Surgical lights

Berchtold Chromophare D 650: troubleshooting and error codes

The ServiceForge knowledge base holds 56 documented symptoms for the Berchtold Chromophare D 650, with 66 ranked causes, 67 diagnostic checks with test points and expected values, and 2 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Red LED indication on reverse polarity protection module high voltage

LED on reverse polarity protection module shows red instead of green, or no indication at all

Ranked causes

1. Wrong polarity (reversed positive and negative connections) (common)
2. Alternating current (A.C.) supplied instead of D.C. (occasional)
3. No voltage connected to input terminals (occasional)

First check

Verify input cable polarity

Test point: terminals 2 and 3
Expected: black cable on terminal 2 (negative), red cable on terminal 3 (positive)

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

A.C. voltage supplied to light electronics high voltage

Direct A.C. voltage applied to light intensity power circuit board (part no. 65604) destroys electronics

Ranked causes

1. A.C. voltage directly connected without filtering board (common)
2. Filtering board omitted when only D.C. available (rare)

First check

Verify input voltage type before connection

Test point: Main supply input
Expected: D.C. voltage 23–26 V or A.C. voltage with filtering board installed

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Glare or tissue damage from thermal radiation patient safety

Operator vision impaired or tissue heating/drying at surgical site; cover glass or filter system compromised

Ranked causes

1. Cover glass or filter system damaged or destroyed (common)
2. Improper distance from patient surface (occasional)

First check

Inspect cover glass and filter system for damage

Test point: Light emission surface
Expected: Cover glass intact, filter system undamaged

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Incorrect ceiling installation or mounting patient safety

Light mounting to operating room ceiling does not follow BERCHTOLD procedures; risk of ceiling damage and light falling.

Ranked causes

1. Installation not performed per BERCHTOLD mounting instructions or by unauthorized personnel (unknown)
2. Electrical installation not per IEC 60364-7-10 or missing fuse protection and mains switch (unknown)

First check

Verify light secured to ceiling using BERCHTOLD anchor plate and spacer block per mounting instructions

Test point: Ceiling mounting bolts and anchor plate
Expected: Secure mounting with no movement or play when gently pushed

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Red indication on reverse polarity protection LED caution

The LED (V3) on the reverse polarity protection module illuminates red

Ranked causes

1. Reverse polarity (input connections reversed) (common)
2. AC voltage applied instead of DC voltage (occasional)

First check

Measure voltage polarity and type at input terminals

Test point: Terminal 1 to Terminal 2 (input)
Expected: 24–27 V D.C. with correct polarity (red positive, black negative)
Tools: DMM with polarity indication

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reverse polarity protection LED not illuminated high voltage

No indication on LED V3 of the reverse polarity protection module, suggesting no voltage is connected or module is non-functional.

Ranked causes

1. No voltage connected to input terminal (common)
2. Reverse polarity protection module malfunction (occasional)

First check

Measure input voltage at terminal 1

Test point: Terminal 1 input
Expected: 24 – 27 V D.C., 24-27 V
Tools: DMM

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reverse polarity protection LED showing red indication high voltage

Red LED on reverse polarity protection module indicates wrong polarity or AC voltage applied instead of DC.

Ranked causes

1. Reversed input polarity (common)
2. AC voltage supplied instead of DC (occasional)

First check

Check voltage polarity at input terminals

Test point: Terminal 2 (negative) and Terminal 3 (positive)
Expected: negative (black cable) at terminal 2, positive (red cable) at terminal 3
Tools: DMM

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reverse polarity protection LED shows no indication

LED on reverse polarity protection module is not lit, indicating no voltage or module failure

Ranked causes

1. No input voltage (common)
2. Reverse polarity protection module fault (occasional)

First check

Measure input voltage at terminals 1 and 2

Test point: terminal 1 (positive), terminal 2 (negative)
Expected: 24–27 V D.C., +3 V
Tools: DMM

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reverse polarity protection LED shows red indication high voltage

Red LED on reverse polarity protection module indicates wrong polarity or AC voltage applied

Ranked causes

1. Input polarity reversed (common)
2. AC voltage applied instead of DC (occasional)

First check

Verify input cable polarity at reverse polarity protection module

Test point: terminal 2 (negative), terminal 3 (positive)
Expected: Red cable at terminal 3, black cable at terminal 2

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: 24 V DC power supply voltage high voltage

Verify terminal block and sliding contact voltages under load and no-load conditions

Ranked causes

1. Power supply out of specification (unknown)

First check

Measure DC voltage at terminal block under load

Test point: Terminal block
Expected: 24 V, +1.5 / -0.3 V
Tools: DMM

5 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: DC alignment of halogen lamp voltage high voltage

Terminal voltage under load on ceiling tube exceeds 24.5 V DC, causing halogen lamp tension to exceed safe operating limit (22.0 V +/- 0.2 V), affecting lamp life and illumination.

Ranked causes

1. Terminal voltage exceeds 24.3 V DC due to power supply or circuit characteristics (common)

First check

Switch on emergency supply and light

Test point: Ceiling terminal
Expected: Light activates with emergency supply

2 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: EndoLite bulb voltage high voltage

Set maximum EndoLite bulb output voltage via adjustable resistor R21 on touch control board back side

Ranked causes

1. Initial calibration or voltage drift (unknown)

First check

Measure EndoLite bulb voltage at R21 adjustment test point

Test point: TP on touch control board back side (Part no. 68823/68824/68825/68826)
Expected: max. 11.0 V A.C. und D.C. RMS, -1 V
Tools: DMM (AC/DC RMS capable)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: halogen bulb voltage high voltage

Set maximum halogen bulb output voltage via adjustable resistor R20 on touch control board back side

Ranked causes

1. Initial calibration or voltage drift (unknown)

First check

Measure halogen bulb voltage at R20 adjustment test point

Test point: TP on touch control board back side (Part no. 68823/68824/68825/68826)
Expected: D 650: 22.0 V A.C. und D.C. RMS; D 650plus/D 530plus/D 530: 22.8 V A.C. und D.C. RMS, +0.3 V
Tools: DMM (AC/DC RMS capable)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Halogen lamp voltage alignment high voltage

Terminal voltage under load on ceiling tube exceeds 24.5 V D.C., causing halogen lamp tension to exceed safe 22.0 V setpoint, reducing lamp life and illumination stability

Ranked causes

1. Excessive terminal voltage on ceiling supply (common)

First check

Measure terminal voltage on ceiling terminal under load with emergency supply on

Test point: Ceiling tube terminal
Expected: 24.0 V D.C., +0.3 V

1 more check with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Main bulb voltage adjustment high voltage

Set maximum bulb voltage via adjustable resistor R 20

Ranked causes

1. Bulb voltage out of specification (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Spring arm height adjustment

Adjust spring arm to horizontal position suitable for low ceiling installation

Ranked causes

1. Spring arm requires positioning adjustment (occasional)

First check

Remove protective cap from spring arm

Test point: spring arm cap
Expected: cap removed

2 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Spring arm height position

Adjust the spring arm to a horizontal position suitable for low ceiling installations

Ranked causes

1. Spring arm requires height position adjustment for ceiling clearance (common)

First check

Remove the cap from the spring arm assembly

Test point: Spring arm cap
Expected: Cap removed without damage
Tools: Standard hand tools

2 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Transformer secondary tap adjustment high voltage

Set transformer secondary tap to match emergency supply terminal voltage with reference value measured behind filtering board

Ranked causes

1. Transformer secondary tap requires adjustment to correct voltage output (common)

First check

Measure terminal voltage on ceiling terminal

Test point: ceiling terminal
Expected: matches reference value (D.C.)
Tools: voltmeter, DMM

1 more check with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Weight compensation on spring arm caution

Light head drifts upward or moves downward on the spring-balanced support arm; requires adjustment of circular nut on acrobat arm.

Ranked causes

1. Spring arm tension misaligned (common)

First check

Observe light head position during arm movement

Test point: Spring-balanced support arm
Expected: Light head remains level without drifting

2 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Chromophare D 530plus/D 500plus/D 530/D 500 spring arm adjustment (classic cardanic) caution

Weight compensation adjustment procedure for D 530plus, D 500plus, D 530, and D 500 models with classic cardanic spring arm support.

Ranked causes

1. Spring arm requires weight compensation calibration (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Chromophare D 650plus/D 650 spring arm adjustment (classic cardanic) caution

Weight compensation adjustment procedure for D 650plus and D 650 models with classic cardanic spring arm support.

Ranked causes

1. Spring arm requires weight compensation calibration (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Collision damage to supporting arms or lamp housings patient safety

Supporting arms or lamp housings struck, dented, or parts knocked off; risk of debris falling into surgical area.

Ranked causes

1. Contact between arms and housings during installation or movement (unknown)

First check

Visually inspect supporting arms and lamp housings for contact marks, dents or missing parts

Test point: All supporting arms and lamp housing exteriors
Expected: No dents, cracks, contact marks or loose parts

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Control unit malfunction or fault indicator illuminated caution

Red fault indicator on control unit illuminates, indicating fault in main circuit of control electronics; light operates at maximum intensity and cannot be controlled

Ranked causes

1. Main circuit control electronics fault (rare)

First check

Observe red fault indicator on control unit and test control key functions

Test point: Control unit indicator and keys
Expected: No red fault indicator; all keys function normally and adjust light intensity

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Control unit not responding to key inputs

Individual function keys do not control light intensity or movement; light operates at maximum luminous intensity only.

Ranked causes

1. Control electronics main circuit fault or keypad malfunction (unknown)

First check

Activate individual function keys and observe light response

Test point: Control unit keypad and main circuit
Expected: Each key controls corresponding function; light intensity variable

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Electrical system missing fuse protection or mains switch high voltage

On-site electrical installation lacks required fuse protection or all-pole mains disconnect switch.

Ranked causes

1. Electrical installation not completed per code or requirements omitted (unknown)

First check

Verify fuse protection installed in electrical circuit

Test point: Circuit fuse or breaker location
Expected: Fuse installed with rating appropriate to light specification

1 more check with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Halogen lamp replacement high voltage

Surgical light halogen lamp has failed or needs replacement; reserve lamp management procedure

Ranked causes

1. Halogen lamp failure or routine replacement (common)

First check

Switch off lighting system

Test point: Main power switch
Expected: System powered off and cooled

1 more check with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

High terminal voltage with cable voltage drop

Terminal voltage under load exceeds 2.0 V DC above set-point, preventing alignment to maximum allowed lamp tension when light intensity power circuit board is in separate wall box.

Ranked causes

1. Excessive voltage drop in supply cable to separate wall-mounted power circuit board (occasional)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Improper light positioning

Inadequate or uneven illumination of surgical field due to incorrect light distance from patient

Ranked causes

1. Light positioned too close to patient surface (occasional)

First check

Measure distance from light emission surface to patient surface

Test point: Light head to surgical field
Expected: Minimum 60 cm

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Inadequate or incorrect illumination of surgical field patient safety

Surgical area may not be properly illuminated for recognition and treatment of patient condition

Ranked causes

1. Light positioned too close to patient surface (occasional)

First check

Measure distance from light emission surface to patient surface

Test point: Light emission surface to surgical field
Expected: Not less than 60 cm

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Lamp failure with automatic switchover to reserve caution

Red indicator lights up on lamp housing when main lamp fails and system switches to reserve lamp

Ranked causes

1. Main halogen bulb end of life or failure (common)

First check

Observe red indicator on lamp housing

Test point: Lamp housing indicator
Expected: Red indicator lit

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light assembly instability or falling objects in surgical area patient safety

Placing or hanging objects on lamp housing or arms may compromise fixing stability and cause objects to fall into surgical field

Ranked causes

1. Objects placed on or hung from lamp housing or arms (occasional)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light assembly overheating during operation caution

Covering lamp housing during operation prevents heat exchange and risks overheating the surgical light

Ranked causes

1. Lamp housing covered during operation (occasional)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light does not emit after power-on patient safety

Main lamp fails to produce light output when unit is switched on; in combination lights, additional lamp also does not emit.

Ranked causes

1. Main lamp failure or incorrect installation (unknown)

First check

Verify light emission from main lamp after power-on

Test point: Main lamp housing
Expected: Light emitted from main lamp

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light emission lens damaged or broken patient safety

Lens of lamp housing is damaged or broken, risk of glass splinters falling into surgical area

Ranked causes

1. Impact or collision damage to lamp housing lens (occasional)

First check

Inspect light emission lens for damage or cracks

Test point: Lens surface of lamp housing
Expected: Lens intact, no cracks or chips visible

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light failure during operation patient safety

Reserve lamp auto-switch or APU switchover activated; single light units have incomplete component redundancy

Ranked causes

1. Lamp failure or electronic monitoring system fault (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light failure during surgery patient safety

Surgical light stops functioning during patient treatment, loss of illumination in operating field

Ranked causes

1. Component failure (not all components duplicated in single light) (occasional)

First check

Verify light configuration in operating room

Test point: Installed light units
Expected: Two or more light heads in combination for critical surgical operations

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light glare or eye injury patient safety

Operator or patient eye damage from high illumination intensity or reflected light beams

Ranked causes

1. Direct viewing of switched-on light or reflective objects in beam path (occasional)

First check

Check for reflective objects in light beam

Test point: Operating field and light path
Expected: No reflective objects present in beam

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light head drifts upward

The light head moves upward unintentionally during use

Ranked causes

1. Cardan arm requires tension adjustment (common)

First check

Locate the circular nut in the cardan arm adjustment

Test point: One of two windows on the cardan arm
Expected: Circular nut becomes visible
Tools: Phillips screwdriver, steel pin diameter 4 mm

1 more check with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light head moves downward caution

Spring arm support does not maintain light head position; head drifts downward

Ranked causes

1. Weight compensation spring arm tension insufficient (common)

First check

Observe light head position after manual repositioning

Test point: Light head
Expected: Head maintains position without drifting downward

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light housing stability compromised or objects fall into surgical area patient safety

Heavy objects placed on or hung from lamp housing; mechanism damaged; risk of contamination or patient injury

Ranked causes

1. Objects placed on lamp housing or arms (occasional)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Light overheating caution

Excessive heat buildup in lamp housing, potential thermal shutdown or damage

Ranked causes

1. Lamp housing covered during operation (occasional)

First check

Verify lamp housing is uncovered

Test point: Lamp housing exterior
Expected: No covering or obstruction present

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Main lamp failed caution

Red indicator lights up on lamp housing; system automatically switches to reserve lamp

Ranked causes

1. Halogen bulb end of life (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Mechanical instability or falling objects patient safety

Light fixture becomes unstable or objects fall from arms/housing into surgical field, risk of contamination or injury

Ranked causes

1. Objects placed or hung on lamp housing or arms (occasional)

First check

Inspect lamp housing and arms for objects

Test point: Entire light fixture
Expected: No objects on housing or hanging from arms

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Movement mechanism not operating smoothly caution

Mechanical movement of supporting arms or rotation mechanism restricted, stiff, or not functioning

Ranked causes

1. Mechanical friction, misalignment, or wear in movement mechanism (occasional)

First check

Manually operate all movement axes (swivel and rotate) for smooth operation

Test point: Supporting arms and lamp housing pivots
Expected: Smooth, unrestricted movement in all directions without grinding or binding

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

No indication on reverse polarity protection LED

The LED (V3) on the reverse polarity protection module does not light up (neither green nor red)

Ranked causes

1. No voltage connected to input terminals 1-3 (common)

First check

Measure voltage at input terminals

Test point: Terminal 1 to Terminal 2 (input)
Expected: 24–27 V D.C., 24–27 V
Tools: DMM

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Output voltage exceeds specification high voltage

Light body output voltage above maximum rated value

Ranked causes

1. Power circuit board malfunction or misconfiguration (unknown)

First check

Measure output voltage at light connector

Test point: Pins 3 and 1 (or 4 and 2)
Expected: max. 22.6 V A.C./D.C., not to exceed 22.6 V
Tools: DMM

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Red indicator light displayed caution

Control unit electronics fault indicated by red indicator light

Ranked causes

1. Fault in control unit electronics (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reserve lamp warning indicator not functioning caution

Red warning indicator does not illuminate when reserve lamp is activated, or reserve lamp fails to switch on when main lamp fails

Ranked causes

1. Main lamp failure with defective reserve lamp mechanism (rare)

First check

Simulate main lamp failure and observe reserve lamp activation and indicator

Test point: Red warning indicator on lamp housing
Expected: Red indicator illuminates and reserve lamp swings into position when main lamp fails

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reserve lamp warning indicator not illuminating

Red warning indicator on lamp housing does not light when reserve lamp activates after main lamp failure.

Ranked causes

1. Reserve lamp indicator malfunction or electrical fault (unknown)

First check

Observe reserve lamp warning indicator when main lamp fails or is removed

Test point: Red warning indicator on lamp housing
Expected: Red warning indicator illuminates

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reverse polarity protection LED showing green indication

Green LED is illuminated on the reverse polarity protection module, indicating correct polarity and functioning module.

Ranked causes

1. Normal operation (common)

First check

Confirm LED status

Test point: Indication LED V3
Expected: green

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Reverse polarity protection LED shows green indication

Green LED on reverse polarity protection module indicates correct polarity and module functioning

Ranked causes

1. Normal operation (common)

Reverse polarity protection module not functioning high voltage

Module does not indicate green LED despite correct polarity and D.C. voltage supplied

Ranked causes

1. Reverse polarity protection module failure (rare)

First check

Verify all input and output cable connections are secure

Test point: terminals 1–6
Expected: all cables firmly seated, correct polarity confirmed

1 more check with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Risk of eye injury from bright light patient safety

Operator or staff may suffer glare or eye damage from looking directly into switched-on light or from reflective objects in the beam path

Ranked causes

1. Direct viewing of operating light or reflective objects in beam path (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Terminal voltage exceeds maximum safe level high voltage

Terminal voltage under load on ceiling tube higher than 2.0 V D.C. prevents halogen lamp voltage alignment to maximum allowed setpoint

Ranked causes

1. Cable voltage drop exceeds 2.0 V D.C. (occasional)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Tissue damage from thermal radiation patient safety

Heat injury, tissue necrosis, drying of surgical wound tissue due to exposed infrared radiation

Ranked causes

1. Damaged or destroyed cover glass or filter system (occasional)

First check

Inspect cover glass and filter system for damage

Test point: Cover glass and filter assembly
Expected: No cracks, discoloration, or deterioration visible

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Tissue damage from thermal radiation exposure patient safety

Surgical area may be heated, dried out, or suffer necrosis if light cover glass or filter is damaged

Ranked causes

1. Damaged or destroyed cover glass or filter system (occasional)

First check

Inspect cover glass and filter system for damage

Test point: Cover glass and filter system
Expected: No damage or destruction visible

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Error codes

Code	Meaning	Trigger	Severity
`Fault`	Control unit has a fault	LED indicator on control unit	error
`Fault LED (red)`	Fault in the control unit electronics	Indicator light shows red	warning

Likely causes and actions for each code are in ServiceForge. Connect ServiceForge to your AI

Community

0 fixes logged by technicians through their AI, with outcomes, for this model.

ServiceForge knowledge base record. Field-unverified unless technicians confirmed it. A teaching summary of the record, not a service manual. Export 2026-10-14.