Stryker Berchtold CHROMOPHARE Service And Parts Manual
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Stryker Berchtold CHROMOPHARE Service And Parts Manual

Surgical lights, single and combination lights
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CHROMOPHARE®
Surgical Lights, Single and Combination Lights
Service and Parts Manual

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Summary of Contents for Stryker Berchtold CHROMOPHARE

  • Page 1 CHROMOPHARE® Surgical Lights, Single and Combination Lights Service and Parts Manual...

  • Page 3: Table Of Contents

    Table of Contents 1. Warnings and Cautions ........................1 2. Product Symbols ..........................2 3. ESD Procedure ............................. 3 Electrostatic Discharge ........................3 3.1. 3.2. Electrostatic Dissipative Wrist-Straps ....................3 4. Comprehensive Tools .......................... 4 4.1. Required Tools.............................4 4.2. Optional Tools .............................4 5.
  • Page 4 Replacing Spring Arm for Wall Mounted Single Light ..............27 7.6. 7.7. Replacing Spring Arm for VPA ......................29 7.8. Replacing VPA POD ..........................29 Replacing the Light Head or Monitor Yoke ..................29 7.9. 7.9.1 Classic Cardanic for Light Head or Monitor Yoke ................. 30 7.9.2 Flat Cardanic ............................
  • Page 5 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 E550/650 (Halogen) and E655/805 (HID) Light Head Maintenance ..........92 9.4.1 Dome Removal and Replacement Exx0/Exx5 ................

  • Page 6: Warnings And Cautions

    • 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.

  • Page 7: Product Symbols

    Note: The device does not contain any hazardous materials. Legal regulations may include specifications regarding the disposal of this product. Please contact Stryker/Berchtold to withdraw this device from service for discard.

  • Page 8: Esd Procedure

    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.

  • Page 9: Comprehensive Tools

    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 flat head screw driver • Snap ring plier •...

  • Page 10: System Architecture

    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. Version Number Model Number Year of Manufacture (A=1993, B=1994, etc.) Sequential Numbering CE Mark Symbol for Camera Preparation (optional) Health Industry Bar Code...

  • Page 11: Chromophare (Ceiling)

    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.

  • Page 12: Single Light, Flat Cardanic (N.c.)

    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.

  • Page 13: Single Light, New Flat Cardanic (N.f.c)

    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.

  • Page 14: Chromophare E 520, E 550, E 558, F 528, F 628 (Wall)

    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.

  • Page 15: Single Light, New Flat Cardanic (N.f.c)

    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.

  • Page 16: Chromophare E 520, E 550, E 558, F 528, F 628 (Mobile)

    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.

  • Page 17: E Series Without Emergency Power

    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.

  • Page 18: F Series (Mobile)

    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.

  • Page 19: Chromophare Vpa Video/Power Arm

    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.

  • Page 20: Vpa Video Power Arm/Light/Flat Panel Combinatio

    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.

  • Page 21: Chromoview Monitor Supports(Yoke)

    5.7. ChromoView Monitor Supports(Yoke) 5.7.1 Single Monitor Support Arm 5.7.2 Dual Monitor Support Arm...

  • Page 22: Unpacking/Packing

    For obvious damage to the component delivered contact technical support for proper disposition and replacement component. To limit damage, use the original packaging when returning a product to Stryker/Berchtold. Provide the following information: Account’s Name and Address, Serial Number(model plate), and a description of the defect.
  • Page 23 3. Place the cushioning into the corresponding recesses as shown in the illustration. 4. Position the Light Head in accordance with the cut-out and in accordance with the diagram. 5. The cardanic suspension MUST be pressed into the cushioning. 6. Place the carton segment onto the light head such that the recesses match the cushioning. Caution: If the cushioning is not placed into the correct cut-outs and the cardanic suspension is not pressed firmly into the cushioning, there is a risk that the Light Head could sustain damage during transport.

  • Page 24: Suspension Maintenance

    7. Suspension Maintenance 7.1. Leveling Suspensions 1. Single or dual light or any combination on suspension, place the light head of flat panel under the center of the mount. Example: Dual Suspension with Single Suspension with Lighthead Lightheads Under Center Under Center 2.

  • Page 25: Replacing The Ceiling Tube

    5. This illustrates using ever other stud for leveling purposes. Make a triangle for less adjustment points. 6. With the arms in opposite directions to distribute the weight equally make the adjustments, with the level or levels attached to the arms slowly turn the bottom nuts until the arm is level and if doing a dual check the other arm for level and make adjustments as necessary.
  • Page 26 Note: Ensure ceiling tube is level using a digital level. 5. Apply flat washers and mounting nuts to three threaded bolts by hand, spaced at 120° intervals. 6. Align the ceiling tube vertically in the room using a level and the adjustment screws on the ceiling side. 7.

  • Page 27: Replacing A Suspension For Lights And Light/Flat Panel Combination Suspensions

    Replacing a Suspension for Lights and Light/Flat Panel Combination Suspensions WARNING: Before performing the following steps, the electricity for the Lights and/or Monitors has to be powered OFF. Note: When replacing a Suspension with a Flat Panel Arm the cables shall be back pulled from the doc station.
  • Page 28 4. Remove the safety shoulder screw (1) and tighten to 5 N-m using 5mm hex key. 5. Lower arm and attach replacement arm to lift for installation. 6. Raise arm up to the ceiling tube and attach plug-in connectors 4-7. 7.

  • Page 29: Replacing The Horizontal Arm On A Wall Single Light

    7.4. Replacing the Horizontal Arm on a Wall Single Light WARNING: Before performing the following steps, the electricity for the Lights and/or Monitors has to be powered OFF. CAUTION: There is a risk of injury from spring-loaded joints. If the spring arm is released under tension, it will move quickly and uncontrollably, possibly causing injury or damage to equipment.

  • Page 30: Replacing A Spring Arm For Light Head Or Flat Panel Support Arm (Ceiling Suspension)

    10. Reconnect the cables to the terminal block. Cantilever Wall bracket green/yellow connect to green/yellow white connect to black connect to black 11. Reinstall the cover cap (1). 12. Reinstall cap screws (2). 13. Install brake screw (3). 14. Install Spring Arm as instructed in section 7.6. 15.
  • Page 31 WARNING: Before performing the following steps, the electricity for the Lights and/or Monitors has to be powered OFF. 4. Remove the spring arm. 5. Insert the spring arm (1) into the horizontal arm (2) in the direction of the arrow. Note: Ensure that the holes in the spring arm are lined up with the bore holes on the horizontal arm.

  • Page 32: Replacing Spring Arm For Wall Mounted Single Light

    7.6. Replacing Spring Arm for Wall Mounted Single Light WARNING: Before performing the following steps, the electricity for the Lights and/or Monitors has to be powered OFF. CAUTION: There is a risk of injury from spring-loaded joints. If the spring arm is released under tension, it will move quickly and uncontrollably, possibly causing injury or damage to equipment.
  • Page 33 9. Install two Circlips in the grooves (1) and ensure that the Ciirclips are completely snapped into their corresponding groove. Note: Ensure that the holes in the spring arm are lined up with the bore holes on the horizontal arm. 10.

  • Page 34: Replacing Spring Arm For Vpa

    7.7. Replacing Spring Arm for VPA WARNING: Spring arm for VPA is a DEPOT Level Repair. 7.8. Replacing VPA POD WARNING: VPA POD is a DEPOT Level Repair. 7.9. Replacing the Light Head or Monitor Yoke WARNING: Before performing the following steps, the electricity for the Lights and/or Monitors has to be powered OFF.

  • Page 35: Classic Cardanic For Light Head Or Monitor Yoke

    7.9.1 Classic Cardanic for Light Head or Monitor Yoke Note: When replacing the Monitor Yoke the cables shall be back pulled from the doc station. Note: The following steps apply to all E and F Series Light Heads being installed on a Classic Spring Arm.

  • Page 36: Flat Cardanic

    7.9.2 Flat Cardanic WARNING: Failure to install the locking segment WILL result in the Light Head or Monitor Yoke falling. Failure to secure the lock bushing with the screw may result in the locking segment to disengage resulting in the Light Head or Monitor Yoke falling. 1.

  • Page 37: New Flat Cardanic (N.f.c)

    WARNING: Failure to plug in the contacts correctly may result in permanently damaged or destroyed connectors. 6. Insert the journal of the light bow (1) until it reaches the spring arm (2). 7. Screw in the shoulder screw (3) in until the light head is just un-braked. 8.
  • Page 38 6. Remove the Light Head and Cardanic from the spring arm. 7. With the replacement Light Head, align the contact pins inside the journal of the light bow. WARNING: Failure to plug in the contacts correctly may result in permanently damaged or destroyed connectors.
  • Page 39 11. Install the flat head brake screw (2) into the free thread. 12. Remove the circlip retainer and the shipping lock. 13. Slide the plastic sleeve into the locked position. Adjust the braking force with the brake screw as such that the Light Head is easy to move but remains stationary in the desired position.

  • Page 40: Adjusting Suspension Brakes For Lights, Flat Panels, And Vpa

    7.10. Adjusting Suspension Brakes for Lights, Flat Panels, and VPA WARNING: Failure to properly install the shoulder screw and secure the lock bushing with the break screw may result in the Light Head falling. Note: Turning the brake screw clockwise will increase the braking action and turning the brake screw counterclockwise will decrease the braking action.

  • Page 41: Cardanic Brakes On A Classic

    7.10.3 Cardanic Brakes on a Classic 1. Adjust the braking effect on the cardanic joint using brake screw (B3) 7.10.4 Cardanic Brakes on the Flat Cardanic 1. Adjust the braking effect to suit the cardanic joint using brake screw (B4) 7.10.5 Cardanic Brakes on New Flat Cardanic 1.

  • Page 42: Light Head Brakes

    7.10.6 Light Head Brakes 1. Adjust the braking effect to suit the rotational movement of the Light Head. 7.10.7 VPA Spring Arm Brakes 1. Adjust the braking effect to suit the rotational movement of the horizontal arm using brake screws.

  • Page 43: Adjustments For Lights, Flat Panel, And Vpa Suspensions

    7.11. Adjustments for Lights, Flat Panel, and VPA Suspensions 7.11.1 Spring Arm Height Adjustment for Lights and Flat Panel Spring Arms 1. Remove the covering cap using a small screwdriver. The height adjustment screw for the height stop is beneath the cover cap (HB). 2.

  • Page 44: Height Adjustment For Nfc Spring Arms

    Note: Turning the height screw in the clockwise direction reduces the height and in a counter clockwise direction increases the height. 7.11.3 Height Adjustment for NFC Spring Arms 1. Slide the plastic sleeve forward; exposing the adjustment slot. 2. Bring the spring arm to a position whereby the adjustment nut (2) is visible in the slot. 3.

  • Page 45: Vpa Spring Arm Up/Down Brakes

    7.11.5 VPA Spring Arm Up/Down Brakes 1. The vertical movement of the spring assist arm can be adjusted by increasing or decreasing the brake screws applied to the brake. 2. First remove the (3) cover plate screws and remove the cover plate. 3.

  • Page 46: Vpa Height Stop Detents

    7.11.6 VPA Height Stop Detents 1. The Detent System will maintain vertical position of the spring arm at 20 degree increments; a total movement of 60 degrees. The Ball Spring Plunger should be fastened with Loctite applied to threads and inserted completely to function properly. Note: The Detent Stops are not adjustable.
  • Page 47 3. Remove the screw holding harness connectors in the spring arm (both front and back). Cut wire set and remove. 4. Tape pins and end of wires together to keep them protected during assembly. 5. Pull wire set thru spring arm and install female 7 pole connector in front part of arm, install screw by tighten fully then back of ¼...
  • Page 48 6. Pin out female connector as follows: Note: Standard Pinout for 7-Pole Spring Arms. 1) Rose Can-buss high 2) Grey Can-buss low 3) Yellow Y (camera) 4) Brown C (camera) 5) PE Green/Yellow Gnd 6) L black 1 + 24vdc 7) Ctr Black 2 - 24vdc 7.
  • Page 49 8. Install bearing housing, inspect bearings for proper movement. 9. Install washer over bearings. 10. Install snap ring check for proper operation. Install spring arm and test light as per class requirements.

  • Page 50: Spring Arm Cover Replacement

    7.13 Spring Arm Cover Replacement 79999 Side cover 1 & 2 79998 Back Elbow Cover 1 & 2 79997 Spring Arm Joint Cover 1 & 2 80657 Blue Tab 74191 Safety Sleeve 77235 Countersunk Screw w/Tuflock, M4X8-A2, Din 966 80664 Countersunk Screw Raised Head, M4X16-A2, Din 966...
  • Page 51 79999 Side cover 1 & 2 79998 Back Elbow Cover 1 & 2 80657 Blue Tab 74182 Spring Arm Cover 80664 Countersunk Screw Raised Head, M4X16-A2, Din 966 Screw, ISO 7047-H M3X0.5X6. CR-OHMS, SS 77235 Countersunk Screw w/Tuflock, M4X8-A2, Din 966...

  • Page 52: Dual Flat Panel Arm Maintenance

    84398 Front Spring Arm Cover 79998 Back Elbow Cover 1 & 2 79999 Side cover 1 & 2 80664 Countersunk Screw Raised Head, M4X16-A2, Din 966 77235 Countersunk Screw w/Tuflock, M4X8-A2, Din 966 80657 Blue Tab 7.15 Dual Flat Panel Arm Maintenance Note: Only configure the height-adjustment of the Dual Flat Panel Spring Arm after a successful weight counterbalance.
  • Page 53 7.15.2 Dual Flat Panel Spring Arm Height Adjustment Note: The Dual Flat Panel Arm is configured to have a height-adjustment of 40° upwards and downwards when delivered. The height stop can be set to 20°. WARNING: The Dual Flat Panel Spring Arm is under a high level of tension. The arm can move uncontrolled and may result in injuries.
  • Page 54 7. Bring the spring arm to its highest position. 8. Apply the 147mm cover strap on the rear hinge, in the lower channel. 9. Apply the 130mm cover strap on the front hinge, in the upper channel. 10. Bring the spring arm to its lowest position. 11.
  • Page 55 7.15.4 Adjusting the Brakes WARNING: Risk of injury if braking action of joint fails. If the brake screws are lubricated or residual lubrication is left on them, they lose their braking action and the articulated joints will not stop as desired when moved. Note: Turning the brake screw in the clockwise direction increases the braking effect and turning in and anticlockwise direction reduces the braking effect.

  • Page 56: Servicing Suspension Stop Rotation

    7.15.8 Brakes, Monitor Suspension, Version I (tilt movement) 1. Adjust the braking effect to suit the rotational movement of the Dual Flat Panel Arm using brake screw (B1). 7.15.9 Brakes, monitor Suspension, Version II (tilt movement) 1. Adjust the braking effect to suit the rotational movement of the Dual Flat Panel Arm using brake screw (B3).
  • Page 57 3. Continue to turn the horizontal arm until the internal stop screw (3) is visible. 4. Unscrew the internal stop screw. Note: If the internal Suspension stop is broken, a removal tool may be needed to remove the broken screw. 5.

  • Page 58: Horizontal Arm Maintenance

    7.17 Horizontal Arm Maintenance WARNING: Before performing the following steps, the electricity for the Lights and/or Monitors has to be powered OFF. 7.17.1 Replacing Height Compensation Tube (HCT) on Horizontal Arm The HCT is a vertical down tube, available in varying lengths, used to put the spring arms are in an equal horizontal plane.
  • Page 59 7. Insert the height Compensation tube into the horizontal arm. In so doing, make sure that the holes of the height Compensation tube line up with the holding holes in the horizontal arm. 8. Insert the round-headed screw (1) into the upper screw thread and tighten to 5 N-m. 9.

  • Page 60: Replacing Internal Wiring On Horizontal Arm (Light Suspension Only)

    7.17.2 Replacing internal wiring on Horizontal Arm (light suspension only) 1. Secure power to the system from the circuit breaker. 2. Remove Light Head from Spring Arm per section 7.9. 3. Remove Spring Arm per section 7.5. 4. Remove 2 cross head screws on the bottom of the horizontal arm next to the central shaft to access the contact block.
  • Page 61 e. Run wires thru the HCT down the horizontal arm and out the access of the contact block. f. Replace the 5mm hex screw on the side of the HCT and tighten. g. Proceed to step 8. 7. For units with no HCT a.

  • Page 62: Replacing Suspension Bottom Cap (Jar Cover)

    7.18 Replacing Suspension Bottom Cap (Jar Cover) 1. If replacement of the bottom suspension cap (Jar cover) becomes necessary, obtain a replacement kit (pn 107120). 2. Verify that the 3 screws are present in the cap as shown. 3. If applicable, remove the existing cover from the bottom of the suspension. 4.

  • Page 63: Suspension Mounted Endolite

    7.19 Suspension Mounted EndoLite 7.19.1 General Information The ENDO light is an accessory option that mounts to the Chromophare suspension. It is mounted to the central bearing shaft assembly attached to the bottom of a horizontal arm. It provides background light when the full light of a surgical light is not needed.

  • Page 66: Endo Repair

    7.19.2 Endo Repair WARNING: Disconnect all power supplies before removing the EndoLite assembly. Failure to do so will result in damage to the circuit board. 1. Determine if the issue is circuit board related or cable connection issue by verifying all connections and checking voltages.

  • Page 67: Replacing The Slip Ring (Commutator) On An F Gen Light

    7. To remove Driver PCB circuit board, piece 6, remove three (3) screws and pull up gently to unseat the 8 pin socket connected to the LED circuit board, remove and place aside Driver board. To remove the LED Circuit board, Piece 7, remove the 3, 10mm standoffs. 8.
  • Page 68 5. Remove the three screws from the Endo light or jar cover and set them aside. WARNING: To prevent electrocution and burns, make sure the power to the light system is turned off. 6. If you have an Endo light: a.
  • Page 69 9. Remove the c-clip with the correct c-clip pliers. 10. Use a #6 Allen wrench to remove the brake screw of the extension arm. 11. Use a rubber mallet or your hand and tap down on the top of the extension arm to remove the central axis.
  • Page 70 12. Remove the set screw from inside the slip ring (Commutator). 13. Disconnect the cabling for the slip ring at the ceiling. Cut off the end of the connectors and pull the cabling down and out of the system. 14. Remove the slip ring. 15.

  • Page 71: Cardanics

    8. Cardanics WARNING: Ensure Lights are powered off prior to performing service. Cardanic Replacement 8.1.1 Cardanic Replacement for EXX0/EXX5 Light Heads (Halogen/HID) CAUTION There is a risk of injury from spring-loaded joints. If the spring arm is released under tension, it will move quickly and uncontrollably, possibly causing injury or damage to equipment.
  • Page 72 5. Remove the Cardanic from the light body by gently rotating back and forth while pulling cardanic away from light body. 6. When cardanic is off pull wire sets out of the light body ensuring all connectors are protected. 7. With the replacement Cardanic, fish wire sets thru side of the light body, then align the cardanic bow onto the light body journal and install cardanic by gently rotating back and forth while pushing cardanic onto the light body journal.

  • Page 73: Cardanic Replacement For Exx8 Light Heads (E Led)

    10. Install dome onto Light Head ensuring gasket is not damaged. 11. Install Light Head on to Spring Arm. 12. Adjust brakes in order to achieve the desired braking action. 13. Complete operational check of Light, Cardanic and Spring Arm. 8.1.2 Cardanic Replacement for EXX8 Light Heads (E LED) CAUTION There is a risk of injury from spring-loaded joints.
  • Page 74 3. Remove screws holding in the focus mechanism plastic ring in place. 4. Remove LED face glass using gasket removal tool set to allow access to wire sets. 5. Remove the four screws holding the tube in place.
  • Page 75 6. Disconnect wiring red and black 24vdc and 4 pin Molex can/camera and ground from inside of cardanic. 7. Remove the Cardanic from the light body by gently rotating back and forth while pulling cardanic away from light body. 8. When cardanic is off pull wire sets out of the light body ensuring all connectors are protected. 9.

  • Page 76: Cardanic Replacement For Fxx8 Light Heads (F-Gen)

    12. Reinstall tube using the four screws removed in earlier step. 13. Install Led face glass using gasket tool. 14. Install plastic ring for focus mechanism. 15. Install light head on to spring arm. 16. Adjust brakes in order to achieve the desired braking action. 17.
  • Page 77 2. Remove the joint cover and 7-pole rotating connector from the end of the cardanic. 3. Utilizing outer straight tipped slip ring pliers; remove Internal Blind Snap Ring. 4. Remove the two spring washers 83222 from the cardanic. 5. Remove the cardanic from the light head. Note: Step 6 is only for Variants 83469, 83470, and 83289.
  • Page 78 7. Screw the 83273 coupling for the light control with the connector 77612 with (1) 83523 screw. 8. Slide cardanic onto the side bearing. 9. Secure the safety screw 83217. 10. Secure the brake screw 83264.
  • Page 79 WARNING: The following steps are critical to the security of the cardanic to the Light Head. 11. Place two spring washers 83222 into the back of the interior joint. 12. Place the snap ring 83224 onto the tool “FGEN 1-1”. 13.
  • Page 80 14. Slide the tool “FGEN 1-2” up to make contact with the snap ring. Ensure that the snap ring is oriented as shown. WARNING: Wiring can be damaged. Be careful when inserting the fixture into the joint. 15. Align the tool to allowing guiding of the wiring along the slot as shown. 16.
  • Page 81 21. Attach the cover 83467 to the middle joint and secure with the two screws 223. Note: Steps 22-25 for Variants 83468(AC Cardanic, Cover with 7-Pole). 22. Tuck the connector cable back into the cardanic joint area. 23. Ensure that the 7-pole rotating connector is aligned so that it mates with the plug.
  • Page 82 24. Insert the plug and seat into the connector. 25. Secure the connector cap with (4) 64662 screws. Note: Steps 22-25 for Variants 83468(AC Cardanic, Cover with 7-Pole). 26. Put wiring through the housing. 27. Secure the housing with (3) 87200 screws, (3) 378 washers, and (3) 1229 washers.
  • Page 83 28. Plug in the programmed light control set. 29. Tuck the wiring for the control pad into the cardanic. 30. Ensure the blue ribbon cable is not caught during the connection. 31. Secure the front cover to the housing. 32. Secure (1) 67589 screw into the rear of the assembly.
  • Page 84 Note: Steps 22-25 for Variants 83468(AC Cardanic, Cover with 7-Pole). 33. Pull the cable through the coupling 83273 as shown. 34. Ensure that the 7-pole rotating connector is aligned so that it mates with the plug. 35. Insert the plug and seat into the connector. 36.
  • Page 85 38. Plug in the programmed light control set. 39. Tuck the wiring for the control pad into the cardanic.
  • Page 86 40. Ensure the blue ribbon cable is not caught during the connection. 41. Secure the front cover to the housing. 42. Secure (1) 67589 screw into the rear of the assembly.

  • Page 87: Light Head Maintenance

    9. Light Head Maintenance Light Handles / Focus Mechanism Chromophare E 558, E 668, E 778, F 528, F 628 Light Handle Assembly (LED) 1. Handle 2. Sleeve Chromophare E 655, E 805 Light Handle / Focus Mechanism Assembly (HID) 1.

  • Page 88: Light Handle Replacement

    9.1.1 Light Handle Replacement Note: For HID and Halogen lights, the handle has glass bulbs on the distal end. Use caution not to damage bulbs during removal and installation 1. Position the light head so that the face glass is facing upwards. 2.

  • Page 89: E558/668/778 (E Led) Light Head Maintenance

    E558/668/778 (E LED) Light Head Maintenance 9.3.1 Accessing the light head internals 1. Remove the light head from the spring arm per section 7.9 and place it on a clean dry surface with the glass facing up. 2. Remove focus handle assembly and place in safe place. 3.

  • Page 90: Lower Glass Replacement

    9.3.2 Lower Glass Replacement 1. Remove protective film from new outer glass. 2. Proceed to section 9.3.6 to reassemble the light head. 9.3.3 Frame/Frame Seal/Glass Seal Replacement 1. Loosen but do not remove the retaining screws on fixing plates and slide them toward the center of the light head for removal of the frame and seal gasket.
  • Page 91 2. Carefully remove damaged frame or gaskets being replaced 3. Install frame to dome gasket onto frame. 4. Ensure profile is fully engaged then place frame onto dome center. 5. Place fixing plates onto side of frame in a crisscross pattern. Tighten each one only slightly (Do not tighten fully on this step).

  • Page 92: Distribution Board

    9.3.4 Distribution Board The distribution board sends power to the LEDs and directs the Can-bus communications to and from each module location. Distribution board showing connection points 1. To access the distribution board, remove the 4 screws holding the center housing in place. 2.
  • Page 93 Module wiring locations on distribution board 4. Remove the 5 screws (4 corners and 1 in the center) holding the distribution board in place and lift the distribution board out of the light head. 5. Place the new board with the same orientation and secure with the 5 screws removed in step 4 above. Note: Grounding screw.

  • Page 94: Led Module Replacement

    6. Replace all of the connectors removed in step 3. Ensure all connections are firmly seated. 7. While holding the center housing assembly above the distribution board, replace the D-Sub connectors removed in step 2. Ensure all connections are firmly seated. 8.
  • Page 95 WARNING: Secure power to the lighting system prior to completing the steps below. 1. Remove bad module by removing the three perimeter screws and loosening the center post screw. Module Fastener locations 2. Pull out the LED module and disconnect the two plugs on the LED control boards. 3.

  • Page 96: Light Head Reassembly (Refer To 9.3.1 For Illustrations)

    4. Connect the 2 plugs to the new module as before. 5. Place the new module routing the wiring underneath using the same path as previously used. 6. Install the perimeter screws and the center post screw. 7. Proceed to section 9.3.6 to reassemble the light head. 9.3.6 Light Head Reassembly (Refer to 9.3.1 for Illustrations) 1.

  • Page 97: E550/650 (Halogen) And E655/805 (Hid) Light Head Maintenance

    6. Tighten all screws on Ring A and install focus handle. 7. Clean face glass prior to installing light. 8. Reinstall the light head onto the spring arm per section 7.9. 9. Restore power to the system. Insure all modules illuminate and that all controls operate properly. E550/650 (Halogen) and E655/805 (HID) Light Head Maintenance HID Technology –...

  • Page 98: Endolite

    5. To install the dome: (a) Fit new gasket onto edge of frame (if needed), making sure the gasket is not stretched. To keep the gasket from stretching, push back on the gasket every 3-4 inches until the complete unit is installed. (b) If present, connect the EndoLite wiring back to CPU connector J8.

  • Page 99: Lower Glass Assembly

    Parts List 64696 – Endo Bracke 64698 – Endo Cover Ring 66437 – Pivot for Endo Dome (Rivnut) 232 – M4 x 0.7 x 8 screw 64771 – Endo Socket 59833 – Endo Bulb 12V/20W 33 - Washer 39409 – M2.5 x 45 screw 62408 –...

  • Page 100: Replacing The Filter Glass Assembly

    9.4.4 Replacing the Filter Glass Assembly FILTER GLASS ASSEMBLY E655/805 E550/650 Shutters Open Shutters Closed Filter Glass w/ Heat Plate Note: For E655 and E805, the shutters must be fully closed for the following steps. (E650 is a halogen light and has no shutters). 1.
  • Page 101 E 550/650 Arrangement E655/805 Arrangement 7. For E655/805, mark and remove the white wire from the top of the heat plate. The 2 red wires must be disconnected at terminals 2 and 3 on the EVG board. EVG E655 EVG E805 8.
  • Page 102 12. Insert the filter glass assembly into the light, matching the position of the shutter motor with the match mark on the reflector. Connect the 6 pin quick connector for the shutter motor assembly on the way in. 13. Reinstall heat plate carefully insert screws and tighten. 14.

  • Page 103: Circuit Boards

    9.4.5 Circuit Boards 1. Secure power to the system at the circuit breaker prior to proceeding. 2. To gain access to the circuit boards, remove the dome per section 9.4.1. 3. The boards are clipped to the inside of the light frame. These illustrations show the location of the boards for the HID and Halogen lights.

  • Page 104: Camera Board (Only With In-Light Option)

    Part Number Light model(s) 79946 E 805 79947 E 655 79948 E 550/650 Note: The wiring arrangement. Label and remove the connectors from the board. c. Unclip the board from the frame. d. Each CPU is assigned a unique address based on the configuration of the light in the room. This is done with a series of dip switches in the center of the CPU board.

  • Page 105: Dimming Control Board (E550/650)

    The camera board routes power and Can-bus communication signals to the in-light camera (if installed). To replace: a. Locate the camera board. b. Note the wiring arrangement. Label and remove the connectors from the board. c. Unclip the board from the frame. d.

  • Page 106: Light Head Dome Cover Replacement For F528/F628

    The EVG board provides power to the HID (primary) and Halogen (backup) bulbs. It also provides a high voltage surge to ignite the gas in the HID bulb for starting. The board is attached to the frame of the light with fasteners to allow for heat dissipation.
  • Page 107 4. Remove the cover from the light head. 5. Get the replacement light cover. 6. Put the new cover on the light. Make sure the Berchtold logo faces the cardanic arm. 7. Make sure that the seam lines up with the cardanic arm and that the cover goes over the top of all hook and loop tape mounts.
  • Page 108 9. Once the hook and loop tape is fully aligned around the circumference , press down around the edges of the cover to engage the hook and loop tape completely. You should be able to feel and hear when the tape is completely engaged. 10.

  • Page 109: Control Panels

    10. Control Panels 10.1 Halogen and HID light controls (Exx5/Exx0) 1. Control circuits Cardanic and wall a) Controller options are available in Single, Double or Triple control, wall mounted box (CFWP), SK (power supply) box mounted or on the individual light head or spring arm. The wall control is available in flush mounted, using a supplied recessed box, or surface mounted on a painted mounting box mounted on the surface of the wall.
  • Page 110 b) Secure power to the system c) Each circuit board is held in with screws and washers and connected to the Can-Bus string with a 4-pole Molex cable for control and power to the wall control. d) Remove screws and disconnect can-bus cables from board to be replaced. e) Set the dip switches on the new board to match the board being replaced.
  • Page 111 4. HID (Exx5) Keypad Service menu a) To access the service menu, press and hold the hidden Service Menu button for until the Standby LED blinks green and the first LED of the brightness display lights up green. b) Use the brighten (large bulb) button to select menu item 1, 4 or 6. This is displayed by the lighting 1, 4 or 6 LEDs of the brightness display and pressing the Sleep (moon) key to confirm.
  • Page 112 d) Four LEDs is the command to reset the CPU. If the reset is successful, the amber indicator on the cardanic will go out for 1-2 seconds. Note: This will clear the internal memory of the light head CPU. This will reset the 15 minute cool down timer for the HID bulb.

  • Page 113: Led Light Controls - E Led And F-Generation (Exx8/Fxx8)

    f ) Press the Brighter and Darker buttons to adjust the bulb voltage to the target value of22.8 V ± 0.5 V. Note: By pressing the Darker button, the bulb voltage is reduced in about 0.1 V increments. By pressing the Lighter button, the bulb voltage is increased in about 0.1 V increments.
  • Page 114 2. Controller functions a) The On/Off button on the keypad will blink once every 5 seconds when the light is off. This is the normal “standby” behavior. b) When utilizing any touchpad function; press and hold the button for 2-5 seconds to accomplish activation of that function.
  • Page 115 c) One LED is the command to reset the keypad. If the reset is successful, the keypad will cycle. Note: This command does not alter software programmed addressing. d) Three LEDs is the command for Can-bus ID addressing. This sets the can-bus ID of the light. The procedure is in step 5 below.
  • Page 116 Disconnecting Can-bus at the suspension c) Using the Service Menu on the keypad of the light you want to address, go to option 3, and press the On/Off button to confirm. Note: This will then send a signal on the can-bus to the light head distribution board and all its LED modules changing their can-bus ID to match the keypad.
  • Page 117 will cycle. Note: This command does not alter software programmed addressing. d) 2 LEDs is the command for Keypad Addressing. The graphic below describes its functionality. e) The 3 and 4 LED commands are used together for Light Head addressing. The graphic below describes their functionality.
  • Page 118 7. F-Generation (Fxx8) - Touch screen The CHROMOPHARE F-Generation added the option for Interactive Touch Screen controls from the wall, the light head cardanic, or both. The touch screens include controls to adjust: • Intensity • Focus • Color Temperature •...
  • Page 119 Slide the DIP switch no. 3 to ON position as shown below. Plug in the power / CAN connector and wait until the program “TSLIB calibration utility” starts on the screen. c) Calibrate the touch controller by pressing the finger on the crosshair positions until the program “TSLIB test program”...
  • Page 120 c) In the service main menu, press “Addr” to start the addressing mode. All available light heads will be listed. “Addr” button in All available light heads listed service main menu Select to address d) Connect the touch display to the dedicated light by pressing the number of the light head. 10.
  • Page 121 11. Touch Screen CAN bus termination – Wall Controls The touch screen controls should work properly as configured; however, in cases where the cable length exceeds about 20 meters, the CAN bus system may not properly recognize the controls. In these cases, the CAN Bus connection must be terminated (120 Ohm) by setting DIP switch number 4 on the touch screen circuit board.

  • Page 122: Power Supply Service Instructions

    11. Power Supply Service Instructions 11.1 General Information Chromophare power supplies can be mounted 2 ways depending on the desired configuration: • Tube mounted – Electrical components are mounted directly to the ceiling tube. Tube mounted components for 2 lights •...

  • Page 123: Sk Boxes

    11.2 SK Boxes 1. SK Box Layout Internals of an SK box with components for 2 lights. Each plate of components may be removed from the SK box by removing the four indicated screws. Each plate of electronics contain: 1 – Terminal/Fuse/ Grounding blocks.
  • Page 124 2. Component replacement To replace the Transformer: • Turn off the main power at the circuit breaker • Note and record the location of all wires and disconnect wiring from the transformer. • Remove the four indicated mounting screws. • Replace the transformer. Reassemble in reverse order.
  • Page 125 Fuse block replacement: • Turn off the main power at the circuit breaker • Work with the hospital/electrician to ensure power to the room and the Chromophare system is turned off. Carefully disconnect the Chromophare system from hospital mains. WARNING: Failure to turn off the main power to the Chromophare system prior to disconnecting wires can result in electrical shock.

  • Page 126: Tube Mounted Power Supplies

    • Remove existing “N” label from the existing neutral block for reuse. • Using service kit P41494: • Connect the 8 amp fuse (500393) to the fuse clamp (39965) and secure by twisting clockwise. Add end bar (39967) to the fuse clamp.
  • Page 127 • Using service kit P41494: • Connect the 8 amp fuse (500393) to the fuse clamp (39965) and secure by twisting clockwise. Add end bar (39967) to the fuse clamp. • Mount the new Line, Neutral, and Ground blocks to the DIN rail as described. The arrows on the fuse clamps must be facing the tube when electronics are tube mounted.
  • Page 128 • Add label “N” to each terminal block. Add label “L” to each fuse clamp. • Reconnect Chromophare system wires to the new blocks: black wire to Line block (fuse clamp), white wire to Neutral block (not fused), each green and yellow wire to a ground block.
  • Page 129 11.3 Tube mounted power supplies 1. Tube mounted Power supply layout Tube mounted power supplies have the same components and wiring as the SK box version. They are mounted around the base of the ceiling tube flange. Ceiling tube with components for 2 lights plus a camera distribu- Tube mounted power supply shown including the fused tion board terminal and grounding blocks...

  • Page 130: Camera Distribution Board

    11.4 Camera distribution board If the lighting system is configured to utilize a Chromovision® In-line HD Camera system, a camera distribution board may also be installed on the ceiling tube. 1. Component replacement Turn off the main power at the circuit breaker. If also replacing the CAN bus cable, note that the wiring colors may have changed.

  • Page 131: Preventative Maintenance

    12. Preventative Maintenance Preventative Maintenance instructions are located in BWI160314.01 Preventative Maintenance Data Sheet CHROMOPHARE, E-Series and Flat Panel and BWI160314.08 Preventative Maintenance Data Sheet CHROMOPHARE, F-Generation and Flat Panel.

  • Page 132: Contact Information

    13. Contact Information Contact Stryker Customer Service with questions or concerns. Stryker Communications 571 Silveron Blvd. Flower, Mound, TX 75028 Toll Free: (866) 841-5663 1-972-410-7100 For international service locations, refer to the Stryker website at the following URL: www.stryker.com.
  • Page 133 Stryker Communications 571 Silveron Blvd. Flower Mound, TX 75028 1-866-841-5663 www.stryker.com Stryker Corporation or its divisions or other corporate affiliated entities own, use or have applied for the following trademarks or service marks: the Stryker and Berchtold logos. All other trademarks are...

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