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Service Manual evo LIGHT 700

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SERVICE MANUAL
evoLight 500/700
CONTENTS
1. DESCRIPTION ................................................................................................ 3
1.1. Control at the user panel ............................................................................. 3
2. OPENING OF THE HOUSING ....................................................................... 4-5
3. DESCRIPTION OF HARDWARE ...................................................................... 6
3.1. PCBS ........................................................................................................ 7
3.1.1. OPL12001 PCB CPU ........................................................................... 7
3.1.2. D6316 12C PCB Keypad ...................................................................... 8
3.1.3. OPL12001 Driver PCB LED Driver .................................................... 8-9
4. SCHEME FOR FAIL SAFETY ........................................................................... 10
4.1. CPU – fail (complete failure) ...................................................................... 10
4.2. CPU failure by disturbance or program failure .............................................. 11
4.3. The driver LT3956 .................................................................................... 11
4.4. PCB CPU RX63N with connection to the LED Driver PCB .............................. 11
4.4.1.1. Temperature control ....................................................................... 11
4.4.1.2. Voltage control ............................................................................... 11
4.4.1.3. Current control ............................................................................... 11
5. STARTUP AND SERVICE ............................................................................... 12
5.1. Interfaces of the CPU PCB OPL12001 ........................................................ 12
5.1.1. Pin assignment X4 ............................................................................. 12
5.1.2. Pin assignment X7 ............................................................................. 13
5.1.3. Pin assignment X8 ............................................................................. 13
5.1.4. Pin assignment 3 ............................................................................... 13
5.2. Interface connection of the Driver PCB OPL12001 ....................................... 14
5.2.1. View ................................................................................................ 14
5.2.2. Pin assignment X1 to X10 ................................................................... 14
5.2.3. Pin assignment X11 ........................................................................... 14
6. SERVICE MENU ............................................................................................ 15
6.1. Main menu .............................................................................................. 15
6.2. Description of the different menus ............................................................. 16
6.2.1. Menu light control ............................................................................. 16
6.2.2. Menu parameter ............................................................................... 16
6.2.2.1. Light parameters ............................................................................ 17
6.2.2.1.1. Adjust light parameters ................................................................ 17
6.2.2.1.2. Offset parameter MOD1 to MOD10................................................. 18
6.2.2.1.3. Temperature Offset ..................................................................... 18
6.2.2.1.4. Correction value – Calibration of current and voltage ....................... 19
6.2.2.1.5. Log file page 1 ............................................................................ 20
6.2.2.2. System parameter.......................................................................... 20
6.2.2.3. Set parameter ............................................................................... 21
6.2.3. Hardware tests ................................................................................. 21
6.2.3.1. Adc menu ...................................................................................... 22
6.2.3.2. IO menu ....................................................................................... 22
6.2.4. Failure messages .............................................................................. 23
6.2.5. Failure messages .............................................................................. 23
1
7. WARNINGS AND FAILURE MESSAGES .......................................................... 24
7.1. State of failure ........................................................................................ 24
7.2. Failure description............................................................................... 25-26
8. INSTALLATION AND SERVICE POWER SUPPLY ............................................ 27
8.1. Hardware ................................................................................................ 27
8.2. Connections ............................................................................................ 28
8.3. Installation.............................................................................................. 29
8.3.1. Mains connection .............................................................................. 29
8.3.2. Emergency power ............................................................................. 29
8.3.3. Connection of surgical light ................................................................ 29
8.4. Service ................................................................................................... 30
8.4.1. Operating display with LEDs ................................................................... 31
9. CONNECTIONS OF THE MOBILE STAND........................................................ 32
2
1. DESCRIPTION
The service manual describes the configuration of the surgical light and its control.
There will be a difference between user and technical service.
The user just has the capacitive control panel and the handle for use.
There is a RS232 for the start of operation and for the service. The location of this interface is
the PCB of the CPU.
1.1. Control at the user panel
The control of the light head for the user is performed via control panel (capacitive control) at
the front glass.
Control panel:
ON/OFF
With the ON/OFF button the light head will be switched ON or OFF.
The green LED at the ON/OFF button shows, that power is attached
to the light head
MINUS
The illuminance of the light head is decreased while pushing the button
MINUS one time. Permanently holding the button decreases of the
illuminance step by step until the lowest illuminance is reached.
PLUS
The illuminance of the light head is increased while pushing the button PLUS
one time. Permanently holding the button increases the light head step by
step until the highest illuminance is reached.
Functional LED‘s
Between the PLUS and Minus button are 3 functional LEDS located.
They are showing the grade of illuminance. LED 1 stands for illuminance
level 1-3, LED 2 stands for illuminance level 4-6 and LED 3 stands for
illuminance level 7-9.
AMBI
Pushing the button AMBI switches over to the endoscopic light and back to
the regular surgical light respectively. The illuminance of the endoscopic
light can also be adjusted with the plus and minus buttons.
3
2. OPENING OF THE HOUSING
For accessing the LED blocks and the light field adjustment the front glass has to be opened.
Therefore the following steps are necessary:
1. Remove of the inner handle
2. Remove of the handle mechanic of the inner handle
4
3. Remove of the front glass
Suction cups are a helpful tooling to perform the removal of the face glass
Attention:
The capacitive control on the front glass has a ribbon cable wire connection
Remove connector carefully
For accessing the LED blocks and their connections remove
the plastic cover of the LED blocks.
5
3. DESCRIPTON OF HARDWARE
Block wiring diagram
Power Supply
28V
Control – I2C
Panel
Current source1
with switching
regulator LT3956
Current source2
with switching
regulator LT3956
CPU
With 13 PWM
channels
Power in 20V to 32V
Power PCB:
5V
3,3V
Current source3
with switching
regulator LT3956
TemperatureVoltageCurrentcontrol
Current source1
0 with switching
regulator LT3956
6
3.1. PCBS
THE LIGHT HEAD HAS 4 PCBS:
1. PCB Microcontroller OPL12001
- Size: 135mm x 45mm
- Renesas RX63N CPU
- Power supply +5V and +3,3V
- Interface for endoscopic light
- 3 x SCI interfaces (RS232 und TTL)
- 2 x I2C interfaces for control panel and temperature control
2. PCB Control interface I²C
- Size: 43mm x 25mm
- Connector for capacitive control
- Connector for pcb microcontroller
3. PCB Driver OPL12001_DRIVER
- Size: 145mm x 78mm
- Connectors for power supply, EMC filter
- Current measuring
- Voltage measuring power in
- 10 x LED driver with LT3956
- Logic for fail safe
3.1.1.
7
OPL12001
PCB CPU
3.1.2.
D6316 I2C PCB Keypad
3.1.3.
OPL12001 Driver PCB LED Driver
Component side
Fuse 5A
MT
Measuring
current r
Hall-Sensor
max. 5A
Power supply
Ub
GND
PE
LED Driver
Modul
with
LT3956
Suppressor
chokel 4A
Mono-Flip flop
for fail safety
8
Solder side
Temperature
sensor LM75
over I2C-Bus
9
Tristate
Driver for fail
safety
4. SCHEME FOR FAIL SAFETY
4.1. CPU – fail (complete failure)
At a failure of the CPU the light head should work at 50% of the maximal current (illuminance)
Functioning
The driving of the LED drivers is performed via PWM (pulse-width modulation control).
The driver pcb has a part where the PWM signal is changed into an analog signal and has at the
same time the safety mechanism.
The following picture shows the schematic for illustrate.
Testing:
Attach power
to Driver PCB
and remove
CPU PCB
Description of the signals
Signal for LED driver Voltage analog 0V to 0,95V
REF_MOD0 to REFMOD9
PWM Signal of CPU
ERROR_ALL1
ERROR_ALL2
Signal of Mono-Flop 1 triggers module1 to 5
Signal of Mono-Flop 2 triggers modul6 to 9
The two Mono-Flops are triggered cyclical from the CPU with the port (ERROR_TRIGGER)
Cycle time approx. 1,0 sec. until the light head reacts with the 50%.
10
4.2. CPU failure by disturbance or program failure (infinite loop)
It is possible to disturb the CPU with EMC and get it out-of-step operation. For the case the CPU
(RX63N) has a watch dog control, which has to be triggered regularly from the software (no in
cyclic interrupts). If the watch dog control is not triggered within a time of approx. 1s, a
hardware reset will be performed. The System is booting and the software takes care to get the
same condition as before the incident.
4.3. The driver LT3956
Many safety features are already integrated in the driver LT3956.
 Limitation of the voltage in case no LEDs are attached
 At short circuit there is just a minimal current (not the predetermined)
 High input voltage tolerance (up to 80V)
 Temperature control and switching off (Internally Chip temperature intern > 165°C)
4.4. PCB CPU RX63N with connection to the LED Driver PCB
4.4.1.1.
Temperature control
On the back side of the Driver PCB is a chip for temperature measurement (LM75).
This chip is monitored from the CPU via the I²C bus.
If the temperature reaches a level above 70° C the current will be reduced for about
25%, until the temperature drops to 65 ° C. (Hysteresis)
4.4.1.2.
Voltage control
A 12 bit analog digital converter in the CPU controls the supply voltage (20 to 32V).
At overvoltage or undervoltage the LED Driver will be switched off after 2s and the
failure information will be shown at the control panel. If the voltage control detects a
normal voltage, the electronic switches back to the same condition as before the
overvoltage and undervoltage respectively.
4.4.1.3.
Current control
The total current of the LED driver is measured via a current sensor IC (ACS712ELCTR05B-T). This component passes an analog voltage over to a second 12 bit analog digital
converter. At over current, the LED driver will be switched off after 2s and the failure
information will be shown at the control panel. If the current control detects a normal
current, the electronic switches back to the same condition as before the over current.
11
5. STARTUP AND SERVICE
5.1. Interfaces of the CPU PCB OPL12001
For the startup and for service the CPU PCB offers a RS232 connection.
Baud rate: 38400, 8, N, 1
X6 Pin1
I2C Panel
JTAG
X4 Pin 1
X7 Pin1
1 x seriell
TTL Video
X8 Pin 1
Video
X3 Pin1
Light field and
intensity control
Note processor interface:
COM1 (sci0)  connector X7
COM2 (sci3)  connector X4
COM3 (sci6)  connector X4
5.1.1. Pin assignment X4
RS232
Pin
1
2
3
4
5
Pin Assignment
TxD3
RxD3
TxD6
RxD6
GND
Function
Send COM2
Receive COM2
Send COM3
Receive COM3
Ground
Description
VT100 Terminal
VT100 Terminal
None (Reserve)
None (Reserve)
12
5.1.2. Pin assignment X7
TTL – Signal and Video In
Pin
1
2
3
4
5
6
7
8
Pin Assignment
+5V
TxD0
RxD0
(RTS, CTS)
GND
C In
Y In
Video GND
Function
Versorgung CAM-Adapter
Send COM1
Receive COM1
Optional
Ground
Description
-CAM-Interface
CAM-Interface
--Video signal
Video signal
Video signal
5.1.3. Pin assignment X8
Video Out
Pin
1
2
3
Pin Assignment
Video GND
Y out
C out
Function
Description
Video signal
Video signal
Video signal
5.1.4. Pin assignment X3
Field size adjustment in intensity adjustment
Pin
1
2
3
4
1
2
4
13
Pin Assignment
CW
CCW
NC
GND
Function
Signal for field size and intensity plus
Signal for field size and intensity minus
Reference
5.2. Interface connection of the Driver PCB OPL12001
5.2.1. View
Feed-in of the complete module
Fuse
5A MT
Current
sensor
X5
X4
X3
X2
X11
+Ub
0V
PE
X1
X10
X9
X8
X7
X6
CPU
Connector
5.2.2.
- LED
1
+ LED
Pin assignment X1 to X10
Connector designation
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
5.2.3.
2
Function
LED Driver
LED Driver
LED Driver
LED Driver
LED Driver
LED Driver
LED Driver
LED Driver
LED Driver
LED Driver
module
module
module
module
module
module
module
module
module
module
1
2
3
4
5
6
7
8
9
10
Pin assignment X11
Pin description
X11. + Vp
X11.0V
X11.PE
Function
Positive voltage +20V to 32V
GND (0V)
Earth GND
14
6. SERVICE MENU
The connector X4 of the CPU PCB OPL12001 can be connected with a PC; the service menu can
be opened with a VT100 terminal program (Hyperterminal, Putty).
The service menu offers access to the software, controlling the light head, adjust parameter and
perform hardware tests, shows failure messages and a log file. It is a text menu with and has a
hierarchical structure.
For the first display in the main menu the ESC button has to be pushed.
With the specified numeric entry the named menu area are accessible.
Entry of V shows the hardware and software version.
6.1. Main menu
15
6.2. Description of the different menus
6.2.1. Menu light control
The entry of the characters shown in the square brackets leads to the assigned change.
The entry of ESC moves one level up in the menu.
6.2.2. Menu parameter
Entry of the specified numeric number opens the submenus. Hitting the ESC button guides on
level up.
16
6.2.2.1.
Light parameters
6.2.2.1.1.
Adjust light parameters
In this menu for each of the 3 LED block types (LED in focal point - M1-M5, LED half defocused –
M6-M7, LED defocused – M8-M10) the driving current for the different field sizes can be
adjusted. Minimal current and maximal current can be entered. The current values between Min
and Max are calculated from the software in a linear way. These values are safed in the Kat1
parameters.
Entry of the first character (e.g. <A>) in the square brackets picks a register. An entry has to be
finished with ENTER.
<1> safes all values and brings the change immediately to the LED modules
<7> and <8> are changing the field size
<9> loads the DEFAULT values, which are stored in the program flash
17
6.2.2.1.2.
Offset parameter MOD1 to MOD10
With this parameter a offset can be added to each of the modules.
The value area is +/- 100mA. If the value is 0, nothing is added.
The borderlines of 0 and 370mA will not be crossed.
6.2.2.1.3.
Temperature Offset
Temperature increasment leads to a reduced light output.
A simple algorithm operates against this problem.
The actual temperature will be subtracted by 20. The value will be multiplied with the sensitivity
scale factor = 3.00 (0 to 300) (1= 0,01) and added to the actual value of current.
The borderlines are 50mA.
This value is safed in the Kat1 Flash.
18
6.2.2.1.4.
Correction value - Calibration of current and voltage
The electronic should be calibrated for each light head. Due to tolerances the light head does not
know the correct borderlines for current and voltage.
Default values are given and they will be written into the parameters Class 1 (Kat1) parameters
during the startup.
The calibration will be performed as following (the light head should be adjusted to the largest
light field and the maximum intensity):
1. Measuring of current (I) and voltage (U) at the PCB Driver (U at Input Connection,
I at Fuse). Alternative a power supply with voltage and current display can be used.
2. Set gain value at <2> UB Voltage Gain to 1000.
3. Divide the external measured voltage with the shown voltage of UB, the result is the
gain.  U / UB = Gain
(e.g. original UB = 24895, U = 26140  26140/24895= 1.050)
4. Entry the calculated value in <2> UB voltage Gain.
5. Switch Off the LEDs by pressing [P]
6. Entry at <3> current sensor Offset = 0 and at <4> current sensor Gain = 1000
7. Entry the shown value of the current sensor with the opposite sign at <3>
e.g. view: -156  Entry: 156
8. Switch ON the LEDs by pressing [P]
9. Divide the external measured current value I with the shown value of the current
sensor, the result is the gain.
 I / current sensor = current sensor Gain
10. Entry the calculated value in of the Gain in <4>
11. Hit the ENTER button to save the values in the parameter KAT1
19
6.2.2.1.5.
6.2.2.2.
Log file page 1
System parameter
20
6.2.2.3.
6.2.3.
21
Set parameter to default
Hardware tests
6.2.3.1.
Adc menu
6.2.3.2.
IO menu
22
6.2.4.
Failure messages
6.2.5.
Failure statistic
23
7. Warnings and Failure Messages
7.1. State of failure
Depending on the state of the failure the will be shown differently after connection of the supply
voltage.
State1: Voltage is connected. Initialization of controller, controller registers and stack pointer,
port configuration. At this level the failure message can be shown at the 3 SMD LEDs of the CPU
PCB. If a failure occurs during the initialization of the interfaces of the controller, these 3 LEDS
are showing with a assigned code (color, blinking frequency) the failure.
State2: After the initialization of the SCI interface (RS232) and the menu system a failure can
be seen in the VT100 terminal program or at the 3 CPU LEDs. I2C interface initialization failures
can be detected easier. The log file in the E2 Flash is active now for saving warnings and
failures.
State3: The I2C interface is initialized without failures. Warnings and failures of the light head
are shown now with the 3 LEDs of the control panel.
Generally:
Numbers of failure ax: 1 to 7  Binary display at the LEDs of the capacitive control panel
(See Table)
A failure is showing a problem of one or more of the module drivers, the supply voltage
or the temperature.
The software tries to attenuate a failure, e.g. by switching off of a single driver
A failure will be signalized through a blinking of the ON/OFF LED
The code of the failure will be shown at the capacitive control electronic LEDs,
they are blinking as well.
The failure message will be shown for approx. 5s after switching ON/OFF.
Depending on the failure is there just a limited control possible.
If there is a critical failure, which can damage the light head, the modules will be
switched OFF. For switching them ON again, the failure has to be cleared.
24
7.2. Failure description
The failure signalling is performed through the LEDs of the capacitive control panel.
The ON/OFF LED is showing that there is an incidence of a failure.
The signalling LEDs for the illuminance are showing the failure as binary code.
In case of a failure all LEDs are blinking at the same frequency.
Err No
0
1
Code
Code designation
Description and action
ERROR_NO
No failure
ERR_MODUL FAILURE
A LED driver is detected as defect while the light
head is switched ON, is shown at the panel with the
ON/OFF LED operation indicator (blinking for
approx. 5s), afterwards appears the normal
display.
Control with the buttons is possible
 Module will be disabled
2
ERR_OVERVOLTAGE
3
ERR_UNDERVOLTAGE
Supply voltage is above 38V
The ON/OFF LED operation indicator, is blinking
Switching ON of the light head is NOT possible.
Drops the voltage below 37V (Hysteresis of 1V) the
light head goes back to normal condition
(Absolute limit for overvoltage of the
electronic is 40V --> hardware defect!)
Supply voltage is below 20V
The ON/OFF LED operation indicator, is blinking
Switching ON of the light head is NOT possible.
Rises the voltage above 22V (Hysteresis of 2V) the
light head goes back to normal condition.
The total current rises above the limit of 4,9A.
The ON/OFF LED operation indicator, is blinking
This could be after the connection with the power
supply
4
ERR_OVERCURRENT
• Without switched ON light head.
 Hardware defect. Light head cannot
be switched ON
• With switched ON light head
 Possible Module defect
5
25
ERR_OVERTEMPERATURE
The temperature of the light head increases 70°C
Is shown at the panel with the ON/OFF LED
operation indicator (blinking for approx. 5s),
afterwards appears the normal display.
Control with the buttons is possible.
Failure will be stored in the log file
Action:
The current of the modules will be
decreased for about 25%.
After going below 65°C (5°C Hysteresis) the
normal condition will be established.
Err No
Code
Code designation
Description and action
ERR_MODUL_OVERCURRENT
Additonal info for ERR_MODULFAILURE
ERR_MODUL_UNDERVOLTAGE
Additonal info for ERR_MODULFAILURE
Will be shown only in the log file
NT
Will be shown only in the log file
6
7
ERR_MODUL_OVERPOWER
ERR_I2C_CHANNEL0
ERR_I2C_CHANNEL1
ERR_TCA6416
ERR_LM75
ERR_FLASH_ERASE
ERR_FLASH_WRITE
ERR_FLASH_READ
ERR_FLASH_CRC_KAT1
ERR_RAM_TEST
Additonal info for ERR_MODULFAILURE
Will be shown only in the log file
During the initialization of the I2C0 a failure
occurred
Failure number in sub error
During the initialization of the I2C3 a failure
occurred
Failure number in sub error
During the access of the panel with the
component TCA6416 a failure occurred.
Failure number in sub error
During access of the temperature measuring
component LM75 a failure occurred.
Failure number in sub error
During erasing of the E2 data flash a failure
occurred. Failure number in sub error
During writing in the E2 data flash a failure
occurred. Failure number in sub error
During reading of the E2 data flash a failure
occurred. Failure number in sub error
Parameter of the Kat1 are twice available, they
are safed through a checksum.
Memory test detected a failure.
Failure address in sub error
26
8. INSTALLATION AND SERVICE POWER SUPPLY
8.1. Hardware
To Surgical Light
28V DC
Mains Voltage
100-240V AC
50-60Hz
Wire:
Emergency Power In
24V DC
Wire:
Wire:
3x1,5mm²
<25m --> 3x 1,5mm²
25-50m --> 3x 2,5mm²
<25m
--> 3x1,5mm²
25-50m --> 3x2,5mm²
The power supply consists of a switched power supply (100-240V AC) with DC output (28V) and
a switching electronic to emergency power in case a mains power interruption.
27
Mains power
supply
PCB with
switch over to
emergency
8.2. Connections
Voltage IN:
100-240V AC
24V DC
Voltage OUT to surgical light: 28V DC
Input
Input
Surgical Light
Mains voltage Emergency power
28V DC
100 – 240V AC 24V DC
28
8.3. Installation
Only qualified and authorized qualified persons are allowed to install the power supply.
The power supply can be installed in a switch cabinet or at the ceiling flange of the drop tube
8.3.1.
Mains connection
L N PE
L N PE
The mains connection hast to be performed with an approved cable.
Mains voltage:
Wire cross section:
8.3.2.
100 - 240V AC
1,5 - 2,5mm²
Emergency Power
The emergency power connection hast to be performed with an approved cable.
Emergency Voltage: 24 - 32V DC
Wire cross section: 1,5 - 2,5mm²
Max. length:
15m
8.3.3.
Connection of surgical light
The connection for the surgical light must be running on an appropriate legal line.
Wire cross section:
Max. length:
29
2,5mm²
20m
8.4. Service
Fuse F1
Fuse F2
Fuse F3
Fuse F4
Micro fuse:
The changing of the fuses is processed through pulling out of the defect micro fuse and
the pushing in of the new fuse.
Only fuses with the same technical specification are allowed.
Before changing the mains fuses F1 and F2 it has to be secured that the mains power is
switched OFF and secured against switching ON.
The protection against contact of F1 and F2 has to be removed before switching the fuse.
After the change the protection has to be mounted again.
F1, F2
Micro Fuse, 5x20mm, 2,5A Time-Lag T, H, 250V AC, UL: 115 V - 300 VDC
F3
Miniature Fuse, 5x20mm, 6,3A Time-Lag T, 250V AC
F4
Miniature Fuse, 5x20mm, 5A Time-Lag T, 250V AC
30
8.4.1.
Operating display with LEDs
28V DC Output
voltage of
switching power
supply
24V DC
Emergency
power supply
31
24 / 28V DC
Output to
surgical light
9. CONNECTIONS OF THE MOBILE STAND
Input
Mains voltage
100 – 240V AC
Output
28V DC
32
This document is under the protection of the right of reproduction of the company evonos GmbH & Co.KG, Tuttlingen.
It may also be modified by third parties without the express written permission of the company evonos GmbH & Co.KG,
Tuttlingen, modified, extended, reproduced or passed on.
evonos GmbH & Co.KG, Tuttlingen reserves the right to change the right design and content without prior notice.
evonos GmbH & Co.KG
Stockacher Str. 134
D-78532 Tuttlingen
Tel.
+49 (0)7461-1718959
Fax
+49 (0)7461-1718957
[email protected]
www.evonos.de
ARTICLE NUMBER: DOC-02-000003-GB
SERVICE MANUAL SURGICAL LIGHT 500/700
Rev. 3.0
20.10.2015
33
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