support 13. Control Unit
4. Height Adjustment Tube 9. Panel Frame
5. Spring Arm 10. Rail

7
S
5.2.3 Single Light, Flat Cardanic (N.C.)
1. Ceiling Cover 5. Horizontal Gimbal Joint 9. Light-Output Surface (Facing)
2. Ceiling Tube Ø 125 mm 6. Light Head Hood Support 10. Handle Assembly
3. Horizontal Arm 7. Panel Frame 11. Control Unit
4. Spring Arm 8. Rail
5.2.4 Light Combination, Flat Cardanic (N.C)
1. Ceiling Cover 5. Spring Arm 9. Rail
2. Ceiling Tube Ø 125 mm 6. Horizontal Gimbal Joint 10. Light-Output Surface (Facing)
3. Horizontal Arm 7. Light Head Hood Support 11. Handle Assembly
4. Height Adjustment Tube 8. Panel Frame 12. Control Unit

8
S
5.2.5 Single Light, New Flat Cardanic (N.F.C)
1. Ceiling Cover 6. Panel Frame
2. Ceiling Tube Ø 125 mm 7. Rail
3. Horizontal Arm 8. Light-Output Surface (Facing)
4. Spring Arm 9. Handle Assembly
5. Horizontal Gimbal Joint 10. Control Unit
5.2.6 Light Combination, New Flat Cardanic (N.F.C)
1. Ceiling Cover 7. Light Head Hood Support
2. Ceiling Tube Ø 125 mm 8. Panel Frame
3. Horizontal Arm 9. Rail
4. Height Adjustment Tube 10. Light-Output Surface (Facing)
5. Spring Arm 11. Handle Assembly
6. Horizontal Gimbal Joint 12. Control Unit

9
S
5.3 CHROMOPHARE E 520, E 550, E 558, F 528, F 628 (Wall)
Note: Suspension in use applies to both E and F series Lights.
5.3.1 Single Light, Classic Cardanic (A.C)
1. Transformer Housing 6. Vertical Gimbal Joint 11. Panel Frame
2. Mains Switch 7. Control Unit 12. Rail
3. Wall Bracket 8. Horizontal Gimbal Joint 13. Underglass
4. Horizontal Arm 9. Light Head Hood Support 14. Camera Cable Connection Socket
5. Spring Arm 10. Handle Assembly
5.3.2 Single Light, Flat Cardanic (N.C)
1. Transformer Housing 6. Vertical Gimbal Joint 11. Panel Frame
2. Mains Switch 7. Control Unit 12. Rail
3. Wall Bracket 8. Horizontal Gimbal Joint 13. Underglass
4. Horizontal Arm 9. Light Head Hood Support 14. Camera Cable Connection Socket
5. Spring Arm 10. Handle Assembly

10
S
5.3.3 Single Light, New Flat Cardanic (N.F.C)
1. Mains Switch 6. Spring Armt 11. Panel Frame
2. Transformer Housing 7. Horizontal Gimbal Joint 12. Rail
3. Camera Cable Connection Socket 8. Control Unit 13. Light Head Hood Support
4. Wall Bracket 9. Underglass
5. Horizontal Arm 10. Handle Assembly

11
S
5.4. CHROMOPHARE E 520, E 550, E 558, F 528, F 628 (Mobile)
5.4.1 E Series With Emergency Power
1. Stand Base (control unit, main fuses, batteries, charger) 7. Side Shaft Control Panel
2. On/OFF Switch 8. Lamp Frame
3. Control Unit 9. Rail
4. Stand Pillar 10. Light-Emission Lens
5. Spring Arm 11. Hand Grip
6. Light Head Hood Holder

12
S
5.4.2 E Series Without Emergency Power
1. Base 6. Stand Pillar 11. Rail
2. Main Fuse Mount 7. Spring Arm 12. Light-Emission Lens
3. Connector Port for Camera Cable 8. Light Head Hood Holder 13. Handle
4. Transformer, Electronics 9. Side Shaft Control Panel
5. Control Unit 10. Lamp Frame

13
S
5.5 F Series (Mobile)
1. Stand Base 7. Light Fram
2. Charge Level Display and On/OFF Switch 8. Rail
3. Double Castors with Parking Brake 9. Light Head Cover Casting
4. Cable Hook 10. Underglass
5. Tubular Stand 11. Replaceable Sleeve
6. Spring Arm

14
S
5.6. Chromophare VPA Video/Power Arm
5.6.1 VPA Single (Stand-Alone) Mount
1. Ceiling Cover 6. Service Pod
2. Ceiling Tube Ø 125 mm 7. 115V Duplex Power Outlet
3. Horizontal Arm 8. Data Plates
4. Height Adjustment Tube 9. Cord Management
5. Spring Arm 10. AccessHandle
5.6.2 VPA Video Power Arm/Light Combination
1. Ceiling Cover 7. 115V Duplex Power Outlet
2. Ceiling Tube Ø 125 mm 8. Data Plates
3. Horizontal Arm 9. Cord Management
4. Height Adjustment Tube 10. Access Handle
5. Spring Arm 11. Light Head

15
S
5.6.3 VPA Video Power Arm/Light/Flat Panel Combinatio
1. Ceiling Cover 7. 115V Duplex Power Outlet
2. Ceiling Tube Ø 125 mm 8. Data Plates
3. Horizontal Arm 9. Cord Management
4. Height Adjustment Tube 10. Access Handle
5. Spring Arm 11. Light Head
6. Service Pod 12. Monitor Yoke
5.6.4 Shoulder Mount VPA Video Power Arm/Light/Light/Flat Panel/Shoulder
1. Ceiling Cover 7. 115V Duplex Power Outlet
2. Ceiling Tube Ø 125 mm 8. Data Plates
3. Horizontal Arm 9. Cord Management
4. Height Adjustment Tube 10. Access Handle
5. Spring Arm 11. Light Head
6. Service Pod 12. Monitor Yoke