Booms and Lights Installation and Service Manual July 2011

Stryker Booms and Lights Installation and Service Manual

This manual contains confidential information that shall not be disclosed or duplicated for any reason other than to use and maintain a Stryker Booms and Lights. This restriction does not limit the right to use information contained in this manual, if it is obtained from another source without restriction. The information subject to this restriction is contained in all pages of this manual. © June 2011 Stryker Communications. All rights reserved. Information in this document is subject to change without notice. Stryker, Stryker logo, Visum®, and StrykeCam® 2 are registered trademarks of Stryker All rights reserved. Stryker Booms and Lights Installation and Service Manual 1004-400-061 REV YB

S Contents 1. Warnings and Cautions... 10 1.1

Safeguards and Precautions... 10

1.2

Warnings... 10

2. Product Symbol Definition... 11 3. Tool List... 13 3.1

Required Tools... 13

3.2

Optional Tools... 13

4. Unpacking... 14 4.1

Halogen Light... 14

4.1.1 4.1.2 4.1.3 4.2

Suspension Box...14 Accessory Box...14 Light Head Boxes...14

LED Light... 15

4.2.1 4.2.2 4.2.3

Suspension Box...16 Accessory Box ...16 Light Head Boxes 1 and 2...16

4.3

Flat Panel Arms ... 17

4.4

Booms... 17

5. Preparing the Mounting (Interface) Plate... 18 6. Preparing the Suspensions... 19 6.1

Installing the Cable Kit for Lights... 19

6.2

Surgical Lights... 20

6.2.1 6.2.2 6.2.3

Standard Horizontal Arm...20 Extended Horizontal Arm...20 Alternate Light Installation Instructions...21

6.3

Flat Panel... 22

6.4

Booms... 22

6.5

Routing Cables... 24

7. Installing the Suspension and Boom Arms... 25 7.1

Alternate Light Installation Instructions (Continued)... 26

5

S 8. Installing Light Heads... 27 8.1

LED and Halogen... 27

8.1.1 8.1.2

Standard Light...27 Low Ceiling Light...28

9. Powering the System... 31 9.1

Halogen Lights... 31

9.1.1 9.2

LED Lights... 32

9.2.1 9.3

Power Supply Box Wall Mount (Optional)...32

Power Supply Box Connections... 33

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4

Electrical and Data Connections...31

Power...34 Control...34 Wall Control Unit Port ...35 SORN...35 SIDNE...35 Expansion Port (Optional)...35

Visum LED New Installation Setup... 36

9.4.1 9.4.2 9.4.3 9.4.4 9.4.5

Required Tools...36 Installing USB to RS-232 Adapter (for laptops without Serial Ports)...36 Connecting a Laptop to the SIDNE Port on Visum LED System...37 Visum LED Main Menu...39 New Installation...39

10. Monitor Assembly... 40 10.1 Light Flat Panel or Single Panel installation ... 40 10.2 Adjusting the Yoke... 41 10.2.1 10.2.2

Adjusting the Width...41 Adjusting the Height...45

10.3 Attaching the Monitor... 46 10.4 Balancing the Monitor... 48 10.5 Adjusting the Brakes... 50

11. Boom Shelf Attachment and Adjusting Brakes/Stops... 51 11.1 Boom Shelf and Accessories Attachment... 51 11.1.1

FLEXiS Shelf Installation...51

6

S 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6 11.1.7

FLEXiS Handle to MFR Bracket Installation...54 FLEXiS Handle to Service Head Installation...56 Installing Auxiliary Plates...58 Installing Other Accessories...59 Installing GCX Accessory Track on OSC600 Down Tube...59 Drawer Installation...59

11.2 Lights and Flat Panel Arms... 60 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.3

Height Adjustment...60 Tension Adjustment...62 Adjusting the Friction Brakes...62 Adjusting the Brake Force of the Extension and Spring Arms...64 Adjusting Down Tube Screws...64

Adjusting the Cardanic Suspension... 66

11.4 Boom Arms... 67 11.4.1 11.4.2

OSC400...67 OSC600...70

12. Installing Covers... 72 12.1 Lights and Flat Panel Suspension... 72 12.2 Booms... 72 12.3 Tandem... 73 12.4 Cable Covers... 75 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5

Flat Panel/Light/Light Suspension...75 Light/Flat Panel Suspension - Teacup Installation...75 MMP200, OSC400, and OSC600...76 Mounting Motor Ring Covers...77 Replacing Rear End Spring Arm Covers...77

12.5 Installing a Flexstrip Kit (Dual Flat Panel Arm Only)... 78

13. Accessories... 79 13.1 Lights... 79 13.1.1 13.1.2 13.1.3 13.1.4 13.1.5

Halogen In-Light Camera and Weighted Light Handle Assemblies...79 LED In-Light Camera and Weighted Light Handle Assemblies...79 Field Upgrade for StrykeCam In-Light Camera...79 Power Supply Box Components...81 Camera Installation...82

7

S 14. Legacy... 84 14.1 Suspension Installation... 84 14.2 Installing Spring Arms (if necessary for lights only suspension)... 84 14.3 Standard Width Yoke... 87 14.4 Halogen Light Flat Panel Stop Replacement... 87 14.5 Variant... 89 14.6 Installing GCX Accessory Track on OSC400 Service Head... 89

15. Cleaning and Completion... 93 16. Servicing the Visum 600/450... 94 16.1 Electronic Control System... 94 16.2

Power Supply Box... 96

16.2.1

Halogen Power Supply Box Troubleshooting Guide...96

16.3

Wall Control... 99

16.4

Plug Layout of the Electronic Control System... 101

16.5

Plug Allocation... 101

16.5.1 16.5.2 16.5.3 16.5.4 16.5.5 16.5.6

Location of the Plug and Diagnostic LEDs on the Terminal...102 Plug Allocation Operating Console and Diagnostic LEDs...103 Plug Locations of the Power Box...103 Connections at the front:...104 Connections at the back:...105 Connection Structure of Systems...107

16.6 Can Bus Troubleshooting... 110 16.6.1

Light Block Diagram...110

17. Servicing Booms... 114 17.1

System operation... 114

17.2

Troubleshooting... 114

17.2.1 17.3

Air Leaks...115

Miscellaneous Hardware Parts List... 117

17.4 Replacing the Trim Strip ... 119 17.5 Replacing Med Gas... 120 17.5.1 17.5.2

Replacing a Nitrogen Regulator...120 Replacing Med Gas Plate...120

8

S 17.6 Replacing the Brake Bladder... 121 17.7 Reassembling the Service Head... 127 17.7.1 17.7.2 17.7.3 17.7.4 17.7.5 17.7.6

Removing and Attaching the Front and Back Plates...127 Removing and Attaching the MFR...128 Removing Extrusions...129 Installing Extrusions...129 Removing Modules...130 Installing Modules...132

17.8 Replacing the Motor... 133 17.9 Electro-Pneumatic (EP) Module... 135 17.9.1 17.9.2

Removing the Electro-Pneumatic (EP) Module...135 Installing an Electro-Pneumatic (EP) Module...135

17.10 Generation 1 Service Head... 136 17.10.1 17.10.2

Replacing a Shelf with Brake...136 Replacing the Brake Button...138

18. Servicing the LED... 140 19. Replacement Part Numbers... 141 20. Contact Information... 144

9

S 1. Warnings and Cautions Please read this manual and follow its instructions carefully. The words WARNING, CAUTION, and Note carry special meanings and should be carefully reviewed:

1.1

Warning

The personal safety of service personnel may be involved. Disregarding this information could result in injury to the patient.

Caution

Special service procedures or precautions must be followed to avoid damaging the equipment.

Warning

A warning with a lightening bolt warns of hazardous voltage. All service must be performed by authorized personnel.

Note

Special information to make maintenance easier or important information more clear.

Safeguards and Precautions

Stryker trained personnel are the only personnel authorized to install the equipment described in this manual. Incorrect operation or negligence of safety measures may cause damage to the equipment, bodily injury or death. Thoroughly read this manual before use. • • •

1.2

Do not add additional weight to the surgical lights. Do not place anything over the surgical lights. Do not look directly into the surgical light while powered on.

Warnings

1. Be a qualified/trained installer for this equipment. 2. Test this equipment prior to release for use by hospital personnel. 3. Disconnect the unit from the electric outlet before inspecting or servicing system components. Note that more than one electrical supply may be used. Disconnect all power sources before inspecting. 4. The electrical installation of the operating room must comply with any applicable IEC, CEC, NEC requirements as well as the local codes and pre-installation manual. Caution

Carefully unpack the unit and check to ensure that no damage occurred during shipment. If damage has occurred, please contact Stryker Communications.

10

S 2. Product Symbol Definition The following symbols may be found on the Stryker Booms and Lights equipment: An exclamation mark within a triangle is intended to alert the user to the presence of important operating and maintenance (service) instructions in the literature accompanying the product. A lightning bolt within a triangle indicates the presence of hazardous voltage. Refer all service to authorized personnel. Denotes usage tips and useful information. Denotes compliance to European Community Directive 93-42-EEC.

EDS (29AZ)

EDS (29AZ)

(13PZ)

Indicates the product is compliant “Medical Electrical Equipment with Respect to Electrical Shock, Fire, and Mechanical Hazard only in accordance with UL60601-1. Indicates the product is compliant “Medical Electrical Equipment with Respect to Electrical Shock, Fire, and Mechanical Hazard only in accordance with CAN/CSA C22.2 No601.1. Indicates the product is compliant “Medical Electrical Equipment with Respect to Electrical Shock, Fire, and Mechanical Hazard only in accordance with UL60601-1, CAN/CSA C22.2 No601.1. Indicates hot surfaces. Denotes compliance to CSA Standard C22.2, 60601.1 - M90, AS 3200, IEC 60601, IEC 60601-2-41, UL 60601, EN 60601 Denotes the date the equipment was manufactured. Denotes the manufacturer of the device. A yellow box with a hand within a triangle is intended to warn the user of the presence of an electrostatic sensitive device. Follow ESD prevention procedures. Denotes product/part number. Denotes product/serial number. Denotes lot or batch number. The acceptable wattage input range for this product.

11

S In accordance with European Community Directive 2002/96/EC on Waste Electrical and Electronic Equipment, this symbol indicates that the product must not be disposed of as unsorted municipal waste but should be collected separately. Note: The device does not contain any hazardous materials. Legal regulations may include specifications regarding the disposal of this product. We request that you contact Stryker when you plan to withdraw this device from service for discard.

12

S 3. Tool List 3.1 • • • • • • • • •

3.2 • • • • • • • •

Required Tools Genie lift or equipment lift, SLC-12 or equivalent Torpedo level Metric allen set (Shortened 3mm) Small and large phillips head Small and Large flat head screwdriver 24mm (15/16 inch) wrench Snap ring plier (adjustable to 15mm) Torque Wrench (in. lbs.) Torque Wrench (ft. lbs.)

Optional Tools Porta band saw Large hand file 1/2 inch Drill/Driver Tape measure Drill bit set Hand tool pouch Adjustable wrench Roofer’s square

13

S 4. Unpacking 4.1

Halogen Light Warning

Use caution when lifting heavy objects to avoid serious bodily injury or damage to the equipment.

The equipment will arrive in shipping boxes on two separate pallets and may be arranged as depicted in the images below. The shipping boxes should contain all the necessary components required to install the halogen light system. Use the image and list below to determine where each component of the light suspension is packaged. Down Tubes

Ceiling Covers

Suspension

Accessory Box Light Head Light Head

Suspension

Light Head Light Head

Pallet

4.1.1 •

Suspension Box

Light Suspension • Suspension (Single, Dual, or Triple) • Spring Arms • Installation Hardware • Flat Panel Cable Kit

4.1.2 • •

Pallet

Accessory Box

Wall Control Unit and Cable Kits Power Supply Box

4.1.3

Light Head Boxes

• Halogen light heads • Light Handle Assemblies • StrykeCam® In-Light Camera (if purchased) • Sterilizable Light Handle • Sterilizable Camera Handle (if StrykeCam was ordered) If any parts are missing, contact the Shipping and Receiving Department to verify whether a shipping box(es) was left behind. If all boxes were delivered and parts are unaccounted for, call and inform your Project Manager of the missing items. 14

S Use box cutters to open the shipping box along the seams. Note

Notice that the boxes have “break away” panels to allow easy access to the parts.

Verify that all parts are present and visibly undamaged.

4.2

LED Light Warning

Use caution when lifting heavy objects to avoid serious bodily injury or damage to the equipment.

The equipment will arrive in shipping boxes and may be arranged as depicted in the image below. The shipping boxes should contain all the necessary components required to install the Visum® LED light system. Use the image and list below to determine where each component of the light suspension is packaged. Light Head

Light Head

Light Head

Light Head

Suspension

Accessory Box

Suspension

Accessory Box

Pallet *The outlined boxes represent a double shipment of supplies. Orientation of packaging may arrive differently.

15

S Accessory Box

Accessory Box

Light Head

Light Head

Light Head

Light Head

Suspension

Suspension Pallet

4.2.1 •

Suspension Box

Light Suspension • Suspension (Single, Dual, or Triple) • Spring Arms • Installation Hardware • Flat Panel Cable Kit • Tea Cup (EHA only)

4.2.2

Accessory Box

(There are three boxes within the Accessory Box) • • • •

Ceiling Cover (Box 1) Wall Control Unit and Light Cable Kits (Box 2) Power Supply Box and Bezel (Box 3) Down Tube Extended Horizontal Arm Packaging

4.2.3 • • • • •

Light Head Boxes 1 and 2

LED light heads Light Handle Assemblies StrykeCam® 2 In-Light Camera (if purchased) Sterilizable Light Handle Sterilizable Camera Handle (if StrykeCam 2 was ordered)

16

S If any parts are missing, contact the Shipping and Receiving Department to verify whether a shipping box(es) was left behind. If all boxes were delivered and parts are unaccounted for, call and inform your Project Manager of the missing items. Use box cutters to open the shipping box along the seams. Note

Notice that the boxes have “break away” panels to allow easy access to the parts.

Verify that all parts are present and visibly undamaged.

4.3

Flat Panel Arms

The equipment will arrive in a shipping box on one pallet. The shipping box should contain the Flat Panel Arm System and Ceiling Covers. The Flat Panel Arm will be fully assembled and completely wired out of the crate. Uncrate pallet and open the shipping box. Use box cutters to open the shipping box along the seams. Verify that all parts are present and visibly undamaged.

4.4

Booms

Each Boom will arrive in a shipping box on one pallet. The shipping box should contain a Boom Arm, Service Head, shelves (if applicable), and Ceiling Covers. Use box cutters to open the shipping box along the seams. Verify that all parts are present and visibly undamaged.

17

S 5. Preparing the Mounting (Interface) Plate Remove the hardware bag from the suspension box. Note

Ensure all-thread rods do not interfere with the application of ceiling cover by performing a dry fit. The all-thread rods should not extend below the base of the cover. If they do, cut the rods back. 1. Install six hex nuts below Mounting (Interface) Plate to align flange top approximately even with the bottom of finished ceiling. 2. Use a Torpedo Level to verify that the nuts are level. Measure two sets at a time.

3. Place flat washers and Plastic Isolation Discs (required in Europe) below each hex nut to hold in place. Note Caution

Plastic Isolation Discs are only required in Europe. No more than 8 inches of exposed all-thread rod is allowed between the Preinstallation Plate and the down tube flange for Seismic considerations. No more than 2 inches of exposed all-thread rod is allowed for Zone 4 installations. Cover Size 180 mm (7 inches) 153 mm (6 inches) 80 mm (3 inches) 64 mm (2.5 inches)

18

S 6. Preparing the Suspensions 6.1

Installing the Cable Kit for Lights

1. Route the power and control cables between the power supply box and the suspension structure. Verify that the light connectors remain near the ceiling plate, as shown in the figure below. 2. (For LED only) Route the S-Video cable through the pre-installed conduit between the super structure and video output location. Note

Consult your Project Engineer and/or room drawings to determine the video output location.

3. Pull the cable between the wall control unit and the power supply box. One end of the wall control unit cable is unterminated. 4. Cut the wall control unit cable to length and terminate it. Connect the wires into the female connector according to the schematic chart shown below. P1

Schematic

P2

RED

Schematic

P1

P2

BLK WHT GRN

SHLD

SHLD

Wall Control Unit Cable Pin Configuration - LED (left) Halogen (right) 5. Solder the Shield Conductor to the DB9 female connector chassis as shown below.

DB9 Female Connector Shield Conductor

Soldered Shield Conductor

19

S 6.2

Surgical Lights 6.2.1

Standard Horizontal Arm

1. Load the suspension shipping box onto a heavy machinery lift device. 2. Cut cardboard 9 inches from the top of the box to facilitate hanging suspension. Be careful not to cut cables or scratch the suspension. 3. Mount down tube onto suspension. Use the six flat head socket cap screws (taped to down tube) to attach the down tube to the central axis spindle. Tighten all screws with a torque wrench set to 100 lb-in (8.33 lb-ft, 11.3 Nm). Once all screws have been tightened, retighten each screw to ensure correct torque is set. If you are installing a flat panel along with a dual light suspension, verify that the flat panel cable kit is routed through the opening in the down tube. 4. Position the suspension assembly directly below the mount site. 5. Go to Section 7, “Installing the Suspension” to complete installation.

6.2.2

Extended Horizontal Arm

1. Remove all accessories and the cardboard box. 2. Position Genie Life so that forks are underneath the highlighted areas shown in the following figure.

Brown packaging is wood

3. Mount down tube onto suspension. Use the six socket cap screws to attach the down tube to the central axis spindle. Tighten all screws with a torque wrench set to 354 lb-in (29.5 lb-ft, 40 N-m). Once all screws have been tightened, retighten each screw to ensure correct torque is set. If you are installing a flat panel along with a dual light suspension, verify that the flat panel cable kit is routed through the opening in the down tube. 4. Position the suspension assembly directly below the mount site.

20

White packaging is styrofoam

S 6.2.3

Alternate Light Installation Instructions

1. Load the suspension shipping box onto a heavy machinery lift device. 2. Cut cardboard 9 inches from the top of the box to facilitate hanging suspension. Be careful not to cut cables or scratch the suspension.

Hex Nut Flat Washer Lock Washer Hex Nut

Note

When necessary, Plastic Isolation Discs surround the mounting plate, but are only required in Europe.

3. Raise the down tube toward the mount site. 4. Guide the all-thread rods through the holes located on the down tube flange. The down tube flange must press lightly against the hardware assembly. 5. Place a flat washer on alternating all-thread rods followed by a hex nut; tighten the hex nut. 6. Use a Torpedo Level to verify the down tube flange is level across three horizontal planes. If the flange is not level, adjust the hex nuts until the Torpedo Level indicates the down tube flange is level across three horizontal planes. Confirm that the down tube is also level by placing the Torpedo Level on the down tube at three, evenly-spaced locations.

7. Install a flat washer, lock washer, and hex nut on the remaining all-thread rods. Note

Plastic Isolation Discs are only required in Europe.

8. Tighten the hex nuts to 75 ft-lbs. Ensure the lock washers are fully compressed. 9. Remove the hex nuts from the all-thread rods applied in step 5 and install a lock washer and hex nut.

21

S 10. Use a Torpedo Level to verify that the down tube flange is level across three horizontal planes. 11. Connect the ground wire (found on the down tube flange) to the ground lug located in the ceiling. 12. Refer to Section 7 to complete installation.

6.3

Flat Panel 1. Place the suspension onto a heavy machinery lift device. 2. Use zip ties to tie the horizontal arm and Spring Arm together to prevent swinging during installation. 3. Raise the Flat Panel Arm for installation; position the arm so the stop is in the specified location (the Project Manager should have this information).

Note

6.4

The normal stop position is above the bed, allowing 330° of rotation of the upper arm, with the 30° “dead” spot.

Booms

Due to door entry height, the flange and drop tube may be removed for entry into the room. The flange and drop tube must be reinstalled before installation of the equipment boom. If the MMP200/OSC600 Service Head is not assembled: 1. Place pallet securely on material lift (e.g., Genie Lift). 2. Determine the orientation of the service head before attaching to the down tube, feel for the notch. The notch will be mounted to the front of the service Head.

22