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ServiceManual CL 300 Surgicalllluminator SolarTecSource270 CL 100Surgicalllluminator SolarTecSource100 WelchAllyn Lighting Products 4 6 1 9J o r d a nR o a d Skaneateles Falls,NY 13153-0187 PN: LB-MANCLSERVRev.A Tableof Contents ------1-1 GENERA I NL F o R M A T T o N - - 1-1 T E C H N T CH AE L L PI N F o R M A T T o N ----- S E R V I C E N T E R- -S- - - 1-2 WARRANTY -.----.1-3 SYSTEM S Y M B o LD E S C R I P T I o N S ------- 1-4 --- --W A R N I N GASN DP R E C A U T I o -N- S W a r n i n g- - - - - - 1-5 1-5 CautionO P E R A T I NI N GS T R U C T I o N S --- 1-5 ---- 1-6 1'6 Conlrols -'---- PowEO R N / O FSFw r r c H . ------ F | B EPRo R r M U L TLI I N K TEMX P A N S I oPNo R T -I N S T A L L A TAI oNNDU S E( o P T I O N A L ) L i c HA T ] - T E N U A TCTooNNT R o-L- - - L A M PL I F El N D r c A T o R . - - -- -...- - 1-8 ---1-8 L I G HSTo U R c E P o w E RS u p p l yw r r HC o N T R oELL E c r R o N r c s M U L TL| i N K TPMo R T A NM D U L TLr T N K T EM x p A N s r oPNo R T - S E R V T- C E 16 -1-7 ---------1-7 -'l-7 P r i n c i p l e sO f O p e r a t i o nR E P L A C E MLEAN MTP S- 16 -----. ---1-8 ---- -1-8 ---------1-8 --------- C L E A N T -N- -G- - - 1-9 --1-9 .- S U R G T CI LALLU M T N A T o R 1-9 ------1-9 M U L TL| T N K E oN o R T- - - - - - - T xMp A N s r P -- 1-10 T o o L SR E o U I R E D --- - -G -T R o U B L E S H o o T- N 1-11 - - - - - 1-11 ... -'I-12 C L 1 0 0S u R G r c AI L r LUMTNAToR C L 1 O OS U R G I C IALLL U I \ , I I N AD T IoSRA S S E M B-L- Y- T E S T# 1 : B L o W NF U s E s - - 1-12 TEST W A T TP O W ESRU P P T Y # 2 :1 O O T E S T # 3C:o o L r NFGA N- - - -------- TEST#4: LED/OVEBTEMP SWITCH . 1-13 .1-13 - - - -' 1.13 T E s r # s :M r c R oL I N K @ F T B ETR E s r- - T E S T # 6P: o w E RS u p p L yC A L T B R A I o N C L 1 O OS U R G I C AIL L U M I N A T oDRI S A S S E M B L Y PoWER S U P P LRYE M o V A L -- - ------- 1-13 - 1-14 - - - 1.15 - - 1-15 PLATFoRM EMoVAL -------- 1-16 F R o NBT E Z ERLE M o V A L REMoVAL FANDEFLECToR -------- 1-16 1 16 C H A S SFI A S NR E M o V A L L E D / O V E R T EHMAPR N E SRSE M o V A L L A M PC A B L R E EMoVAL I N T E R L oS Cw K r r c HR E N t o v A L PoWER E N T RM Y O D U LR EE M o V A L 1 0 0 S U R G T C I A L L U M TNAT RoERP A TPFA R T L CL Sr s r - - C L 3 0 0S U R G T CI LALLU M T N A T o R C L 3 O OS U R G I C AIL L U M I N A T oDRI S A S S E M B L Y TEsr#1:BLowN FusEs TEST#2: AuxrLrARy BoARDlNpurTERMTNALS T E s r # 3C : o o L r NFGA N- - - T E s r# 4 : L E DO P E R A T o N TEST#5: MIcRoLINK@ FTBER TEST C L 3 O OS U R G I C AILI I U M I N A T o R DISASSEMBLY ----I N T E R NMAoLD U LREE M o V A- L PoWERSUPPLY REMoVAL ( p A R r PCBA N o .A 4 - 1 0 6 7 0R) E M o V A L l G N r r oR RE M o V A L L | N EF T L T ERRE M o V A L C H A S SF I SA NR E M o V A L PowER E N T RM Y o D U LR EE M o V A L PLATFoRM EMoVAL F R o NB T E Z ERLE M o V A L B L o w EFRA NR E M o V A. -L LAMP C A B LR E E M o V A -L- - LLUMTNAT RoERP A TPR A R T LSr s r - - C L 3 0 0 S U R G T CIA '- ------- 1-17 -. -.. - 1-17 - --- 1-17 - - - -' 1-18 -. - _ 1-18 ----- 1-19 -- - ----'l 25 - - - 1-27 ---- 1-21 - - - - 'l-27 127 ----- 1-27 - - - 1-2A .. - 1-29 ------129 129 ------- 1,30 .--- -- 1-31 -- . - 1-31 ---- 1-32 -------- 1-33 ------ 1-34 ----- 1-34 --------1-34 --- 1 35 ----- 1-36 G L o S S A RoYF T E R N 4 S F I N A LI N S P E C T I o N C L 1 O OS U R G I C IALLL U M I N A T o R C L 3 O OS U R G I C IALLL U M I N A T o. .R . SPEcrFlcAroNS T H E o R Y oO FP E R A T I o N L r G HSr o u R c E R E P L A C E ML E AN MTP SP o w E RS u p p L yw r r HC o N T R oELL E c r R o N r c s M U L TLI I N K TPMo R T A NM D U L TLr T N K T EM x p A N S t oPNo R T - - ------ 1-42 -- 1-43 -.. - 1-43 - 1-43 --- 1-45 ----- 1-46 ------1-46 -------1-46 --- - -- 1-46 ---------1-46 ,I-47 C L 1 O OS U R G I C AI LLL U M I N A T C oR I R C U IDTI A G R A M --- ---- C L 3 O OS U R G I C AILL L U M I N A T oCRI R C U ID TIAGRAM . -. - - - - 1-48 GENERALINFoRMATToN '100 T h eW e l c hA l l y nC L S u r g i c al l l u m i n a t oarn dt h e W e l c hA l l y nC L 3 0 0 S u r g i c al l l u m i n a t oprr o v i d eb r i l l i a n t p h y s i c i aann ds u r g e o nT. h e l a m p sp r o d u c eh i g hi n t e n s i t yl i g h tn e a r l yi d e n t i c at lo t h e s p e c t r u m i l l u m i n a t i of n orthe o f s u n l i g h tS. p e c i afle a t u r e si n c l u d et h e a b i l i t yt o u s e e i t h e ra C o g e n tO p t i c sM i c r oL i n k @F i b e ro r a c o n v e n t i o n a l f i b e rb u n d l e . TECHNTCAL HELPlNFoRrvrATroN O n l yf u l l yt r a i n e da n d p r o p e r l ye q u i p p e dp e r s o n n esl h o u l dp e r f o r ma l l s e r v i c ea n d r e p a r r su, s r n gq e n u r n e t a r r a n t ya n dc o u l d r e p l a c e m e npta r t sa n dc o r r e c p t r o c e d u r e sF.a i l u r e t o d o s o w i l l i n v a l i d a tteh e p r o d u c w performance. compromiseinstrumentsafety and R e a da n d u n d e r s t a nadl l s a f e t yw a r n i n g sa n ds e r v i c en o t e sp r i n t e di n t h i sS e r v i c eM a n u a l a n dt h e O p e r a t i n g , r phone M a n u a l sp, a r tn u m b e rL B - I V A N - 1 0 0 W 2 7 0lW f t .h e r ei s a n yd o u b ta b o u ta n y p r e c a u t i oonr p r o c e d u r ef o h e l p .o r t o o r d e ra d d i t i o n aclo p i e so f t h e O p e r a t i n M g a n u a lc, o n t a c t : Customer Service Welch Allyn, Inc. 4619 Jordan Road. PO Box 187 SkaneatelesFalls,NY 13153-0187USA Telephone: 1-315-685-2993o1 1-866-801-8428 FAX: 1-315-685-2999 Techncial Assistance Telephone: 1-315-685-4233,7:00am-3:00pm(EST) W h e n c a l l i n gr,e f e rt o t h e m o d e ln u m b e rs h o w no n t h e d a t al a b e l f, o u n do n t h e b a c ko f y o u rS u r g i c al l l u m i n a t o r . " T r o u b l e s h o o t i"n g p a g e T e c h n i c aals s i s t a n cies c o n t a i n e d in 1 1 o f t h i sm a n u a l . on PN: LB-MANCLSERVBev.A Welc$11ytt' SeRvrceCENTERS lf you havean equipmentproblemthat you cannotresolve,you may callthe Welch AllynServiceCenternearest you for assistance.Technicalservicesupportrs availableby telephoneon norma businessdays at the phone n u m b e r sl i s t e db e l o w .l f y o u a r e a d v i s e dt o r e t u r na p r o d u c t o W e l c hA l l y nf o r r e p a i ro r r o u t i n em a r n t e n a n c e , r i t h t h e s e r v r c ec e n t e .n e a r e syl o u . s c h e d u l et h e r e D a iw BEFORERETURNINGA PRODUCTFORREPAIRYOU MUST OBTAINAUTHORIZATIONFROM WELCH ALLYN. AN RMA (RETURNMERCHANDISEAUTHORIZATION}NUMBERWILL BE GIVENTO YOU BY OUR SERVICEPERSONNEL.BE SURETO NOTETHIS NUMBER ON THE OUTSIDEOF YOUR SHIPPINGBOX. RETURNSWITHOUTAN RMA NUMBERWILL NOT BE ACCEPTEDFORDELIVERY. USA CUSTOMERS CANADA CUSTOMERS Welch Allyn, Inc., U.S.A. 4 6 1 9J o r d a nR o a d , Y 13153-0187 S k a n e a t e l eFsa l l sN Tel:1-315-685-2993 Fax:315-685-2999 Welch Allyn, Ltd., Canada '160 M a t h e s o nB l v d .E . ,U n i t# 2 M i s s i s s a u g aC,a n a d aL 4 Z 1 V 4 Tel:905-890-0004 Fax:905-890-0008 INTERNATIONALCUSTOMERS Welch Allyn, GmbH Zollerstrasse 24 72417 JunEngen,Germany, fel: 011-49-7 477-9211-73 Fax.011-49-7477-9271-93 Welch Allyn, Ltd., Singapole 300 BeachRoad,#25-08 The Concourse Singapore199589 Tel:011 65-291-0882 F a x :0 1 1 - 6 5 - 2 9 1 - 5 7 8 0 Welch Allyn, Ltd., Australia Metro Center Unit 5 38 SouthStreet R y d a l m e r eN, S W2 1 1 6 ,A u s t r a l i a T e l :0 11 - 6 1 - 2 9 4 - 1 8 3 - 1 5 5 F a x :0 11 - 6 1 - 2 9 4 - 1 8 3 - 6 5 0 Welch Allyn, China Room708, 22'/ lluang Pi Road,North CentralPlaza S h a n g h a2i 0 0 0 0 3 P R .C h i n a T e l :0 1 1 - 8 6 - 2 1 - 6 3 2 7 9 6 3 1 Fax. O11'86-21-63279632 Welch Allyn, Japan Bon Marusan8F,3-5-1Kanda J i n b o - C h oC, h i y o d a - K u T o k y o1 0 1 - 0 0 5 1 Japan T e l :0 11 - 8 1 3 - 5 2217 3 9 1 f ax. 0 11-813-3261-7372 LATIN AMERICANCUSTOMERS MD Intemational 11300 N.W. 41st Street M i a m i ,F L 3 3 1 7 8U S A Tel: l-305-669-9003 F a x :1 - 3 0 5 - 6 6 9 - 1 9 7 1 1 2 WELCHALLYN WARRANTY W e l c hA l l y nw a r r a n t st h e C L 3 0 0 o r C L 1 0 0S u r g i c al l l u m i n a t owr h e n n e w t o b e f r e e o f d e f e c t si n m a t e r i aal n d workmanshipand to pertormin accordancewith manufacturer's specificatrons when subjectto normaluse and s e r v i c ef o r a p e r i o do f o n e y e a rf r o m d a t eo f p u r c h a s ter o m W e l c hA l l y no r a n a u t h o r i z eadg e n t .W e l c hA l l y nw i l l e i t h e rr e p a i ro r r e p l a c ea n y c o m p o n e n tfso u n dt o b e d e f e c t i v eo r a t v a r i a n c e f r o m m a n u f a c t u r e rs' sp e c l f i c a t i o n s w i t h i nt h i st i m e a t n o c o s tt o t h e c u s t o m e rl.t s h a l lb e t h e p u r c h a s e r r' se s p o n s i b i l ittoy r e t u r nt h e i n s t r u m e nt to t h e a u r h o r i z eddi s t n b J t o ra,g e n t .o r s e r v i c er e p r e s e n t a t r v e . WelchAllynwarrantsthe lampto be free of defectsin materialsand workmanshiptor a periodof 6 monthsfrom t h e d a t eo f p u r c h a s eT. h i sw a r r a n t yd o e sn o t c o v e rt h e l a m pf o r b r e a k a g o e r f a i l u r ed u e t o t a m p e r i n gm , isuse, n e g l e c ta, c c i d e n t si m , p r o p e irn s t a l l a t i o m n ,o d i f i c a t i o n , i p p i n go, r f r o m i m p r o p em sh r aintenance se , r v r c eo, r procedures. cleaning Thrswarrantyis void if the instrumentis not used in accordancewith manufacturer's recommendations or if r e q u i r e ds e r v i c ei s p e r f o r m e db y o t h e rt h a nW e l c hA l l y no r a n a u t h o r i z eadg e n t .P u r c h a s d e a t ed e t e r m r n e s w a r r a n t yr e q u i r e m e n t sN.o o t h e re x p r e s so r i m p l i e dw a r r a n t yr s g r v e n . P N :L B M A N C L S E R VF e v .A Velc$1yt ' SYSTEM SYMBoLDEscRtPTtoNs A A A t t e n t i o nR : e a dO p e r a t i n g M a n u afl o r W a r n i n g sP, r e c a u t i o nas n , d I n s t r u c t i o nf so r U s e Caution- Hot SurfaceArea A Ra^la^a tr,,c6 ec lr,4ert orl 250V5A 5A,250V A - Highvoltage WARNING is present I Symboo l n p o w e rs w i t c hi n d i c a t eps o w e ri s o f f w h e n p r e s s e d S y m b o il n e l e c t r i c ar la t i n gs i g n i f i e A s C m a i n sp o w e r + @ |- ^.*l | |f l H i g hI n t e n s i t yL i g h t ProtectiveEarthGround t4__l Temperature Storage Range @ Maximum Storage Humidity tr aPxg T y p eB F e q u r p m e n tC, l a s sI Not protectedagainstthe ingressof water Manufacturedin accordancewith the relevantregulationsand technicalrequirementsof Japan. WELCHALLYN WARNINGS AND PRECAUTIoNS e /-\ l\ WARNING . K e e oo u t o l r e a c ho f p a t i e n t . . N o t s u i t a b l et o r u s e i n t h e p r e s e n c e of a flammable a n e s t h e t im c i x t u r ew i t h a i r o r w i t h o x y g e no r n i t r o u so x i d e . . Disconnectfrom the patientbeforethe dischargeof a cardiacdefibrillator. . E L E C T R I C ASLH O C KH A Z A R DD . o n o t r e m o v et h e t o o c o v e r . . . . . . . . r lA R o u t i n e ley x a m i n et h e p o w e rc o r da n d p i u g .D o n o t u s e i f i n s p e c t i o rne v e a l sd a m a g eR . e p l a c eo n l y with approvedhospitalgradepower cord and plugwith appropriateelectricalrating. Do not olacethe exooseddistalend of the Micro Link@Fiberor fiber bundleattachedto eithera headlightor other accessory.Failureto observethese precautionsmay resultin burnsto skin, c l o t h i n go, r o t h e rm a t e r i ailn a d v e r t e n tpl yl a c e di n f r o n to f t h e M i c r oL i n k @F i b e ro r f i b e rb u n d l e . H i g he n e r g yr a d i a t e d l i g h tg u i d e dt h r o u g he n d o s c o p em s a y g i v er i s et o h i g ht e m p e r a t u r eisn f r o n to f t h e l i g h to u t l e ta n dt o t h e t i p o t t h e i n s t r u m e n t . Use care not to pointthe distalend of the fiber or headliqhtdirectlyat the eye when unit is operating. T h e b r i l l i a nl ti g h to u t p u tf r o m t h e u n i tc a n c a u s ee y e i n j u r yp e r R P 2 7. 1 ( ' 1 9 9 41 9 9 5T h r e s h o l L dimit I n d i c e sF, i n adl r a t tM a r c h V a l u e s{ o r C h e m i c aSl u b s t a n c easn dP h y s i c aAl g e n ta n dB i o l o g i c aElx p o s u r e 3,1995). Appliedpartsattachedto this equipmentshouldbe approved1) to the MedicalDeviceDirective(93/ TestingLaboratory(UnitedStates),and3) by 42/EEC)(Europe),2) approvedby a NationallyRecognized (Canada) a StandardsCouncilof Canadaaccreditedlaboratory to the appropriatemedicalstandards. The use of non-approved componentsmay compromisesafety. D u r i n gl i { et h r e a t e n i npgr o c e d u r e si t,i s r e c o m m e n d etdo h a v ea b a c k u pL i g h ts o u r c ea n da n a d d i t i o n a l r e o l a c e m e nl at m o . m a yc a u s ep r e m a t u r e T h e l i g h ts o u r c el a m p sa r e h i g h l yp r e s s u r i z e ad n, yd a m a g eo r i m p r o p ehr a n d l i n g f a i l u r eo r e x p l o s i o n of the lamp. The light sourcelampsare hot immediatelyafter use,allow the lampto cool for five (5)minutesafter peakin the light Sourcesapproximately 60 secondsafterthe LightSourceis operation.Temperatures poweredoff. CAUTION . Do notplaceanythrng on topof theLightSource. Do notstoreliquidabovethe LightSource. . . C l o g g e do r b l o c k e dv e n t sm a yc a u s eL i g h tS o u r c eo v e r h e a t i nagn dw i l l r e s u l ti n t h e r m a sl h u t d o w n . K e e pt h e L i g h tS o u r c ec l e a ro f a n yo b s t r u c t i o n s . F u l l yc l o s et h e a t t e n u a t obr e f o r et u r n i n go n t h e L i g h tS o u r c eo r w h e n o p e r a t i o n ablu t n o t i n u s e . PN: LB-MANCLSERVRev.A Welc$11yn. OPERATTNGlNsrRucloNs CONTROLS PowERON/OFFswrrcH l "Hospital P l u gh o s p i t agl r a d eP o w e rC o r di n t oa g r o u n d e d" H o s p i t aG r a d e "o r U s e " r e c e p t a c lteo e n s u r e grounding reliability. PressMain PowerSwitch ON (l pressedin). T h e l a m pw i l l c o n t i n u et o o p e r a t eu n t i l t h ep o w e rs w i t c hi s m o v e dt o t h e O F Fp o s i t i o n( O p r e s s e di n ) .l f t h e l a m p cannotbe startedor stops operatingsee Section8: Troubleshooting. NOTE: . . l t i s n o r m a tl o h e a rc l i c k i n g( 1 0p u l s e so r l e s s )b e fo r e t h e l a m pi s s t a r t e d . To insureproperoperation,wait thirty (30)secondsbetween on/off cycles. F|BERPoRT To increasethe versatilityand applicability of use,the LightSourcesare designedto use eithera Micro Link@Fiber o r a t i b e rb u n d l ev i at h e M u l t iL i n k r MP o r ta n d M u l t iL i n k r ME x p a n s i oP nort. Cable Gompatibility Multi Linkn Port Table Multi Link- Expansion Port Micro Link@ Fiber KarlStorz ACMI Olympus Wolf, Dyonics F o rc a b l e sw i t h n o M u l t i L i n k r ME x p a n s i oP n o r tr e q u i r e d : 1 . C l o s et h e l i g h ta t t e n u a t oor r t u r nt h e L i g h tS o u r c eo f f . r 6 WELCHALLYN 2 . C o n n e ct h e l n s t r u m e net n d o f t h e M i c r oL i n k @ F i b e ro r f i b e rb u n d l et o t h e i n s t r u m e n t . , n t i lf u l l ye n g a g e d( s n a ps o u n d )t,h e L r g h tS o u r c ee n d i n t ot h e M u l t iL i n k r MP o r t . 3 . I n s e r tu 4 . T u r no n L i g h tS o u r c e .A d j u s t h e l i g h ta t t e n u a t otro t h e r e q u i r e di l l u m i n a t i ol n evel. MULT|L|NK'" ExpANsroNPoRT- lNsrALLATroN aNo UsE (oproNAL) CAUTION: T h e M u l t iL i n k r ME x p a n s i oP n o r tc o n t a i n so p t i c ael l e m e n t st h a tc a n b e c o m ed a m a g e di f d r o p p e d or aouseo. NOTE: T h e M u l t iL i n k r M Fiber E x p a n s i oPn o r tm u s tb e f u l l ye n g a g e di n t ot h e L i g h tS o u r c eb e f o r ei n s e r t i n g Bundle. To use the l\4ultiLinkrMExpansionPort performthe followingoperations: 1 . C l o s et h e l i g h ta t t e n u a t oor r t u r nt h e L i g h tS o u r c eo f f . 2 . R e m o v ei,f a n y ,M i c r oL i n k @ F i b e ro r f i b e rb u n d l ef r o m t h e M u l t i L i n k r MP o r t . 3 . I n s e r t h e M u l t iL i n k r ME x p a n s i oP n o r t ,p r e s sa n dt u r n c l o c k w i s eu n t i li t l o c k si n t op l a c e . 4. Connectthe fiber bundleto the instrument. 5 . I n s e r tu , n t i lf u l l ye n g a g e dt,h e L i g h tS o u r c ee n d o f t h e f i b e rb u n d l ei n t ot h e M u l t iL i n k r ME x p a n s i oP no r t . 6 . T u r no n L i g h tS o u r c e .A d j u s t h e l i g h ta t t e n u a t otro t h e r e q u i r e di l l u m i n a t i ol n evel. To removethe Multi LinkrMExpansionPort performthe followingoperations: 1 . T u r nt h e L i g h tS o u r c eo f f . 2 . R e m o v et h e f i b e rb u n d l e . 3. Turnl\,4ulti LinkrMExpansionPortcounter-clockwise until unlockedand remove. LrcHTATTENUATToN CoNTRoL M o v i n gt h e i l l u m i n a t i ownh e e lu p * i n " r " u r " . l i g h to u t p u t .M o v i n gt h e w h e e ld o w n - r e d u c e sr r g n o t utput. LAMP LrFElNDrcAToR A y e l l o w i n d i c a t o rl i g h t l o c a t e do n t h e c o n s o l ew i l l l i g h t w h e n t h e r e i s a p p r o x i m a t e l y5 0 h o u r s r e m a i n i n go n t h e l a m p . A n e w R e p l a c e m e n tL a m p s h o u l d b e a v a i l a b l ea t t h i s p o i n t . O n c e t h e r e m a i n i n gh o u r s h a v e b e e n e x h a u s t e dt h e l a m p w i l l t u r n o t f . PN: LB-MANCLSERVREV.A Welc\Allyn. PRINCIPLES OF OPERATION LtcHTSouRcE T h e S u r g i c al l l u m i n a t o rcso n s i s o t f anenclosure h o u s i n ga h i g hi n t e n s i t yl a m p ,p r o p r i e t a royp t i c apl l a t f o r mu, s e r controlsand indicators,and a power supplywith controlelectronics.Coolingis providedvia internalfans. In the eventthat the fan(s)malfunctionsor if adequateair flow is blockedand/orthe internaltemperatureof the device exceedsthe engineeringspecifications, an internalthermalprotectionmechanismwill automatically shut off power to the lamp. After cooling,the LightSourcesmay be restarted. REPLAcEMENT LAMPs T h e l a m p sa r e h i g hp r e s s u r eh, i g hi n t e n s i t ya n d l o n gl i f eL i g h tS o u r c e s T . h e ya r e m o u n t e di n t oa p a t e n t e dl a m p f i x t u r ew h i c h i s d e s i g n e dt o a l l o wb o t he a s ya n d r a p i de x c h a n g ei n t h e f i e l da s w e l l a s e n s u r i n gp r e c i s ea l i g n m e n t t o t h e o p t r c apl l a t f o r m . PowERSupply wrrx CoNTRoLELEcrRoNtcs All the electricityto the LightSourceis controlledthroughthe ON/OFFswitch. Powerto energizeand operatethe lamp,tans,and controlcircuitryis providedby a custom designed,wattageregulated,switchingpower supply. The operationallife of the lamp and lamp life indicatorare controlledby a lamp voltagemonatoring circuit. MuLr LtNxn PoRTANDMULT|L|NK* ExpANsroN PoRT Internal,to both the Multi LinkrMPortand Multi LinkrMExpansionPort,are patentedcouplingopticsand mechanics designedto producethe highestoutput powers. Internalto the LightSourcesare fans and heatsinksdesignedto r e d u c et e m p e r a t u r east t h e o p t i c acl o u p l i n gj o i n t st h e r e b ym i n i m i z i ntgh e p o s s i b i l i toyf d a m a g et o M i c r oL r n k @ F i b e ra n df i b e rb u n d l e s . 1 B WELCHALLYN SERVTCE CLEANTNG 1 . P r i o rt o c l e a n i n gt ,u r nt h e p o w e rs w i t c hO F Ea n dd i s c o n n e cpt o w e rs o u r c ef r o m b o t ht h e L i g h tS o u r c ea n d t h e w a l lo u t l e t . 2 . C l e a nt h e e x t e r n asl u r f a c e sb y w i p i n gw r t ha c l o t hd a m p e n e dw i t h 1 0 % b l e a c hs o l u t i o nD . O N O TI M M E R S E . r R o u t i n e l iyn s p e c a t n dc l e a na l l a i ri n t a k e s/ o u t f l o w sa t t h e r e a ro f t h e c h a s s i sf o r l i n to r o t h e rd e b r i s . . F o l l o wt h e m a n u f a c t u r e ri'nss t r u c t i o nwsh e n C l e a n i n tgh e f i b e rb u n d l e so r a c c e s s o r i euss e dw i t h t h e l i g h t source. 3 . W i p et h e p o w e rc o r dw i t h a c l o t hd a m p e n e dw i t h 1 0 7 ob l e a c hs o l u t i o na n dw a t e r .D O N O TI I V I M E R S E D .O N O TR E C O N N E CW TE T . 4 . D O N O Tw i p e d o w n a n y l e n s e so r w i n d o w s . 5 . D O N O Tp l u gt h e p o w e rs o u r c ei n t oa w a l l o u t l e tu n t i li t i s t h o r o u g h ldyr y . SURGtcAL ILLUMtNAToR T h e c o n s o l em a y b e c l e a n e du s i n ga c l e a ns o f t c l o t hw i t h t h e f o l l o w i n gc l e a n i n g agents: E n z y m a t iS c o l u t i o n( E n z o l ) lsopropylAlcohol H y d r o g e nP e r o x i d 3 e% USP 2 % Gl u t a r a l d e h y dSeo l u t i o n Soapand Water 'lOo/o b l e a c hs o t u t t o a n n dw a t e r C A U T I O N : D o n o t s p l a s hc l e a n i n g a g e n t si n t oa n y o p e n i n g ss,e a m so r e l e c t r i c aclo m p o n e n t s . MULT|L|NK* ExPANsroN PoRT The outsidesurfacesmay be cleanedwith a soft cloth usingthe following: i s o p r o p yAl l c o h o l Soapand Water The glasssurfacesmay be cieanedby the followingmethods: A cottonswab moistenedwith lsopropylAlcohol Blow with dry compressedair NOTE: Use care in cleaningthe opticalsurfacesof the Multi LinkrMExpansionPortto preventscratches. PN:LB-MANCLSERVRev.A 1-9 'IVelc$;1*. TooLsREoUIRED . " Slottedscrewdriver,lessthan 6 long . # 1 P h i l l i pS s c r e w d r i v elre, s st h a n6 " l o n g . # 2 P h i l l i pS s c r e w d r i v elre, s st h a n6 " l o n g . O p e ne n d w r e n c hs e t - E n g l i s ho r 5 / 1 6 " . N e e d l en o s ep l i e r s . N u t D r i v e rS e t- E n g l i s ho r 3 / 1 6 " , 1 1 4 " , 5 1 1 6 " . N u t D r i v e rS e t- M e t r i co r 1O m m . D e e pw e l l s o c k e ts e t a n dw r e n c h( 2 )- C L 1 0 0S u r g i c al l l u m i n a t o r . N o n - c o n d u c t i vpeo t a d j u s t i n g t o o l- C L 1 0 0S u r g i c al l l u m i n a t o r . Lightoutputpower meter with head.CoherentLasermate1D or equivalent(meter),HeadModel 1d10- CL 1 0 0S u r g i c al l l u m i n a t o r . Laght outputmeter- Labsphere ModelFIMS-400P or equivalent thatmeasures in lumens- CL300Surgical llluminator o C a I b r a t e oR M S D r g i t aM l u l t i m e t e (r D M M ) 1,10 WELCHALLYN ThouBLESHoorNG CL 1o0 SURGTCAL ILLUMTNAToR Symptom L a m pf a i l st o s t a r ta n d f a n sa r e n o t r un n i n g . Cause No power to unit C h e c kp o w e rs u p p l yc o r da n do u t l e t Linevoltageis <90 VAC Referto HospitalEngineering department "Test #1: Blown Inspect,replaceand retest.Go to F u s e s "o n p a g e1 2 . F u s e sb l o w n Safetyinterlockopen Power supplyfailure Lampfailsto start and f a n sa r e r u n n i n g . | ^'n^ ^h' '+^ ^al ^t.^. Lo, r,P r,,urr u, I o, rel operatingfor a few m inutesand restartsafter coolrng. I n di c a t o rl i g h to n a n d lampshuts off Remedy C h e c ka n dt i g h t e ns l o t t e ds c r e wo n l a m pf i x t u r e accessdoor "Test #2: 100WATTPower Supply"on Go to p a g e1 3 L a m pn o t i n l i g h ts o u r c e ( a u d i b lcel i c k i n gh e a r d ) I n s t a lal 1 0 0 Wr e p i a c e m e nl at m p ,m o d e l9 0 1 3 3 . Defectivelampcable (discolored, bent or broken prongs) ( a u d r b lcel i c k i n gh e a r d ) Reolace a n d r e t e s tl a m oc a b l e . Defectivepower supply (discoloreb de , n to r b r o k e n prongs) ( n oa u d i b l ec l i c k i n gh e a r d ) I n s p e cw t i r i n ga n di f i t i s f i n e ,r e p l a c ea n dr e t e s t power supply. I n a d e q u a taei rf l o w f o r c o o l i n gL, i g h tS o u r c eo v e r lemperalUre F a nf a i l u r e A i l o w2 " ( 5 1 m m )c l e a r a n caet b a c ko f u n i t ;i n s u r e vents are cleanand not that air intake-outflow blocked.Allow unit to cool and then restart " 'l "Test #3: CoolingFan on page 3. Go to l l l u m i n a t oi sr o v e r h e a t i nngo t d u et o c l e a r a n c e . Verifyoperationof fans.Cleanfans and internal componentsof dust. Lamp rs at the end oi life,but a m b e rL E Di s i n o p e r a t i v e . VerifyLED flickerson when it is first turnedon. lf "Test not, go to #4: LED/OvertempSwitch" on p a g e1 3 . L a m pl i f ee x c e e d e d . I n s t a lal 1 0 0 Wr e p l a c e m e nl at m p ,m o d e l9 0 ' 1 3 3 . L a m pc a b l ed e f e c t r v e . R e p l a c ei ' p r o n g sa r e d i s c o l o r e db.r o k e no. r b e n t Powersupplyout of calibration. "Test To go #6: Power SupplyCalibration"on p a g e1 4 . R e p l a c e m e nLta m pw i l l Lampis not orientedcorrectly Rotatelamp 180' and re-insert not seat into LightSource I n c o r r e cRt e p l a c e m e nLta m p I n s t a lal 1 0 0 Wr e p l a c e m e nl at m p ,m o d e l9 0 1 3 3 . P N :L B - M A NC L S E R VB e v .A Velc$11yn. Symptom Low l i gh t oulpul F i b e rb u n d l ew i l l n o t Installin LightSource " " A u d i b l e c l i c k i n go r a r c i n gs o u n dd u r i n gt h e l a m pi g n i t i o np r o c e s s Cause Remedy Fiber D a m a g e dM i c r oL i n k @ o r f i b e rb u n d l e C h e c ke n d so f M i c r oL i n k @F i b e ro r f i b e rb u n d l e f o r d a m a g eR w i t h n e w M i c r oL i n k @ Fiber . eplace "Test o r f i b e rb u n d l eG . ot o # 5 : M i c r oL i n k @F i b e r '13. T e s t "o n p a g e Fiberbundlenot connected correctly. Re-insertf iber bundlecorrectly. L a m pn e a re n d o f u s a b l el i f e l n s t a l l a1 0 0 Wr e p l a c e m e nl at m p ,m o d e l9 0 1 3 3 . F i l t e ra s s e m b l yo n p l a t f o r m contamrnated. C l e a no r r e p l a c ef i l t e ra s s e m b l ya s n e c e s s a r y . Minors dirty. Cleanmirrors. B r o k e nm i r r o r s . Replaceplatform. M i s a l i g n em d i r r o r s( p o s s i b l e if unit suffersdamage) lf abovestepsfail to improveoutput, replaceand retestplatform. Dirtyor damagedinternal mooute. Inspect,clean,and replaceif necessary. "Operating Instructions" on page6 Usecompatible bundle design N o t a c o m p a t i b l fei b e rb u n d l e See "Operatrng I n s t r u c t r o n so"n p a g e6 I n s t a l l / F e m o vMeu l t i L i n k r M ExpansionPort See Multi LinkrMExpansionPort installed RemoveMulti LinkrMFxpansionPort No problem Normaloperation CL lOOSURGICAL ILLUMINAToR DISASSEMBLY NOTE: For all tests, remove9 screws from top cover. NOTE: Do not operateunit with the top cover removedfor more than 5 minutesor the unit will overheat. TEST#1: BLowN FUsEs The purposeof this test is to determinethe sourceof a short circuitcausingfusesto blow. Referto the Block D i a g r a mo n p a g e4 7 . Replaceand retestthe fuses. lf unit functionsnormally,inspectfuses that were blown. lf solderis meltingout of the end of the fuse and the glassis not blackened,removeand replacethe power entry module.Thisfault occurs when the prongof the fuse holdermakespoor contactwith the fuse. The prongwill look discoloredand pitted where it contactsthe fuse. WELCHALLYN l f t h e f u s eb l o w sa g a r nI,n s p e ctth e p o w e rs u p p l ya n dt h e w i r i n gt o r d a m a g e do r b u r n tc o m p o n e n t sR. e m o v ea n d replaceany visuallydefectivecomponents. l f v i s u a Il n s p e c t i odno e sn o t y i e l da n ye v i d e n c eo f d a m a g er, e m o v ea n d r e p l a c ep o w e rs u p p l ya n d r e t e s t . IEST#2: lOOWATT PowERSUPPTY V e r i f yo p e r a t i n vgo l t a g ei s p r e s e n ot n p o w e rs u p p l yi n p u tt e r m i n a l sC. o n n e c m t e t e ra n ds e t t o v o l t sA C t o J 1 a n d J 2 t e r m i n a l sW . h e n p o w e ri s a p p l i e dt o t h e u n i t ,v e r i f yt h e o p e r a t i n vgo l t a g ei s d i s p l a y e od n t h e m e t e r .N O T E : Verifythe lampaccessdoor is closed. lf voltageis present,repraceand retestpower supply. l f v o l t a g ei s n o t p r e s e n ti,n s p e ct h e f u s e s ,w i r i n g ,p o w e re n t r ym o d u l e l,i n ef i l t e r a , n d i n t e r l o c sk w i t c h . TEST#3: CooLINGFAN The purposeof this test ls to verifythe operattonof the lampcoolingtan. V i s u a l l iyn s p e c ft o r a b r o k e nt a n .W h e nt h e u n i t i s p o w e r e du p , l o o kf o r a f a n n o t t u r n i n g l.f f o u n d ,r e m o v et o p c o v e ra n di n s p e c ft a n .R e p l a c e a n y b r o k e nf a n s . lf fan is inoperativeand not broken,measureusingDMM set for VoltsDC for 12VDCon fan connector. . lf voltageis present,replaceand retestfan. . lf voltageis not present,replaceand retestpower supply. IEST#4: LED/OVERTEMP SwITcH The purposeof this test is to veriiy properoperationof the LED. Visuallyinspectthat LED/overtempswitch harnessis connectedto the power supply.Verifycontinuityof wiring a n d L E Dw i t h D M M s e t t o t h e D i o d eS c a l e D . M M s h o u l dr e a d= . 7 V D C . . l f t h e D M M r e a d i n gd o e sn o t m a t c h ,r e p l a c ea n d r e t e s t h e L E Dh a r n e s s r l f D M M r e a d i n gm a t c h e sa b o v e ,r e p l a c ea n d r e t e s t h e p o w e rs u p p t y . TEST#5: MIcRo LINK@FIBERlEsT The purposeof this test is to verifythe operationof the Micro Link@Fiber. W i t h t h e i l l u m i n a t oorn , c o n n e c t h e f i b e ra n dt h e h e a d l i g h O t . v e ra d i s t a n c eo f a t l e a s tf i v et e e t ,a d j u s t h e s p o t d r a m e t et'o t h e l a r g e sst t z e . . l f t h e i n t e n s i t yo f l i g h ti s n o t c o n s i s t e ntth r o u g h o utth e l i g h ts p o ta n dr o t a t i n gt h e d i s t a e l n d c o n n e c t odr o e s n o t c a u s et h e s h a p et o c h a n g et,h e h e a d l i g hi ts t h e m o s t l i k e l yc a u s eo f t h e f a u l t . l f t h e i n t e n s i t yi s n o t c o n s i s t e nwt i t h a l t e r n a t i nlgi g h ta n dd a r kr i n g sp r e s e n tt,h e f i b e ri s b r o k e na t t h e d i s t a l O v e rt h e s a m ed i s t a n c ea, d j u s t h e h e a d l i g ht to t h e s m a l l e sdt i a m e t e sr p o t .A t t h i s a d j u s t m e n t h , e h e a d l i g hi ts f o c u s e dl.t a n y s p o t i r r e g u l a r i t i e a sr e p r e s e n th, o l dt h e h e a d l i g hstt e a d yw h i l er o t a t i n gt h e d i s t a e l nd(black) connector. PN: LB-MAN-CLSEBV Rev.A 1,13 Welc\Allyn' . lf the locationof the defectsmove,removethe fiber,cleanthe end with distilledwater,reconnectthe unit,and test. Replacethe fiber if detectsare still present. . lf the locationof the defectsremainstationary, the fault is within the headlight. TEST#6: PowERSUPPLY CAL|BRAT|oN The purposeof this test is to verifythe operationof the power supply. Applypower to unit,once the lamp lights,connectthe DIVIV(setto volts DC)to the lampcablewires on the p o w e rs u p p l yT. h e p o s i t i v el e a do f D M M t o t h e H V + t e r m i n aol n t h e p o w e rs u p p l ya n dt h e n e g a t i v el e a do f t h e D M M t o t h e L a m pR e t u r n- t e r m i n aol n t h e p o w e rs u p p l yW . A R N I N GD: o n o t c o n n e c tD I V Mt o w i r e sp r i o rt o t u r n i n gt h e u n i to n .W h e n t h e l a m pi g n i t e st,h e r ei s a p p r o x i m a t e2l y5 k Vo n t h e t e r m i n a l w s h i c hc o u l dd a m a g et h e D M M . M o n i t o rt h e v o l t a g ed i s p l a y eodn t h e f l u k ew h e n t h e L E Df i r s tt u r n so n .V e r i f yt h e v o l t a g ei s b e t w e e n1 7 . 0 0 and18.00v. ' lf the voltageis less than 17.00VDC,removeand replacethe power supplyor returnthe unit for recalibration. l f t h e v o l t a g ei s b e t w e e n1 7 . 0 0 V D C a n d 1 8 V D Cr, e m o v ea n d r e p l a c et h e l a m pf i x t u r e . o lt the voltageis more than 18.00DC,contactthe Welch AllynTechnicalServicesDepartmentat 1-315-685-2993or 1 315-685-4233, 7:00am-3:00pm(EST). WELCHALLYN ILLUMTNAToRDrsAssEMBLy CL 100 SURGTCAL PowERSUPPLY REMoVAL 'l . Bemovethe 9 screwssecurinqthe toDcoverand removethe cover. 2 . R e m o v et h e 3 s c r e w sf r o m t h e b o t t o ms i d eo f t h e b a c kp a n e . 3 . D i s c o n n e cwt i r e sf r o m J 1 a n dJ 2 o n t h e p o w e rs u p p l v D . i s c o n n e cf at n c o n n e c t ofrr o m J 4 . 4. Removethe 2 screwsfrom the bottom chassis,securingthe centerbaffle(seefigurebelow). lC" Screws s e c u r i n gc e n t e r baffleto bottom c h a s sr s o o w 5 . R e m o v et h e n u t t h a ts e c u r e st h e c e n t e rb a f f l et o t h e b a c kp a n e l . 6 . Pullbackpanelout and move to the platformside of the chassisto garnaccessto the backof the power supply. PN: LB MAN'CLSERVRev.A 1 1 5 Welc$;1yt ' 7 . Removethe two white lampcablewires and disconnectthe 4 wire connector.Removethe supplyand baffle. 8 . Removethe 4 screws from the cornersof the power supply.Removesupply. 9 . Reinstallatio i snt h e r e v e r s ep r o c e s sw i t h t h e b r o w nw i r e g o i n gt o J 1 a n dt h e b l u ew i r e g o i n gt o J 2 . T h e l o n g e r of the two lampcablewires attachesto the (+) lamp HV terminaland the shorterwire attachesto the (-)lamp " r e t u r n .R e f e rt o P h o t o8 " o n p a g e2 4 t o c o n n e c t h e H V + a n d l a m pr e t u r n- t e r m i n a l sa s s h o w n . PLATFoR'U REMovAL 'L Remove9 screwssecuringtop coverand removethe cover.Removethe 5 screws securingthe front bezelto t h e b o t t o mc h a s s i sa n d p u l lf r o n tp a n e lo u t f r o m c h a s s i sR . e m o v et h e l a m pf r o m t h e p l a t f o r m . 2. Removethe 2 screws from the fan deflectorassemblv. 3. Removethe 4 screwsf rom the cornersof the platform. 4. As necessary,removethe 2 screwsfrom the f ilterassembly. . einstallatio 5 . R e m o v et h e p l a t f o r mR i snt h e r e v e r s ep r o c e s sI.n s t a l l t h ef r o n tb e z e a l n d c h e c kf o r p r o p e r movementof attenuator.Loosenplatformscrewsand repositronas necessary. FRONT BEZELREMoVAL 1. Remove9 screwssecuringtop coverand removethe cover.Removethe 5 screwssecuringthe front bezelto t h e b o t t o mc h a s s i sa n d p u l lf r o n tp a n e lo u t f r o m c h a s s i s . 2. Removewires from power switch notingwire localions.Pushon switch from the insideto removethe switch from the bezel. 3. Usinga sharpknife,removethe blackRry from the LED wires where it mountsto the tront bezel.Once removed,applyacetoneto the LEDandthe front bezelto weakenthe glue bondand removethe LEDfrom the front bezel. 4. Installationis the reverseprocess.To attachthe LED,ensureboth paneland LED surfacesare clean.Use superglue,loctite430 to mount the LED.Use RTVsealantDow Corning737 to sealthe LED,preventingany l i g h tf r o m t h e i l l u m i n a t opra s s i n gt h r o u g h . FANDEFLECTOR REMOVAL 1. Remove9 screws securingtop coverand removethe cover. 2 . R e m o v et h e 5 s c r e w ss e c u r i n g t h e f r o n tb e z e lt o t h e b o t t o mc h a s s i sa n d p u l l f r o n tp a n e lo u t f r o m c h a s s i s . 3 . Removethe overtempswitch f rom the fan deflector. 4 . Carefullyremovethe heat shrinktubingfrom the fan wiring harness. 5 . Disconnectthe connectorand removeit from the power supply. 6. Installationis the reverseprocesswith installingnew heat shrinktubingover fan connector. WELCHALLYN CHAssrsFANREMovAL T. Remove9 screws securingtop coverand removethe cover.Remove4 screws securingthe fan to the back pane. 2 . R e m o v eh e a ts h r i n kt u b i n gf r o m t h e f a n c o n n e c t o rD. i s c o n n e catn d r e m o v et h e w i r e t i e sf r o m t h e h a r n e s sa t t h e p l a t f o r mm o u n t s .R e m o v et h e f a n . 3. Installation is the reverseprocess. LED/OVERTEMP HARNESS REMovAL 1. Remove9 screwssecuringtop coverand removethe cover.Removethe 5 screwssecuringthe front bezelto l ut fromchassis. t h e b o t t o mc h a s s i sa n d p u l l t r o n tp a n e o 2. Removethe overtempswitch from the fan deflectorassembly.Removethe wire tie f rom the overtempswitch harnessat the platform. Usinga sharpknife,removethe blackRTVfrom the LED wires where it mountsto the front bezel.Once removed,applyacetoneto the LEDand the front bezelto weakenthe glue bondand removethe LEDfrom the front bezel. 4. Removethe 3 wire ties and removethe harness. 5. lnstallationis the reverseprocess.To attachthe LED,ensureboth the paneland the LED surfacesare clean. ( l o c t i t e4 3 0 )t o m o u n tt h e L E D .U s e R T Vs e a l a n(tD o wC o r n i n g7 3 7 )t o s e a lt h e L E Dp r e v e n t i n g U s es u p e r g l u e a n y l i g h tf r o m t h e i l l u m i n a t ot or p a s st h r o u g hS . e ef i g u r eb e l o wf o r r o u t i n go f w i r e s . LAMPCABLEREMovAL 1. RemoveI screwssecuringthe top coverand removethe cover.Removethe 3 screwsfrom the bottom of the . l i d eb a c kp a n e tl o t h e s i d e . b a c kp a n e l .R e m o v et h e n u t s e c u r i n gc e n t e rb a f f l et o t h e b a c kp a n e l S PN: LB-MAN-CLSERV Rev.A 117 Welc\ffiytt. 2 . R e m o v et h e n u t f r o m t h e w i r e t i e c l a m ps e c u n n gt h e l a m pc a b l et o t h e b o t t o mc h a s s i sR . e m o v et h e l a m p cablefrom the power supplyand removethe cable. 3 . I n s t a l l a t i oi sn t h e r e v e r s ep r o c e s sw i t h t h e l o n g e rc a b l ew r r eg o i n gt o t h e H V +t e r m i n aol n t h e p o w e rs u p p l y a n d c o n n e c t i n tgh e s h o r t e rw i r e t o t h e L a m pR e t u r n- t e r m i n a lV. i e wt h e u n i tf r o m t h e r e a ra n dc o m p a r et h e "Photo H V + a n dt h e L a m pR e t u r n- a r e c o n n e c t e d 8 " o n p a g e2 4 . a s s h o w ni n INTERLoCK SwtrcH REMovAL 1. Removethe 9 screws securinothe toDcoverand removethe cover. 2 . D i s c o n n e ct th e w i r e st r o m t h e i n t e r l o c sk w i t c h . 3. Removethe two nuts from the interlockswitch and remove. 4. Instaliationis the reverseprocess,connectingthe wires to the terminalsmarkedCOM and NO. PowERENTRYMoDULEREMoVAI 1. Remove9 screwssecuringthe top coverand removethe cover.Removethe 3 screwsfrom the bottom of the backpanel.Bemovethe nut securingcenterbaffleto the backpanel. 2 . R e m o v et h e 4 s c r e w ss e c u r i n gt h e c h a s s i sf a n . R e m o v et h e w i r e sf r o m P E M . 3 . Removethe two nuts securingthe PElvlto the back panel.Removethe PEM. 4. lnstallationis the reverseprocesswith the tollowingrequirements: . The starwasher is locatedbetweenthe PEM flangeand the paintedsurfaceside of the back panel. The flat washer is installedon the other side of the paneland is securedwith the nut. Rotatethe screw so that you can later installthe power cord retainer. The brown wire is connectedto the terminalmarkedas P on the PEM.The blue wire is connectedto the t e r m i n am l a r k e da s N o n t h e P E N /T] .h e g r e e nw i r e f r o m t h e b a c kp a n e li s c o n n e c t e d t o t h e g r o u n dt e r m i n a lo n t h e P E M . r 1B WELCHALLYN CL 100 SuRGrcArILLUMTNAToR REpAtR PARTSLtsr PartNumber 90133 LB-MAN.1OOW27OW A0-10756 A0-10768 Description Photo # Bubble# Ouantity l OOWREPLACEMENT LAMP 'l MANUAL,1OOW2TOW SOLARTEC PANEL, BOTTOIV, 27OW L A B E LW , A R N I N GI,L L U I V I N A T O R S 1 1 'l 1 1 12 PAINTED, SCREW, XLS SCREW, #8-32X 3/8,PHPS scREW,#6-32X 1/4,PHSS XLS,BUIVPER,RUBBER, 5/8 1 2 3 1 4 4 1 5 2 1 6 4 10 1- 0 0 6 8 S E M S ,# 6 - 3 2X 5 i 1 6 P H P S 1 1 I A0-10683 2 2 8 1 A0-10721 TOEXLSCHASSIS COVER, KAPTON TAPE, IOP COVER, XLS 9 1 A 0 - t0 8 2 8 ,]OOW P A N E LF, R O N TS, O L A R T E C 3 10 1 u50087 u50081 u50085 u50075 l O O WI N T E R N AM L O D U L EA S S E M B L Y 3 3 3 3 1 t 1 12 13 1 14 1 3 15 1 3 to 1 3 17 3 3 18 '19 4 4 20 1 4 21 1 1 4 A0-10714 1 0 10 0 3 3 101-0022 016-0005 A 0 - 1 0 71 A0-10856 213-0017 102-0012 44-10650 A4-10647 A0-10746 l O O WF A ND E F L E C T OARS S E M B L Y l O O WF I L T R E ASSEMBLY l O O WA L I G N E DP L A T F O R M F A N ,C H A S S I SX, L S PANEL,BACKWAVEPATTERN POWERENTRYMODULE/LINEFILTER, FUSED KEPS,#6.32,W/CONICAL WASHEB WtREHARNESS, l OOW ON/OFF, POWER SUPPLY XLS OVERTEMP/LED SW]TCH ASSEMBLY A0-10712 B A F F L EC, E N T E RX,L S 4 A0-'r0843 F O A M ,I G NT O R 4 101-0062 1 'l 1 S E M S ,# 6 3 2 X 9 / 1 6P H P S 5 22 40 23 207-0007 , 2MM G U A R DF, A N 9 5 24 1 105-0008 C O R D ,R E T A I N I NC GL A M P 5 I r06-0011 S T A N D O F#F8, , . 7 5 1 5 208-0016 F U S E5, A S H E E TI I I 6 44-10465 W I R EP, E MT OD I N 6 101-0073 S C R E W#, 8 - 3 2X 3 / 4 " , P H P S 6 010-0016 TUBING, HEATSHRINK 3/4" BLACK 6 I010061 4 ,H P S S C R E W#, 4 - 4 0 X 1 1 P 6 25 26 27 28 29 30 31 32 1 0 10 0 3 8 PN: LB-MAN.CLSERV ReV.A PLUG,6/25 7 1 4 2 1 4 z.za 4 1 Welc$11*. Part Number Photo # Bubble# Ouantity W A S H E H ,C O L O H C O A I I I ) 7 33 1 104-0008 104-0007 102-0001 W A S H E RS, E F R A T E D 7 W A S H E RF, L A T 7 NUT,HEX 7 104-0019 W A S H E R#,4 t X I t R N A I T O O T H 7 A0-10864 LAMP, CABLE, 3OK 8 C A B L ET I E ,S M A L L4 " 8 104 0006 112-0001 124 Description 1 35 36 31 38 39 1 1 2 1 8 WELCHALLYN PHoro1 --. (' lc" ,, c <-;-2 5 - =---|' / ) e . "t-.......-o a.--.-r PHOTO2 P N :L B M A N C L S E R VB E v A . 1-21 Welc$;1*' PHoTo3 19 12 10 11 14 18 17 15 PHoTo4 21 WELCHALLYN PHoTo5 23 ?4 PHoTo6 31 30 PN: LB-MAN-CLSERV Rev.A Welc\ffi*' PHoro7 PHoTo8 WELCHALLYN CL 300 SuRGrcAr ILLUMTNAToR Symptom L a m pf a i l st o s t a r ta n d f a n sa r e n o t r u n n i n g . Cause N o p o w e rt o u n i t C h e c fp o w e rs u p p l yc o r da 1 do u t l e l Linevoltageis <90 VAC R e f e rt o H o s p i t aEl n g i n e e r i ndge p a r t m e n t F u s e sb l o w n Inspect,replaceand retest.Go to " F u s e s o n p a g e2 7 . Satetyinterlockopen C h e c ka n dt i g h t e ns l o t t e ds c r e wo n l a m pf i x t u r e a c c e s sd o o r "Test G ot o # 2 : A u x i l i a rB y o a r dI n p u tT e r m i n a l s p a g e 27 an Powersupplyor auxiliary boardtailure L a m pf a i l st o s t a r ta n d t a n sa r e r u n n i n g . Lamp shutsoff after operatingfor a few m Inutes and restarts I n d i c a t ol r g h to n a n d l a m ps h u t so f f Remedy "Test #1: Blown L a m pn o t i n l i g h ts o u r c e ( a u d i b lcel i c k i n gh e a r d ) I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 . D e f e c t i v el a m pc a b l e (discoloreb de , n to r b r o k e n prongs) ( a u d i b l cel i c k i n gh e a r d ) Replace a n d r e t e s tl a m pc a b l e . Defectivepower supply (discolored, bent or broken prongs) ( n oa u d i b l ec l i c k i n gh e a r d ) Inspectwiringand if it is fine, replaceand retest power supply. l n a d e q u a taei rf l o w f o r c o o l i n gL, i g h tS o u r c eo v e r IemperaTUre A l l o w2 " ( 5 1 m m )c l e a r a n caet b a c ko f u n i t ,i n s u r e vents are cleanand not that air intake-outflow blocked.Allow unit to cool and then restart F a nf a i l u r e Goto l l l u m i n a t oi sr o v e r h e a t i nngo t d u et o c l e a r a n c e . Verifyoperationof fans.Cleanfans and internal componentsof dust. L a m pi s a t t h e e n d o f l i i e ,b u t a m b e rL E Di s i n o p e r a t i v e . VerifyLED flickerson when it is first turned on. lf " not, go to "Test f4 LED Operatron on page27. L a m pl i f ee x c e e d e d . I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 . Lampcabledelective. B e p l a c ei f p r o n g sa r e d i s c o l o r e db,r o k e n o, r b e n t . "Test # 3 . C o o l i n gF a n " o n p a g e2 7 . R e p l a c e m e nLta m pw i l l Lampis not orientedcorrectly R o t a t el a m p1 8 0 "a n dr e - i n s e r t not seat into LightSource l n c o r r e cR t e p l a c e m e nLta m p I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 . PN. LB-MAN-CLSERV Rev.A Welc\ffiyr.. Symptom Low light output Cause Remedy Filterassemblyon platform contamrnated. Cleanor replacefiltersas necessary. Mirrorsare dirty. C l e a ntnemrrrors. Broken mirrors. Replaceplatform. (possible l f a b o v es t e p sf a i l t o i m p r o v eo u t p u t ,r e p l a c ea n d Misaligned mirrors if unitsuffersdamage) retestplatform. D a m a g e dM i c r oL i n k @F i b e r o r f i b e rb u n d l e F i b e ro r f i b e rb u n d l e C h e c ke n d so f M i c r oL i n k @ f or damage.Replacewith new Micro Link@Fiber "Test #5: Micro Link@Fiber or fiber bundle.Go to Test" on page28. Fiberbundle not connected correctly. Be-insertf iber bundlecorrectly. L a m pn e a re n d o f u s a b l el i f e F i b e rb u n d l ew i l l n o t i n s t a liln L i g h tS o u r c e " clicking " Audible or arcrng soundduringthe process lampignition I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 . "Operating N o t a c o m p a t r b lfei b e rb u n d l e S e e I n s t r u c t i o n so"n p a g e6 U s ec o m p a t i b l b e u n d l ed e s i g n "Operatrng Install/Remove I n s t r u c t r o n so"n p a g e6 Multi LinkrM See ExpansionPort Multi LinklMExpansionPort B e m o v eM u l t i L i n k r ME x p a n s i oP nort No problem Normaloperation W E L C HA L L Y N CL 300 SURGTGAL ILLUMTNAToRDrsAssEMBLy NOTE: Forall tests, remove9 screwsfrom top cover. N O T E : D o n o t o p e r a t eu n i tw i t h t h e t o p c o v e rr e m o v e df o r m o r et h a n5 m i n u t e so r t h e u n r tw i l l o v e r h e a t . lEsT #1: BLowNFUsEs T h e p u r p o s eo f t h i st e s t i s t o d e t e r m i n e t h e s o u r c eo f a s h o r tc i r c u i tc a u s i n gf u s e st o b l o w .R e f e rt o t h e B l o c k D i a g r a mo n p a g e4 8 . R e p l a c ea n d r e t e s t h e f u s e s .l f u n i tf u n c t i o n sn o r m a l l yi ,n s p e cftu s e st h a tw e r e b l o w n .l f s o l d e ri s m e l t i n go u t o f t h e e n d o f t h e f u s ea n dt h e g l a s si s n o t b l a c k e n e dr e , m o v ea n d r e p l a c et h e p o w e re n t r ym o d u l eT. h i sf a u l to c c u r s when the prongof the fuse holdermakespoor contactwith the tuse.The prongwill look discoloredand pitted where it contactsthe fuse. l f v i s u a il n s p e c t i odno e sn o t y i e l da n ye v i d e n c eo f d a m a g er, e m o v eJ 2 a n dJ 3 f r o m a u x i l i a rbyo a r d( b l u ea n db r o w n w i r e st h a tc o n n e c tP C B Aa u x ii a r yb o a r dt o t h e p o w e rs u p p l yR f u s e sa n dt u r n s y s t e mo n . R e m o v ep o w e r . eplace a n d i n s p e c ft u s e s . l f t h e f u s e sa r e b l o w n ,r e m o v ea n d r e p l a c et h e P C B Aa u x i l i a rbyo a r d( p a r tn o .A 4 - 1 0 6 7 0 ) . . l f f u s e sa r et i n e ,r e m o v ea n d r e p l a c et h e p o w e rs u p p t y . TEsr#2: AuxtLtARyBoARDlNpur TERM|NALS V e r i t yo p e r a t i n vg o l t a g ei s p r e s e n ot n a u x i l i a rbyo a r di n p u tt e r m r n a l sC. o n n e c m t e t e ra n ds e t t o v o l t sA C t o J 1 a n d J 4 t e r m r n a l sW. h e n p o w e ri s a p p l i e dt o t h e u n i tt h e o p e r a t i n vg o l t a g ev, e r i f yi t i s d i s p l a y e od n t h e m e t e r .N O T E : Verifvthe lamoaccessdoor is closed. lf voltageis present,replaceand retestauxiliaryboard. lf voltageis not present,inspectthe fuses,wiring,power entry module,linefilter,and interlockswitch. N O T E : l f l a m pi s n o t o n a n dv o l t a g ei s p r e s e n tc, h e c ki f t h e p o w e rs u p p l yi s d e f e c t i v e . lEsr #3: CooUNGFAN T h e p u r p o s eo f t h i st e s t i s t o v e r i t yt h e o p e r a t i o o n f t h e l a m pc o o l i n gf a n . V i s u a l l iyn s p e c ft o r a b r o k e nf a n .W h e nt h e u n i ti s p o w e r e du p , l o o kt o r a f a n n o t t u r n i n g l.f f o u n d ,r e m o v et o p c o v e ra n d i n s p e cfta n . R e p l a c e a n yb r o k e nf a n s 'l2VDC l f f a n i s i n o p e r a t i vaen dn o t b r o k e n m , e a s u r eu s r n gD M M s e t f o r V o l t sD Cf o r o n f a n c o n n e c t o r sJ ,l T i s { o r t h e l a m pf a n ( e x h a u s ta)n dJ 1 0 1 o rt h e p o w e rs u p p l y( i n t a k e ) . . lf voltageis present,replaceand retestfan. . lf vo tage is not present,replaceand re-testauxilraryboard. IEST#4: LED OPERATIoN The purposeof this test is to verifyproperoperationof the LED. V i s u a l l iyn s p e c t h a tJ 1 i s c o n n e c t e d t o t h e a u x i l i a rbyo a r d V . e r i f yc o n t r n u i tovf w i r i n ga n d L E Dw i t h D M M s e t t o t h e D i o d eS c a l e D . M M s h o u l dr e a d= . 7 V D C . P N :L B M A N - C L S E R R V e v .A Welc$1yn. . l f t h e D M M r e a d i n gd o e sn o t m a t c h ,r e p l a c ea n d r e t e s t h e L E Dh a r n e s s . . f D M M r e a d i n gm a t c h e sa b o v e ,r e p l a c ea n d r e t e s t h e a u x i l i a rbyo a r d . TEST#5: MIcRo LINK@FIBERTEST The purposeof this test is to verifythe operationof the Micro Link@Fiber. W i t h t h e i l l u m i n a t oorn , c o n n e c t h e f i b e ra n dt h e h e a d l i g h O t . v e ra d i s t a n c eo i a t l e a s tf i v ef e e t ,a d j u s t h e s p o t d i a m e t etro t h e l a r g e sst i z e . . l f t h e i n t e n s i t yo f l i g h ti s n o t c o n s i s t e ntth r o u g h o utth e l i g h ts p o ta n dr o t a t i n gt h e d i s t a e l n d c o n n e c t odr o e s n o t c a u s et h e s h a p et o c h a n g et,h e h e a d l i g hi ts t h e m o s t l i k e l yc a u s eo Jt h e f a u l t . . l f t h e i n t e n s i t yi s n o t c o n s i s t e nwt i t h a l t e r n a t i nlgi g h ta n dd a r kr i n g sa r e p r e s e n tt,h e b r o k e nf i b e ri s b r o k e na t t h e d r s t ael n d . O v e rt h e s a m ed i s t a n c ea, d j u s t h e h e a d l i g ht to t h e s m a l l e sdt i a m e t e sr p o t .A t t h i sa d l u s t m e n t h , e h e a d l i g hits f o c u s e d l.f a n ys p o t i r r e g u l a r i t i e a sr e p r e s e n th, o l dt h e h e a d l i g hst t e a d yw h i l er o t a t i n gt h e d i s t a l e n d( b l a c k ) connector. . lf the locationof the defectsmove,removethe fiber,cleanthe end with distilledwater,reconnectthe unit,and test. Replacethe fiber if defectsare still present. . lf the locationof the defects remainstationary, the fault is within the headlight. WELCHALLYN ILLUMTNAToR CL 300 SURGICAL DrsAssEMBLy NOTE: All servicingrequiresremovalof the top cover.Removethe 9 screwsand removethe cover. INTERNAL MODULE REMovAL 1 . R e m o v et h e t o p c o v e r . 2 . R e m o v et h e f r o n tb e z e b l y r e m o v i n gt h e 5 s c r e w ss e c u r i n g t h e f r o n tb e z e tl o t h e b o t t o mc h a s s i s . 3 . P u l lt h e i n t e r n am l o d u l eo u t o f t h e p l a t f o r ma s s e m b l y . 4. Installationis the reverseprocesswith the flat edgeson the gray portionof the internalmodulealignedso rt l n dt h e b l a c kd o t i n t h e g r a yp l a s t i ct o t h e b o t t o mr i g h t . w i l l f t i n t ot h e r e c e s s e d a r e ao f t h e f r o n tp a n e a PowERSUPPLY REMovAL 1 . B e m o v et h e t o p c o v e r . 2. Removethe front bezelby removingthe 5 screws securingthe front bezelto the bottom chassis. 3 . R e m o v et h e a i r d u c ts t r a pa n da i r d u c t . 4 . R e m o v et h e 5 w i r e sf r o m t h e P C B Aa u x i l i a rbyo a r d( p a r tn o .A 4 - 1 0 6 7 0 ) . 5. Removethe 7 wires f rom the power supply. NOTEP : u l lo r p r yt h e w i r e ss t r a i g hut p . R o c k i n g t h e w i r e t o r e m o v ei t f r o m t h e p o w e rs u p p l ym a yd a m a g et h e t e r m l n a l ' s o l d e rj o i n to n t h e p o w e rs u p p l yb o a r d . P u l io r p r yw i r e t e r m i n asl t r a i g hut p . Do not rockto remove. U s e b e n tt i Dn e e d l en o s eo l i e r st o o r v t h e t e r m i n aol f f .T h e h a n d l eo f a s c r e w d r i v ei rs u s e da s t h e f u l c r u m . PN: LB-MAN-CLSERV ReV.A TVelc$1*. 6 . R e m o v et h e 4 s c r e w sf r o m t h e p o w e rs u p p l ya n dp u l l t h es u p p l yo u t o f t h e f r o n tt o r e m o v e . 7. Installationis the reverseprocesswith the wires locatedas forrows: . P 1 o n p o w e rs u p p l yt o J b o n P C B A( p a r tn o .A 4 - 1 0 6 7 0-)r e dw i r e . P 2 A - U s e dt o c o n f r g u r teo 2 3 0 vo p e r a t i o n o n l y- N O T U S E D . P 2 o n p o w e rs u p p l yt o J 4 o n P C B A( p a r rn o .4 4 - 1 0 6 7 0-) b r o w nw i r e . P 3 o n p o w e rs u p p l y t o J l o n P C B A( p a r tn o .4 4 1 0 6 7 0 ) b l u e w i r e . P4 on power supply- blackwire from red/blackpair- housedin tubing o P 5 o n p o w e rs u p p l y- r e d w i r e f r o m r e d / b l a cpka i r- h o u s e di n t u b i n g . P 1 1o n p o w e rs u p p l y- r e d o r w h i t e w i r e f r o m r e d / b l a cpka i r( t h t nw i r e p a i r ) . P12 on power supply- blackwire from red/blackparr(thinwire pair) PCBA (PARrNo. 44-10670) REMovaL '1. Removepower as notedabove. 2. Notthe location a n d r e m o v ec o n n e c t o rfsr o m J 6 , J 7 , J 9 , J 1 0 ,J 11, a n dJ 1 2 . 3. Usinga short#1 screwdriver,removethe 4 screwsfrom the cornersof PCBA(partno. A4-10670)and remove PCBA. 4 . I n s t a l l a t i oi sn t h e r e v e r s ep r o c e s sU . s et h e b l o c kd i a g r a m sa s n e c e s s a rtyo r e c o n n e ctth e w i r e s .S e ef i g u r e below for properwire routing. WELCHALLYN IGNIToR REMovAL 1 . R e m o v et h e t o p c o v e r . t e 2 l a m pc a b l ew i r e sa n dt h e r e d a n d b l a c kw i r e sf r o m t h e i g n i t o rN . o t et h e w i r e l o c a t i o n s . 2 . D i s c o n n e ct h 3. Remove4 screws,securingrgnitormoduleto the centerbaffle.Screwsare locatedon the other side of the centerbaffle. 4. Installation is the reverseprocess.NOTE:becausethe screwdriverwill not directlyreachthe lower screws, I n s t a l l i nagn dr e m o v i n gt h e s c r e w sl n t ot h e i g n i t o tr o t a p t h e h o l e sp r i o rt o i n s t a l l i ntgh e i g n i t o ri n t h e u n i tw i l l 5 . R e c o n n e ct th e w i r e sa s f o l l o w s{ s e ef i g u r ef o r o r i e n t a t i o n ) . . R e dw i r e t o t h e l o w e rc e n t e rm o s tt e r m i n a l . . Blackwire to the lower outermosttermina. - l a m pc a b l ew i r e t o t h e t o p l e f t t e r m i n a(l s h o r t ew r ire). + l a m pc a b l ew i r e t o t h e t o p r i g h tt e r m i n alll o n g e w r ire). LINE FILTERREMOVAL 1. R e m o v et h e t o p c o v e r . PN: LB MAN CLSERVREv.A Welc$1ytt' 2 . R e m o v et h e s c r e w ss e c u r i n gt h e c e n t e rb a f f l et o t h e b a c kp a n e la n dt h e b o t t o mc h a s s i s( s e ef i g u r eb e l o w ) . X L SR u b b e rB u m p e r Hexheadscrew securingcenter batfleto sideof bottomcnassts a rentdr baffleto bottomchassis a Screw securing centerbaffleto b a c kp a n e l 3. Removethe wires from both ends of the linefilter.Note locationof wires. 4. Removethe 2 screws securingthe linefilter and remove. 5. Installationis the reverseprocesswith the followingrequirements: . The end of the filter with 3 terminalsis on the platformside of the centerbaffle. . The green (ground)wire goes to the terminaldirectlymountedto the metalsurtace. . The bluewires go to the terminalsnearestthe fans on both ends.The brown wires go to the centermost termrnals. CHAssrsFANREMovAL '1 . Removethe top cover. 2. Removethe 4 screwssecuringthe fan and the wire guard.NOTE:to removethe fan from the lampside of the u n i t ,r e m o v et h e f a n o n t h e p o w e rs u p p l ys i d e .T o r e m o v et h e l a m pf a n ,p u s ht h e s p l i tg r o m m e tt h r o u g ht h e center baffle,then pull the wires out of the grommet. 3. Disconnectthe fan connectorfrom the PCBAAuxiliaryboard(partno. A4-10670)and remove. WELCHALLYN 4. InstalatlonisthereverseprocesswithJ11forthefanonthelampsrdeandJl0forthefanonthe s u p p l ys i d e .R o u t et h e w i r e sa s s h o w ni n f i g u r e sb e l o w . W i r e B o u t i n go n l g n i t o ra n d P C B A ( p a r tn o .4 4 - 1 0 6 7 0 ) C h a s s i sF a nW r r eR o u t i n g T h el a b eo l n t h e l a m ps i d ef a n f a c e so u t ,t h e l a b e o l n t h e p o w e rs u p p l ys i d ef a c e si n ( s e ef i g u r eb e l o w ) . POWER ENTRYMoDULEREMoVAL T . R e m o v et h e t o p c o v e r . 2. Removethe 3 screws securingthe backpanelto the bottom chassisand the 1 screw back panelto center baffle. 3 . R e m o v et h e 3 w i r e t e r m i n a l sf r o m p o w e re n t r ym o d u l e . 4. Move backpanelas necessaryto gainaccessto nuts securingthe PEM (powerentry module). 5. R e m o v en u t sf r o m t h e P E Ma n dr e m o v em o d u l e . PN: LB-MAN.CLSERV ReV.A Welc$11yr.. 6. Installation is the reverseprocesswith the followingrequirements. . The lockwasher is insertedbetweenthe PEIV1 and the paintedside of the back panel. . The flat washeris insertedbetweenthe non-paintedside of the back paneland the nut. o T h e g r e e n( g r o u n dw) i r e i s c o n n e c t e d t o t h e t e r m i n a l s o l d e r eddi r e c t l yt o t h e m e t a ls u r f a c eT. h e b l u ew i r e is connectedto the terminallabeledN and the brown wire to the terminalmarkedP PLATFoRM REMoVAL '1 . Removethe top coverand removethe lamp. 2. Removethe front bezelby removingthe 5 screwsthat secureit to the bottom chassis.Removethe internal mooute. 3. Removethe two screws from the air duct strapand removethe duct. 4. Removethe 4 screws securingthe plat{orm. 5 . R e m o v et h e l a m ps h r o u df r o m t h e p l a t f o r m . 6 . R e m o v et h e p l a t f o r ma n dt h e t h e r m i s t oar s s e m b l yf r o m J 1 2 . 7. Installation is the reverseprocess.When installingthe platform,verifythat the shroudduct,the strap,andthe internalmoduleare installed.Reattachthe front bezeland checkfor attenuatorwheel alignment. . Botatethe wheel acrossits adjustmentrangeand if the wheel movesfreely,continue,if it does not move freely,loosenthe platformscrewsand repositionthe platformso the wheel rotatesfreely. FRoNTBEZELREMoVAL 1. Removethe top cover. 2. Removethe 5 screws, securingthe front bezelto the bottom chassis. 3. Notingthe wire locations,removethe wires from the power switch. Pushout the power switch. 4. Usinga sharpknife,removethe blackRW from the LED.Once removed,applyacetoneto the areabetween t h e L E Da n dt h e f r o n tp a n e tl o l o o s e nt h e q l u eb o n d .R e m o v et h e L E D . 5. Installationis the reverseprocesswith the LED gluedto the front panelusingLoctite430 or equivalent.Once s e t ,a p p l yo p a q u es e a l a n tD , o w C o r n i n g7 3 7 o r e q u i v a l e ntto, t h e a r e aa r o u n dt h e L E Dt o p r e v e n tl i g h tf r o m t h e i l l u m i n a t opra s s i n gt h r o u g ht h e L E D . BLowERFANREMovAL 1 . R e m o v et h e t o p c o v e r . 2. Removethe front bezelas describedoreviouslv. 3 . R e m o v et h e a i r d u c t s t r a pa n d d u c ta s d e s c r i b e d above. I -34 WELCHALLYN 4 . R e m o v ee l e c t r i c aclo n n e c t oJr g f r o m P C B A( p a r tn o .4 4 - 1 0 6 7 0 ) . 5 . R e m o v et h e 2 n u t s ,s c r e w s ,a n ds p a c e r st h a t m o u n tt h e b l o w e rf a n t o t h e b l o w e rb r a c k e t . 6 . i n s t a l l a t i oi n s t h e r e v e r s ep r o c e s sw i t h t h e f o l l o w i n gr e q u i r e m e n t s : . Spacera s r ei n s t a l l eo d n t h e s c r e w sb e t w e e nt h e b r a c k eat n dt h e f a n . LAMPCABLEREMoVAL I R e m o v et h e t o p c o v e r . 2 . O p e nt h e l a m pa c c e s sd o o r ,o p e nt h e l a t c h a , n dd i s c o n n e ccta b l e . 3 . D i s c o n n e ct h t e l a m pc a b l ew i r e sf r o m t h e i g n i t o r . 4 P u l ll a m oc d b l eo u t t h r o u g l t-h e l a ' n pa c c e s sd o o r . 5 . I n s t a l l a t i oi sn t h e r e v e r s ep r o c e s sw i t h t h e f o l l o w i n gr e q u i r e m e n t s . . B e m o v et h e n y l o nw i r e t i e f r o m t h e l a m pc a b l e . Feedthe wires throughthe spacebetweenthe linefilter andthe centerchassis. Connectthe shorterwire to the top left terminalon the ignitor.Connectthe longerwire to the top, right t e r m i n a lI.n s t a ltlh e t e r m i n a l sb e t w e e nt h e t w o f l a t w a s h e r s( s e ef i g u r ef o r w i r e r o u t i n g ) . W i r e R o u t i n go n l g n r t oar n d P C B A ( p a r tn o .4 4 - 1 0 6 7 0 ) PN: LB MAN CLSERVRev.A Welc$11*' CL 300 SURGTCAL ILLUMTNAToR REPATR PARTSLrsr Part Number Description 9 0 12 5 2 7 W RE P L A C E M tN I LAMP Photo # Bubble# 'l t B - M A N - 1 O O W 2 7 O W MANUAL,1OOW2TOWSOLARTEC A0-10880 LABEL,PROTECTIVE EARTHGROUND BETEL27A TOPCOVER, LENGTHENED A0-10797 RM-LBL-023 A0-10755 A0-10714 0uantity 'I 1 1 EXTERNAL MODULEHOLDER,27OW 2 3 S C R E WP , A I N T E DX, L S 4 Itt 5 1 6 4 7 8 1 101-0033 101-0022 A0-10907 SCREW, #8 32 X 3/8,PHPS CHASSIS BASE 2 2 2 2 10 1 - 0 0 6 8 S E M S ,# 6 - 3 2X 5 / 1 6 ,P H P S 2 9 8 016-0005 X L S ,B U M P E RR, U B B E R5,/ 8 2 10 4 S E M S ,# 6 . 3 2X 9 / 1 6 P H P S 2 11 I , 2MM G U A R DF, A N 9 12 13 2 CORD,RETAINING CLAMP 2 2 F U S E5, A S H E E TI I I 1 A0-10904 B A C KP A N E L 15 213-0019 ROCKEB SWITCH, WHITE ON/OFF, 2 3 3 3 3 3 3 3 3 3 3 4 26 4 27 u 5 0 11 7 u50111 DUCI NOZZLE BLOWER, 27OW STRAEAIR DUCT 27OWLAMP SHROUDSUB-ASSEN/ BLY 27OWADJUSTED POWER SUPPLY 4 28 4 29 213-0018 S W I T C HI,N T E R L O C K S,N G LP O L E 4 30 1 1A20012 K E P S#, 6 _ 3 2W , C O N I C A LW A S H E R 4 31 3 210-0001 L I NE F I L T E R6,. 0 4 , F L A N G E 4 32 I A0-10768 101,0062 207-0007 105-0008 208-0016 A0-10906 A0- 10905 L A B E LW , A R N I N GI.L L U M I N A T O F S S C B E W#, 6 - 3 2X 1 / 4 ,P H S S BLOWER BRACI..ET CENTERBAFFLE 44 10670 PCBAA , UXILIARY 2 1 80 0 0 3 I G N I T O F2, 7 0 W P I A0-10864 101-0078 CABLE, LAMP,3OK TENSIONWIRE RETAINER X 1/4,FHD,StT82DG SCREW,4-40 44-10680 W I R EH A R N E S SL,E D / A U ) ? P S 105-0010 1 1 20 0 0 1 A 0 - 10 8 12 A0-10814 C A B L ET I E ,S M A L L4 " 8 2 16 1 17 1 18 1 19 1 20 21 22 23 1 24 25 1 4 1 1 ,l 1 '1 1 ,l WELCHALLYN PartNumber Description Photo# Bubble# 101-0059 S I M S , # 6 - 3 2X 1 i 4 P H P S 4 33 213-0017 P O W E RE N I R YM O D U L E/ L I N EF I L T E R , F U SE D 4 34 101-0084 S C R E W#, 6 T H D F R M G ,P H P S 4 35 u50123 u50125 2 7 O WI N T E R N AM L O D U L ES U BA S S M B 4 27OWFILTER ASSEMBLY 5 36 31 S C R E W#, 4 - 4 0X 1 / 4 ,P H P S 5 38 27OOW A L I G N E DP L A T F O R M 5 39 S C R E W#, 8 - 3 2X 3 / 4 " , P H P S 5 101-0061 u 5 0 115 101-0073 0uantity 2 4 2 4 6 A4-10672 FAN,BACK, 3 WIRE,27OW WIREHARN ESS,FILTEF/GFOUND 44-10673 W I R EH A R NE S S ,S W I T C H / F I L T E R 6 A 4 - 1 Q 647 W I R EH A R NE S S A , C/FILTER 6 109-0006 B U S H I N GO, P E N E D / C L O S E.D 5O , O 6 44 10675 W I R EH A R N E S SA,C / S W I T C H 6 46 6 47 1 44-10655 44 10465 W I R E ,P E MT O D I N 41 2 6 44 44-10676 WIRE HARNESS,FILTER/PS 6 48 1 44-10678 W I R EH A R N E S SA,U X T P S 7 AO 1 A4-10677 W I R EH A R NE S S ,O N / O F F / A U X 7 50 1 S E M S ,4 - 4 0X 3 / 8 ,P H P S 7 51 4 44-10683 F A N ,B L O W E RT, E F L O NW I R E 7 52 1 1 0 10 0 8 3 S C E E W4, . 4 0X 1 1 / 4 " , P H P SS, S 7 53 2 1 0 6 - 0 051 S P A C E Rf 4 , U N I h B D , 1 1 4o d , 1 l 4 l 7 54 102-0008 NUT,KEP,4-40, HEX 1 55 2 2 1 0 6 - 0 01 #8 STANDOFF , ,.751 7 56 4 NUI HEX 8 57 1 WASHER,FLAT I 58 8 59 1 I 60 2 PLUG,6/25 8 61 1 WASHER, COLOR COATED I 62 1 101-0085 102-0001 104 0007 104 0008 104-0019 101-0038 104-0006 PN: LB-MANCLSERVRev.A W A S H E RS, E R R A T E D W A S H L Rt,' 4 E X I L R N A LT O O T F 'I Velc$11ytr. PHoro1 PHoro2 9 11 1-3E WELCHALLYN PHoTo3 t8 25 17 PHoro4 30 33 32 34 P N :L B - M A NC L S E R VR e v .A Welc$11ytt* PHOTo5 PHoro6 WELCHALLYN PHoro7 PHOTo8 P N :L B - M A NC L S E B VR e VA . Velc\Allyn. GLoSSARY oF TERMS AC A l t e r n a t i nC g urrent COM g o m m o nw i r e t e r m r n a t r o n F o u n do n p o w e rc o n n e c t o r ss,w i t c h e se, t c . . .i n d i c a t i nC DMM D i g i t aM l ultiMeter F i b e rO p t i cB u n d l e A n y o f a n u m b e ro f l i g h tt r a n s m i s s i odne v i c e sc h a r a c t e r i z ebdy u s e o f m u l t i p l eh, a i rt h i n strandsof claddedglassfibers.Usedto deliverlightfrom illuminatorbox to work area. Leakage Current U s u a l l ya s p e c i f i e dm a x i m u ma m o u n t o f a l l o w a b l ec u r r e n tt o p a s s t h r o u g hi s o l a t e d electricalcomponentswhen subiectedto very high electricalpotentials. LED L i g h tE m i t t i n gD i o d e M e t a lH a l i d e A n y o f a n u m b e ro f m e t a l l i c o m p o u n d su, s u a l l yi o d i d e st h a ta r e u s e di n t r a c ea m o u n t si n dischargelight sources.lvletalhalidesare incorporatedto producethe destredspectral contentot the light source. NO N o r m a l l yO p e n ,F o u n do n s w i t c h e si n d i c a t i nngo r m a l l yo p e nt e r m i n a t t o n . P CB o a r d P r i n t e dC i r c u i B t oard PEM P o w e rE n t r yM o d u l e FTV RoomTemperature Vulcanizing Silicone TRMS accuracyof digitalmultFmeters. True Root Mean Squared- usedto characterize VDC Voltage-DirectCurrent Xenon An elementag l a s u s e d c o m m o n l yu s e d i n l i g h t i n gp r o d u c t s .U s e d a s a n e v a p o r a n t s u p p r e s s a ni nt t u n g s t e nh a l o g e nl a m p so r l i g h te m i s s i o ni n g a s e o u sd i s c h a r g lea m p s . WELCHALLYN FINAL INSPECTIoN T h e p u r p o s eo f p r e v e n t a t r vmea r n t e n a n crest o p r o - a c t i v erl ye d u c eo r e l i m i n a t e f u t u r ep r o b l e m sK. e e p i n g the light g o o d s o u r c ei n o p e r a t i n cgo n d i t i o n e n s u r e st h a ti t w i l l p e r f o r mr e l i a b l ay n ds a f e l yE . v e r ys i xt o t w e l v em o n t h s y, o u should: N O T E :P e r f o r mh y p o ta n dg r o u n dc o n t i n u i ttye s t so n t h e u n r tb e f o r eb e g i n n i n tgh e f i n a li n s p e c t i o n . CL 100SuRGrcAr ILLUMTNAToR . h e c kf o r t h e f o l l o w 1 . S e t T I M Et o s t a r t .T u r no n t h e S Y S T E NB i Ie . g i nt h e f i f t e e n( 1 5 )m i n u t eB U R N - l Np e r i o dC ing: . D r dt h e y e l l o wL E D l i g h tb r i e f l y ? . D i dt h e l a m ps t a r t ?C l i c k i n gb e f o r et h e l a m pi g n i t e sr s n o r m a l( 1 0c l i c k so r l e s s ) . o A r e t h e f a n sr u n n i n g ? 2 . A f t e rt h e f i f t e e n( 15 ) m i n u t eb u r n - i ni n s e r t t h eP O W E R T E S T F I B Ei R n t o t h e P o r t .O p e nt h e a t t e n u a t of ru l l y a n d m e a s u r et h e l i g h to u t p u t .R o t a t et h e p r o x i m ael n d t o m a x i m i z ep o w e ro u t p u ta n dc h e c kt h e f o l l o w i n g : . Doesthe connectorinsertsmoothly? . Doesthe attenuatormove smoothly? . D o e st h e L r g h tO u t p u tm e a s u r e> 7 5 0 m i l l i w a t t s L ? i g h to u t p u t< 3 7 5 i s c o n s i d e r etdh e e n d o f t h e l i f eo f the lamp. . Turnthe system off and on again3 more times. Does it lightabruptlyand properly? l f t e s t i n gh a sP A S S E Dc,o n t i n u el.f u n i tf a i l st e s t i n gt,r o u b l e s h o oats n e c e s s a r y . CL 3OOSURGIcAt ILLUMINAToR IMPORTANTClickingbeforethe LAMP ignitesis normal(10 clicksor less).Do not hot re-strikein succession. ( 4 5 )s e c o n d se a c ht i m e b e f o r et u r n i n go f f . T h e I L L U M I N A T Om Ru s tr e m a i ni l l u m i n a t efdo r a m i n i m u mo f f o r t y - f i v e Wait thirty (30)secondsbetween eachre-strike. T u r nt h e I L L U M I N A T OoRf f a n do n a o a i nt h r e e1 3 )m o r et i m e s .T h e I L L U M I N A T Om R u s t r e m a i ni l l u m i n a t efdo r a m i n i m u mo f f o r t y j r v e( 4 5 )s e c o n d se i c h t r m eb e f o r et u r n i n go f f. U s r n ga T I M E R w , a i tt h i r t y( 3 0 )s e c o n d sb e t w e e n r e - s t r i k e sC. l r c k i n bg e fo r e t h e L A M Pi g n i t e si s n o r m a (l 1 0c l i c k so r l e s s ) D . o e si t l i g h tp r o m p t l ya n dp r o p e r l y ? l f t e s t i n gh a sP A S S E Dc,o n t i n u el.f u n i tf a i l st e s t i n g t, r o u b l e s h o oats n e c e s s a r y . . h e c kf o r t h e f o l 1 . S e tT I M Et o s t a r t .T u r no n I L L U M I N A T O R B.e g i nt h e f i f t e e n( 1 5 )m i n u t eB U R N - l Np e r i o dC lowrng: . D i dt h e y e l l o wL E Dl i g h tb r i e lfy ? . D i dt h e l a m ps t a r t ?C l i c k i n gb e fo r e t h e l a m pi g n i t e si s n o r m a (l 1 0c l i c k so r l e s s ) . . A r e t h e f a n sr u n n i n g ? PN: LB-MAN-CLSEFV Rev.A 1-43 Welc\ffi*' 2 . A f t e rt h e f i f t e e n( 1 5 )m i n u t eb u r n - i ni n s e r t h e P O W E RT E S TF I B E Ri n t ot h e P o r t .O p e nt h e a t t e n u a t ofru l l y a n d m e a s u r et h e l i g h to u t p u t .R o t a t et h e p r o x i m ael n d t o m a x i m i z ep o w e ro u t p u ta n dc h e c kt h e f o l l o w i n g : . Doesthe connectorinsertsmoothly? . Doesthe attenuatormove smoothly? . D o e st h e L r g h tO u t p u tm e a s u r e> 3 6 1 l u m e n s ?L i g h to u t p u t< 2 0 0 i s c o n s i d e r etdh e e n do f t h e l i f eo f t h e lamp. WELCHALLYN SPEcIFIcATIoNS Physical x 2 8 6 m m Wx 2 8 6 m m D / 4 . 0 k 9 ) " x 1 1 . 2 5 "D / 9 . 0 1(b1 4 0 m m H S i z e/ W e i g h t( C L1 0 0 ) 5 . 5 " H x 1 1 . 2 5 W " (140mmH x 2 8 6 m m Wx 3 2 4 m m D / 5 . 0 k 9 ) S l z e/ W e i g h t( C L3 0 0 ) 5 . 5 H x 1 1 . 2 5 " W x 1 2 . 7 5 "D / 11. ' 1 l b e r o u n dt o p ,b a c ka n ds i d e s SpaceRequirements M i n i m u m2 " ( 5 1 m m )a i r s p a c a ne Paintedsurfaces- polyuretha F i ni s h Lamp '100W XenonArc 2 7 0 WS h o r tA r c D C M e t a lH a l i d e LampType Power Requirements Electrical 100-240VAC50/60H2 Amperage 2 . 5 A m p s@ 1 2 0 V( S u r g i c al lll u m i n a t oCr L 1 0 0 ) ' 1 2 0 V( S u r g i c a l 4 A m p s@ l l l u m i n a t oCr L 3 0 0 ) Salety Compliance U12601-2 1 n d e d , C S A y ' C A N - C 2N 2 .o2. 6 0 1 - 1 - M 9 0 , cD. 6 0 6 0 1 -:' 1 9 9 0A m e n d .2 , l E C 6 0 1 -:11 9 8 8 / E N s ) ,J I ST 1 0 0 1: 1 9 9 2 , l E C 6 0 1 - 1 - 2 : 1 9 9 36/0E6N0 1 - 1 - 2 : 1 9( 9C3l a s B 78737 l E C 6 0 12 - 18 : 19 9 6 / E N6 0 6 0 1 - 2 -81: 19 9 6 IECClassification TypeBF,Classl lPXO Operation Continuous The CE mark on this productindicatesthat it has beentestedto and conformswith the provisionsnoted E M Cd i r e c t i v e . M e d i c aD l e v i c eD i r e c t i v a e n d8 9 / 3 3 6 E E C w i t h i nt h e 9 3 l 4 2 l E E C y anager Eu r o p e a nR e g u l a t o rM EUContact: W e l c hA l l y nL t d . C o u n t yM e a t h ,R e p u b l i oc f l r e l a n d Tel353 46 67700 Fax353 46 27128 P N :L B M A N C L S E B VR C vA . Welc$11ytt. THEoRY oF OPERATToN LIGHT SoURcE T h e L i g h tS o u r c e sc o n s i s o t f a n e n c l o s u r eh o u s i n ga, h i g hi n t e n s i t yl a m p ,p r o p r i e t a royp t i c apl l a t f o r mu, s e r i n d i c a t o r s , c o n t r o l sa n d a n da p o w e rs u p p l yw i t h c o n t r oel l e c t r o n i c sC.o o l i n gi s p r o v i d e dv i a i n t e r n af la n s .I n t h e event that the fan(s)malfunctionsor if adequateair flow is blockedand/orthe internaltemperatureof the device n echanism w i l l a u t o m a t i c a lsl yh u to f f l r o t e c t r om e x c e e d st h e e n g i n e e r i nsgp e c i f i c a t i o nasn, i n t e r n atlh e r m a p . f t e rc o o l r n gr,e s t a r t h e L r g h tS o u r c e s . p o w e rt o t h e r a m p A REPLAcEMENT LAMPS The lampsare high pressure,high intensityand long life Light Sources.They are mountedinto a patentedlamp l i x t u r ew h i c h i s d e s i g n e dt o a l l o wb o t he a s ya n d r a p i de x c h a n g ei n t h e f i e l da s w e l l a s e n s u r i n gp r e c i s ea | g n m e n t to the oDticalDlatform. Powen Suppr-ywrrH CoNTRoLELEcrRoNrcs All the electricityto the LightSourceis controlledthroughthe ON/OFFswitch. Powerto energizeand operatethe lamp,fans,and controlcircuitryis providedby a customdesigned,wattageregulated,switchingpower supply. d y a l a m pv o l t a g em o n i t o r i n cgi r c u i t T h e o p e r a t i o n al i lf eo f t h e l a m pa n dt h e l a m pl i f ei n d i c a t oar r e c o n t r o l l e b PoRT MULT|LtNKn PoRTANDMULT|L|NK* ExpANSroN Internal,to both the multi LinkrMPort and Multi LinkrMExpansionPort,are patentedcouplingopticsand mechanicsdesignedto producethe highestoutput powers.Internalto the LightSourcesare fans and heatsinks d e s i g n e dt o r e d u c et e m p e r a t u r east t h e o p t i c acl o u p l i n g J o i n t st h e r e b ym i n i m i z i ntgh e p o s s i b i l i toyf d a m a g et o M i c r oL i n k @F i b e ra n df i b e rb u n d l e s . 1-46 WELCHALLYN ILLUMTNAToR CL 100 SURGTCAL CrRcurr DTAGRAM POWER DIAGBAM SUPPLY BLOCK @]4VDC 100240vAc El\,41 FILTEB & FUSE t--r/ | I I LAI'/P I "\l LAI\,4P ATERT OUTPUT O.I SHUT DOWN INPUT 2 [email protected] PN:LB MAN CLSERVBCv.A \Velc\ffi*' CL 3OOSURGICAL ILLUMINAToR CIRCUIT DIAGRAM -: > E c a - 3 = i----.*. 148 WELCHALLYN