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

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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

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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 LEDs 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.

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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

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 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.

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3. DESCRIPTON OF HARDWARE

Block wiring diagram

Power Supply Control I2C

28V Panel

Current source1
with switching
regulator LT3956

Current source2
CPU with switching
With 13 PWM regulator LT3956
channels
Current source3
with switching
regulator LT3956

Power in 20V to 32V Temperature-

Power PCB: Voltage-
5V Current-
3,3V control
Current source1
0 with switching
regulator LT3956

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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 IC

- 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. OPL12001 PCB CPU

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3.1.2. D6316 I2C PCB Keypad

3.1.3. OPL12001 Driver PCB LED Driver

Component side

Fuse 5A Measuring LED Driver

MT current r Modul
Hall-Sensor with
max. 5A LT3956

Power supply Suppressor Mono-Flip flop

Ub chokel 4A for fail safety
GND
PE

8
 Solder side

Temperature Tristate
sensor LM75 Driver for fail
over I2C-Bus safety

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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 Signal of Mono-Flop 1 triggers module1 to 5

ERROR_ALL2 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%.

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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 > 165C)

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 IC 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 (ACS712ELCTR-
05B-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.

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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 X7 Pin1 X8 Pin 1

JTAG X4 Pin 1
I2C Panel 1 x seriell Video
TTL Video

Note processor interface: X3 Pin1

COM1 (sci0) connector X7 Light field and
intensity control
COM2 (sci3) connector X4
COM3 (sci6) connector X4

5.1.1. Pin assignment X4

RS232

Pin Pin Assignment Function Description

1 TxD3 Send COM2 VT100 Terminal
2 RxD3 Receive COM2 VT100 Terminal
3 TxD6 Send COM3 None (Reserve)
4 RxD6 Receive COM3 None (Reserve)
5 GND Ground

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5.1.2. Pin assignment X7
TTL Signal and Video In
Pin Pin Assignment Function Description
1 +5V Versorgung CAM-Adapter --
2 TxD0 Send COM1 CAM-Interface
3 RxD0 Receive COM1 CAM-Interface
4 (RTS, CTS) Optional --
5 GND Ground --
6 C In Video signal
7 Y In Video signal
8 Video GND Video signal

5.1.3. Pin assignment X8

Video Out
Pin Pin Assignment Function Description
1 Video GND Video signal
2 Y out Video signal
3 C out Video signal

5.1.4. Pin assignment X3

Field size adjustment in intensity adjustment
Pin Pin Assignment Function
1 CW Signal for field size and intensity plus
2 CCW Signal for field size and intensity minus
3 NC
4 GND Reference

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5.2. Interface connection of the Driver PCB OPL12001

5.2.1. View
Feed-in of the complete module

Fuse Current
5A MT sensor

X5
X4
X3
X2
X11
X1
+Ub
0V X10
PE X9
X8
X7
X6

CPU 2 - LED
Connector
1 + LED

5.2.2. Pin assignment X1 to X10

Connector designation Function

X1 LED Driver module 1
X2 LED Driver module 2
X3 LED Driver module 3
X4 LED Driver module 4
X5 LED Driver module 5
X6 LED Driver module 6
X7 LED Driver module 7
X8 LED Driver module 8
X9 LED Driver module 9
X10 LED Driver module 10

5.2.3. Pin assignment X11

Pin description Function

X11. + Vp Positive voltage +20V to 32V
X11.0V GND (0V)
X11.PE Earth GND

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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

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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.

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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

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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.

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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

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6.2.2.1.5. Log file page 1

6.2.2.2. System parameter

20
6.2.2.3. Set parameter to default

6.2.3. Hardware tests

21
6.2.3.1. Adc menu

6.2.3.2. IO menu

22
6.2.4. Failure messages

6.2.5. Failure statistic

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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.

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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 Code Code designation
0 ERROR_NO
1 ERR_MODUL FAILURE
2 ERR_OVERVOLTAGE
3 ERR_UNDERVOLTAGE
4 ERR_OVERCURRENT
5 ERR_OVERTEMPERATURE
25
Description and action
No 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
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
Without switched ON light head.
Hardware defect. Light head cannot
be switched ON
With switched ON light head
Possible Module defect
The temperature of the light head increases 70C
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 65C (5C Hysteresis) the
normal condition will be established.
Err No Code Code designation Description and action
6
7
ERR_MODUL_OVERCURRENT Additonal info for ERR_MODULFAILURE
Additonal info for ERR_MODULFAILURE
ERR_MODUL_UNDERVOLTAGE
Will be shown only in the log file
NT Will be shown only in the log file
Additonal info for ERR_MODULFAILURE
ERR_MODUL_OVERPOWER
Will be shown only in the log file
During the initialization of the I2C0 a failure
ERR_I2C_CHANNEL0 occurred
Failure number in sub error
During the initialization of the I2C3 a failure
ERR_I2C_CHANNEL1 occurred
Failure number in sub error
During the access of the panel with the
ERR_TCA6416 component TCA6416 a failure occurred.
Failure number in sub error
During access of the temperature measuring
ERR_LM75 component LM75 a failure occurred.
Failure number in sub error
During erasing of the E2 data flash a failure
ERR_FLASH_ERASE
occurred. Failure number in sub error
During writing in the E2 data flash a failure
ERR_FLASH_WRITE
occurred. Failure number in sub error
During reading of the E2 data flash a failure
ERR_FLASH_READ
occurred. Failure number in sub error
Parameter of the Kat1 are twice available, they
ERR_FLASH_CRC_KAT1
are safed through a checksum.
Memory test detected a failure.
ERR_RAM_TEST
Failure address in sub error

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8. INSTALLATION AND SERVICE POWER SUPPLY

8.1. Hardware

To Surgical Light
28V DC

Wire:
Mains Voltage <25m --> 3x 1,5mm
Emergency Power In
100-240V AC 25-50m --> 3x 2,5mm
24V DC
50-60Hz
Wire:
Wire: <25m --> 3x1,5mm
3x1,5mm 25-50m --> 3x2,5mm

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: 100 - 240V AC

Wire cross section: 1,5 - 2,5mm

8.3.2. Emergency Power

The emergency power connection hast to be performed with an approved cable.

Emergency Voltage: 24 - 32V DC

Wire cross section: 1,5 - 2,5mm
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: 2,5mm

Max. length: 20m

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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 24 / 28V DC
Emergency Output to
power supply surgical light

31
9. CONNECTIONS OF THE MOBILE STAND

Input
Output
Mains voltage
28V DC
100 240V AC

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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
info@evonos.de
www.evonos.de

ARTICLE NUMBER: DOC-02-000003-GB

SERVICE MANUAL SURGICAL LIGHT 500/700
Rev. 3.0
20.10.2015

33