Trumpf Xenion Helion Service manual
XENION® HELION® Surgical Lighting System
Service Manual
To the Service technician,
Please read through this service manual with great care and comply with the safety information and requirements for servicing.
CE markingCE marking
CE marking
CE markingCE marking
This item of equipment is a Class I medical device as defined by
the European Medical Device Directive (MDD) 93/42/EEC, June
1993, Appendix IX.
Conformity
The manufacturer declares that this product conforms to the fundamental requirements according to MDD Appendix I and documents this by means of the CE marking.
What equipment forms the subject of this service manual?What equipment forms the subject of this service manual?
What equipment forms the subject of this service manual?
What equipment forms the subject of this service manual?What equipment forms the subject of this service manual?
The surgical lighting system with the following variants:
• 1 to 4-fold suspension with the following types of lamp:
HELION
®
with halogen lamp:
• HELION S; HELION M/M+; HELION L/L+.
XENION
®
with metal vapour lamp:
• XENION M/M+; XENION L/L+.
And the following optional equipment:
• TFT flat screens 15
“ and 19“,
• HELION M/M+; L/L+; XENION M+ with fixed focus camera.
• TruVidia camera system.
TT
echnical Customer Service is at your disposal,echnical Customer Service is at your disposal,
T
echnical Customer Service is at your disposal,
TT
echnical Customer Service is at your disposal,echnical Customer Service is at your disposal,
• if you have any questions on disassembly, repairs or settings,
or
• if you would like to re-order spare parts.
2
Sales
Service
Visit us on the Internet
How to contact usHow to contact us
How to contact us
How to contact usHow to contact us
• TRUMPF KREUZER Medizin Systeme GmbH + Co. KG
• Benzstrasse 26
• 82178 Puchheim, Germany
• Telephone: +49 / (0)89 / 8 09 07 - 0
• Fax: +49 / (0)89 / 8 09 07 - 2 22
• Telephone: +49 / (0) 180 / 2 25 41 35
• Fax: +49 / (0) 36 71 / 58 61 75
© TRUMPF KREUZER, 2004
• Edition: 03/2005, Version 1 (15.03.2005)
www.Trumpf-med.com
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB
Notes relating to this documentation
Copyright
We reserve the right to
make changes
Copyrights
Translations
Trademarks
• The information contained in this service manual and parts
thereof are the intellectual property of TRUMPF KREUZER
Medizin Systeme GmbH + Co. KG and is protected by national and international copyright and other laws for the protection of intellectual property.
• Any duplication, reproduction, translation, microfilming storage - in either electronic or magnetic form - processing as
electronically or magnetically stored data, copying or distribution of these documents and/or the information contained
herein or parts thereof without the prior written approval of
TRUMPF KREUZER Medizin Systeme GmbH + Co. KG is hereby
strictly prohibited.
TRUMPF KREUZER Medizin Systeme GmbH + Co. KG shall
assume no liability whatsoever on the basis of, or in association with, the use of said information prohibited in this manner
by any person or company.
• TRUMPF KREUZER Medizin Systeme GmbH + Co. KG reserves
the right to amend, delete or modify in any other manner all
information contained herein at any time and on any grounds
without prior notice.
We are constantly engaged on the further development of our
products and reserve the right to make changes to the scope
of supply in terms of design, equipment or technology.
• TRUMPF KREUZER Medizin Systeme GmbH + Co. KG explicitly reserves all rights under the copyright laws.
• The German-language version of this service manual shall be
binding as regards translations into foreign languages.
• The HELION
®
and XENION® lamps are registered trademarks
of TRUMPF KREUZER Medizin Systeme GmbH + Co. KG.
• All trademarks mentioned in this service manual are the sole
property of the respective manufacturers.
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB 3
Contents
11
Important Information for the Service TImportant Information for the Service T
1
Important Information for the Service T
11
Important Information for the Service TImportant Information for the Service T
1.1 Information for the service technician .......................... 8
1.2 Tools and equipment required .................................... 8
1.3 Proper servicing ........................................................ 9
1.4 Warranty and liability ................................................. 9
1.5 Disposal ................................................................... 9
22
YY
our Safety is Important to Usour Safety is Important to Us
2
Y
our Safety is Important to Us
22
YY
our Safety is Important to Usour Safety is Important to Us
2.1 Symbols used in this service manual ......................... 10
2.2 Symbols on the equipment ....................................... 10
2.3 Overview of the most important safety information ..... 11
33
Observe these WObserve these W
3
Observe these W
33
Observe these WObserve these W
44
TT
able - Table - T
4
T
able - T
44
TT
able - Table - T
55
Changing the LChanging the L
5
Changing the L
55
Changing the LChanging the L
roubleshooting and Proubleshooting and P
roubleshooting and P
roubleshooting and Proubleshooting and P
ork Rork R
ulesules
ork R
ules
ork Rork R
ulesules
ampamp
..........................................................................................
amp
.............................................
ampamp
..........................................................................................
..............................................................
...............................
..............................................................
........................................................................
....................................
........................................................................
ossible Rossible R
ossible R
ossible Rossible R
echnicianechnician
echnician
echnicianechnician
emediesemedies
emedies
emediesemedies
............
......
............
............
......
............
1010
10
1010
1313
13
1313
1414
14
1414
1717
17
1717
88
8
88
5.1 Changing the lamp of the HELION S ........................ 17
5.2 Changing the lamp of the HELION M/M+ / L/L+ ..... 17
5.3 Changing the lamp of the XENION M/M+ ...............18
5.4 Changing the lamp of the XENION L/L+ ..................19
66
Setting the LSetting the L
6
Setting the L
66
Setting the LSetting the L
6.1 Setting the luminous field for the
HELION M/M+ / L/L+ ........................................... 20
6.2 Setting the luminous field for the XENION M/M+ ...... 21
6.3 Setting the luminous field for the XENION L/L+ ......... 22
6.4 Setting the luminous field for the XENION M
with fixed focus camera ........................................... 22
77
RR
eplacing the Feplacing the F
7
R
eplacing the F
77
RR
eplacing the Feplacing the F
88
TT
esting the Servomotor for theesting the Servomotor for the
8
T
esting the Servomotor for the
88
TT
esting the Servomotor for theesting the Servomotor for the
HELION M/M+ L/L+HELION M/M+ L/L+
HELION M/M+ L/L+
HELION M/M+ L/L+HELION M/M+ L/L+
8.1 Testing the polarity of the servomotor ........................ 24
8.2 Testing the servomotor ............................................. 25
99
TT
esting the Input Vesting the Input V
9
T
esting the Input V
99
TT
esting the Input Vesting the Input V
uminous Fuminous F
uminous F
uminous Fuminous F
ilter Glass Assemblyilter Glass Assembly
ilter Glass Assembly
ilter Glass Assemblyilter Glass Assembly
ieldield
........................................................................
ield
....................................
ieldield
........................................................................
....................................................................................
..........................................
....................................................................................
oltagesoltages
oltages
oltagesoltages
..........................................................................
.....................................
..........................................................................
............................................
......................
............................................
2020
20
2020
2323
23
2323
2424
24
2424
2626
26
2626
4
9.1 Testing the input voltage of the transformer ............... 26
9.2 Testing the mains fuse for the building
power supply .......................................................... 26
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB
Contents
1010
TT
esting the Electrics of the Support Systemesting the Electrics of the Support System
10
T
esting the Electrics of the Support System
1010
TT
esting the Electrics of the Support Systemesting the Electrics of the Support System
10.1 Testing the voltage at the sliding contact in the extension
arm........................................................................ 27
10.2 Replacing the sliding contact in the extension arm/
Testing the slip ring on the central column ................. 28
10.3 Dismantling the light head ....................................... 29
10.4 Testing the cables in the spring arm that lead to the
contact block
in the extension arm ................................................29
10.6 Testing the cables in the extension arm...................... 30
10.7 Replacing the cables in the extension arm .................31
10.8 Dismantling the central column ................................31
10.9 Replacing the slip ring ............................................. 32
1111
TT
esting the Electrics of theesting the Electrics of the
11
T
esting the Electrics of the
1111
TT
esting the Electrics of theesting the Electrics of the
..........................
.............
..........................
2727
27
2727
HELION M / L LHELION M / L L
HELION M / L L
HELION M / L LHELION M / L L
11.1 Testing the voltage at the focus unit .......................... 33
11.2 Testing the voltages and cables in the lamp ............... 34
1212
TT
esting the Electrics of theesting the Electrics of the
12
T
esting the Electrics of the
1212
TT
esting the Electrics of theesting the Electrics of the
HELION M+ / L+ LHELION M+ / L+ L
HELION M+ / L+ L
HELION M+ / L+ LHELION M+ / L+ L
12.1 Testing the voltage at the focus unit .......................... 36
12.2 Testing the operating voltages, fuse and
cables in the lamp ................................................... 37
12.3 When the dimmer is defective .................................. 39
1313
TT
esting the Electrics of theesting the Electrics of the
13
T
esting the Electrics of the
1313
TT
esting the Electrics of theesting the Electrics of the
XENION M/M+ / L/L+ LXENION M/M+ / L/L+ L
XENION M/M+ / L/L+ L
XENION M/M+ / L/L+ LXENION M/M+ / L/L+ L
13.1 Testing the operating voltages, fuses and
cables in the lamp ................................................... 40
13.2 When the dimmer is defective .................................. 42
1414
FF
unctional Check, Hand-unctional Check, Hand-
14
F
unctional Check, Hand-
1414
FF
unctional Check, Hand-unctional Check, Hand-
ampamp
........................................................................................
amp
............................................
ampamp
........................................................................................
ampamp
............................................................................
amp
......................................
ampamp
............................................................................
ampamp
............................................................
amp
..............................
ampamp
............................................................
Over and CustomerOver and Customer
Over and Customer
Over and CustomerOver and Customer
3333
33
3333
3636
36
3636
4040
40
4040
InstructionInstruction
Instruction
InstructionInstruction
14.1 Important Information .............................................. 43
14.2 Inspection intervals and authorised staff ....................43
14.3 Monitoring activities ................................................ 44
14.4 Testing the function of the lamps............................... 48
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB 5
......................................................................................................................
...........................................................
......................................................................................................................
4343
43
4343
Contents
15 T15 T
15 T
15 T15 T
15.1 Data sheets ............................................................ 50
15.2 Circuit diagrams and set values ................................ 52
echnical Descriptionechnical Description
echnical Description
echnical Descriptionechnical Description
15.2.1 HELION M/M+; HELION L/L+; HELION XL+ ..52
15.2.2 XENION M/M+; XENION L/L+........................ 53
15.2.3 XENION M / M+ ............................................ 54
15.2.4 XENION L/L+ ................................................. 55
15.2.5 HELION M+; HELION L+
with wall control panel ..................................... 56
15.2.6 XENION M/M ; XENION L/L+
with wall control panel ..................................... 57
15.2.7 24 V power supply AC/DC HELION M/M+;
HELION L/L+ ; HELION XL+;
XENION M/M+; XENION L/L+........................ 58
15.2.8 TruVidia combination
with HELION M/M+; HELION L/L+; HELION XL+;
XENION M/M+; XENION L/L+ lamps ...............59
15.2.9 7-pole plug -> cardanic suspension
TruVidia 8-pole DIN socket ...............................60
15.2.10 5-pole plug TFT LCD monitor with cardanic suspen-
sion; (optional DC/DC converter) ...................... 61
15.2.11 TFT LCD monitor .............................................. 62
15.2.12 TFT LCD monitor
with monitor power supply unit .......................... 63
15.2.13 Plug connector -> TruVidia spring arm .............. 64
15.2.14 Plug connector -> spring arms
3-pole / 5-pole / 7-pole................................... 65
15.2.15 HELION M/L light head ....................................66
15.2.16 HELION M/L light head
with fixed focus camera .................................... 67
15.2.17 HELION M/L light head
with TruVidia .................................................... 68
15.2.18 HELION M+/L+ light head .............................. 69
15.2.19 HELION M+/L+ light head
with wall control panel ..................................... 70
15.2.20 HELION M+/L+ light head
with fixed focus camera .................................... 71
15.2.21 HELION M+/L+ light head
with TruVidia .................................................... 72
15.2.22 HELION M+/L+ light head
with fixed focus camera and wall control panel... 73
....................................................................................
..........................................
....................................................................................
5050
50
5050
6
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB
Contents
15.2.23 XENION M light head ...................................... 74
15.2.24 XENION M light head
with wall control panel ..................................... 75
15.2.25 XENION M light head
with fixed focus camera .................................... 76
15.2.26 XENION M light head
with TruVidia .................................................... 77
15.2.27 XENION L light head ........................................78
15.2.28 XENION L light head
with wall control panel ..................................... 79
15.2.29 XENION L light head
with TruVidia .................................................... 80
15.2.30 XENION M+ light head.................................... 81
15.2.31 XENION M+ light head
with wall control panel ..................................... 82
15.2.32 XENION M+ light head
with fixed focus camera .................................... 83
15.2.33 XENION M+ light head
with TruVidia .................................................... 84
15.2.34 XENION M+ light head
with fixed focus camera and wall control panel... 85
15.2.35 XENION L+ light head .....................................86
15.2.36 XENION L+ light head
with wall control panel ..................................... 87
15.2.37 XENION L+ light head
with TruVidia .................................................... 88
15.2.38 HELION/XENION transformer connector ........... 89
15.3 Test report .............................................................. 90
16 T16 T
16 T
16 T16 T
echnical Dataechnical Data
echnical Data
echnical Dataechnical Data
........................................................................................................
....................................................
........................................................................................................
9191
91
9191
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB 7
1 Important Information for the Service Technician
Only for trained and authorised
fitters
Servicing in accordance with
this service manual
Use original parts only
In case of problems
Defective parts
Repairs outside the scope of
the repair order
No unauthorised or
temporary repairs
1.11.1
1.1
1.11.1
This service manual is intended only for service technicians
trained and authorised by TRUMPF KREUZER Medizin Systeme GmbH + Co. KG.
Information for the service technicianInformation for the service technician
Information for the service technician
Information for the service technicianInformation for the service technician
• Servicing must be carried out in steps according to this service
manual.
• The safety, reliability and performance of the equipment is only
ensured where TRUMPF KREUZER original parts are used.
• If, when dismantling, making repairs or settings, you encounter problems which are not covered by this service manual or
not covered in sufficient detail, you should immediately contact your nearest TRUMPF KREUZER Customer Service Centre
for your own safety and that of the hospital staff and patients.
Only carry out repairs that you are familiar with from your
training and which are included in this service manual.
• Replace any defective parts with TRUMPF KREUZER original
parts.
If it should be necessary to replace parts outside the scope of
the repair order, discuss this work with the customer first.
• Unauthorised or temporary repairs are not permitted even if
requested by the customer.
Comply with all the requirements from the current laws, regulations and standards.
• For information and to order spare parts please contact
TRUMPF KREUZER Service
(Telephone: +49 / (0) 180 / 225 4135).
1.21.2
1.2
1.21.2
TT
ools and equipment requiredools and equipment required
T
ools and equipment required
TT
ools and equipment requiredools and equipment required
• Basic equipment:
- fitter’s tool set,
- cordless screwdriver
• Measuring instruments:
- luxmeter (for measuring light intensity),
- voltmeter (for making electrical measurements).
• For fitting/dismantling heavy components:
- Lifting equipment with a permitted load of at least 200 kg. The
lift must correspond at least to the height of the ceiling.
- Ladder with necessary length.
• Accessories:
- cable ties
8
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB
1 Important Information for the Service Technician
Check the installation position
of the cables
Installing safety devices
Before the functional check
Check the PE connections
Carry out functional check
1.31.3
1.3
1.31.3
Observe the following rules when carrying out service work:
• Put the cables back in their original installation position.
• Install or renew all safety devices such as covers, cable ties,
• Check cables that have been detached or been renewed against
• Check that the earth connections comply with the current stand-
• Carry out a functional check according to Chapter 14:
1.41.4
1.4
1.41.4
TRUMPF KREUZER Medizin Systeme GmbH + Co. KG assumes
no liability for the reliable and proper functioning of the
surgical lighting system if:
• installation, modifications and repairs are not performed by
• The electrical installation of the respective equipment does not
• The surgical lighting system is used other than for its intended
PP
roper servicingroper servicing
P
roper servicing
PP
roper servicingroper servicing
Check the cables when positioning the lamp etc. to ensure
they are not severed or squashed.
cable holders, cable shields, ground, equipotential bonding
and earth connections.
the circuit diagrams in this service manual to ensure they have
been properly connected.
ards in your country.
“Functional Check, Hand-Over and Customer Instruction”.
WW
arranty and liabilityarranty and liability
W
arranty and liability
WW
arranty and liabilityarranty and liability
TRUMPF KREUZER service technicians or persons authorised
by TRUMPF KREUZER.
comply with the regulations currently applicable.
purpose as stated in the operating instructions.
1.51.5
1.5
1.51.5
• Please dispose of the packaging materials according to the
• Observe that it is compulsory to recycle removed components,
DisposalDisposal
Disposal
DisposalDisposal
applicable guidelines for disposal.
particularly electronic components and cables.
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB 9
2 Your Safety is Important to Us
DANGER
WARNING
CAUTION
NOTE
2.12.1
2.1
2.12.1
Important information is shown in this service manual and
on the equipment using symbols and key words.
Signal words such as DANGER, WARNING or CAUTION indicate the level of risk. This is visually emphasised by the
different triangle symbols.
The signs have the following meanings:
Symbols used in this service manualSymbols used in this service manual
Symbols used in this service manual
Symbols used in this service manualSymbols used in this service manual
Failure to comply will certainly result in
severe or even fatal injury.
Failure to comply may result in
severe or even fatal injury.
Failure to comply may result in
minor or moderate injury or damage to property.
Offers tips on usage and handy information.
Electric shock
Falling load
Sudden release
of spring arm
Biohazard
Laser radiation
Danger of
tripping
Danger of an electric shock which may result in severe or even
fatal injury.
Danger of a falling load when in the installation area under a light
system or following incorrect installation.
Danger of sudden release of the spring arm when dismantling the
lamps.
Danger of infection due to the lighting system not being cleaned
and disinfected.
Danger of eye damage due to the optional laser (Class 2) in the
central hand grip.
Danger of tripping and falling over tools or components in the
hospital staff’s path.
2.22.2
2.2
2.22.2
Symbols on the equipmentSymbols on the equipment
Symbols on the equipment
Symbols on the equipmentSymbols on the equipment
10
ATTENTION! Comply with operating instructions.
CE conformity marking with
number 0123 of notified body.
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB
2 Your Safety is Important to Us
2.32.3
2.3
2.32.3
Hazards from electric shockHazards from electric shock
Hazards from electric shock
Hazards from electric shockHazards from electric shock
DANGER – power supply and emergency power supply:
During all servicing the building power supply and the emergency
power supply must be de-energised all-pole disconnection and
prevented from being switched back on again.
DANGER – Electric shock - High voltage 300 V:
The ballast in XENION lamps produces a starting voltage of
300 V:
When carrying out measurements in the lamps and when the power
is switched on:
• cordon off the installation site,
• avoid all contact with conductive parts.
Overview of the most important safety informationOverview of the most important safety information
Overview of the most important safety information
Overview of the most important safety informationOverview of the most important safety information
FF
alling lighting system partsalling lighting system parts
F
alling lighting system parts
FF
alling lighting system partsalling lighting system parts
DANGER – Falling lighting system parts:
During servicing it is not permitted to stand under the lighting system.
Sudden release of spring armSudden release of spring arm
Sudden release of spring arm
Sudden release of spring armSudden release of spring arm
WARNING - Sudden release of spring arm:
• The spring arm is under high tension. If the lamp is not removed in the uppermost spring arm position, the spring arm
releases suddenly, springing upwards, and can cause serious
injury.
• Only dismantle the lamp when the spring arm is in the uppermost position.
Eye damage due to the optional laserEye damage due to the optional laser
Eye damage due to the optional laser
Eye damage due to the optional laserEye damage due to the optional laser
WARNING – Laser radiation (LASER CLASS 2) -
Do not look directly at the beam from the central hand grip:
Laser radiation does not constitute a danger to persons who are
not anaesthetised, due to the blink reflex.
Nevertheless, to avoid damaging your eyes you should not look
directly at the laser beam.
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB 11
2 Your Safety is Important to Us
2.32.3
2.3
2.32.3
FF
F
FF
WARNING – Failure of the spare lamp:
Always change both lamps. When replacing the lamp always replace the entire lamp unit.
In the case of HELIUM models, the lamp base must also be replaced.
Damage to components of the lighting systemDamage to components of the lighting system
Damage to components of the lighting system
Damage to components of the lighting systemDamage to components of the lighting system
CAUTION – Damage to lamps:
Handle and insert new lamps by the packaging film/using a soft
cloth only.
Overview of the most important safety informationOverview of the most important safety information
Overview of the most important safety information
Overview of the most important safety informationOverview of the most important safety information
(cont(cont
’d)’d)
(cont
’d)
(cont(cont
’d)’d)
ailure of the lamps during an operationailure of the lamps during an operation
ailure of the lamps during an operation
ailure of the lamps during an operationailure of the lamps during an operation
Before initial operation of the lighting systemBefore initial operation of the lighting system
Before initial operation of the lighting system
Before initial operation of the lighting systemBefore initial operation of the lighting system
WARNING – Malfunction:
Before the initial operation of the lighting system the electrical
supply has to be checked and approved by qualified staff.
12
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB
3 Observe these Work Rules
WARNING – Risk of infection:
Ask a doctor about the possible risks (e.g. hepatitis B) of
being a service technician.
After consulting a doctor, get yourself vaccinated against
hepatitis B. A booster is required every 10 years.
Disinfection of the equipment must be organised in good
time before servicing and must be carried out by the operator.
• Servicing must only be carried out on lighting systems which
have been cleaned and disinfected,
• Comply with hygiene guidelines concerning cleaning, disinfection and clothing,
• Only work in the operating theatre with the permission of the
user,
• Observe the code of practice in force at the medical facility,
particularly in the operating theatre,
• If you have any symptoms, consult a doctor immediately.
Inform your doctor that you have worked in hazardous areas –
even after several months.
WARNING – Wear protective eyewear:
Wear protective eyewear in case of a possible risk to eyes,
in particular when carrying out the following work:
• hammering pins or similar components in/out,
• removing tensioned springs and fuses,
• when drilling,
• when soldering,
• when using solvents, cleaning agents or other chemicals.
CAUTION – Tripping and falling:
• Put dismantled components or tools somewhere that nobody
can trip and fall over them.
• Keep your work place clean and tidy during and after servicing.
7200791 Service Manual for the HELION® XENION® Surgical Lighting System GB 13
4 Table – Troubleshooting and Possible Remedies
Fault Possible causes Possible remedy Section
LED lamp indicator lit up Lamp defective Change lamp 5
Luminous field too small/
luminous intensity too low
Noises in the light head Loose parts in the light
HELION light head Possible causes Possible remedy Section
Inconsistent, off-centre luminous
field with HELION
M / M+/ L / L+ only
No light No input voltage Check building power supply 9.1
Maladjusted limit stops Adjust luminous field 6
Check light head/focus unit/ replace
head/focus unit
Servomotor polarity incorrect/
servomotor defective
Mains fuse of building power
supply defective
Electrical connections for lamp,
cardanic suspension, spring arm
or extension arm interrupted
Defective sliding contact in
extension arm
Defective cable in light
head/cardanic suspens ion
Defective cable in spring arm Check/replace internal electrical
filter glass assembly or defective
parts
Check polarity of
servomotor/replace focus unit
Check mains fuse at automatic circuit
breaker
Check internal electrical supply lines
of lamp, cardanic suspension, spring
arm or extension arm
Replace sliding contact in extension
arm/check slip ring on central column
Check/replace internal electrical
supply line in light head/
replace cardanic suspension
supply line in spring arm
7 ff.
8
9.2
10
10.1
10.2
10.3
10.4
10.4
10.5
Defective cable in extension arm Check/replace internal electrical
supply line in extension arm
Defective slip ring on central
column
Contact areas burnt/damaged HELION M / M+ / L / L+:
Line contact on PCB in light head
defective/
PCB defective/fuse on PCB
defective/cables in light head
defective
Line contact on PCB in light head
defective/
PCB defective/fuse on PCB
defective/cables in light head
defective
Replace slip ring on central column 10.8
Check operating voltage on focus
unit/replace unit
HELION M / M+ / L / L+:
Check positioning of cables on PCB
and control panel/
replace PCB/replace lamp supply
lines
HELION M / L:
Check positioning of cables on PCB
and control panel/
replace PCB/replace cables in light
head
10.6
10.7
10.9
11.1
12.1
11.1
12.1
11.2
14
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
4 Table – Troubleshooting and Possible Remedies
Fault Possible cause Possible remedy Section
No light Line contact on PCB in light head
defective/
PCB defective/
fuse on PCB defective
Check positioning of cables on PCB
and control panel/
replace PCB/replace fus e/
replace cables in light head
12.2
Line contact on PCB in light head
defective/
PCB defective/
fuse on PCB defective
No dimmer function Line contact on PCB/control
panel in light head defective
Check positioning of cables on PCB
and control panel/
replace PCB/replace fus e
Check positioning of cables on PCB
and control panel
13.1
13.2
®
XENION® Surgical Lighting System GB
157200790 Service Manual for the HELION
4 Table – Troubleshooting and Possible Remedies
XENION light head
No light No input voltage Check building power supply 9.1
Mains fuse for building power
supply defective
Electrical connection for lamp,
cardanic suspension, spring arm
or extension arm interrupted
Defective sliding contact in
extension arm
Defective cable in light
head/cardanic suspension
Defective cable in spring arm Check/replace internal electrical
Defective cable in extension arm Check/replace internal electrical
Defective slip ring on central
column
Contact areas burnt/damaged Check operating voltage at focus
Check mains fuse at automatic circuit
breaker
Check internal electrical supply lines
for lamp, cardanic suspension, spring
arm or extension arm
Replace sliding contact in extension
arm/check slip ring on central column
Check/replace internal electrical
supply line in light head/
replace cardanic suspension
supply line in spring arm
supply line in extension arm
Replace slip ring on central column 10.8
unit/replace unit
9.2
10
10.1
10.2
10.3
10.4
10.4
10.5
10.6
10.7
10.9
13.1
Line contact on PCB in light head
defective/
PCB defective/fuse on PCB
defective/cables in light head
defective/ballast defective
The halogen lamp does not light
up when switched on
Only the halogen lamp lights up Metal vapour lamp
No dimmer function Line contact on
Dimmer functioning incorrectly Reversed potentiometer polarity Change potentiometer polarity
Halogen lamp defective/no
power supply available
defective/power supply to
electronics too low/high
PCB/potentiometer/ballast in
light head defective
Check positioning of cables on PCB
and control panel/replace PCB/
replace fuse on PC B/
replace cables in light head
XENION L / L+ only:
Replace lamp/check voltage of
electronics
XENION L / L+ only:
Replace lamp/check LED indicator on
the electronics/check voltage
Check positioning of cables on
PCB/potentiometer/control
panel/replace potentiometer
13.1
5.4
13.2
16
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
5 Changing the Lamp
Figure 01
Figure 02
5.15.1
5.1
5.15.1
Changing the lamp of the HELION SChanging the lamp of the HELION S
Changing the lamp of the HELION S
Changing the lamp of the HELION SChanging the lamp of the HELION S
The lamp does not light up.
Removal:
1. Carefully turn the lamp holder 2 and remove it
from the HELION S lamp 3.
2. Carefully remove the old lamp 1 from the lamp
holder 2 and dispose of it in the appropriate
manner.
Installation:
3. Fit the new lamp 1 holding it by the packaging
film/using a soft cloth and fit the components as
described above, but in the reverse order.
5.25.2
5.2
5.25.2
Changing the lamp of the HELION M/Changing the lamp of the HELION M/
Changing the lamp of the HELION M/
Changing the lamp of the HELION M/Changing the lamp of the HELION M/
M+ / L/L+M+ / L/L+
M+ / L/L+
M+ / L/L+M+ / L/L+
The display 8 is lit up. The lamp is defective.
Removal:
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
WARNING – Failure of the spare lamp:
• Always change both lamps.
• When replacing the lamp always replace the
lamp base too.
2. Undo the three screws 3 and remove the focus
unit 4.
3. Unscrew the two cross-recessed head screws 5
and remove the old lamp 6 together with the
base 7 by pulling it upwards and dispose of it in
an appropriate manner.
Installation:
4. Fit the new lamp 6 together with the base 7
holding it by the packaging film/using a soft cloth
and fit the components as described above, but
in the reverse order.
5. Insert the focus unit 4 into the lamp so that both
the plug connectors 9 are aligned.
6. Tighten the three screws 3 by hand.
7. Attach the central hand grip 2.
®
XENION® Surgical Lighting System GB
177200790 Service Manual for the HELION
5 Changing the Lamp
Figure 03
5.35.3
5.3
5.35.3
Removal:
1. Unlock the central hand grip 2 by means of the
2. Undo the three screws 3 and remove the focus
3. Remove the old metal vapour lamp 4 by pulling
Installation:
4. Fit the new metal vapour lamp 4 holding it by
5. Insert the focus unit 5 into the lamp so that both
6. Tighten the three screws 3 by hand.
7. Attach the central hand grip 2.
Changing the lamp of the XENION M/Changing the lamp of the XENION M/
Changing the lamp of the XENION M/
Changing the lamp of the XENION M/Changing the lamp of the XENION M/
M+M+
M+
M+M+
unlocking device 1 and remove it.
unit 5.
it upwards and dispose of it in an appropriate manner.
the packaging film/using a soft cloth and assemble
the components as described above, but in the
reverse order.
the plug connectors 6 are aligned.
18
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
5 Changing the Lamp
Figure 04
5.45.4
5.4
5.45.4
Removal:
Changing the lamp of the XENION L/Changing the lamp of the XENION L/
Changing the lamp of the XENION L/
Changing the lamp of the XENION L/Changing the lamp of the XENION L/
L+L+
L+
L+L+
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
2. Undo the three screws 3 and remove the focus
unit 9.
3. Turn the aperture attachment 5 45 degrees to
the left (anti-clockwise) and remove by pulling upwards.
WARNING – Failure of the spare lamp:
• Always change both lamps (supplied as a
set).
4. Using a screwdriver, push out the old halogen lamp
4, remove it from the aperture attachment 5
and dispose of it in an appropriate manner.
5. Remove the old metal vapour lamp 6 by pulling
it upwards and dispose of it in an appropriate manner.
Installation:
6. Insert the halogen lamp 4 together with the accompanying plastic mount 8 into the aperture
attachment 5.
7. Insert new metal vapour lamp 6 holding it by the
packaging film/using a soft cloth.
8. Insert the aperture attachment 5 so that the surface 7 and the connector A are aligned.
9. Assemble the components as described above, but
in the reverse order.
10.Insert the focus unit 9 so that both the plug connectors A are aligned.
11.Attach the central hand grip 2.
®
XENION® Surgical Lighting System GB
197200790 Service Manual for the HELION
6 Setting the Luminous Field
Figure 01
6.16.1
6.1
6.16.1
Setting is described using the HELION L as an example.
Removal:
Setting the luminous field for the HELI-Setting the luminous field for the HELI-
Setting the luminous field for the HELI-
Setting the luminous field for the HELI-Setting the luminous field for the HELION M/M+ / L/L+ON M/M+ / L/L+
ON M/M+ / L/L+
ON M/M+ / L/L+ON M/M+ / L/L+
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
2. Undo the three screws 3 and remove the focus
unit 9.
3. Using an Allen key size 25 6:
- unscrew the long cheese head screw 5 a short
way,
- screw the short cheese head screw 7 in a short
way.
Installation:
4. Fit the components as described above, but in the
reverse order.
WARNING – Electric Shock:
The following adjustments must be made
with the power supply switched on.
Cordon off installation site and proceed
with great care.
5. Switch on the power supply and the lamp.
6. Mark the maximum and minimum luminous field
diameters on the hand grip according to the lamp
specification 8.
Removal:
7. Switch on the power supply and the lamp.
8. Undo the three screws 3 and remove the focus
unit 9.
9. With an Allen key size 2.5 6 adjust the long cheese head screw 5 and the short cheese head screw
7 according to the markings.
Installation:
10.Fit the components as described above, but in
reverse order.
20
Functional test:
11. Carry out functional test.
12. Repeat procedure if necessary.
13. Fix the long cheese head screw 5 and the short
cheese head screw 7 with screw-locking varnish.
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
6 Setting the Luminous Field
Figure 02
6.26.2
6.2
6.26.2
Removal:
Setting the luminous field for the XENI-Setting the luminous field for the XENI-
Setting the luminous field for the XENI-
Setting the luminous field for the XENI-Setting the luminous field for the XENION M/M+ON M/M+
ON M/M+
ON M/M+ON M/M+
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
2. Unscrew the set screw 6 and remove the focus
hand grip 5.
3. Using a screwdriver for cross-recessed head
screws:
- unscrew the recessed head screw 7 a short way,
- screw the cross-recessed head screw 9 in a short
way.
Setting:
WARNING – Electric Shock:
The following test must be carried out with
the power supply switched on.
Cordon off installation site and proceed
with great care.
4. Switch on the power supply and the lamp.
5. Set the maximum and minimum luminous field diameters according to the lamp specification (see
Technical Data), and pull the pivot 8 outwards
while turning it.
6. Attach the focus hand grip 6 and tighten the set
screw 5.
Functional test:
7. Carry out functional test.
8. Repeat procedure if necessary.
Removal:
9. Switch on the power supply and the lamp.
10.Undo the three screws 3 and remove the focus
unit 4.
11.Fix set screws 7/9 in each of the threads of the
adjusting plate A with screw-locking varnish.
Installation:
12.Fit the components as described above, but in
reverse order.
Functional test:
13.Carry out functional test.
®
XENION® Surgical Lighting System GB
217200790 Service Manual for the HELION
6 Setting the Luminous Field
Figure 03
Figure 04
6.36.3
6.3
6.36.3
Removal:
1. Unlock the central hand grip 2 by means of the
2. Unscrew the four cross-recessed head screws 6
3. Set the maximum and minimum luminous field
Functional test:
4. Carry out functional test.
5. Repeat procedure if necessary.
6. Fix the cross-recessed head screws 4/5 with
Installation:
7. Fit the components as described above, but in
6.46.4
6.4
6.46.4
Setting the luminous field for the XENI-Setting the luminous field for the XENI-
Setting the luminous field for the XENI-
Setting the luminous field for the XENI-Setting the luminous field for the XENION L/L+ON L/L+
ON L/L+
ON L/L+ON L/L+
unlocking device 1 and remove it.
and remove the trim ring 3.
diameters on the two cross-recessed head screws
according to the lamp specification 4/5.
screw-locking varnish.
reverse order.
Setting the luminous field for the XENI-Setting the luminous field for the XENI-
Setting the luminous field for the XENI-
Setting the luminous field for the XENI-Setting the luminous field for the XENION M with fixed focus cameraON M with fixed focus camera
ON M with fixed focus camera
ON M with fixed focus cameraON M with fixed focus camera
Removal:
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
2. Unscrew the cross-recessed head screw 3.
3. Set the maximum and minimum luminous field
diameters according to the lamp specification by
adjusting the ribbed surface 4.
4. Tighten the cross-recessed head screw 3.
Functional test:
5. Carry out functional test.
6. Repeat procedure if necessary.
7. Fix the cross-recessed head screw 3 with screwlocking varnish.
Installation:
8. Fit the components as described above, but in
reverse order.
22
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
7 Replacing the Filter Glass Assembly
Figure 01 Dismantling the lamp cover:
1. Lift the sealing lip 1, unscrew the sheet-metal
screws 2 and put the sheet-metal clips 5 in a
safe place.
2. Unscrew the two set screws 4 and push back the
plastic cover 6 from the lamp.
3. Remove the lamp cover 3.
Dismantling the filter glass assembly:
CAUTION – Damage to reflector:
• Do not touch the reflector on the inside of
the lamp,
• When unscrewing the four countersunk Allen screws 8 hold on to the SUB-D connector (HEL)/high-voltage contact plug
(XEN) B.
4. Hold the internal hexagon nut 9 securely with a
fork wrench and unscrew the four countersunk Allen screws 8.
5. Remove the plastic ring 7.
6. Lift the filter glass assembly A and SUB-D connector (HEL)/high-voltage contact plug (XEN) B
carefully up and out of the lamp.
7. Disconnect the connecting lines C from the electronics.
Installing the filter glass assembly:
8. Fit the new filter glass assembly (the connecting
lines are also supplied) as described above, but
in reverse order.
Functional test:
WARNING – Electric Shock:
The following test must be carried out with
the power supply switched on.
Cordon off installation site and proceed
with great care.
9. Switch on the power supply and the lamp.
10.Carry out functional test.
Installing the lamp cover:
11.Insert the sheet-metal clips 5 into the lamp cover
3 and install the lamp cover 3 as described
above, but in reverse order.
12.Check the secure positioning of the lamp cover
3.
®
XENION® Surgical Lighting System GB
237200790 Service Manual for the HELION
8 Testing the Servomotor for the HELION M/M+ / L/L+
Figure 01
8.18.1
8.1
8.18.1
Dismantling the focus unit:
TT
esting the polarity of the servomotoresting the polarity of the servomotor
T
esting the polarity of the servomotor
TT
esting the polarity of the servomotoresting the polarity of the servomotor
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
2. Undo the three screws 3 and remove the focus
unit 4.
3. Remove the central lamp 5 using a soft cloth.
Fitting the focus unit:
4. Insert the focus unit 4 into the lamp so that both
the plug connectors 7 are aligned.
5. Switch on the power supply and the lamp.
Functional test:
6. Remove the focus unit 4 from the lamp again.
If the remaining lamp 5 is not in the centre:
• check if the position of the cables 6 is preventing
the lamp 5 from swivelling,
• change the polarity of the servomotor.
Changing the polarity:
7. Lift the sealing lip 8, unscrew the sheet-metal
screws 9 and put the sheet-metal clips C in a
safe place.
8. Unscrew the two screws B and push back the
plastic cover E from the lamp.
9. Remove the lamp cover A.
10.Change the cables of the servomotor D on the
PCB.
Functional test:
WARNING – Electric Shock:
The following test must be carried out with
the power supply switched on.
Cordon off installation site and proceed
with great care.
11.Switch on the power supply and the lamp.
12.Carry out functional test. If the remaining lamp 5
is not in the centre:
• test the servomotor according to Chapter 8.2:
24
Installing the lamp cover:
13.Insert the sheet-metal clips C into the lamp cover
A and fit the lamp cover A as described above,
but in reverse order.
14.Check the secure positioning of the lamp cover
A
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
8 Testing the Servomotor for the HELION M/M+ / L/L+
Figure 02
8.28.2
8.2
8.28.2
Dismantling the focus unit:
TT
esting the servomotoresting the servomotor
T
esting the servomotor
TT
esting the servomotoresting the servomotor
1. Unlock the central hand grip 2 by means of the
unlocking device 1 and remove it.
2. Undo the three screws 3 and remove the focus
unit 4.
3. Swivel the two lamps 5 onto the middle axis represented by the dashed line.
Fitting the focus unit:
4. Insert the focus unit 4 into the lamp so that both
the plug connectors 7 are aligned, then activate
the lamp.
Functional test:
5. Remove the focus unit 4 from the lamp again.
If the two lamps 5 are still on the middle axis
represented by the dashed line:
• check if the position of the cables 6 is preventing
the lamps 5 from swivelling,
• Test the connection of the servomotor to the electronics.
Replacing the focus unit (servomotor):
6. If the two lamps 5 are still on the middle axis
represented by the dashed line:
• the servomotor is defective.
• Replace the entire focus unit 4.
®
XENION® Surgical Lighting System GB
257200790 Service Manual for the HELION
9 Testing the Input Voltages
Figure 01
9.19.1
9.1
9.19.1
The input voltage is measured at the transformer terminal 1. Depending on the installation location, the
transformer is installed on the ceiling tube 2, in the
control cabinet or on a mounting plate 3.
Testing the input voltage:
1. Remove covers etc, open the control cabinet.
2. Switch on the power supply.
3. Using a voltmeter, measure the input voltage at
• If there is no input voltage, inform the customer’s
TT
esting the input voltage of the transesting the input voltage of the trans
T
esting the input voltage of the trans
TT
esting the input voltage of the transesting the input voltage of the trans
formerformer
former
formerformer
WARNING – Electric Shock:
The following test must be carried out with
the power supply switched on.
Cordon off installation site and proceed
with great care.
the transformer terminal 1:
technicians.
--
-
--
Figure 02
9.29.2
9.2
9.29.2
The mains fuse is tested at the fuse terminal 1. Depending on the installation location, the fuse terminal
1 is installed on the ceiling tube 2, in the control
cabinet or on a mounting plate 3.
Testing the mains fuse:
1. Switch off the power supply.
2. Remove covers etc, open the control cabinet.
3. Remove the mains fuse at the fuse terminal 1,
TT
esting the mains fuse for the buildingesting the mains fuse for the building
T
esting the mains fuse for the building
TT
esting the mains fuse for the buildingesting the mains fuse for the building
power supplypower supply
power supply
power supplypower supply
test it and replace if necessary.
26
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
10 Testing the Electrics of the Support System
Figure 01
10.110.1
10.1
10.110.1
TT
esting the voltage at the sliding con-esting the voltage at the sliding con-
T
esting the voltage at the sliding con-
TT
esting the voltage at the sliding con-esting the voltage at the sliding con-
tact in the extension armtact in the extension arm
tact in the extension arm
tact in the extension armtact in the extension arm
The input voltage is measured at the contact block 3
in the extension arm 2.
1. Remove the cover 1 from the extension arm 2.
Testing the input voltage at the contact block:
WARNING – Electric Shock:
The following adjustments must be made
with the power supply switched on.
Cordon off installation site and proceed
with great care.
2. Switch on the power supply and the lamp.
3. Using a voltmeter, measure the input voltage at
the contact block 3:
• check the proper positioning of the cables,
• if there is still no input voltage, the sliding contact
in the extension arm 2 must be tested according
to Section 10.2 and replaced if necessary.
®
XENION® Surgical Lighting System GB
277200790 Service Manual for the HELION
10 Testing the Electrics of the Support System
Figure 02
10.210.2
10.2
10.210.2
Removal:
1. Remove the cover 1 from the extension arm 2.
2. Unscrew the two socket head cap screws size 5 4
3. Disconnect the cables at the terminal block 5
Testing the slip ring on the central column:
4. Before fitting a new sliding contact 6 check that
5. Carry out a contact resistance test between the
• If the resistance is infinite, the slip ring must be
- 10.3 Dismantling the light head,
- 10.5 Dismantling the spring arm,
- 10.8 Dismantling the central column,
- 10.9 Changing the slip ring.
RR
eplacing the sliding contact in the exeplacing the sliding contact in the ex
R
eplacing the sliding contact in the ex
RR
eplacing the sliding contact in the exeplacing the sliding contact in the ex
tension arm/testing the slip ring on thetension arm/testing the slip ring on the
tension arm/testing the slip ring on the
tension arm/testing the slip ring on thetension arm/testing the slip ring on the
central columncentral column
central column
central columncentral column
NOTE – in the case of 7-pole sliding contacts:
Disconnect the low-voltage plug connection
3.
and put them in a safe place.
and remove the sliding contact 6.
the slip ring on the central column is functioning
properly:
terminal block on the transformer and the slip ring
in the extension arm:
replaced in accordance with the following sections:
--
-
--
28
Installation:
5. Fit the new sliding contact 6 as described above,
but in reverse order.
6. Fit the cover 1.
7200790 Service Manual for the HELION® XENION® Surgical Lighting System GB
10 Testing the Electrics of the Support System
Figure 03
10.310.3
10.3
10.310.3
1. Place the spring arm 1 (in the example: Acrobat
2. Unscrew the cross-recessed head screw 3 and
3. Using a small screwdriver, remove the locking seg-
4. Remove the light head 6 with cardanic suspensi-
Dismantling the light headDismantling the light head
Dismantling the light head
Dismantling the light headDismantling the light head
WARNING - Sudden release of spring arm:
• The spring arm 1 is under high tension. If
the lamp 6 is not removed in the uppermost spring arm position, the spring arm
1 releases suddenly, springing upwards,
and can cause serious injury.
• Only dismantle the lamps 6 when the spring arm 1 is in the uppermost position.
2000) in the uppermost position.
push the sleeve 5 up.
ment 4 from the slot 2 and put it in a safe place.
on from the spring arm 1 and carefully put it
aside.
10.410.4
10.4
10.410.4
1. Carry out an all-pole contact resistance test bet-
• If the resistance is infinite, the spring arm must be
• If the resistance is almost zero, the cables in the
- Carry out a contact resistance test between the
TT
esting the cables in the spring armesting the cables in the spring arm
T
esting the cables in the spring arm
TT
esting the cables in the spring armesting the cables in the spring arm
that lead to the contact block in the exthat lead to the contact block in the ex
that lead to the contact block in the ex
that lead to the contact block in the exthat lead to the contact block in the ex
tension armtension arm
tension arm
tension armtension arm
ween the spring arm (sliding coupling) and the
contact block in the extension arm:
replaced in accordance with Section 10.5.
light head and the cardanic suspension must be
tested:
input terminal of the electronics and the sliding
connector on the cardanic suspension (replace
entire cabled cardanic suspension if necessary).
--
-
--
®
XENION® Surgical Lighting System GB
297200790 Service Manual for the HELION
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