X7000 Light Source Repair Manual Oct 2004

Warranty Stryker Endoscopy warrants the X-7000 Light Source against defects in both materials and workmanship to the registered owner at the time of purchase. All components are covered by the warranty for a period of one year from the date of purchase. This warranty does not apply to any unit which has been the subject of misuse, abuse, neglect, improper installation or operation or that which has been altered, adjusted, or tampered with by any person other than Stryker Endoscopy authorized service personnel. The customer is responsible for returning the defective equipment to the factory at his or her own expense. Stryker Endoscopy or its representative will service the unit, repair or replace any defective parts thereof, and return the unit.

shall Stryker Endoscopy be liable for any breach of warranty in any amount exceeding the purchase price of the product. No agent, employee or representative of Stryker Endoscopy has the authority to bind the Company to any other warranty, affirmation, or representation concerning this instrument. This warranty is valid only to the original purchaser of Stryker Endoscopy products directly from Stryker Endoscopy or from a Stryker Endoscopy authorized agent. The warranty cannot be transferred or assigned by the original purchaser. The X-7000 Light Source warranty is void if any WARNINGS, CAUTIONS, or NOTES are disregarded.

If, upon examination, it is determined that the fault has been caused by misuse or abnormal conditions of operation, the repairs will be billed to the customer in the same manner as out-of-warranty repairs.

All Stryker products are warranted against defects in materials and workmanship.

Products repaired by Stryker Endoscopy will be issued a 30 day repair warranty against defects in both materials and workmanship, provided the original warranty period has expired. This warranty applies only to products that have been repaired by Stryker. Instruments submitted due to defects in materials and workmanship during the warranty period will be repaired at no charge to the customer.

© Stryker and Stryker Endoscopy are registered trademarks of Stryker Corporation.

The warranty as set forth herein is exclusive and in lieu of all other warranties, remedies, obligations, and liabilities of Stryker Endoscopy Inc., expressed or implied, including the implied warranties of merchantability and fitness for use and of consequential damages. These products are being sold only for the purpose described herein, and such warranty only runs to the original purchaser. In no event

Table of Contents 1.0 INTRODUCTION 1.1 Scope...1 1.2 Responsibility...1 1.3 Upgrades...1 1.4 Equipment Overview...1 1.5 Service Options...1 1.6 Maintenance Precautions...1 1.7 Factory Service Instructions...2 1.8 Required Equipment...2 1.9 Required Skills...2 1.10 Required Replacement Components...2 2.0 DIAGNOSTICS AND CORRECTIVE MAINTENANCE 2.1 General Recommendations...3 2.2 Power Requirements...3 2.3 Ambient Requirements...3 2.4 Connections and Wiring...3 2.5 Verify Operation...3 3.0 REPAIR CHECKLIST AND MATRIX 3.1 Diagnostic Analysis Checklist...5 3.2 Repair Matrix ...6 4.0 COMPONENT REMOVAL AND REPAIR 4.1 Component Replacement Instructions...7 4.1.1 Component Removal Table...7 4.1.2 Individual Replacement Instructions...8 4.2 Console Cover Removal ...8 4.3 Power Source Components...9 4.3.1 Control Board Replacement...9 4.3.2 Lamp Ballast Replacement...10 4.3.3 AC Inlet Board Replacement...11 4.3.4 Ballast Fan Replacement...12 4.4 Light Source Components...12 4.4.1 Bulb Fan Replacement...12 4.4.2 Bulb Board Replacement...13 4.4.3 Shutter Replacement...13 4.4.4 Hot Mirror Replacement...13 4.4.5 Motor Mount Replacement...14 4.4.6.1 Motor Replacement...15 4.4.6.2 Integrating Rod Replacement...15

4.5 Front Panel Components...16 4.5.1 Jaw Handle Replacement...16 4.5.2 Potentiometer Knob Replacement...16 4.5.3 Front Panel Replacement...17 4.5.4 Jaw Assembly Replacement...17 4.5.5 Power Switch Replacement...18 4.5.6 Display Board Replacement...18 4.6 Fuse Replacement...19 4.6.1 Rear Panel Fuses...19 5.0 ELECTRONIC PROCEDURES 5.1 Required Skills...20 5.2 Alignment and Calibration...20 6.0 FINAL ASSEMBLY AND TESTING 6.1 Required Skills...21 6.2 Assembly...21 6.3 Electrical Current Leakage Test...21 6.4 Hi-Pot Test...22 7.0 APPENDIX 7.1 Assembly Diagram...23 7.2 Parts Listing...23 7.3 Reference Documents...23 8.0 WARRANTY ...24 9.0 SERVICE ...24 10.0 OTHER SERVICE ...25

1.0 Introduction 1.1 SCOPE This manual is intended to be used as a reference guide for electronics technicians and the Stryker Repair Team in the analysis and repair procedures for the X-7000 Light Source. It is meant to be used in conjuction with the Stryker X-7000 Universal Light Source Operating and Maintenance Manual (Stryker P/N 1000-400-651) and does not replace existing documentation. Stryker Endoscopy maintains a complete repair department for the sole purpose of providing efficient and reliable service. 1.2 RESPONSIBILITY Stryker Endoscopy accepts full responsibility for the effects on safety, reliability, and performance of the equipment only if readjustments, modifications and repairs have been carried out exclusively by a person specifically authorized by Stryker Endoscopy to do so. In no event shall Stryker Endoscopy be liable for incidental or consequential damages in connection with or arising from the performance or use of its products after unauthorized modification or repair performed by individuals other than Stryker Endoscopy perosnnel. 1.3 UPGRADES The Stryker Endoscopy X-7000 Light Source is a high performance device designed for use with Stryker Endoscopy medical video cameras to provide outstanding illumination of the surgical site across all endoscopic applications. With the proper light cable and adapters, it can be connected to any flexible or rigid endoscope. Stryker Endoscopy reserves the right to incorporate improvements without notice. However, updated parts will be fully interchangeable with older versions and will offer at least the same level of quality and performance.

tive for up-to-date information on available options and upgrades to equipment as well as updates to this manual. 1.4 EQUIPMENT OVERVIEW The Stryker Endoscopy X-7000 Light Source consists of the light source, power cord, and Operation and Maintenance Manual. Replacement or spare lamps can be purchased separately. 1.5 SERVICE OPTIONS The user is advised to return a malfunctioning unit to Stryker Endoscopy for repair or replacement, where specialized equipment and technicians are available to perform repairs while maintaining full product quality and safety. In the event that the user decides to undertake repair procedures, Stryker Endoscopy recommends that these be carried out only by qualified technicians with proper test equipment listed in this manual, so that the safety of operators and patients may not be compromised. 1.6 MAINTENANCE PRECAUTIONS WARNING: The incorrect use of any of the required tools and techniques may risk damage to the equipment or injury to the person carrying out the procedure, subsequent operators, or patient. Repairs should be made ONLY by those that have been specificallytrained in the use of all pertinent equipment andtechniques. Stryker Endoscopy cannot continue to guarantee compliance to UL, CSA, TUV, or other labeled safety standards if service is performed by anyone other than Stryker Endoscopy Personnel.

Stryker Endoscopy will inform customers of significant upgrades to the product. Contact your Stryker representa-

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1.7 FACTORY SERVICE INSTRUCTIONS

1.9 REQUIRED SKILLS

If service is needed either during or after the warranty period:

Each diagnostic and repair procedure described in this manual requires a technician qualified by training or experience in the following areas:

Contact Stryker Endoscopy at 1-800-624-4422 or contact your local Stryker Endoscopy sales representative. If needed, a loaner unit may be requested during the time of your unit repair.

•Basic electronics techniques •Multimeter operation

Package the X-7000 carefully in the original shipping container, if possible.

If a repair procedure necessitates replacements parts, please refer to the Appendix (page 22).

Ship the Stryker Endoscopy X-7000 Light Source, prepaid and insured, to: Stryker Endoscopy Customer Service Attention: Repair Department 5900 Optical Court San Jose, CA 95138 1.8 REQUIRED EQUIPMENT Most of the procedures described in this manual require the following basic tool kit: • • • • • • • • • • • • • • • • • •

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Small flat blade screwdriver Medium Philips screwdriver 8” adjustable wrench Needlenose pliers Small wire cutting pliers Wire stripper Soldering iron and solder Multimeter Stryker medical video camera Stryker Scope Fiber optic cable Glass fuse puller Shorting clip Bio Tek Model 170 Analyzer or equivalent current leakage tester Nut drivers 11/32” and 5/16” Open end wrenches 7/16” and 1/2” Set of standard allen wrenches / hex keys Hi-Pot Tester

1.10 REQUIRED REPLACEMENT COMPONENTS

2.0 Diagnostic and Corrective Maintenance 2.1 GENERAL RECOMMENDATIONS The Stryker Endoscopy Model X-7000 Light Source is a precision instrument which has been engineered and manufactured with great care to ensure the safety of operators and patients. In order to maintain the high level of safety and reliability required of the X-7000, it is important to fully understand and comply with all required procedures set out herein. If some part of a procedure is omitted or adequate equipment is not used, the safety and performance of the device may be unknowingly compromised. It is strongly recommended that if any element in these procedures is beyond the scope of the technician’s training, refer to section 1.7 for information on obtaining fully qualified professional service at Stryker Endoscopy.

NOTE: A proper electrical installation procedure will ensure that all associated signal cabling is correctly installed prior to applying AC power to the system. 2.3 AMBIENT REQUIREMENTS Ensure that: • The distance between the X-7000 Light Source and the associated devices does not exceed the available cable length. • Controls will be easily accessible to operator. • Ventilation is not obstructed around the unit. Avoid locations with excessive heat or temperature fluctuations, such as direct sunlight. 2.4 CONNECTIONS AND WIRING

WARNING: As is the case with all AC powered devices, dangerous voltages are present. If adequate safety precautions are not taken, results may include damage to the equipment, injury, or death. It is imperative that these procedures be approached only by trained technicians with proper equipment after fully reading and understanding the steps involved. 2.2 POWER REQUIREMENTS

Please refer to the procedures detailed in the X-7000 Universal Light Source Operating and Maintenance Manual (Stryker P/N #1000-400-651). 2.5 VERIFY OPERATION After ensuring that both power and signal connections have been correctly made, place the power switch in each unit to the “ON” position. Check that an image is present on the monitor.

• There is one AC power cord for the X-7000 Light Source. A separate AC power cord is normally required for any other instrument being used. • Each instrument is clearly marked for power requirements at the AC power cord connection. • Testing the outlet for proper grounding and polarity is highly recommended prior to connecting the X-7000 Light Source. If available, a ground-fault-interrupt type outlet will provide an additional level of safety.

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3.0 Repair Checklist and Matrix 3.1 INITIAL REPAIR CHECKLIST The following page is intended for use by qualified Stryker personnel only. Complete a copy of the checklist and file it in the DHR. 3.2 REPAIR MATRIX #1 3.3 REPAIR MATRIX #2 The Repair Matrices are intended for use by qualified Stryker personnel only, in conjuction with section 4.0 (Component Removal and Repair). See page 6 and 7 for Repair Matrices.

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5900 Optical Court San Jose, CA 95138 t: 408 754 2000 f: 408 754 2505 www.stryker.com

DIAGNOSTIC ANALYSIS CHECKLIST

Endoscopy

CHECK DATE: _______________NAME: _____________________ SERIAL #: ___________________

What is the customer complaint?

General Assembly Check Points Yes/No Is there any visual damage on the unit? Are the door switches plastic or metal? Are there screws on the door switches? What is the Rev of the control board? (Rev. stamped on control board) Does the front display board backlight turn on when the device Does warm message appear when the unit is powered on? Does the unit turn on the front panel LEDs as expected after warm message? What is the software version number? How many hours are there on the bulb?

Details

System Checks Does the unit have D53 and D54 chips? (Rev. F and prior versions only) Does the unit turn on the bulb when the interlocks are closed? (door and light cable) Does the unit show the brightness properly? Does the unit switch between run/standby? Does the unit switch between auto/manual? When the cable is pulled out, does the bulb turn OFF? If not, record the voltage between TP20 and GND. When the door is opened, does the bulb turn OFF? If not, record the voltage between TP23 and GND.

Yes/No

Details

Failure Diagnostics Is power button flashing when powered on? Disconnect the ballast from the control board and connect the jumper cable, Does the bulb turn ON? If the bulb does not turn on, Measure the boost voltage. Measure the 5-V line voltage on the jumper. Measure the 12-V line voltage on the jumper.

Yes/No

Other Observations:

Staff Recommendation:

Cable in:

Cable out:

Door open:

Door closed:

Details

Boost voltage = 5-V line value = 12-V line value =

3.2 REPAIR MATRIX Use the following matrix to identify failure and repair codes. Refer to section 4.0 for repair instructions.

FAILURE CODES

BUR

BAR

RCR

DFR

NSP

NHL

NFP

Replace Ballast Fan

Replace Ribbon Cable

Replace Feet

Replace Slide Pot Knob

Replace Jaw Handle

Replace Front Panel

NSH Replace Shutter

NC1

NFG Replace Hot Mirror

Replace Bulb Fan

NFU Replace Fuse

2 1

1 2

2

3 3 3

2 4

1 1 2

1

5 3

1 1 3 3 2 2

Replace Cover

NSW Replace Power Switch

4 1

1 1 2 4 2

CHR

IRR Replace Integrating Rod

3 4 5 3 2 1 3

Replace Chassis

BBR Replace Bulb Board

1

EBF

NPB Replace AC Inlet Board

4 2 2

Replace Ethernet Board

NMO Replace Motor

4

NJW

NLL Replace Bulb Assembly 1

Replace Jaw Assembly

NCB 3 1 2 3

2 3

Replace Eprom / Upgrade EPR Software (in-house) NDB Replace Display Board

NLB

Replace Control Board

Error Code Failures E1F E-1 E2F E-2 E3F E-3 E5F E-5 E6F E-6 Power Failures PSF Power Switch Failure LPF No Power FBF Flashing Power Button BUF "Bulb" in Bulb Hours PFF Power only to Front Panel Light Output Failure NLF No Light Output SBY Unit won't exit Standby Mode LLF Low Light Output BHF Bulb Hours not Displayed DCF Delayed Ignition, Clicking DPF Delayed Ignition, Popping STR Strobing Light LOF Light Stays On Input/Output Ports PSF Permanent Sidne Failure ISF Intermittent Sidne Failure ECF Ethernet Communication Failure VIF Video Failure Board/Component Failures CBF Control Board Failure LBF Ballast Failure DBF Display Board Failure BJW Jaw Assembly Failure BAF Bulb Assembly Failure BBF Bulb Board Failure EBR Ethernet Board Failure PBF AC Inlet Board Failure FMO Motor Failure IRF Integrating Rod Failure BFG Hot Mirror Failure BSH Shutter Failure PSF Power Switch Failure BSP Slide Pot Knob Failure BHD Jaw Handle Failure EPF Eprom Failure FUF Fuse Failure RBF Ribbon Cable Failue FNF Fan Failure Cosmetics CHF Damaged Chassis COF Damaged Cover DFF Damaged/Missing Feet FPF Damaged Front Panel

Replace Ballast

REPAIR CODES

4

1 2 1

5 3

4

3

3 3

4

6

6 7

2

4

2 1

5

8

2

6 1

1 2 2 1

2 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2

1 1 1

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4.0 Component Removal and Repair 4.1 COMPONENT REPLACEMENT INSTRUCTIONS

4.1.1 Component Removal Table

Required skills: Basic electronics techniques.

NOTE: All components in previous columns must be removed before removing a component.

WARNING: The incorrect use of any of the required tools and techniques may risk damage to the equipment or injury to the person carrying out the procedure, subsequent operators, or patient. Repairs should be made ONLY by those that have been specifically trained in the use of all pertinent equipment andtechniques. The following instructions apply to the removal of components from the X-7000. To remove a component for replacement or repair will require the removal of certain other components. Components must be removed in the order listed in the following procedures. The table in section 4.1.1 shows the order in which components must be removed according to the basic physical assembly of the X-7000. To remove a component for replacement, or repair, begin with section 4.2 and proceed accordingly to the appropriate section.

1

2

3

Control Board

Ballast

AC Inlet Board

4

5

Ballast Fan

Bulb, Bulb Fan

Bulb Board Shutter

Hot Mirror

Motor Mount Assembly

Motor

Integrating Rod

Slide Button, Jaw Knob

Front Panel

Power Switch Display Board Jaw Assembly

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4.1.2 Individual Replacement Instructions

4.2 CONSOLE COVER REMOVAL

NOTE: Before removing any component in the X-7000, the Console Cover must be removed (refer to section 4.2).

Tools Required: Basic Tool Kit

To remove and repair any of the following components, proceed to section 4.3 (Power Source Components): • Control Board (4.3.1) • Lamp Ballast (4.3.2) • AC Inlet Board (4.3.3) • Ballast Fan (4.3.4) To remove and repair any of the following components, proceed to section 4.4 (Light Source Components): • Bulb (4.4.1) • Bulb Fan (4.4.2) • Shutter (4.4.3) • Hot Mirror (4.4.4) • Motor Mount (4.4.5) • Motor (4.4.6.1) • Integrating Rod (4.4.6.2) To remove and repair any of the following components, proceed to section 4.5 (Front Panel Components): • Jaw Handle (4.5.1) • Potentiometer Knob (4.5.2) • Front Panel (4.5.3) • Jaw Assembly (4.5.4) • Power Switch (4.5.5) • Display Board (4.5.6) To remove and repair any of the following components, proceed to section 4.6 (Rear Board Components): • Fuses (4.6.1)

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• Remove power cord. • On the back of the unit, remove the two screws attaching the console to the unit. • Open the lamp door latch on the side of the unit and open the door. • Slide the cover back, then lift off.

4.3 POWER SOURCE COMPONENTS 4.3.1 Control Board Replacement Tools Required: Basic Tool Kit • Remove power cord and console cover (procedure 4.2). • Disconnect connectors and attached wires. • Remove the 5 screws attaching the control board to the ballast. • Unscrew the nut and washer on the BNC connector. • Remove the old control board. • Install a new control board with 4 screws. • Reattach the connectors to their original locations, including attaching the ground for the ribbon cable with the 5th screw. • Screw washer and nut onto BNC. • Perform calibration (procedure 5.2). • Reinstall the console cover. • Perform Electrical Current Leakage Test (procedure 6.3).

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4.3.2 Lamp Ballast Replacement Tools Required: Basic Tool Kit • Remove power cord and console cover (procedure 4.2). • Remove the control board (procedure 4.3.1). • Label and disconnect the three power input cables located at the rear of the ballast. • Remove the bulb holder assembly. • Using the X-Long Magnetic Phillips screwdriver, remove the 4 screws attaching the lamp ballast to the chassis. • Replace the lamp ballast assembly. • Install new ballast assembly using an X-Long Magnetic Phillips screwdriver. • Reconnect all cables previously disconnected. • Reattach the control board to the chassis. • Reinstall the console cover. • Perform Electrical Current Leakage Test (procedure 6.3). • Perform Hi-Pot test (procedure 6.4).

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4.3.3 AC Inlet Board Replacement Tools Required: Basic Tool Kit • Remove power cord and console cover (procedure 4.2). • Remove the control board (procedure 4.3.1). • Remove the lamp ballast (procedure 4.3.2). • Remove the 2 bolts from the 2 nuts. • Remove the 1-2 screws from the AC inlet board (number of screws varies by revision). • Remove the wiring harness from the J2 connector.

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4.3.4 Ballast Fan Replacement

4.4 LIGHT SOURCE COMPONENTS

Tools Required: Basic Tool Kit

4.4.1 Bulb Fan Replacement

NOTE: BOTH fans must be replaced if one fan malfunctions. • Remove power cord and console cover (procedure 4.2).

Tools Required: Basic Tool Kit NOTE: BOTH fans must be replaced if one fan malfunctions.

• Remove the black ribbon cable.

• Remove power cord and console cover (procedure 4.2).

• Remove the fan wire harness assembly.

• Remove the bulb module.

• Note the fan orientation.

• Detach the wire harness from the control board.

• Remove the 2 nuts attaching the fan to the Chassis and remove the sub-assembly.

• Remove the 2 nuts attaching the bulb fan housing assembly to the chassis.

• Remove the 4 screws from the fan mounts.

• Note the fan orientation.

• Remove the malfunctioning fan(s) and replace. Ensure the correct orientation.

• Remove the 4 nuts attaching the bulb fan to the fan mounts/fan ducts.

• Reinstall the 2 fan mounts with the 4 screws.

• Reinstall the new fan onto the mounts/duct with 4 bolts, ensuring the correct orientation.

• Reinstall the 2 nuts. • Reinstall the fan assembly onto the chassis with 2 nuts. • Reinstall the black ribbon cable, fan wire harness assembly, and console cover.

• Reconnect the wire harness.

• Perform Electrical Current Leakage Test (procedure 6.3).

• Replace the bulb module and cover.

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4.4.2 Bulb Board Replacement • Remove power cord and console cover (procedure 4.2). • Remove the bulb. • Remove the bulb fan (procedure 4.4.1). • Remove the 2 wire harnesses. • Remove the bulb board and replace. 4.4.4 Hot Mirror Replacement • Reinstall the 2 wire harnesses, bulb fan, bulb, and cover. • Remove power cord and console cover (procedure 4.2). • Remove the bulb (procedure 4.4.1). • Remove the shutter (procedure 4.4.3). • Remove the 2 Allen screws. • Remove the hot mirror mount and replace. • Reinsert the 2 Allen screws. • Replace the shutter, bulb, and cover. 4.4.3 Shutter Replacement • Remove the power cord and console cover (procedure 4.2). • Remove the bulb (procedure 4.4.1). • Remove the Allen screw from the shutter shaft. • Remove the shutter and replace. • Reinsert the Allen screw. • Replace the bulb and cover.

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4.4.5 Motor Mount Replacement • Remove power cord and console cover (procedure 4.2). • Remove the bulb (procedure 4.4.1). • Remove the hot mirror (procedure 4.4.4). • Remove the 2 Phillips screws from beneath the hot mirror. • Remove the 2 nuts. • Remove the motor wire harness from the control board. • Remove the motor mount assembly with the motor attached, and replace. • Replace the wire harness. • Reinsert the 2 nuts and 2 Phillips screws beneath the hot mirror. • Replace the hot mirror, bulb, and cover.

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4.4.6.1 Motor Replacement • Remove power cord and console cover (procedure 4.2). • Remove the motor mount (procedure 4.4.5). • Remove the 4 Allen screws. • Remove the motor and replace. • Reinsert the 4 Allen screws. • Replace the motor mount and cover. 4.4.6.2 Integrating Rod Replacement • Remove power cord and console cover (procedure 4.2). • Remove the motor mount (procedure 4.4.5). • Remove the 2 screws and the cover. • Slide the integrating rod out. • Swab the rod holder with alcohol. • Insert new integrating rod. • Reinsert the 2 screws. • Replace the cover and motor mount.

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4.5 FRONT PANEL COMPONENTS

4.5.2 Potentiometer Knob Replacement

4.5.1 Jaw Handle Replacement

• Remove power cord.

• Remove power cord.

• If potentiometer knob is damaged or detaches from the front panel, but the protruding metal tab is still connected, perform the following repair steps:

• Remove the set screw from the bottom of the jaw handle. • Remove the jaw handle from the actuator shaft. • Ensure that the jaw handle key (P/N 105-186-472) stays in place on the actuator shaft. • Replace the jaw handle onto the actuator shaft.

• Remove the set screw from the bottom of the potentiometer knob. • Remove the knob from the slide pot of the front panel. • Loosely screw the set screw into the bottom of the potentiometer knob.

• Secure the jaw handle in place using the set screw. • Reinsert the set screw and reinstall the cover.

• With the screw hole facing down, insert the potentiometer knob onto the slide pot. • Secure the knob in place by screwing in the set screw. • If the potentiometer knob is damaged or detaches from the front panel, and the protruding metal tab is also damaged or disconnected, replace the display board and potentiometer knob.

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