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Manual Reference
Dräger Polaris 600 Instructions for Use, document 9054591, current English edition; applicable Polaris 600 Mobile supplement; and current controlled technical documentation. Verify the exact ceiling, wall, mobile, camera, display-mount, handle, and arm configuration before service.
Manufacturer Recommendation / AEM Status
Dräger requires the complete light and arm system to be checked for operational readiness before each use. Service personnel must complete a documented inspection every 12 months, including completeness, functional and visual condition, arm deformation or looseness, paint damage, cracked plastic, and correct presence/position of plastic components.
Every 2 years, specialized service personnel must perform IEC 62353 electrical safety, verify full arm rotation and end positions, inspect and service horizontal/vertical joints, check the height stop and circlip, verify load balancing and spring force, inspect the central axis/swivel/spring arms and welds for collision damage, and repeat the functional/visual checks. The Polaris 600 Mobile battery is also replaced every two years under the applicable supplement. Do not replace the two-year specialized service with the annual inspection or extend an interval through an AEM program without the facility's documented risk assessment and approval.
What This PM Procedure Covers
- Identity, configuration, documentation, history, and service status
- Light heads, lenses, handles, controls, indicators, arm system, stops, joints, covers, and mounting
- Operational readiness, illumination adjustment, positioning, balance, and drift
- Sterilizable/disposable handle security and Sterile Touch Control when fitted
- Optional MedView camera, remote control, display mount, and video functions
- Mobile stand, casters, brakes, power supply, and two-year battery when applicable
- Two-year mechanical service and IEC 62353 electrical safety
- Cleaning, restoration, and CMMS documentation
Required Tools and Equipment
- Current Dräger Polaris 600 Instructions for Use, configuration-specific supplements, and controlled technical service documentation
- Electrical safety analyzer suitable for IEC 62353 testing
- Manufacturer-specified hand tools, torque tools, lubricants, and adjustment fixtures for authorized two-year service
- Known-good sterilizable handle or approved disposable-handle interface, as configured
- Optional calibrated illuminance/photometric instrument only when required by the controlled technical procedure
- Known-good MedView camera/video receiver, display, and remote-control test components when fitted
- Correct Polaris 600 Mobile replacement battery when due
- Manufacturer-compatible reprocessing supplies and facility-required personal protective equipment
Step-by-Step PM Procedure
1. Remove From Clinical Use and Isolate Power
Action: Schedule the room/system out of service, confirm no procedure depends on the light, and allow hot surfaces to cool. For service requiring access to energized components, disconnect all poles at the mains connection and prevent unintended reconnection. Apply facility lockout/tagout requirements.
Expected outcome: The surgical light cannot be used or unexpectedly energized during maintenance.
2. Verify Identity and Configuration
Action: Record asset tag, serial number, software/version information where displayed, system type, number of light heads, arm arrangement, mounting type, controls, handles, camera, display mount, video receiver, and mobile configuration/battery when present.
Expected outcome: The system matches the CMMS record and all configuration-specific instructions are identified.
3. Review History and Service Status
Action: Review prior PM, repairs, drift or positioning complaints, impact/collision events, intermittent illumination, control or video failures, fluid intrusion, recalls/field actions, and annual/two-year service dates. Resolve open corrective work before release.
Expected outcome: Relevant history is documented and no overdue specialized service or unresolved safety issue remains.
4. Verify Documents, Labels, and Completeness
Action: Confirm the applicable instructions are available. Inspect ratings, warning labels, serial labels, equipment identification, covers, handles, controls, accessories, cables, and installed options against the IFU.
Expected outcome: Documentation and labels are legible and the medical-device combination is complete and correctly configured.
5. Inspect Light Heads and Optical Surfaces
Action: Inspect each light head, lens/light-emitting window, housing, seams, ventilation areas, control panel, inner handle, gimbal, covers, and fasteners. Look for cracks, discoloration, deformation, loose parts, paint damage, fluid entry, contamination, heat damage, or missing/mispositioned plastic components.
Expected outcome: Light heads are clean, complete, undamaged, and mechanically secure.
6. Inspect Handles and Sterile Interfaces
Action: Inspect sterilizable handles for cracks, deformation, discoloration, peeling, wear, or insecure engagement; replace damaged handles. Install the handle or approved disposable sleeve and confirm it engages audibly and cannot be pulled off. Inspect Sterile Touch Control functions when fitted.
Expected outcome: Each handle is intact, correctly attached, secure, and functional without risk of falling into the operating field.
7. Inspect the Complete Arm and Mounting System
Action: Inspect ceiling/wall/mobile mounting, central axis, swivel arms, spring arms, gimbal joints, welding seams, circlips, covers, cable paths, stops, fasteners, and interfaces. Look for collision marks, cracks, bending, looseness, corrosion, paint damage, pinched cables, or unauthorized changes.
Expected outcome: The entire suspension and mounting system is complete, aligned, and free of structural damage or looseness.
8. Verify Movement, Positioning, and Drift
Action: Move each light head and arm through the intended clinical range without forcing a stop or colliding with another component. Verify smooth horizontal/vertical movement, full required rotation, correct end positions and height stop, balanced spring-arm behavior, and stable positioning at multiple locations.
Expected outcome: Movement is smooth and controlled, stops function correctly, and no light head or arm drifts after positioning.
9. Verify Power-Up and Light Controls
Action: Restore power in a safe configuration and turn on every light head. Verify power/status indicators, wall and light-head controls, light on/off, intensity adjustment, light-field diameter, color-temperature selection, and synchronization functions that are installed.
Expected outcome: Every configured control responds correctly and illumination is stable, even, and free of flicker or unexpected shutdown.
10. Complete the Before-Use Readiness Check
Action: Confirm the surface has no damage or wear, illuminance can be adjusted at every intended control, each light positions easily without drifting, and the handle or disposable sleeve is firmly fitted. Repeat for every light head.
Expected outcome: The complete light system meets Dräger's operational-readiness requirements.
11. Verify Optional Camera and Video Functions
Action: When MedView is fitted, inspect the camera lens, housing, controls, remote, video receiver, network/video connections, display, display mount, and cables. Verify camera power, image, focus/zoom/rotation functions as configured, remote response, and secure display positioning. The camera is for documentation and training, not diagnosis or surgical decision-making.
Expected outcome: Installed camera/video components operate reliably, cables and mounts are secure, and the image is stable.
12. Verify Mobile Configuration
Action: For Polaris 600 Mobile, inspect the stand, column, handles, base, casters, brakes, power cord, connectors, charger, battery compartment, and equipotential connection. Verify stable movement and braking, AC operation, battery indication/transfer, charging, and any specified runtime check. Replace the mobile battery every two years.
Expected outcome: The mobile system is stable, rolls and brakes safely, operates from its intended sources, and has a current serviceable battery.
13. Complete the Annual Inspection
Action: Document IFU availability, equipment completeness, functional and visual inspection, arm deformation/looseness, paint and plastic condition, component presence/position, controls, illumination, positioning, handles, and installed options. Use current technical documentation for any criterion beyond the IFU.
Expected outcome: Every 12-month inspection item passes and is traceable to the technician and date.
14. Complete the Two-Year Specialized Mechanical Service
Action: When due, specialized service personnel must verify full rotation/end positions, free movement of horizontal and vertical joints, lubrication where specified, height-stop adjustment, circlip position/form, spring-arm load balancing/force, collision damage, and crack-free welds. Repeat deformation, looseness, paint, plastic, functional, and visual checks.
Expected outcome: The two-year service is complete under the controlled Dräger procedure with all adjustments and replacements documented.
15. Perform Two-Year Electrical Safety
Action: Perform the IEC 62353 electrical safety inspection described below using the complete installed configuration. Do not use an improvised limit or omit a configured display, camera, mobile supply, or other electrically connected component.
Expected outcome: Every applicable electrical-safety measurement meets the current Dräger and adopted-standard limit.
16. Reprocess, Restore, and Document
Action: Reprocess the light heads and reusable handles using the current Dräger instructions, remove test equipment, restore configuration, secure covers and accessories, and complete a final operational-readiness check. Record findings, measurements, battery/parts, adjustments, corrective work, and disposition.
Expected outcome: The Polaris 600 is clean, complete, current on service, and either returned to use with traceable records or clearly removed from service.
Electrical Safety Testing
Dräger assigns electrical safety inspection of the complete light and arm system every 2 years to specialized service personnel in accordance with IEC 62353. First inspect the mains connection, protective-earth/equipotential paths, cords, power supplies, covers, connectors, accessible conductive parts, camera/video/display components, and mobile electrical system when fitted.
Perform the protective-earth and leakage/touch-current measurements applicable to the exact installed construction and record the analyzer, configuration, conditions, current controlled limits, and actual readings. Do not publish or substitute a generic numerical limit. Remove the system from service for damaged insulation, unreliable protective earth, excessive leakage, unexpected energization, or any required test that cannot be completed.
Pass / Fail Criteria
Pass
- Identity, documentation, labels, light heads, optical surfaces, controls, covers, handles, cables, accessories, and installed options pass inspection
- The complete arm/mounting system has no deformation, loose part, cracked weld/plastic, collision damage, missing component, or unsafe paint damage
- All lights power on with stable illumination and every configured adjustment/control operates
- Each head and arm moves smoothly through its intended range, stops correctly, balances, and holds position without drift
- Handles and sterile interfaces are undamaged and securely engaged
- Optional camera/video/display and mobile functions pass or are documented N/A
- Annual inspection and due two-year mechanical, battery, and electrical-safety service are complete
- Final reprocessing, restoration, readiness check, and documentation are complete
Remove From Service
- A light head, mount, arm, weld, circlip, stop, joint, spring, fastener, handle, cable, or cover is damaged, loose, incomplete, or unsafe
- The light flickers, shuts down, cannot be adjusted, or has visibly abnormal illumination
- An arm binds, exceeds its intended stop, is unbalanced, or drifts after positioning
- A sterile handle cannot attach securely or shows wear/material fatigue
- An installed camera, display mount, mobile stand, brake, charger, or battery is unsafe or unreliable
- Annual or two-year service is overdue, electrical safety fails, or required specialized service documentation/personnel are unavailable
Copy/Paste CMMS Work Order Procedure
A surgical light suspended over the operating field presents mechanical, electrical, thermal, and optical hazards. Only qualified personnel should complete this procedure, and specialized service personnel must perform the two-year arm and electrical-safety work using current Dräger technical documentation.