Service Manual

Sim.LED

Doc. ID: 100-0012350-EN – V. 1.3

CO 003-00913

Before starting any work please

read these instructions!
S.I.M.E.O.N. Medical GmbH & Co. KG
In Grubenäcker 18
D-78532 Tuttlingen
Telephone: +49 (0) 7461 90068-0
Fax: +49 (0) 7461 90068-901
E-mail: info@simeonmedical.com
Website: www.simeonmedical.com

Technical Service
S.I.M.E.O.N. Medical GmbH & Co. KG
Telephone: +49 (0) 7461 90068-888
E-mail: service@simeonmedical.com

© S.I.M.E.O.N. Medical GmbH & Co. KG 2015

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 Service Manual Sim.LED

Table of Contents

1 General .................................................................................... 4
1.1 Information regarding this Service Manual .................... 4
1.2 Symbol Explanation ....................................................... 7
1.3 Spare parts .................................................................... 8
1.4 Warranty provisions ....................................................... 9
1.5 Customer service ........................................................... 9
1.6 Incoming inspection during delivery of spare parts ....... 9
1.7 Duties of the operator .................................................. 10
2 Power supply ........................................................................ 12
2.1 Switching power supply ............................................... 12
2.2 Wall control unit ........................................................... 12
3 Technical service Sim.LED 5000-7000 ............................... 13
3.1 Service menu ............................................................... 14
3.2 Working on the light head ............................................ 15
3.2.1 Replacing the control electronics ................. 15
3.2.2 Opening the light head ................................. 19
3.2.3 Replacing the reflector or Sim.POD ............. 22
3.2.4 Closing the light head ................................... 25
3.2.5 2Replacing the distribution board ................. 27
3.2.6 Replacing the film control panel ................... 28
3.2.7 Replacing the cardanic / cardanic cable ...... 30
3.2.8 Replacing the handle units ........................... 41
4 Technical service Sim.LED 3500+, 4500, 350 .................... 43
4.1 Working on the light head Sim.LED 3500+, Sim.LED
4500 ............................................................................. 44
4.1.1 Opening the light head ................................. 44
4.1.2 Replacing the reflector or Sim.POD ............. 44
4.1.3 Closing the light head ................................... 46
4.1.4 Replacing the electronics ............................. 48
4.2 Working on the light head Sim.LED 350...................... 49
5 Maintenance ......................................................................... 50
5.1 Maintenance plan ........................................................ 50
5.2 Technical safety controls ............................................. 51
6 Troubleshooting ................................................................... 53
6.1 Malfunctions Sim.LED ................................................. 53
6.2 Fault analysis, Sim.LED ............................................... 54
6.2.1 Error code Sim.LED SC (up to 2nd
generation) ................................................... 55
6.2.2 Error codes Sim.LED MC/SC starting with
3rd generation .............................................. 56

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Service Manual Sim.LED General

1 General
1.1 Information regarding this Service Manual
Any changes to this medical unit are fundamentally not allowed.
Exceptions are only given to authorised technical specialists
appointed by S.I.M.E.O.N. Medical GmbH & Co. KG.
This Service Manual enables the safe and efficient maintenance
and repair of the Sim.LED. The Service Manual must be stored in
an accessible manner for the lighting manufacturer's service
personnel or for personnel authorised by the manufacturer.
Medical equipment may only be installed, operated, controlled and
maintained by persons who possess the required training,
knowledge and experience.
Persons who perform maintenance and repair must have carefully
read this Service Manual and understood its contents before
starting any work. The basic requirement for a safe work process is
the adherence to all safety and handling instructions in this manual.
Furthermore, local regulations for working with medical equipment
in sterile rooms such as operating theatres, apply.
The illustrations in this manual are provided for basic
understanding and could deviate from the actual design.
The installation and operation of the Sim.LED are described in the
separate Installation Instructions and Instructions for Use.

Safety information
Safety indications are identified in this Service Manual through
symbols.

Risk of death or severe bodily injury!

Non-observance could possibly result in death or severe bodily
injury!

Risk of minor bodily injury or material damages!

Non-observance carries a minor risk of bodily injury or material
damages!

Risk of material damages: Possible damage to or destruction of

the product or other objects, but also loss of data or loss of
working hours due to non-observance of the instructions.

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 Service Manual Sim.LED

General

Symbols
 Indicates handling instructions.
 Indicates a status or an automatic sequence as a result of
a handling step
 “Reference title”, page 24
is a cross-reference to a chapter in this document.
 Instructions for Use of this lighting
is a cross-reference to a separate document.

Cable colours in circuit diagrams

Abbreviation Cable colour (en) Cable colour (ger)

BK Black Schwarz
BU Blue Blau
BN Brown Braun
GN Green Grün
GNYE Green-Yellow Grün-gelb
OG Orange Orange
RD Red Rot
YE Yellow Gelb
TR Transparent Transparent

Copyright protection
This Service Manual is copyright-protected.
Forwarding of this Service Manual to a third party, its reproduction
in any type or form – even if only partial – and the exploitation
and/or dissemination of its contents are not allowed without written
authorisation from the manufacturer.
Infringements will be liable to compensation for damages.
We reserve the right to assert further claims.

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Service Manual Sim.LED General

Limitation of liability
All specifications and instructions in this Service Manual have been
compiled under consideration of applicable norms and standards,
the current state of the art, and our many years of knowledge and
experience.
We will accept no liability, and the warranty and guarantee will
become inapplicable in the event of damages resulting from:
 Non-compliance with this Service Manual
 Non-adherence to the designated use / specific function.
 Use by non-qualified personnel
 Modifications conducted independently
 Technical modifications
 Use of a defective or improperly-repaired unit
 Use of unauthorised spare parts or accessories
The actual scope of delivery may deviate from the explanations or
illustrations provided in this manual in the case of special designs,
the use of additional order options, or due to the most recent
technical changes.

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 Service Manual Sim.LED

General

1.2 Symbol Explanation

The following symbols can be found on Type plate and/or packaging. The symbols must always be taken
into account during.

Follow Instructions for Use

Information on minimum and maximum temperature for storage and transportation.

Information on minimum and maximum atmospheric pressure for storage and

transportation.

Information on minimum and maximum atmospheric humidity for storage and

transportation.

Arrows pointing up, transport and store upright.

Fragile, avoid pressure and shock.

Store in a dry place.

Manufacturer and manufacturing date

Reference number (item number)

Serial number

Class I equipment acc. to IEC 60601-1

Medical Equipment – General Medical Equipment

AS TO ELECTRICAL SHOCK, FIRE AND MECHANICAL HAZARDS ONLY IN ACCORDANCE WITH
ANSI/AAMI ES60601-1 (2005), CAN/CSA-C22.2 No. 60601-1 (2008), IEC 60601-2-41:2009,
UL 60601-1:2006, CAN/CSA-C22.2 No. 601.1, IEC 60601-2-41:2000

CE marking of conformity

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Service Manual Sim.LED General

1.3 Spare parts

Procure spare parts directly from the manufacturer. For the
address, see page 2.

Risk of injury due to the use of incorrect spare parts!

The use of incorrect or defective spare parts may place
personnel and patients at risk as well as cause damages,
malfunctions, or a total breakdown of the unit.
 Only use original manufacturer spare parts or manufacturer-
approved spare parts.
 In case of doubt, always contact the manufacturer.

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 Service Manual Sim.LED

General

1.4 Warranty provisions

The warranty provisions are contained in the manufacturer's
General Business Terms and Conditions.
The manufacturer's warranty is voided if unauthorised spare parts
are used.

1.5 Customer service

Our Customer Service is available to provide technical information.
For contact information, see page 2.
In addition, our personnel is always interested in hearing about new
information and experiences that may arise from use of the product
and that may be valuable for the improvement of our products.

Claims of any type due to damages caused by misuse, alteration or

modification of the surgical lights are excluded.

1.6 Incoming inspection during delivery of spare parts

Inspect the delivery of spare parts for completeness and integrity,
immediately after receipt.
Any transportation damages must be notified immediately.

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Service Manual Sim.LED General

1.7 Duties of the operator

Responsibility to instruct
The operator must inform himself of all applicable accident
prevention and hygiene regulations, and must additionally conduct
a risk assessment at the site where the unit will operate in order to
identify the risks posed by the particular work conditions. The
regulations must be implemented in the form of instructions for
operation of the unit.
During the entire time that the unit is in use, the operator must
check whether the operating instructions that he prepared comply
with current technical regulations. If necessary, they must be
revised.
The operator must clearly establish and manage responsibilities in
the areas of installation, operation, troubleshooting, maintenance
and cleaning.
The operator must ensure that all maintenance intervals and
technical safety controls described in this Service Manual are
adhered to.
The operator must ensure that absolute cleanliness is maintained
when conducting the service activities described in the following.
The operator must ensure that only approved accessories and
accessories released by the manufacturer are used together with
the unit.

Technical safety controls

The operator must allow technical safety controls to be conducted
regularly.
Technical safety controls may only be conducted by the
manufacturer's personnel, or by authorised specialists who have
received written approval from the manufacturer.
The protocol prepared by the authorised specialist, detailing the
measurement procedures, measurement results, and other
evaluations, must be kept until the next control.

No liability in the event of non-

observance of time limits! The manufacturer assumes no liability for personal or material
damages if technical safety controls are not contracted and
conducted within the time limits provided.

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 Service Manual Sim.LED

General

Notification of accidents and

damages Malfunctions or unit defects that lead to bodily injury must be
immediately notified to the authorities in charge and to the
manufacturer.
The authorities in charge may request that the operator submit the
incident being notified to a technical safety evaluation by an
authorised expert, at its own expense, and that the evaluation be
submitted in writing to such authorities. The authorised expert will
be selected in consultation with the authorities in charge.
The technical safety evaluation will include determinations on
 whereupon fault for the incident lies,
 whether the unit was in proper condition,
 whether any further danger exists following rectification of
defects,
 whether new knowledge has been gained, calling for different
or new precautionary measures.

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Service Manual Sim.LED Power supply

2 Power supply
2.1 Switching power supply

1 Line in 100–240 V AC (L, N, PE) 5 Connection to the lights 28 V DC (+, -, PE)

2 Line out 100–240 V (L, N, PE) 6 Connection to the wall control unit
3 Safety Power in 24–28 V DC only (+, -, PE) 7 CAN-connection to the lights (PE, CAN+, CAN-)
4 Safety Power out 24–28 V DC only (+, -, PE)

2.2 Wall control unit

In this example, 2 lights may be connected to the wall control unit. The Sim.CAM SD is also controlled from
the wall control unit. It is connected through the light connection.

The camera Sim.CAM SD must be positioned on light 2;

otherwise, camera control will not be possible!

1 Connection to the switching power supply

2 Control panel, light 1
3 Control panel, light 2
4 Control panel, Sim.CAM SD

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Technical service Sim.LED 5000-7000

3 Technical service Sim.LED 5000-7000

The light bodies are live with a maximum of 24–30 V.

 Disconnect the power supply.

Electrostatic discharges (ESD) can cause damage to electronic
components:

 Ensure that the technician is grounded and that appropriate

safety measures have been taken against ESD.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

3.1 Service menu

Control panel Multicolour lights

 In order to reach the Service menu for the lights, press

the brightness control keys (1) for at least 3 s.
 An error code / warning is displayed on the light
head's control panel
 “Error code Sim.LED SC”, page 55
 “Error codes Sim.LED MC”, page 56.

Leaving the Service menu

If the keys are not pressed for a certain length of time, the control panel automatically returns to normal
mode.
Return quickly to normal mode by pressing the keys (1) simultaneously.

Control panel Singlecolour light 3rd gen.

Control panel Singlecolour light up to 2nd gen.

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 Service Manual Sim.LED

Technical service Sim.LED 5000-7000

3.2 Working on the light head

3.2.1 Replacing the control electronics
 Remove the screws (13) on the service cover (14).
 Lift the service cover (14).
 Remove 4 screws from the electronics (8, photos
below).

 Note the position of all connector pins, then remove all

pins.

 Note the position of the cable in the cable junction

box (1).

 Release cable from the cable junction box (1).

 Replace electronics.
 Screw on the electronics with 4 screws (8). In the
process, ensure that the PE cable on the top left of
the photo is also screwed on.

 Mount all connector pins as noted.

 Connect the cable in the cable junction box (1) as
noted.

 Replace the service cover (14) and screw on.

 Set up the electronics through the service software and
set to the relevant values and figures.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

Cables for MC electronics, and for SC electronics starting with generation 3

1 PE: Power supply PE (GNYE cable) 4 Cable to adjust illuminated field

1 GND: Power supply minus (cable imprint 2) 5 Video cable to cardanic
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 6 cables to the Sim.POD
3 Ribbon cable to the control panel on the cardanic (3 plugs) 8 4 mounting screws for the electronics

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Technical service Sim.LED 5000-7000

Cables for SC electronics up to generation 2

1 PE: Power supply PE (GNYE cable) 4 Cable to adjust illuminated field

1 GND: Power supply minus (cable imprint 2) 5 Video cable to cardanic
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 3 cables to the Sim.POD
3 Ribbon cable to the control panel on the cardanic (2 plugs) 8 4 mounting screws for the electronics

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

Cables for SC and MC electronics with Sim.CAM HD Touch

1 PE: Power supply PE (GNYE cable) 4 Power supply cable to camera

1 GND: Power supply minus (cable imprint 2) 5 6 cables to the Sim.POD
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 4 mounting screws for the electronics
3 Ribbon cable 12-pole for film control panel

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Technical service Sim.LED 5000-7000

3.2.2 Opening the light head

A special tool is required to perform this work:

Observe spare parts list,  page 8.

The light bodies are live with a maximum of 24–30 V.

 Disconnect the power supply.

Electrostatic discharges (ESD) can cause damage to electronic
components:

 Ensure that the technician is grounded and that appropriate

safety measures have been taken against ESD.

Standard: Removing the handle unit / Sim.CAM SD /

Sim.CAM HD Touch.
 Remove 3 knurled screws (1) from the handle unit (2).

 Remove the handle unit (2).

 Remove 4 screws (3) from the glass-fixing plate (4).

 Remove the plate (4).

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

Alternatively: Removing the Sim.CAM HD

 Open the latching tabs (1). The red surfaces must be

visible!

 Remove the handle unit.

 Remove the 3 screws (2) on the glass-fixing HD plate (3).

 Loosen the HD plate (3).

 Remove 2 screws (4) from the camera coupling.

 Remove 5 screws (5) on the inner ring
 Turn the camera coupling in such a manner that it fits
through the cavity (6).

 Remove the HD plate (3). Here, the camera coupling

remains with the light.

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Technical service Sim.LED 5000-7000

Dismounting the glass panel

 Position the glass lifter (4), press firmly and carefully

reverse the clamping lever (5) under pressure.

 The glass lifter will suction firmly onto the glass.

 Place the special tool (6) at the spot by the cardanic where
the seal (7) separates, and lift the small, filler profile in the
middle from its partition point.

 Pull off the filler profile (8).

 Lightly raise the glass lifter (4), so that the glass panel
slides out of the seal.
Important: Do not pull it off in a jerking manner since this will
cause the seal profile to slide out of the housing.
Important: It is possible that the seal profile may stick lightly to
the glass panel. In such a case, it should first be slightly
loosened by hand.
Important: Do not place the filler profile on the ground, it could
become contaminated. If needed, clean the filler profile before
installing.

 Place the glass panel with glass lifters on bottom, on a

secure surface.
Important: Do not touch the inner side of the glass panel. If
necessary, clean any fingerprints using a soft microfiber cloth.
Important: Do not touch the LED!

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

3.2.3 Replacing the reflector or Sim.POD

Important: 2 types of Sim.PODs are used with the MC lighting
series: Cold white (CW) and warm white (WW, marked red).

 When replacing a Sim.POD, ensure that it is being

exchanged for a Sim.POD of identical design!
Overview Sim.LED 5000 with distribution boards (1) to (3).

Overview Sim.LED 7000 with distribution boards (1) to (3).

 Take into account the different arrangements of the

distribution boards in the Sim.LED 5000/7000 MC!

Details for the distribution boards (1) to (3).

 When removing a plug, always note the position!

The wiring diagram shown above is also used for single colour
lights (starting with the 3rd generation)!

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Technical service Sim.LED 5000-7000

 Loosen the middle screw (9) on the Sim.POD (10).

Important: Do not touch the interior of the reflector! Remove

fingerprints with a soft microfiber cloth.

Important: Do not touch the LED!

 Lift the reflector (11).

 Hold the Sim.POD (10) firmly, otherwise the inner side of
the reflector could become scratched.

 Remove the LED connector pin (12) from the distribution

board.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

Removing old Sim.POD

 Remove the Sim.POD (13) from the reflector.

 In doing so, ensure that the cables that must be pulled
out do not touch the inner side of the reflector!

Inserting a new, identical Sim.POD

 From the front, guide the cables through the opening of

the reflector, ensuring that the cables do not touch the
inner side of the reflector!

 Plug the connection cable's connector pin (15) onto the

distribution board.

 Place the 3 projections of the Sim.POD into the

openings (14) in the reflector. Thanks to their irregular
arrangement, the projections prevent incorrect positioning
of the Sim.POD.

 Insert the Sim.POD's projection (top) into the hole (below)

in the housing.
Important: When positioning the reflector, make sure that the
cables are not pinched.

 Tighten the reflector manually.

Functional verification with service connecting

cables, 3- or 9-pole
3-pole cable, REF 142-0013140
9-pole cable, REF 142-0013138

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Technical service Sim.LED 5000-7000

3.2.4 Closing the light head

A special tool is required to perform this work:

Observe spare parts list,  page 8.

 Clean the inner side of the glass panel with Eskanol

10.255 and a lint-free cloth before use,
 “Maintenance plan”, page 50.
 Carefully place the glass panel on the light head in such a
manner that the outer seal slides over the edge of the
glass panel.

 Using the special tool, bring the outer seal over the edge
of the glass panel.

 Place the seal profile loosely around the edge of the glass
panel.

 Insert the end of the seal profile into the special tool,
as shown in the photo.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

 Fit the seal profile using the special tool.

Important: The tool's setting angle should be approx. 45°.
With a setting angle greater than 45°, the seal profile will be
stretched.

 Make sure to fit the seal profile precisely.

 If the end of the seal profile projects, remove the profile

and refit using a smaller setting angle on the tool.

 If the end of the seal profile is too short, remove profile

and refit using a larger setting angle on the tool.
Important: If the seal profile is shortened, there could be
problems fitting the seal profile correctly when servicing the
unit again.

 The seal should end evenly with the glass panel.

 In order to avoid indentations between the outer seal and
the seal profile, do not use the special tool to rework any
points that already close cleanly.

 Screw on the plate and handle,

 “Opening the light head”, page 19.

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3.2.5 2Replacing the distribution board

 To be able to replace the distribution board, first open the light head,
 “Opening the light head”, page 19.

The tool set “LED seal profile” (REF 161-0010482) will be

required to conduct this work.

The light head contains 3 distribution boards. They are located

below the reflectors (see arrows) that lie in the extended
knurled screws.

 Loosen the Sim.POD's middle screw under which the

defective distribution board is located
 “Replacing the reflector or Sim.POD”, page 22.
 Lift the reflector and Sim.POD
 “Replacing the reflector or Sim.POD”, page 22.
Important: Up to 3 reflectors must be removed to be able to
replace the distribution board (see tracings in the photo).
Important: The reflectors overlap one another. When
screwing/unscrewing them, the correct sequence must be
followed. If more than one reflector is unscrewed, the topmost
reflector must be unscrewed first, and it must be screwed back
on last.
 “Replacing the reflector or Sim.POD”, page 22.

 Note the connector pin positions, label the cables.

 Remove the connector pins from the distribution
board (12).

 Also unscrew and remove the neighbouring reflectors.

Important: All cables must be pulled.

 Replace the distribution board.

 Replug the cable's connector pins back into the correct
slots.
Important: In doing so, ensure that the cables are not
pinched.

 Retighten the reflectors,

 “Replacing the reflector or Sim.POD”, page 22.

 After work on the light head is completed:

 “Closing the light head”, page 25.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

3.2.6 Replacing the film control panel

Film control panel MC, and SC starting with generation 3

 Perforate the film control panel (1) with a flat screwdriver

so that it penetrates the film (2) by a max. of 5 mm.

 Pry out the film (1).

 The film panel will be destroyed as a result.
 Remove any adhesive remains.

 Carefully loosen the plug connection (3, 4).

 If the film control panel has a grounding wire (6, see
below), then unscrew it with an Allen key.

 Dispose of the destroyed film control panel.

 Remove the cover film (5) of the adhesive surface from

the new self-adhesive film control panel and make sure
that the grounding wire (6) does not get stuck in the
process.

 Plug the connector pin (3) back into the slot (4).

 Screw on the grounding wire (6) with the Allen key (7).

 Correctly align, position, and press firmly on the new film

control panel, starting from the outside.

 Press firmly once again on the film control panel area that
is bordered in red (1).

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Film control panel SC up to generation 2

 To be able to replace the film panel, first open the light head,
 “Opening the light head”, page 19.

 Pull both connector pins.

 Push the film control panel from the inside, out of the light
head.

 The film panel will be destroyed as a result.

 Remove any adhesive remains.
 Correctly align, position, and press firmly on the new,
self-adhesive film panel, starting from the outside.

 Replug both connector pins back into the correct slots.

 In doing so, ensure that the cables are not pinched.
 After work on the light head is completed:
 “Closing the light head”, page 25.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

3.2.7 Replacing the cardanic / cardanic cable

Only use a cardanic which fits exactly as a replacement part!

Consult the manufacturer’s service department to find out which
cardanic fits the light exactly: service@simeonMedical.com

 To be able to replace the cardanic cable, first open the light head
 “Opening the light head”, page 19.
 To be able to remove the cables, first remove the Service cover for the electronics
 “Replacing the control electronics”, page 15.

Loosen cables for MC electronics, and for SC electronics starting with generation 3

1 PE: Power supply PE (GNYE cable) 4 Cable to adjust illuminated field

1 GND: Power supply minus (cable imprint 2) 5 Video cable to cardanic
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 6 cables to the Sim.POD
3 Ribbon cable to the control panel on the cardanic (3 plugs) 8 4 mounting screws for the electronics

 Note the position of the power supply cables in the cable junction boxes (1), then loosen up the cable
junction boxes (1) and remove the power supply cables.

 Note the position of connector pins (2), (3) and (5), then pull these connector pins.
These cables will next be dragged into the light's housing.

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Loosen the cables for SC up to generation 2 electronics

1 PE: Power supply PE (GNYE cable) 4 Cable to adjust illuminated field

1 GND: Power supply minus (cable imprint 2) 5 Video cable to cardanic
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 3 cables to the Sim.POD
3 Ribbon cable to the control panel on the cardanic (2 plugs) 8 4 mounting screws for the electronics

 Note the position of the power supply cables in the cable junction boxes (1), then loosen up the cable
junction boxes (1) and remove the power supply cables.

 Note the position of connector pins (2) and (5), then pull these connector pins.
These cables will next be dragged into the light's housing.

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Loosen the cables for SC and MC electronics with Sim.CAM HD Touch

1 PE: Power supply PE (GNYE cable) 4 Power supply cable to camera

1 GND: Power supply minus (cable imprint 2) 5 6 cables to the Sim.POD
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 4 mounting screws for the electronics
3 Ribbon cable 12-pole for film control panel

 Note the position of the power supply cables in the cable junction boxes (1), then loosen up the cable
junction boxes (1) and remove the power supply cables.

 Note the position of connector pins (2), (3), and (5), then pull these connector pins.
 Disconnect the coupling (6).
These cables will next be dragged into the light's housing.

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Release cable from the light housing

 Turn over the light.

 Remove the Sim.POD (2) found in the cardanic area.
To do this, loosen up the middle screw (1) of the
Sim.POD (2) using a hexagon screwdriver.

 Remove the Sim.POD (2) and place it on the middle of

the light.
Important: Do not touch the interior of the glass. Remove
fingerprints with a soft microfiber cloth.
Important: Do not touch the LED!

 Pull the ends of the cables (1) through the opening for
electronics.
Important: Do not touch any reflectors in the process!

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Separate the light housing from the cardanic

Important: The safety ring may not be reused, procure a new
safety ring for later mounting.

 Ensure that the light head and cardanic are well

supported – the cardanic will now be released from the
light head:
 Loosen the safety ring (1) using circlip pliers (2) and
remove.

 Carefully pull out the cardanic (2) together with cables

from the light head (1).

Releasing cables from the cardanic

 Remove the cover caps (1) in the cardanic area. To do
so, puncture the caps with a flat screwdriver.

 Procure new caps (1) for later mounting.

 A turning connector is located on the cardan joint (2) to
the spring arm. It will be later disassembled.

 Pull the cable through the opening (2) toward the back,
out of the cardan joint (1).

 Leave the ribbon cable (3) for the control panel (only MC,
and SC starting with 3rd generation), at this spot. It will be
returned to the light head during later assembly.

 Pull the remaining cables through the other cardan joints,

until they hang at the turning connector in the cardan joint
to the spring arm.

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Technical service Sim.LED 5000-7000

Removing cable with turning connector

 Unscrew 2 screws (1) from the turning connector's

adapter using a hexagon screwdriver, and set aside.

 Unscrew the turning connector's adapter (2) using a

Phillips screwdriver (1).

 Set the adapter (2) and 2 screws aside.

Insert new cable

Important: The turning connector may not be damaged;
therefore, leave the protective cap (5) attached!

 Mount the turning connector (4) for the new cable (1) to
the adapter (3) using 2 Phillips screws (2).

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

 Slide the turning connector for the new cable (1), with
protective cap attached, into the cardanic's pin on the
spring arm's side, and affix with 2 hexagon socket
screws (2).

 Starting with the purple cable, carefully insert the

cable (1) into the cardanic in the direction of the arrow
and thread through, free of kinks, to the cardanic's pin
connecting to the light.

 If the cable (1) has been threaded through the cardanic

pin (3) on the light side, as shown in the photograph, also
thread the ribbon cable (2) once again through the
cardanic pins (only MC, and SC starting with 3rd
generation).

 The new protective covers for the cardanic can now be

attached.

Cable for lights with Sim.CAM HD Touch

Connecting the cardanic to the light housing

 Thread cable (2) through the opening (3) into the light
housing.

 Plug the cardanic pin (4) into the opening (3) of the light
head in such a manner, that the pin (1) fits into the
opposing borehole. In the process, guide the cable in
such a manner that it does not come into contact with any
reflectors.

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Technical service Sim.LED 5000-7000

 Secure the cardanic pin in the light housing with a safety

ring (2), using circlip pliers (1).
Important: Do not overstretch the safety ring and make sure
that it glides along the entire circumference of the groove!

 Inspect the safety ring (6) using a circlip gauge (11):

 If the gauge fits in the opening of the safety ring, the
safety ring is not correctly positioned and must be
replaced before proceeding with the assembly.

 If the gauge does not fit in the opening of the safety

ring, the safety ring is correctly mounted.

 Thread the cables (1) through the opening (2) to the

electronics.

 Partition the cables (1) as shown in the photograph, to

allow sufficient space for the Sim.POD that is yet to be
mounted.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

 Re-mount the Sim.POD (2) in the cardanic area. To do

so, tighten the middle screw (1) of the Sim.POD (2) using
a hexagon screwdriver.

Connecting cables to MC electronics, and to SC electronics starting with generation 3

1 PE: Power supply PE (GNYE cable) 4 Cable to adjust illuminated field

1 GND: Power supply minus (cable imprint 2) 5 Video cable to cardanic
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 6 cables to the Sim.POD
3 Ribbon cable to the control panel on the cardanic (3 plugs) 8 4 mounting screws for the electronics

 Mount the power supply cable into the cable junction box (1).
 Connect the CAN cable to the socket (2).
 Connect the ribbon cable's connector pin to the socket (3). Due to the differing number of pins, there is
no risk of confusion in this case.

 Connect the video cable to the socket (5).

 Close the service cover for the electronics,
 “Replacing the control electronics”, page 15.
 After work on the light head is completed:
 “Closing the light head”, page 25.

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Technical service Sim.LED 5000-7000

Connecting cables to SC electronics up to generation 2 electronics

1 PE: Power supply PE (GNYE cable) 4 Cable to adjust illuminated field

1 GND: Power supply minus (cable imprint 2) 5 Video cable to cardanic
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 3 cables to the Sim.POD
3 Ribbon cable to the control panel on the cardanic (2 plugs) 8 4 mounting screws for the electronics

 Mount the power supply cable into the cable junction box (1).
 Connect the CAN cable to the socket (2).
 Connect the video cable to the socket (5).
 Close the service cover for the electronics,
 “Replacing the control electronics”, page 15.
 After work on the light head is completed:
 “Closing the light head”, page 25.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

Connecting cables to SC and MC electronics with Sim.CAM HD Touch

1 PE: Power supply PE (GNYE cable) 4 Power supply cable to camera

1 GND: Power supply minus (cable imprint 2) 5 6 cables to the Sim.POD
1 +24V: Power supply plus (cable imprint 1) 6 Video cable to camera
2 CAN-plug with cable to cardanic 7 4 mounting screws for the electronics
3 Ribbon cable 12-pole for film control panel

 Mount the power supply cable into the cable junction box (1).
 Connect the CAN cable to the socket (2).
 Connect the ribbon cable's connector pin to the socket (3). Due to the differing number of pins, there is
no risk of confusion in this case.

 Connect the video cable to the socket (6).

 Close the service cover for the electronics,
 “Replacing the control electronics”, page 15.
 After work on the light head is completed:
 “Closing the light head”, page 25.

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Technical service Sim.LED 5000-7000

3.2.8 Replacing the handle units

Replacing a standard handle unit / Sim.CAM SD /

SIM.CAM HD Touch
 Disconnect the power supply.
 Loosen 3 knurled screws (1) of the unit (2).
 Remove the unit (2).

 Plug the D-Sub connector (1) found on the rear of the

unit (3) into the socket (4) on the lamp body. In doing so,
press in the entire unit firmly and uniformly.

 Tighten the unit with the knurled screws (2). To do so,

turn the knurled screws in a clockwise direction. When the
knurled screws have been tightened, the position of the
unit must be checked by uniformly pressing on it once
again.

 Slide the sterilisable grip onto the unit and turn until the
safety audibly snaps into position.

 The unit is now ready for use.

 Switch on the power supply once again.

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Service Manual Sim.LED Technical service Sim.LED 5000-7000

Replacing an HD handle unit

 Open the latching tabs (1): The red surfaces must be

visible!

 Remove the handle unit.

 Replace with new handle unit.
 Close the latching tabs (1, image above).

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Technical service Sim.LED 3500+, 4500, 350

4 Technical service Sim.LED 3500+, 4500, 350

The light bodies are live with a maximum of 24–30 V DC.

 Disconnect the power supply.

Electrostatic discharges (ESD) can cause damage to electronic
components:

 Ensure that the technician is grounded and that appropriate

safety measures have been taken against ESD.

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Service Manual Sim.LED Technical service Sim.LED 3500+, 4500, 350

4.1 Working on the light head Sim.LED 3500+, Sim.LED 4500

4.1.1 Opening the light head

 Position the glass lifter (2), press firmly and carefully

reverse the clamping lever (1) under pressure.

 The glass lifter will suction firmly onto the glass.

 Loosen the rubber seal (4) of the glass panel (3), remove
from the lamp body and set aside.
Important: The rubber seal was glued on and may be
destroyed when loosened from the glass panel.

4.1.2 Replacing the reflector or Sim.POD

Important: Do not touch the interior of the glass. Remove

fingerprints with a soft microfiber cloth.

 Remove the nut (2) on the Sim.POD (1).

 Lift the reflector (1).

 Hold the Sim.POD (2) firmly, otherwise the inner side of
the reflector could become scratched.

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Technical service Sim.LED 3500+, 4500, 350

 Pull the Sim.POD's connector pin (2) from the power

supply PCB (1).

 Take note of the cable assignment.

Removing the Sim.POD

 Remove the Sim.POD (1) from the reflector.
 In doing so, ensure that the cables that must be pulled
out do not touch the inner side of the reflector!

Inserting a new Sim.POD

 From the front, guide the cables through the opening of
the reflector.

 Plug the connection cable's connector pin (15) onto the

distribution board.

 Place the 3 projections of the Sim.POD into the

openings (14) in the reflector. Thanks to their irregular
arrangement, the projections prevent incorrect positioning
of the Sim.POD.

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Service Manual Sim.LED Technical service Sim.LED 3500+, 4500, 350

 Insert the projection of the Sim.POD (above) into the

borehole of the housing (below). Thanks to their
arrangement, the projections prevent incorrect positioning
of the Sim.POD.
Important: When positioning the reflector, make sure that the
cables are not pinched.
 Screw the Sim.POD back on and tighten with a 0.7 Nm
torque!

4.1.3 Closing the light head

A special tool is required to perform this work, observe spare

parts list,  page 8.

Important: If required, remove silicone residue from the

housing and/or the seal.
Important: If the old seal is of bad quality, replace the seal.

 Place a rubber seal (7) around the edge of the light head.
 In doing so, make sure that the seam (8) is centred on the
cardanic.

 Press firmly on the rubber seal.

 Clean the glass panel (9) of any silicone residue that may
remain.

 Carefully place the glass panel (9) on the light head.

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Technical service Sim.LED 3500+, 4500, 350

 With the help of the special tool (10), bring the rubber
seal (7) over the glass panel.

 Glue together the loose flaps of cut borders with

transparent silicone (REF 909-0006754).

 Turn over the light head.

 Also glue the reverse side of the rubber seal with silicone.

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Service Manual Sim.LED Technical service Sim.LED 3500+, 4500, 350

4.1.4 Replacing the electronics

 To be able to replace the electronics, first open the light head

 “Opening the light head”, page 44.

The electronics (2) of the light head are affixed to the light
head's housing with 2 screws (3).
To obtain access to the electronics, remove the
5 neighbouring Sim.PODs (1):

 Loosen the central nut of the Sim.POD.

 Lift the Sim.POD
 “Replacing the reflector or Sim.POD”, page 44.
 Pull the connector pin from the electronics (2).
Important: All connector pins must be pulled.

 Loosen the nuts (1) of the electronics (2) with a hexagon

wrench SW 7.

 Remove the electronics (2).

 Correctly place the wire jumper on the new electronics:

 Sim.LED 3500: No wire jumper
 Sim.LED 4500: Wire jumper (1) top
 Sim.LED 3500+: Wire jumper (1) bottom
Important: The wire jumper must be set correctly before the
electronics are supplied with power!

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Technical service Sim.LED 3500+, 4500, 350

 Place new electronics on the insulation rubber rings (4).

 Screw the electronics tightly.
Important: The rubber rings will flatten when the nuts are
tightened. Tighten the nuts lightly only!

 Plug the cable into the correct slot.

Important: In doing so, ensure that the cables are not
pinched.

 Screw the reflectors back on.

 “Replacing the reflector or Sim.POD”, page 44
Important: Tighten the reflectors with 1 Nm.

 After work on the light head is completed:

 “Closing the light head”, page 46.

4.2 Working on the light head Sim.LED 350

Service work is not necessary on the Sim.LED 350 lamp body. In the event of a malfunction, replace the
entire lamp body.

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Service Manual Sim.LED Maintenance

5 Maintenance
The work required for an optimal and failure-free operation of the unit is described in detail in the documents
 “Instructions for Use, Sim.LED surgical lighting” and
 “Installation Instructions, Sim.LED surgical lighting”.

5.1 Maintenance plan

Interval Maintenance work Personnel
Annually Perform technical safety controls. Manufacturer
 Technical safety controls", page 51
As required Check the braking power for the extension arm / light head Operator's medical
and adjust if required. technicians
 “Instructions for Use, Sim.LED surgical lighting” and
 “Installation instructions, Sim.LED surgical lighting”
Before use Replace the sterilisable handle with a cleaned and steam- Medical qualified
sterilised sterilisable handle. personnel
 “Instructions for Use, Sim.LED surgical lighting” and
 “Installation instructions, Sim.LED surgical lighting”
Clean and disinfect the unit. Medical qualified
 “Instructions for Use, Sim.LED surgical lighting” and personnel
 “Installation instructions, Sim.LED surgical lighting”
As required Clean the glass panel from the inside and outside with Operator's medical
Eskanol 10.255 (manufacturer: www.haugchemie.de). In the technicians
process, take note of the manufacturer's technical data
sheet and operating instructions.
Before use Inspection of the products for coating defects, cracks, Operator's medical
deformations, and loose parts. technicians
Annually Check functioning of all Sim.PODs. If needed, replace Operator's medical
defective Sim.POD. 5-year warranty for Sim.PODs of technicians
generations 2 and 3.
 “Replacing the reflector or Sim.POD”, page 44
(Sim.LED 3500+/4500)
 “Replacing the reflector or Sim.POD”, page 22
(Sim.LED 5000/7000)
As required Check the illumination intensity using a calibrated light meter Operator's medical
(Sim.LED 5000/7000). technicians
Annually Inspect the products (visual inspection) and replace if Operator's medical
required. technicians
 “Replacing the electronics”, page 48
(Sim.LED 3500+/4500)
 “Replacing the control electronics”, page 15
(Sim.LED 5000/7000)

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Maintenance

5.2 Technical safety controls

Room/OR No.: Serial number:

Client: Company:

Test OK Not OK N/A

Visual check of the bearer arm system
Serial number, product
Inspect the brake screws
Inspection safety elements for the spring arms and lights
If required, clean the glass panel from the inside and outside with
Eskanol 10.255 (manufacturer: www.haugchemie.de). In the
process, take note of the manufacturer's technical data sheet and
operating instructions!
Visually inspect the operation of all Sim.PODs. If needed, replace
defective Sim.POD.
5-year warrant for Sim.PODs of 2nd and 3rd generation
 “Replacing the reflector or Sim.POD”, page 44
(Sim.LED 3500+/4500)
 “Replacing the reflector or Sim.POD”, page 22
(Sim.LED 5000/7000)
Visual inspection of electronics, replace if necessary
 “Replacing the electronics”, page 48
(Sim.LED 3500+/4500)
 “Replacing the control electronics”, page 15
(Sim.LED 5000/7000)
Function and visual controls for the lighting system
Inspection of electrical conductors, connections,
power supply connections.
Check the illumination intensity using a calibrated light Actual: lx
meter (Sim.LED 5000/7000).

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Electrical inspection of fixed installation according to OK, Not OK,

Measured
DIN EN 62353:2008-08 Not applicable
Ground connection resistance <0.300 Ω
light combination with 10 A test current Brazil: Ω
<0.100 Ω
Touch current on protection class 2 parts <500 µA µA

Electrical inspection of mobile installation according to OK, Not OK,

Measured
DIN EN 62353:2008-08 Not applicable
Ground connection resistance <0.300 Ω
light combination with 10 A test current Brazil: Ω
<0.100 Ω
Unit leakage current <100 µA µA
Touch current on protection class 2 parts <500 µA µA

OK No faults. The surgical light may be further operated.

Not OK The surgical light may not be further operated.
Not OK The surgical light may be further operated despite the fault. A deadline to rectify the
fault has been agreed upon.
Date/signature:

Testing equipment used (ID No.)

Remarks

Date / stamp / signature of partner:

Date / stamp / signature Medical Technology:

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Troubleshooting

6 Troubleshooting
6.1 Malfunctions Sim.LED
The following table describes possible causes for malfunctions and
the actions required to rectify them.
If multiple malfunctions occur, shorten the maintenance intervals in
accordance with the actual faults.
In the case of faults that cannot be rectified using the following
instructions, contact the manufacturer. The Customer Service
address can be found on page 2.

Description of fault Cause Remedial action Personnel

Light head rises or sinks Spring arm defective Replace spring arm Manufacturer
uncontrollably
Light head rises or sinks Spring force is set Set the spring force Operator's medical
uncontrollably incorrectly  “Instructions for Use, technicians
Sim.LED surgical lighting”
 “Installation
instructions, Sim.LED
surgical lighting”
The light head is too The braking power has Set the braking power Operator's medical
tight / too loose been set too low/high.  “Instructions for Use, technicians
Sim.LED surgical lighting”
 “Installation
instructions, Sim.LED
surgical lighting”
The sterilisable handles Sterilisation/disinfection Dispose of and replace Medical qualified
show cracks and are were conducted cracked and porous personnel
porous improperly sterilisable handles,
perform future
sterilisation/disinfection
procedures according
only to the Instructions for
Use
 “Instructions for Use,
Sim.LED surgical lighting”
and
 “Installation
instructions, Sim.LED
surgical lighting”
End of lifespan reached Dispose of and replace Medical qualified
sterilisable handle personnel

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Service Manual Sim.LED Troubleshooting

Description of fault Cause Remedial action Personnel

Unit does not light up Power supply to the Turn on power supply to Medical qualified
room is turned off the room personnel
Unit turned off at the Switch on the unit Medical qualified
mains switch personnel
Power supply is Inspect power and fuses Electrical experts
interrupted qualified for the
medical field
Electronics are Replace electronics Manufacturer
defective
Light is defective Replace light Medical qualified
personnel

6.2 Fault analysis, Sim.LED

Description of fault Cause Remedial action Personnel

LED is lit very faintly Short-circuit Identify and replace Medical qualified
defective Sim.POD personnel
Malfunction control Component defect Replacement of electronics Manufacturer
electronics
Illumination intensity too Glass panel clouded/ Measure actual condition: Manufacturer
low soiled At shunt resistor
(1 Ω) measure the voltage
in mV
mV = mA, because 1 Ω
205 mV = 205 mA
Clean the glass panel
 “Technical safety
controls”, page 51
Malfunction multiple Malfunction of a cable Plug the Molex connector Manufacturer
LEDs harness pin into a different voltage
source until the defective
harness is located.

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Troubleshooting

6.2.1 Error code Sim.LED SC (up to 2nd generation)

 Press the keys “+” and “-” simultaneously for 3 s.
 The error code will be displayed in binary form by the
brightness LED, here as an example:
LED Code = 10101000
Multiple error codes / warnings could be present. Navigation is
conducted with the keys “+” and “-”.
After approx. 30 s, the display returns to normal mode.

Error Type LED code Details

EEPROM data error Warning 11000000 Assembly group /
component defective
Software no longer operable Error 00100000 SW no longer runs through
the normal path
Excessive temperature Warning 10100000 75–79°C, reduced
luminosity
Temperature too high Error 01100000 ≥80°C, reduced luminosity
Supply voltage too low Warning 00010000 <19.2 V (24 V - 20%)
Supply voltage too high Warning 10010000 >31.2 V (24 V + 40%)
Supply voltage extremely high Error 01010000 >40.0 V
CPU voltage(s) low Warning 11010000 Tolerance exceeded
CPU voltage(s) high Warning 00110000 Tolerance exceeded
1 LED branch defective (short-circuit) Error 10110000 Voltage min: 3.6 V
Current: max. current is
limited by the HW
1 LED branch defective (interrupted) Error 01110000 Max. voltage: 45.6 V
Current: 0
≥2 LED branches defective (short-circuit) Error 11110000 Voltage min: 3.6 V
Current: max. current is
limited by the HW
≥2 LED branches defective (interrupted) Error 00001000 Max. voltage: 45.6 V
Current: 0
Light On/Off read back NOK Error 10001000 Redundancy function
returns an incorrect value

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Error Type LED code Details

CAN warning Warning 01001000 CAN connection defective
CAN error Error 11001000 No CAN connection
CAN error Error 10101000 CAN connection broken
Error, temperature sensor Error 01101000 From the controller starting
with V. 02.53

LED code: The respective display code for the 8 brightness LEDs is entered here, e.g. meaning of
11000000: the first 2 brightness LEDs from the left are lit, the others are not.

6.2.2 Error codes Sim.LED MC/SC starting with 3rd generation

Displaying the error code
Your control panel may display the last error code for a light.
If a wall control unit exists, it may also show this display.
The wall control unit also displays error resulting from the
wall control unit itself.

 Press the brightness control keys (1) for a minimum of

3 s.

 The error indication starts with a display of all LEDs

(full display) as a function control.

 Error code display: Lights

 Error code display: Wall control unit

 The sequence of full display – source – error code is

automatically repeated.

 After approx. 30 s, the display returns to normal

mode.

Error Type LED code Details

EEPROM data error Warning 11000000 Assembly group /
component defective
Excessive temperature Warning 10100000 75°C
Temperature too high Error 01100000 >80°C
Reduction of luminosity
by 25%

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Troubleshooting

Error Type LED code Details

Supply voltage too low Warning 00010000 <19.2 V (24 V – 20%)
Supply voltage too high Warning 10010000 >37.0 V
Supply voltage extremely high Error 01010000 >40.0 V
CPU voltage(s) low Warning 11010000 Voltage 1.8 V exceeds
tolerance (<95%),
A/D value: 0xBEF3
CPU voltage(s) high Warning 00110000 Voltage 1.8 V exceeds
tolerance (>105%),
A/D value: 0xD30C
1 LED branch defective (short-circuit) Error 10110000 Voltage min: 1.4 V (0x0064),
Current: max. current is
limited by the HW
1 LED branch defective (interrupted) Error 01110000 Max. voltage: 47.5 V
(0x0D48), Current: 0
≥2 LED branches defective (short-circuit) Error 11110000 Voltage min: 1.4 V (0x0064),
Current: max. current is
limited by the HW
≥2 LED branches defective (interrupted) Error 00001000 Max. voltage: 47.5 V
(0x0D48), Current: 0
CAN error Error 11001000 CAN communication faulty
Error, temperature sensor Error 01101000 Temperature sensor
defective
Key error Error 11101000 Arbitrary key pressed when
powered on
(self-test)
Error disappears when no
key is pressed.
Error, pulse generator Error 00011000 One or both inputs for the
pulse generator (rotating
handle) is set during
switching-on (self-test).
Error disappears when
neither of the inputs is set
(rotating handle is released).

LED code: The respective display code for the 8 brightness LEDs is entered here, e.g. meaning of
11000000: the first 2 brightness LEDs from the left are lit, the others are not.

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