WelchAllyn CL-300 Surgical Illuminator - Service Manual

8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual

1/52

Service

Manual

CL300Surgical l luminator

SolarTec ource270

CL100Surgicall luminator

SolarTec ource

100

WelchAllyn Lighting Products

4619

ordan

Road

Skaneatelesalls,NY 131

3-0187

PN:LB-MANCLSERVRev.A


2/52

Table

f Contents

G E N E R A LN F o R M A T T o N

- - - - - - 1 - 1

TECHNTCALELP NFoRMATToN

- -

1-1

S E R V I C EE N T E R S

- - - -

- - - - -

1 - 2

W A R R A N T Y

- . - - - - . 1 - 3

S Y S T E MY M B o L E S C R I P T I o N S

- - - - - - -

1 - 4

W A R N I N G SN D R E C A U T I o N S

- - - -

- - -

1 - 5

W a r n i n g

- - - - -

1 - 5

C a u t i o n -

- - -

1 - 5

O P E R A T I N GN S T R U C T I o N S

- - - -

1 - 6

Conlro ls

1 '6

P o w E R

N / O F F

w r r c H .

- ' - - - -

1 6

F | B E Ro R r - - - - - - 1 6

MULTI INKTMXPANSIoN

oRT-

NSTALLATIoN

NDUSE

oPTIONAL)

. - - - - - . . . - -1-7

L i c H T ] - T E N U A T T o N

o N T R o L

- - - -

- - - - - - - - - 1 - 7

LAMP IFENDrcAToR

- ' l -7

Pr inc ip les f Operat ion

-

1-8

L I G H To U R c E

- - - 1 - 8

R E P L A C E M E N TA M P S

- - - - - . - - - 1 - 8

PowER upplywrrHCoNTRoLLEcrRoNrcs

--- -

-1-8

M U L T | i N K T Mo R T A N DU L T rT N K T Mx p A N s r o No R T

-

- - - - - - - - - 1 - 8

S E R V T C E

- - - - - - - - -

1 - 9

C L E A N T N G

- - - - -

1 - 9

S U R G T C A LL L U M T N A T o R

. -

- - 1 - 9

M U L T |

T N K T M

x p A N s r o No R T

- - - - - - -

- - - - - - 1 - 9

T o o L SR E o U I R E D

- -

1 - 1 0

T R o U B L E S H o o T N G

- - - -

- - -

1 - 1 1

CL 100SuRGrcArLLUMTNAToR

- - - - -

1-11

CL 1OO URGICALLLUI\ , I INAToRISASSEMBLY

- - -

. . . - ' I -12

TEST

1: BLoWN

UsEs

-

- -

1-12

T E S T

2 :

1 O O A T T

P O W E RU P P T Y

- - - - - - - -

1 - 1 3

T E S T # 3 :o o L r N GA N

- -

. 1 - 1 3

TEST

4:

LED/OVEBTEMPWITCH

.

- - - - '

1.13


3/52

T E s r # s :M r c R o I N K @T B E RE s r

- - - - - -

- -

1 - 1 3

TEST#6: owER uppLy ALTBRAIoN

---- - -

1-14

CL 1OO URGICALLLUMINAToRISASSEMBLY

- - -

1.15

PoWERUPPLYEMoVAL

- -

1-15

P L A T F o R ME M o V A L

- - - - - - - -

1 - 1 6

F R o N TE Z E LE M o V A L

- - - - - - - -

1 - 1 6

FAN

DEFLECToREMoVAL 1 16

C H A S S I S

A N E M o V A L

' - - - - - - - -

1 - 1 7

LED/OVERTEMPARNESSEMoVAL

-.

- . .

-

1-17

LAMP ABLE EMoVAL

- - - -

1-17

INTERLoCK

wrrcH

RENtovAL

- - -

- '

1-18

PoWER NTRY ODULEEMoVAL

-.

- _

1-18

CL

100SURGTCALLLUMTNAToREPATF

ARTSrsr

-- -

- - - - -

1 -19

C L 3 0 0

S U R G T C A LL L U M T N A T o R

- - - - - - - ' l

2 5

CL 3OOSURGICALLLUMINAToRISASSEMBLY

- - -

1-27

T E s r # 1 : B L o w Nu s E s

- - - -

1 - 2 1

TEST 2: AuxrLrARy oARDNpurTERMTNALS

- - - -

' l-27

T E s r # 3 :

o o L r N G

A N

- - -

1 2 7

TEsr

#4:

LED

OPERAToN

---- -

1-27

TEST

5:

MIcRoLINK@ TBEREST

- - -

1-2A

CL 3OO

SURGICAL

IIUMINAToR

ISASSEMBLY

.. -

1-29

I N T E R N A Lo D U L EE M o V A L

- - - - -

- - - - - - 1 2 9

PoWER

UPPLYEMoVAL

129

P C B A

p A R r

o .A 4 - 1 0 6 7 0 )

E M o V A L

- - - - - - -

1 , 3 0

l G N r r o R

E M o V A L

. - - - - -

1 - 3 1

L|NE

TLTER

EMoVAL

-

- -

. -

1-31

CHASSISANREMoVAL

-- - -

1-32

P o w E R N T R Y o D U L EE M o V A L

- - - - - - - -

1 - 3 3

P L A T F o R ME M o V A L

- - - - - -

1 - 3 4

F R o N T E Z E LE M o V A L

- - - - -

1 - 3 4

B L o w E RA N E M o V A L

-

- - - - - - - - 1 - 3 4

L A M P A B L EE M o V A L

- - -

- - -

1 3 5

CL

300SURGTCALLLUMTNAToREPATRARTSrsr

-- -

- - - - -

1-36


4/52

G L o S S A R YF T E R N 4 S

- - - - - -

1 - 4 2

FINALNSPECTIoN

--

1-43

CL 1OO URGICALLLUMINAToR

-. .

-

1-43

CL3OO URGICALLLUMINAToR

. .

-

1-43

SPEcrFlcAroNS

---

1-45

T H E o R Y o FP E R A T I o N - - - - - 1 - 4 6

L r G H ro u R c E

- - - - - - 1 - 4 6

R E P L A C E M E N TA M P S

- - - - - - - 1 - 4 6

PowER

uppLy rrHCoNTRoLLEcrRoNrcs

--- - - -

1-46

M U L T I

I N K T Mo R T A N DU L T rT N K T Mx p A N S t o No R T

- - - - - - - - - - 1 - 4 6

C L 1 O O U R G I C A LL L U M I N A T o R

I R C U I T

I A G R A M

- - - - - - -

, I - 4 7

CL 3OO

SURGICAL

LLUMINAToR

IRCUIT

IAGRAM

.

-. - - - -

1-48


5/52

GENERAL

NFoRMATToN

TheWelch

Al lynCL

100

Surgical

l luminator

nd he WelchAl lynCL 300Surgicall luminator

rov ide

r i l l iant

i l luminat ionor he

physic ian

nd

surgeon. he amps

roduce

igh ntensi tyight ear lydent ical

o the spectrum

of

sunl ight .

pecia l

eaturesnclude

he abi l i tyo useei ther CogentOpt icsMicroLink@ iber r a convent ional

f ber

bundle.

TECHNTCALELPNFoRrvrATroN

Only

ul ly

ra ined nd

proper ly

quipped

ersonnel

hould

erform

l lserv ice nd eparrs,srng

enurne

replacement

arts

nd

correct

rocedures.

a i lure

o do so

wi l l nval idate

he

product

arranty

ndcould

compromise nstrument af ty and

performance.

Read ndunderstandl lsafetywarnings ndserv ice otes

pr inted

n hisServ ice anualandhe

Operat ing

Manuals,

ar t

number

B-IVAN-100W270W.

f

there s anydoubtabout ny

precaut ion

r

procedure,

or

phone

help. r o

order ddi t ionalopies f the Operat ing anual , ontact :

Customer Service

Welch Allyn, Inc.

4619Jordan

Road.

PO

Box 187

SkaneatelesFalls,NY 13153-0187 SA

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)

Whencal l ing,efer o the modelnumber hown

on

he data abel ,oundon he

backof

your

Surgicall luminator .

Technicalss is tances

contained

n

"Troubleshoot ing

on

page

11

of

th ismanual .

PN:LB-MAN

CLSERV

Bev.A


6/52

Welc$11ytt'

SeRvrce

ENTERS

lf

you

havean equipment

problem

hat

you

cannot esolve,

ou

may

call he

Welch

AllynServiceCenternearest

you

or

assistance.

echnical

ervice upport s

available y telephone n norma

business

ays

at the

phone

numbersis ted

elow. f

you

areadvisedo return

product

o WelchAl lyn or repai r

r

rout ine

marntenance,

schedulehe

reDair

i th

he servrce ente.nearesl

ou.

BEFORE

ETURNING PRODUCT

FORREPAIR OU

MUST OBTAINAUTHORIZATION ROMWELCH

ALLYN.AN RMA

(RETURN

MERCHANDISE

UTHORIZATION} UMBERWILL

BE GIVENTO YOU BY OUR

SERVICEPERSONNEL.

E

SURE

TO

NOTETHIS NUMBERON THE

OUTSIDEOF YOUR SHIPPINGBOX.

RETURNSWITHOUT

AN RMA NUMBER

WILL NOT BE ACCEPTED ORDELIVERY.

USA

CUSTOMERS

CANADA

CUSTOMERS

Welch Allyn, I nc.,

U.S.A.

Welch Allyn, Ltd.,

Canada

4619

ordanRoad

'160

Matheson lvd.E. ,Uni t#2

Skaneateles

al ls ,

Y 13153-0187

Miss issauga,

anada 4Z1V4

Tel:1-315-685-2993 Tel:

905-890-0004

Fax:

15-685-2999

Fax:

905-890-0008

INTERNATIONAL

USTOMERS

Welch

Allyn, GmbH

Welch Allyn,

Ltd., Singapole

Zollerstrasse 4

300 BeachRoad, 25-08

72417

JunEngen,Germany,

The

Concourse

fel:

011-49-7

77

9211-73

Singapore 99589

Fax.011-49-7477-9271-93

Tel:011 65-291-0882

Fax:

11-65-291-5780

WelchAllyn, Ltd.,

Australia

Welch Allyn,

China

Metro Center Room708, 22'/ lluang Pi Road,North

Unit5 38 SouthStreet

Central

Plaza

Rydalmere, SW

2116,Austra l ia

Shanghai00003

Tel :

11-61-294-183-155

PR.China

Fax:

11-61-294-183-650

Tel :

11-86-21-63279631

Fax. O11'86-21

6327

9632

Welch

Allyn, Japan

Bon Marusan

F,3-5-1Kanda

Jinbo-Cho,hiyoda-Ku

Tokyo

01-0051

Japan

Tel :

11-813-5217391

f ax.011 813-32617372

LATINAMERICAN

CUSTOMERS

MD Intemational

1

1300 N.W.41

st Street

Miami ,

FL33178USA

Tel:

-305-669-9003

Fax: -305-669-1971

1 2

WELCH

ALLYN


7/52

WARRANTY

Welch

Al lynwarrantshe CL300or CL 100

Surgical

l luminatorhen new to

be

ree

of defects

n mater ia l

nd

workmanship

nd o

pertorm

n

accordance ith

manufacturer's

pecificatrons hen subject o normaluse and

serv iceor

a

per iod

f one

year rom

dateof

purchase

romWelchAl lynor an author izedgent .WelchAl lynwi l l

e i ther

epai r

r replace nycomponentsound o be defect ive r

at

var iancerommanufacturer 's

pecl f icat ions

wi th in

his imeat

no

cost o the customer.t shal l e he

purchaser 's

esponsib i l i tyo return he nstrumento the

aurhor izedis tnbJtor ,gent .

r serv ice

epresentatrve.

WelchAllyn

warrants he lamp o be free of defects n materials nd workmanshipor a

period

of 6

months rom

the

dateof

purchase.

hiswarranty oesnotcover he amp or breakager a i lure ue o tamper ing, isuse,

neglect , cc idents,mpropernsta l lat ion,odi f icat ion,

h ipping,r rom mproper a intenance,ervrce,r

c leaning

rocedures.

Thrs

warranty s void f the instrument s not

used

n

accordance

ith manufacturer'secommendations

r

if

requi red

erv ices

performed

y other hanWelchAl lyn r anauthor izedgent .Purchaseate

determrnes

warrantyequi rements.o

otherexpress r mpl ied arranty s

grven.

PN:LB MAN

CLSERV ev.

A


8/52

Velc$1yt

'

SYSTEMYMBoL EscRtPTtoNs

aPxg

Attent ion: ead

Operat ing anualor Warnings, rec aut ions,nd nstruct ionsor Use

Caution

Hot

SurfaceArea

Ra^la^a t r , ,c6 ec l r ,4er t or l

250V

5A

WARNINGHigh ol tages

present

Symbol n

power

swi tch ndicates

ower

s of f when

pressed

Symbol

n

electr icalat ing igni f ies C mains

ower

High ntensi ty

ight

Protective arth

G

ound

Storage

emperature

ange

Maximum torage umidi ty

Type

BFequrpment, lass

Not

protected

gainst he

ingress

f

water

Manufactured

n accordance ith the relevant egulations nd

echnical

equirements

f

Japan.

A

A

A

5 A , 2 5 0 V

A

I

+

@

| - ^ .* l

| |f l

t4__l

@

tr

WELCHALLYN


9/52

WARNINGS ND PRECAUTIoNS

e

WARNING

/-\

l \

. Keeo ut o l reach f pat ient .

PN:LB-MAN

CLSERV

Rev.A

.

Notsui tableor use n

he

presence

f a f lammable nesthet ic ix ture i th a i ror

wi th

oxygen r

n i t rous

xide.

.

Disconnectrom the

patient

before he discharge f a cardiac efibri l lator.

.

ELECTRICAL

HOCK

AZARD. o not remove he oo cover

.

Rout inelyxaminehe

power

ordand

piug.

Do not

use

f nspect ioneveals

amage.

eplace nly

with approved ospital

rade

power

cordand

plug

with appropriate lectrical

ating.

.

Do not olace he exoosed istalend of the

Micro

Link@

Fiber

or

fiber

bundleattached o either

a

headlight

r otheraccessory.

ailure

o observe hese

precautions

may result n burns o skin,

c loth ing,

r other

mater ia lnadvertent ly

laced

n rontof the MicroLink@ iber r

iber

bundle.

.

High

energy

adiatedight

uided

hrough ndoscopes

ay

give

ise o h igh emperaturesn ront

of

the ight ut let nd o the ipot the nstrument.

.

Use care

not

to

point

he distalend of the

fiber

or

headliqht

irectly

t the eye when unit s operating.

The

br i l l iant

ight

utput

om

he uni tcancause ye

njury

er

RP27 1

( '1994

995Threshold imi t

ValuesorChemical ubstancesndPhysical

gent

nd

Biologicalxposurendices, inal

rat t

March

3 , 1 9 9 5 ) .

.

Applied

parts

attached o this equipment

hould

be

approved ) o the MedicalDeviceDirective

93/

42/EEC)

Europe),

) approved y a Nationally

ecognized esting

aboratory

United

States),

nd

3) by

a Standards ouncil f Canada ccredited

aboratory

Canada)

o the appropriate

edical tandards.

The

use of

non-approved

omponents

may compromise afety.

.

Dur ingi {e

hreatening

rocedures,

t s recommendedo have backup ight ource ndanaddi t ional

reolacementamo.

. The ight ourceamps rehighly ressur ized,nydamage r mproper andl ing aycause remature

fa i lure r explos ion f the

amp.

.

The ight

source

amps

are

hot immediately

fter use,

allow he lamp o cool or five

(5)

minutesafter

operation.

emperatures

eak

n the lightSources pproximately 0 seconds fter he LightSource s

powered

off.

r

CAUTION

lA

.

Donot

place

nythrngn opof heLight ource. o

not

store

iquid

bovehe

Light ource.

.

C logged r b locked ents

may

cause ightSource verheat ingnd

wi l l resul t n hermal

hutdown.

Keep

he LightSource lear

f any

obstruct ions.

.

Ful ly

lose he at tenuator

efore urning n he LightSource r whenoperat ionalut not

n

use.


10/52

Welc$11yn.

OPERATTNGNsrRucloNs

CONTROLS

PowERON/OFF wrrcH

Plug ospi ta l

rade

Power

Cord nto

a

grounded

Hospi ta l

Grade" r

"Hospi ta l

Use"

receptac le

o ensure

grounding

el iabi l i ty .

Press

Main Power

Switch ON

(l

pressed

n).

The ampwi l l

cont inueo operate nt i l the

power

wi tch

s moved

o the OFF

posi t ion

O

pressed

n). f

the

amp

cannot

be startedor stops operating

ee Section : Tro ubleshooting .

NOTE:

.

l t is normal

o hear l ick ing

10

pulses

r ess) ef re he amp s s tar ted.

. To nsureproperoperation, ait thirty(30) econdsbetweenon/offcycles.

F|BER oRT

To ncrease

he

versatility

nd

applicabilityf use, he LightSources redesigned

o use eithera

Micro

Link@

iber

or a t iberbundle ia he Mul t i

L inkrM ortandMul t iL inkrM

xpansion

ort .

Cable Gompatibility Table

For

ables i th no Mul t iL inkrM

xpansionort equi red:

1.

Close

he ight

t tenuator r u rn

he

Light

Source f f .

Multi Linkn Port

Multi Link-

ExpansionPort

MicroLink@ iber

Karl

Storz ACMI

Olympus

Wolf Dyonics

r 6

WELCHALLYN


11/52

2.

Connecthe

nstrument

ndof the

MicroLink@ iber r iberbundle o the nstrument.

3.

Insert ,

nt i l u l lyengaged

snap

ound),he Lrght ource nd

nto

he

Mul t i

L inkrM

ort .

4. Turn n L ight

Source.

Adjust he ight

t tenuatoro

the requi redl luminat ionevel .

MULT|L|NK'" ExpANsroN oRT lNsrALLATroNNo

UsE

(oproNAL)

CAUTION: TheMul t iL inkrM xpansionort onta ins

pt ical

lementshat

can

become

amaged

f

dropped

or

aouseo.

NOTE: TheMul t i

L inkrM xpansion

ortmust

be

ul ly

ngaged

nto

he LightSource efore

nsert ing iber

Bundle.

Touse he l\4ulti inkrM xpansion ortperform he followingoperations:

1.

Close he ight t tenuatorr turn h e LightSource f f .

2. Remove,f

any,

Micro

Link@

iber

r

iber

bundle

rom

he

Mul t i

L inkrM

ort .

3. Inserthe Mul t iL inkrM

xpansion

ort ,

ress

nd urnc lockwise nt i l

t locks nto

place.

4.

Connect he fiberbundle o the instrument.

5. Insert , nt i l u l lyengaged,

he

Light

Source

nd

of

the iberbundlento he Mul t iL inkrM xpansionort .

6. Turn n L ight

Source.

Adjust

he

ight

t tenuatoro the

requi redl luminat ionevel .

To remove

he Multi LinkrM xpansion ort

perform

he followingoperations:

1 . Turn

he LightSource f f .

2. Remove

he

iber

bundle.

3. Turn

\,4ulti

inkrM xpansion

ort

counter-clockwisentilunlocked nd remove.

LrcHTATTENUATToN

oNTRoL

Moving he l luminat ionheelup * in"r"ur" . l ight utput .Moving he wheeldown

-

reducesrgnt utput .

LAMP LrFE NDrcAToR

A

yel low

ndicator ight ocated n the conso lewi l l l igh twhen there s approx imate ly 0 hours

remain ing

n the

lamp. A

new

Replacement amp

shouldbe ava i lab le t th is

po in t .

Once he

remain ing

ourshave been exhausted he lamp w i l l tu rn o t f .

PN:

LB-MANCLSERV

REV.


12/52

Welc\Allyn.

PRINCIPLES F OPERATION

LtcHT ouRcE

The

Surgical

l luminators

onsis t

f anenclosure ousing high

ntensi tyamp,

ropr ietary

pt ical

lat form,

ser

controls

nd

ndicators,

nd a

power

supply

with

controlelectronics.Cooling

s

provided

ia nternal ans. In

the

event

hat the

fan(s)

malfunctions

r

if adequate

ir

low is

blocked

nd/or he internal emperature

f

the

device

exceeds he engineering

pecifications,n nternal hermal

protection

mechanismwill automaticallyhut off

power

o the

lamp. After

cooling, he Light

Sources

may

be

restarted.

REPLAcEMENTAMPs

The amps rehigh

pressure,

igh

ntensi ty nd ong i feLightSources. heyaremounted ntoa

patented

amp

f ix ture

hich s designedo

al lowbotheasyand apid xchange

n

he

ie ld

as

wel l

as ensur ing

rec ise

l ignment

to the optrcal lat form.

PowER

Supply

wrrx

CoNTRoLELEcrRoNtcs

All

he electricityo the LightSource s

controlledhrough he ON/OFF witch.

Power

o energize nd

operate

he

lamp, ans,and control

ircuitry s

provided

y a customdesigned,wattage egulated, witching

power

supply.

The

operational

ife

of the lamp

and

amp ife ndicator

re controlled

y

a

lampvoltagemonatoring

ircuit.

MuLr

LtNxn PoRT NDMULT| |NK* ExpANsr oN oRT

Internal,

o both he Multi LinkrM ort

and

Multi

LinkrM xpansion

ort,

are

patented

oupling pticsand

mechanics

designed o

produce

he highestoutput

powers.

Internalo the LightSources re ansand heatsinks esigned o

reduce

emperaturest the opt ical

oupl ing

oints

hereby

minimiz ing

he

possib i l i ty

f damageo

MicroLrnk@

Fiber nd berbundles.

1 B

WELCH

ALLYN


13/52

SERVTCE

CLEANTNG

1. Pr ior

o c leaning,urn he

power

wi tchOFEanddisconnect

ower

ource

rom

both h e LightSource nd

the wal lout let .

2.

Cleanhe external ur faces y wip ingwrtha c lothdampened i th 10%

bleach olut ion. O NOT

MMERSE.

r

Rout inelynspect

ndclean l la i r

ntakes

out lowsat he rear

f the chassis

or int

or otherdebr is .

.

Fol low he manufacturer 'snstruct ionshenCleaning

he

iber

bundles r accessor iessedwi th he ight

source.

3.

Wipe

he

power

ordwi th a c lothdampened i th 107o

leach olut ion nd

water.

DO

NOT IVIMERSE.

O

NOTRECONNECT

ET.

4.

DO NOTwipedownany e nses r windows.

5.

DO NOT

plug

he

power

sourcentoa wal lout let nt i l t s horoughly

ry.

SURGtcALLLUMtNAToR

The

consolemaybe c leaned s ing c lean of tc lothwi th

he

ol lowing

leaning gents:

Enzymat ic o lut ion

Enzol )

lsopropyl

lcohol

Hydrogen

eroxide

% USP

2% G utaraldehyde

olut ion

Soapand Water

' lOo/o

bleach otut ton

nd

water

CAUTION: Do notsplash leaninggents nto

any

openings,

eams r e lectr icalomponents.

MULT| |NK* ExPANsroNoRT

The outside urfacesmay

be cleaned

with

a soft cloth using he

following:

isopropyl lcohol

Soap

and

Water

The

glass

surfacesmay be cieaned y the followingmethods:

A cottonswab moistenedwith lsopropyl lcohol

Blow with

dry compressed ir

NOTE: Us e care n

cleaninghe optical

urfaces

f the

Multi

LinkrM xpansion

ort

o

prevent

cratches.

PN:LB-MAN LSERV ev.

1 - 9


14/52

'IVelc$;1*.

TooLsREoUIRED

.

Slotted crewdriver,ess

han6

"

long

.

#1 Phi l l ips

crewdr iver,ess han

6"

long

.

#2 Phi l l ips

crewdr iver,ess han

6"

long

.

Open

end

wrench

et- Engl ish r 5/16"

.

Needle ose

pl iers

.

Nut Dr iver et Engl ish

r 3/16" ,114",5116"

.

Nut Dr iver

et

Metr ic

or 1Omm

.

Deepwel l

socket etand

wrench

2)

CL

100

Surgicall luminator

.

Non-conduct ive

ot

adjust ingool CL

100

Surgicall luminator

.

Lightoutput

power

meterwith head.

Coherent asermate D or equivalent

meter),

HeadModel 1d10

CL

100

Surgical

l luminator

.

Laght utputmeter Labsphere odelFIMS-400P

r equivalenthatmeasuresn umens

CL300Surgical

llu-

minator

o

CaIbrateo

MS

Drgi ta l u l t imeter

DMM)

1 , 1 0

WELCHALLYN


15/52

ThouBLESHoorNG

CL 1o0 SURGTCALLLUMTNAToR

Symptom Cause

Remedy

Lamp ai ls o s tar t nd

fansarenot running.

No

power

o unit Check

ower

upply

ordandout let

Line

voltage s


16/52

Symptom Cause Remedy

Lo w

l ig t ou lpu l

DamagedMicroLink@ iber

or berbundle

Check ndsof MicroLink@ iber r iberbundle

for

damage.

eplace i t h new MicroLink@ iber

or iberbundle. o o

"Test

#5: MicroLink@ iber

Test"on

page

13.

Fiber

bundle

not connected

correctly.

Re-insert berbundle orrectly.

Lampnear

endof usable

i fe

lnsta l la 00W eplacementamp,model 0133.

Fi l ter

ssembly n

plat form

contamrnated.

Clean r replacei l ter ssembly s necessary.

Minors dirty.

Clean i rrors.

Brokenmirrors. Replace

latform.

Misal igned i r rors

possib le

if

unit suffersdamage)

lf abovesteps ail o improveoutput, eplace nd

retest

platform.

Dirty

or damaged

nternal

mooute.

Inspect, lean,and replace f necessary.

Fiber

undle

wi l l not

Installn LightSource

Not

a compat ib le

berbundle

See

Operat ing

Instruct ions"n

page

Use ompatib leundle esign

Insta l l /Femove

ul t iL inkrM

Expansion ort

See

Operatrng

Instructrons"

n

page

6

Multi

Lin

rMExpansion ort

insta l led

RemoveMulti LinkrM

xpansion

or t

Audib le

c l ick ingor

arc ing

ound

ur ing

he

lamp

gni t ion

rocess

No

problem

Normal

operation

Velc$11yn.

CL lOOSURGICALLLUMINAToRISASSEMBLY

NOTE: For all ests, emove9 screws rom top cover.

NOTE: Do not operateunit

with

the top cover emoved

or

more han 5 minutesor the unit

will

overheat.

TEST 1: BLowN

FUsEs

The

purpose

of this est is to determine he sourceof a short circuit ausing uses o blo w. Refer o the Block

Diagram n

page

7.

Replace

nd

retest he fuses. f

unit

unctionsnormally,nspect uses hat were blown. f solder s meltingout of

the end of the

fuse

and he

glass

s not blackened,

emove

and

replace

he

power

entry

module.This ault

occurs

when

he

prong

of the fuse holdermakes

poor

contactwith

the

fuse.The

prong

will lookdiscolored nd

pitted

where t contacts he fuse.

WELCHALLYN


17/52

l f

the

use

blowsagarn,nspect

he

power

supply nd he wi r ing or

damaged r burnt omponents. emove

nd

replace

ny

visually

efective omponents.

l f v isual

nspect ion

oes

not

y ie ld

nyevidence

f damage,emove nd eplace

ower

upply

nd etest .

IEST#2: lOOWATT PowERSUPPTY

Veri fy perat ingol tages

present

n

power

upply nput

erminals . onnectmeter nd

set

o vol tsAC

o J1 and

J2 erminals . hen

power

s

appl iedo the uni t , er i fy he

operat ing

ol tage

s displayedn the meter.NOTE:

Verify he lamp

accessdoor s closed.

lf voltage s

present,

eprace

nd retest

power

supply.

l f vol tages not

present ,

nspecthe

uses,

wi r ing,

ower

entrymodule,ine i l ter ,

nd

nter lock

wi tch.

TEST 3: CooLINGFAN

The

purpose

f this est ls to verify

he operatton f the lamp

cooling

an.

Visual ly

nspector a broken an.

When he uni t s

powered

p,

ook or

a fan not urning.f found, emove

op

cover nd nspectan.

Replace ny

broken

ans.

lf fan is inoperative

nd not broken,measure

usingDMM set for VoltsDC or 12VDC

n

fan

connector.

.

lf

voltage s

present,

eplace nd retest an.

.

lf voltag e s not

present,

eplace

nd

retest

power

supply.

IEST#4: LED/OVERTEMPwITcH

The

purpose

f

this

est

is

to veri iy

proper

operation

f the LED.

Visuallynspect hat LED/overtempwitch harness s connectedo the powersupply. erifycontinuity f wiring

andLEDwith DMM

set o the Diode

Scale.

MM

should ead

=

.7VDC.

.

l f

the DMM reading oesnot

match,

eplace

nd etest

he

LEDharness

r

l f

DMM reading atches

bove, eplace nd etest

he

power

uppty.

TEST 5: MIcRo

LINK@

IBEREsT

The

purpose

f this est is to verify

he operation f the Micro Link@ iber.

Wi th

he

l luminator

n,connecthe iberand

he

headl ight .

vera d is tance f at east ive eet ,

adjust he spot

dramete '

o the

argest

tze.

.

l f

the ntensi ty f l ight s not

consis tenthroughouthe ight

potand otat inghe dis ta l ndconnector oes

not

cause he shape o change,

he

headl ight

s he most ikely

ause f the

aul t

.

l f

the ntensi tys not

consis tent i th a l ternat ingight

nddark

ings

resent ,

he iber s broken

t the d is ta l

Over he samedistance, d just

he

headl ight

o the smal lest

iameter pot .At th isadjustment ,he headl ights

focused.

t anyspot r regular i t ies

re

present ,

o ld

he

headl ight

teady hi le otat ing

he

dista l

nd

black)

connector.

PN:

LB-MAN-CLSEBV ev.A

1 , 1 3


18/52

Welc\Allyn'

.

l f

the

location

f the

defectsmove, emove he fiber,

lean he

end

with

distilled ater, econnect

he unit,an d

test. Replace

he fiber f

detectsare still

present.

.

l f the location f the defects emainstationary,he fault s within he headlight.

TEST 6: PowER

SUPPLY AL|BRAT|oN

The

purpose

of this est is

to

verify

he operation

f the

power

supply.

Apply

power

o unit,once

he

lamp

ights, onnect

he DIVIV

set

o volts DC)

o the lamp

cable

wires

on the

power

upply. he

posi t ive

ead

f DMM

to the

HV+

erminal n

the

power

upply nd he negat iveead

f the

DMM to

the LampReturn

terminal n the

power

supply.WARNING: o not

connectDIVM o wi res

pr ior

o

turninghe

uni ton.When he amp gni tes,

here s

approximately5kV n he

erminals h ichcould amage

he

DMM. Moni tor

hevol tage

isplayedn he ukewhen

he LED i rs t urns

on.Ver i fyhevol tages

between

7.00

and18.00v.

'

l f the voltage s less

han 17.00VDC,emove

and replace

he

power

supply

or

return

he unit or recalibration.

l f the vol tage

s between 7.00VDC

nd18VDC,emove

nd

eplace

he amp ix ture.

o

lt the voltage s more

han 18.00DC,

ontact he WelchAllynTechnical

ervicesDepartment

t

1-31

-685-2993 r 1

315-685-4233,:00am-3:00pm(EST).

WELCHALLYN


19/52

CL

100

SURGTCAL

LLUMTNAToR

rsAssEMBLy

PowERSUPPLY EMoVAL

'l

. Bemove he 9 screwssecurinq he

toD

cover

and

remove

he

cover.

2. Removehe 3 screws rom he

bot tom

ide

of the back

pane.

3. Disconnect

i res rom

J1 andJ2 on he

power

upplv.

isconnect

an

connector

rom

J4.

4. Remove

he

2

screws

rom

the bottom chassis, ecuring he centerbaffle

see

igure

below).

Screws

secur ing enter

baffle o bottom

chasss

l C "

o o

w

5 .

6 .

Remove

he

nut hat

secureshe center af f le o the back

panel .

Pull

back

panel

out and move o the

platform

ide

of the chassi s o

garn

access o the backof the

power

supply.

PN:

LB

MAN'CLSERVRev.

A

1 1 5


20/52

Remove he two white lampcablewires and disconnect

he

4 wire

connector.

emove

he supplyand baff

e.

Remove h e 4

screws

rom

the corners f the

power

supply.Remove upply.

Reinsta l lat ions he reverse

rocess

i th

he

brownwire

going

o J1 and he blue

wire

going

o J2.

The onger

of the two

lamp

cable

wires

attaches o the

(+)

amp

HV erminaland he shorterwire attaches o the

(-)

amp

return.Refer o

"

Photo "

on

page

4

o connect he

HV+

and

amp eturn

terminals s shown.

PLATFoR'UEMovAL

'L

Remove

9 screwssecuring op coverand remove he cover.Remove he 5 screwssecuringhe front bezel o

the bot tom hassis nd

pul l

ront

panel

ut

rom

chassis .

emove

he

amp rom

he

plat form.

2. Remove he 2 screws rom

the

fan deflector

ssemblv.

3. Remove he

4

screws

rom

the cornersof

the

platf

rm.

4. As necessary,emove he 2

screws

rom

the

f lter

assembly.

5. Removehe

plat form.

einsta l lat ions he reverse

rocess.

nsta l l theront

bezel ndcheck

or

proper

movement

of attenuator. oosen

platform

screwsand repositron s necessary.

FRONT EZEL EMoVAL

1.

Remove9 screwssecuringop coverand remove he

cover.

Remove

he 5 screwssecuring he

front

bezel o


pul l

ront

panel

ut romchassis .

2. Remove

wires

rom

power

switchnotingwire localions. ushon

switch

rom

the

inside

o

remove he

switch

from

the bezel.

3. Usinga sharpknife,

emove

he blackRry from the LEDwires where t mounts

o

the tront

bezel.

Once

removed,

pplyacetone o the LEDand he front bezel o weaken he

glue

bond

and

remove he LED rom he

front bezel.

4. Installations

the

reverse

process.

o

attach he LED,ensureboth

panel

and LEDsurfaces re clean.Use

superglue,octite430 to mount

he

LED.

Use

RTV

ealantDow Corning 37 o seal he LED,

preventing

ny

l ight rom he l luminator

assing

hrough.

FANDEFLECTOREMOVAL

1.

Remove9 screwssecuring

op

cover

and

remove

he cover.

8.

9 .

Welc$;1yt

'

7 .

2 .

3 .

4 .

5 .

Remove

he 5 screws ecur inghe

ront

bezel o the bot tom hassis nd

pul l f ront anel

ut romchassis .

Remove he overtempswitch rom the fan

def

ector.

Carefully

emove

he

heat

shrink ubing

rom

the

fan

wiring harness.

Disconnect

he connector nd

remove t

from the

power

supply.

6.

Installations

the

reverse

process

with

install ing ew heatshrink ubingover an connector.

WELCHALLYN


21/52

4 .

5 .

CHAssrs

FANREMovAL

T. Remove

9 screwssecuring op cover

and

remove

he cover.

Remove

screwssecuring he

fan to

the back

p a n e .

2. Remove eat

shr inkubing rom he an

connector .

isconnect

nd

emove

he

wire

ies

rom he harness

t

the

plat form

mounts.Remove

he an.

3. Installations the reverse

process.

LED/OVERTEMPARNESSEMovAL

1. Remove

screwssecuring op coverand remove he

cover.

Remove

he 5 screws

securing he front

bezel o


pul l t ront anel

ut romchassis .

2.

Remove

he overtemp witch rom he fan

def

ector

assembly.

emove

he wire ie

f rom

he overtemp witch

harness t the platf rm.

Usinga sharp

knife, emove

he blackRTV rom the LEDwires where t mounts

o

the front bezel.Once

removed,

pplyacetone o the LEDand

he

ront

bezel o

weaken

he

glue

bondand

remove

he

LED rom

he

front bezel.

Remove he

3

wire

ties and

remove

he harness.

lnstallations

the reverse

process.

o attach

he

LED,

ensureboth he

panel

and he

LED

surfaces

re

clean.

Usesuperglue

loct i te

30)

o

mount

he LED.UseRTV ealant

Dow

Corning 37) o seal he LED

prevent ing

any

ight rom

he l luminatoro

pass

hrough.

ee

igure

elow

or rout ing

f

wi res.

LAMP

CABLE

EMovAL

1. Remove screwssecuring

he op coverand

remove

he cover.Remove he 3 screws

rom

the bottomof the

back

anel .

Removehe nut secur ing

enter af f le o the back

panel .

l ide ack

panel

o

the s ide.

PN:

LB-MAN-CLSERV ev.A 1 1 7


22/52

2.

3 .

4 .

Welc\ffiytt.

2.

Remove

he

nut rom

he wire ie c lamp ecunnghe

amp

cable o the bot tom hassis .

emovehe amp

cable

rom

the

power

supplyand remove he cable.

3. Insta l lat ions he reverse rocess i th he onger ablewrregoing o the HV+ erminal n he powersupply

andconnect inghe shorter i re o the LampReturn terminal .

iew

he uni t

rom

he

rear

ndcompare

he

HV+

and he

LampReturn are

connected s shown

n

"Photo

8" on

page

24.

INTERLoCKwtrcH REMovAL

1. Remove he 9 screws securino he toDcoverand

remove

he cover.

2. Disconnecthe wi res rom he nter lockwi tch.

3. Remove he two nuts rom the interlock witchand remove.

4. Instaliations

the reverse

process,

onnectinghe

wires

o the terminals

marked

COM and

NO.

PowERENTRYMoDULEREMoVAI

1.

Remove

9 screwssecuring he top coverand

remove

he cover.

Remove

he 3 screws

rom

the

bottom of the

back

panel.

Bemove

he

nut securing enterbaffle o the back

panel.

Remove

he

4

screws ecur inghe chassis

an.Remove

he

wires rom PEM.

Remove he two nuts securing he PElvl o the ba ck

panel.

Remove he

PEM.

lnstallations the rever se

process

with the tollowing equirements :

.

The starwasher s locatedbetween he PEM langeand he

painted

urface ideof the back

panel.

The

lat

washer s installed

n the othersideof the

panel

and

s

secured

with

the

nut.

Rotate he screw

so

that

you

can

ater nstall he

power

cord etainer.

The

brown

wire is

connected o

the terminalmarked

as

P on the PEM.The bluewire is connected o th e

terminalmarked s N on he PEN/] .he

green

wire rom he back

panel

s connectedo the

ground

ermi-

nalon he

PEM.

r 1 B WELCHALLYN


23/52

CL

100

SuRGrcArLLUMTNAToREpAtR

ARTS tsr

Part

Number

Description

Photo #

Bubble

#

Ouantity

9 0 1 3 3 l OOWREPLACEMENT LAMP

LB-MAN.1OOW27OW

MANUAL,

1OOW2TOW

OLARTEC

'l

A0-10756

PANEL, OTTOIV,

7OW

1 1

'l

A0-10768

LABEL,WARNING,LLUIVINATORS

1

2

1

A0-1

71

4

SCREW,

AINTED,

LS

1

3

1 2

101

0033

SCREW,8-32

3/8,PHPS

1 4

4

101-0022

scREW,

6-32

1/4,

PHSS

1 5

2

016-0005 XLS,

UIV ER, UBBER,

/8

1 6 4

1

1

0068

SEMS,

6-32

5i

16

PHPS

1

1

I

A0-10683

COVER,OEXLSCHASSIS 2

8 1

A0-107

1 KAPTONAPE,

OP

COVER,LS 2

9

1

A0-t

0828 PANEL,

RONT,

OLARTEC

]OOW

3

1 0 1

u50087

l OOWNTERNAL

ODULE SSEMBLY

3

1 t

1

u50081

l OOW ANDEFLECTOR

SSEMBLY

3 12

1

u50085

l OOW ILTE

ASSEMBLY

3

1 3

1

u50075

l

OOW LI GNED LATFORM

3

1 4

1

A0-1071

FAN,

CHASSIS,LS

3 1 5

1

A0-10856

PANEL,

BACKWAVEPATTERN

3

t o

1

213-0017 POWERENTRYMODULE/LINE ILTE ,

FUSED

3

1 7

'l

102-0012

KE S,

6.32,W/CONICAL

ASHEB

3

1 8

4

44-10650

WtRE

ARNESS,

N/OFF,OOW

3

'19

1

A4-10647

POWER

UPPLYLS

4

20

1

A0-10746

OVERTEMP/LED

W]TCHSSEMBLY 4

21 1

A0-10712

B A F F L E ,

E N T E R ,

L S

4

22

1

A0-'r0843

F O A M ,

GN

O R

4

40

1

1 0 1 - 0 0 6 2

SEMS, 6

32

X

9/16

PHPS

5

23

4

207

0007

G U A R D ,

A N ,

2 M M

5 24 1

105-0008 CORD,RETAININGLAMP 5

25

I

r06-0011

S T A N D O F F ,8 , . 7 5 1

5

26

4

208-0016

F U S E ,

AS H E E TI I

6

27

2

44-10465

WIRE, EM

ODIN

6

28 1

101-0073

SCREW, 8-32

3/4" , PHPS

6

29 4

0 1 0 - 0 0 1 6

TUBING,

EAT HRINK

/4"

BLACK

6

30 z . z a

I 0 1

0 0 6 1

SCREW,

4-40X114,HPS

6

31 4

1010038

PLUG,6 /25

7

32 1

PN:

LB-MAN.CLSERV eV.


24/52

Welc$11*.

Part

Number

Description Photo # Bubble

# Ouantity

104

0006

WASHEH,COLOH

COAI I )

7 33 1

1 4-0008

WASHER, EFRATED 7 1

104-0007

WASHER, LAT 7

35

1

102-0001

NUT,HEX

7

36

1

104-0019

W A S H E R ,4 t X I t R N A I

T O O T H

7 31 2

A0-10864

CABLE,

AMP,

OK

8 38

1

1 12-0001

C A B L E

I E ,

M A L L

"

8

39

8

1 2 4

WELCHALLYN


25/52

PHoro1

PHOTO

--.

( '

lc"

, ,

< - ; - 2

c

5

=---|'

e

- / ) .

"t-.......-o

a.--.-r

PN:LB MAN

CLSERV

Ev.

1-21


26/52

Welc$;1*'

PHoTo

1 9

1 2

1 0

1 1

PHoTo4

1 4 1 8 1 7 1 5

2 1

WELCHALLYN


27/52

23

?4

PHoTo

5

PHoTo6

3 1

30

PN:LB-MAN-CLSERV ev.A


28/52

Welc\ffi*'

PHoro7

PHoTo8

WELCHALLYN


29/52

CL 300 SuRGrcArLLUMTNAToR

Symptom Cause

Remedy

Lamp ai ls

o s tar tand

fansarenot running.

No

power

o un i t Checf

power

supply orda1dout le l

Linevoltage s


30/52

Welc\ffiyr..

Symptom

Cause

Remedy

Low lightoutput Filter

assembly n

platform

contamrnated.

Cleanor re place iltersas necessary.

Mirrorsare dirty. Clean

ne

mrrrors.

Broken i rrors.

Replace

latform.

Misal ignedirrors

possible

if

unitsuffers amage)

l f above

teps

ai l to mprove utput , eplace nd

retest

platform.

Damaged icro

Link@

iber

or berbundle

Check ndsof MicroLink@

iber

r

iber

bundle

f or damage.Replace ith new Micro Link@

iber

or

fiber

bundle.Go o

"Test

#5:

Micro Link@

iber

Test"

on

page

28 .

Fiber

bu

ndle

not connected

correctly.

Be-insert berbundle

orrectly.

Lamp

near

endof usable

i fe

Insta l l 270W eplacementamp,model90125.

Fiber

undle

i l l not

insta l l

n L ightSource

Not

a compatrb le

iber

bund le See

Operat ing

Instruct ions"n

page

6

Usecompat ib leundle es ign

Install/Remove

ulti LinkrM

Expansion ort

See

Operatrng

Instructrons"

n

page

6

Multi LinklMExpansion ort Be moveMul t iL inkrM

xpansion

ort

Audiblecl ickingor

arcrngound ur inghe

lampgnit ion

rocess

Noproblem

Normaloperation

WELCH LLYN


31/52

CL

300

SURGTGALLLUMTNAToR rsAssEMBLy

NOTE:

For

all ests, remove9

screws

rom

top cover.

NOTE: Do notoperate n i twi th he op cover emovedor more han5 minutes r he unrtwi l loverheat .

lEsT#1:

BLowNFUsEs

The

purpose

f th is est s o determinehe source f a short

i rcui t

ausinguses

o blow.

Refer

o the Block

Diagram n

page

8.

Replace

nd etest he uses. f uni t unct ions ormal ly ,nspectuses

hatwereblown. f solders mel t ing

ut of

the endof

the

use

and he

glass

s

not b lackened,emove nd eplace

he

power

entry

module. h is

aul toccurs

when

the

prong

of the fuse holdermakes

poor

contact

with

the

tuse.

The

prong

will lookdiscolored

nd

pitted

where t contacts

he fuse.

l f v isualnspect ion

oesnot

y ie ld

nyevidence f damage,

emove

2 andJ3 romauxi l iaryoard

blue

ndbrown

wires

hatconnect

CBA

uxi ary

oard

o the

power

supply. eplace

uses

and urnsystem n. Remove

ower

and nspectuses

.

l f

the

uses

areblown,

emove

nd

eplace

he PCBA

uxi l iaryoard

part

o .A4-10670).

.

l f fusesare ine, emove

nd

eplace

he

power

uppty.

TEsr#2:

AuxtLtARyBoARDNpur TERM|NALS

Veri ty perat ingol tages

present

n auxi l iaryoardnput ermrnals. onnectmeter

andset

o vol ts

AC o J1 and

J4

termrnals.

hen

power

s appl iedo the uni t

he operat ing

ol tage, er i fy

t

is

displayedn he meter.NOTE:

Verifv he lamo

accessdoor

s

closed.

lf voltage s

present,

eplace

nd retestauxiliary

oard.

lf voltage s

not

present,

nspect he fuses,wiring,

power

entry

module,

ine ilter,and nterlock witch.

NOTE: f

lamp s not

on and

vol tages

present ,

heck

f

he

power

upplys defect ive.

lEsr #3:

CooUNGFAN

The

purpose

f th is est s o ver i ty

he operat ionf the

amp

ool ing

an.

Visual lynspector

a brokenan.When he uni t s

powered

p,

ook or

a

fan not

urning.

f found,

emoveop

cover nd nspectan.Replace ny

broken

ans

l f fan s noperat ive

ndnotbroken,measure

srngDMM set

or Vol ts

DC or

l2VDC

on anconnectors,

l

T s or

the amp an

(exhaust)

ndJ101or he

power

upply

intake).

.

lf voltage s

present,

eplace nd retest an.

.

lf vo age s not

present,

eplace

nd

re-test

auxilrary oard.

IEST

#4:

LED OPERATIoN

The

purpose

f

this

est is to

verify

proper

operation f the LED.

Visual lynspecthatJ1 is

connectedo the auxi l iaryoard. er i fy ontrnui tv

f

wi r ing

nd

LEDwith

DMM set o

the

Diode

Scale. MM should ead

=

.7VDC.

PN:LB MAN-CLSERV

ev.


32/52

Welc$1yn.

.

l f the DMM r eading

oes

not match, eplace

nd etest he LED

harness.

.

f

DMM

reading atches

bove, eplace nd etest

he

auxi l iary

oard.

TEST 5: MIcRo LINK@ IBER EST

The

purpose

of this est is to verify he

operation f the

Micro

Link@

Fiber.

Wi th

he

l luminator

n,connect he iberand he headl ight . vera d is tance i at east ive eet ,adjust he spot

diametero the argest

ize.

.

l f the

ntensi ty

f

l ight

s not consis tent

hroughouthe

ight

potand

otat ing

he dis ta l ndconnector oes

not

cause he shape o change,he headl ights

he

most ikely

ause

J he aul t .

.

l f the ntensi tys notconsis tent i th

al ternat ing

ight

nddark

ings

re

present ,

he broken

iber s

broken

t

the d

sta l

nd.

Over he samedistance,djust he headl ighto the smal lest iameter pot .At th isadlustment ,he headl ights

focused.f

anyspot r regular i t iesre

present ,

o ld

he

headl ight

teady

whi le otat inghe

dista lend

black)

connector.

.

l f the location f the defectsmove, emove

he

fiber,

lean he end

with

distilled

water, econnect

he unit,an d

test.

Replace

he fiber f defectsare sti l l

present.

.

l f

the

location

f the defects emain

stationary,he

fault s within he headlight.

WELCHALLYN


33/52

CL 300 SURGICAL

LLUMTNAToR

rsAssEMBLy

NOTE: All servicing equires emoval

f the

top cover.Remove he 9 screwsand

remove

he cover.

INTERNALODULE EMovAL

1. Remove

he op cover.

2. Removehe rontbezel

y

removing

he

5 screws ecur inghe rontbezel o the bot tom hassis .

3. Pul l he nternal odule ut of the

plat form

ssembly.

4.

Installation

s the reverse

process

with the

flat

edgeson the

gray

portion

of the

internalmodule

aligned o

rt

wi l l t in to

he

recessed

rea f the

ront

panel

nd he

black ot n he

grayplast ic

o the bot tom ight .

PowERSUPPLY EMovAL

1. Bemove

he op cover.

2. Remove he front bezel

by

removing

he

5 screwssecuring he front bezel o the botto m chassis.

3. Removehe ai rductst rap ndai rduct .

4.

Removehe 5 wi res rom he PCBA

uxi l iary

oard

par t

o.A4-10670).

5.

Remove

he 7

wires

rom the

power

supply.

NOTE: u l l

r

pry

he wires t ra ight p.

Rocking

he

wire o remove t om he

power

upplymaydamagehe

termlnal 'solder

oint

on he

power

upply oard.

Pul i r

pry

wire erminal t ra ight p.

Do

not rock

o

remove.

Usebent iDneedle ose

ol iers

o

orv

he erminal f f .

Thehandle

f a screwdr iver

s

usedas he ulcrum.

PN: LB-MAN-CLSERV eV.


34/52

TVelc$1*.

6. Remove

he 4

screws

rom

he

power

upply nd

pul l the

supply ut of the ront

o

remove.

7.

Installations

the reverse

rocess

with

the

wires ocated

s forrows:

.

P1

on

power

upply o Jb

on

PCBA

par t

o.A4-10670)red

wire

.

P2A- Used

o confrgure

o 230voperat ion n ly

NOTUSED

.

P2

on

power

upply o J4

on

PCBA

parr

o.44-10670)

brownwire

.

P3

on

power

upplytoJ l

on PCBA

par t

o.44

10670) b luewire

.

P4

on

power

supply

blackwire from red/black

air

housed

n tubing

o

P5on

power

upply red

wire om ed/black

ai r

housedn

ubing

.

P11on

power

supply red

or

whi te

wire rom red/black

ai r

th tn

wire

pai r)

.

P12

on

power

supply blackwire from red/black

arr

thin

wire

pair)

PCBA

(PARr

No. 44-10670)

REMovaL

'1.

Remove

power

as noted

above.

2. Not

he

ocat ion

nd

emove

onnectors

romJ6,J7,

J9,J

10,

J

1

1 andJ12.

3. Usinga short#1

screwdriver,emove

he 4 screws rom

the corners f PCBA

part

no. A4-10670)

nd remove

PCBA.

4.

Insta l lat ions

he reverse

rocess.

se

he block iagrams s necessary

o

reconnect

he wi res.

See

igure

below

or

proper

wire routing.

WELCHALLYN


35/52

IGNIToR EMovAL

1. Remove

he op cover.

2.

Disconnect

he 2

lamp

ablewiresand he

red

andblack

wires om

he

gni tor .

ote he

wire ocat ions.

3.

Remove

screws,securing gnitor

module

o the centerbaffle.Screwsare

ocated

n the othersideof the

center

baff

e.

Installations

the

reverse

rocess.

NOTE:

because

he screwdriver ill not

directly

each he lower screws,

Insta l l ing

nd emovinghe screws nto he gni toro tap he

holes

r io r

o insta l l inghe

gni tor

n he uni twi l l

Reconnect

he

wires

as

ol lows

see

igure or

or ientat ion).

.

Redwire o the ower entermost erminal .

.

Blackwire

to the

lower

outermost ermina

4 .

5 .

-

lampcablewire o the op ef t erminal

shorter

i re) .

+ lampcablewire o the op r ight erminal

longer

i re) .

LINE FILTERREMOVAL

1. Remove he top cover .

PN: LB MAN

CLSERV

REv.


36/52

2. Remove he screws

ecur inghe center af f le o the back

panel

nd he

bot tom

hassis

see

igure e low).

XLSRubber umper

Welc$1ytt'

Hexhead

crew

secu

ing

center

batfleo sideof

bottom nassts

a

rentdr baffle o

bottom hassis

a

Screwsecuring

centerbaffle o

back

panel

3. Remove he wires rom both ends

of

the l ine i l ter.Note ocation f wires.

4. Remove he 2 screws

securing he

line i l ter

and

remove.

5.

Installations he reverse

rocess

with the

following equirements:

.

The

end of the fi l terwith 3 terminals s on the

platform

ideof the centerbaffle.

.

The

green

ground)

ire

goes

o the terminaldirectly

mounted o the metalsurtace.

.

The bluewires

go

to the terminals

nearest

he

fans

on both ends.

The brown wires

go

to the centermost

termrnals.

CHAssrs

FANREMovAL

'1

. Remove

he top cover.

2. Remove he 4 screwssecuring he fan and he wireguard.NOTE: o remove he fan rom he lampsideof the

uni t , emovehe anon the

power

supply

ide. o emove he amp

an,

push

he spl i t

grommet

hroughhe

centerbaffle, hen

pull

he

wires

out of

the

grommet.

3. Disconnecthe

fan

connector rom the PCBAAuxil iary oard

part

no.

A4-10670) nd

remove.

WELCH

ALLYN


37/52

4 . I n s t a l a t l o n i s t h e r e ve r s e p r o c e s s w i t h J 1 1f o r t h e f a n o n t h e l a m p s r d e a nd J l 0 f o r t h e f a n o n t h

supply ide.Route

he wiresas shown n igures

elow.

Wire Bout ing

n gni tor ndPCBA

(part o.44-10670) Chassis anWrreRout ing

The abel

n the amp

ide

an aces

ut , he abel n the

power

upply

ide

aces n

(see

igure

elow).

POWER NTRY

oDULEREMoVAL

T. Removehe op cover.

2. Remove

he 3 screwssecuring he

back

panel

o the

bottom

chassis nd he

1

screw back

panel

o center

baff e.

Remove

he 3 wi re erminalsrom

power

entrymodule.

Move

back

panel

as necessary

o

gain

access o

nuts

securing he

PEM

(power

entrymodule).

Remove uts rom

he PEMand emovemodule.

3.

4 .

5 .

PN:

LB-MAN.CLSERV eV.


38/52

Welc$11yr..

6. Installations

the

reverse

process

with the following equ irements.

.

The

ock

washer s inserted

between he

PEIV1

nd he

painted

ideof the back

panel.

.

The lat

washer s inserted etween

he

non-painted

ideof the back

panel

and he nut.

o

The

green

ground)

i re s

connectedo the erminalsolderedi rect lyo the metal ur face. hebluewire

is connected

o the terminal abeledN

and he brown

wire

to the terminalmarkedP

PLATFoRMEMoVAL

'1

.

Remove he top cover

and

remove

he lamp.

2. Remove

he front bezelby removing

he 5 screws hat secure t to the bottomchassis.Remove he internal

mooute.

3. Remove he two screws rom the air duct strapand remove he duct.

4. Remove he 4

screws securing he

plat{orm.

5. Removehe ampshroud om

he

plat form.

6.

Remove

he

plat form

nd

he hermistor ssemblyromJ12.

7. Installations

he

reverse

rocess.

When installing

he

platform,

erify hat he shroudduct, he strap,and he

internalmodule

are

nstalled.

eattachhe front bezel

and check

or

attenuator

wheel

alignment.

.

Botate

he

wheel

across ts adjustment angeand f

the

wheel moves reely,

ontinue,f

it

does

not

move

freely, oosen he platformscrewsand repositionhe platform o the wheel rotates reely.

FRoNT

EZEL EMoVAL

1.

Remove he top cover.

2. Remove

he 5 screws,

securing he

front

bezel o th e bottom chassis.

3. Noting he wire locations,

emove he wires rom

the

power

switch.

Push

out the

power

switch.

4.

Usinga sharpknife, emove

he black

RW from

the LED.Once emoved, pplyacetone o the areabetween

the LEDand

he

ront

panel

o loosenhe

qlue

bond.Removehe LED.

5. Installations the reverseprocesswith the LEDglued o the frontpanelusingLoctite430 or equivalent. nc e

set ,apply paque

ealant , ow Corning 37or equivalent ,o the

area

round

he

LED o

prevent

ight rom

the l luminator

assing

hrough

he LED.

BLowER ANREMovAL

1. Remove

he op cover.

2. Remove

he

front

bezelas

described reviouslv.

3. Removehe ai rductst rap

ndductas descr ibedbove.

I

-34

WELCH

ALLYN


39/52

4.

Remove lectr icalonnector

g

from PCBA

part

o .44-10670).

5. Removehe 2 nuts,

crews, ndspacershat

mount

he blower an o the

blower racket .

6 .

insta l lat ion

s he reverse

rocess

i th

he

ol lowingequi rements:

.

Spacers re nsta l led

n he screws etween he bracket nd he an.

LAMP

CABLE

EMoVAL

I Removehe

op cover.

2. Open he amp

access oor, p en he

atch,

nddisconnectable.

3. Disconnect

he ampcablewires rom he gni tor .

4 Pul l amocdble ut hrougl -he a 'np ccess oor.

5. Insta l lat ions

he

reverse

rocess

i th

he

ol lowing

equi rements.

.

Bemove he ny lonwire

ie

rom

he

amp

able.

Feed he wires hrough

he spacebetween he

line ilter

and he centerchassis.

Connect he shorterwire to the top left erminalon the ignitor.

Connect he

longerwire

to the top, right

terminal .nsta l lhe erminals etween

he

wo f latwashers

see

igure or

wire

out ing).

WireRout ing

n gnrtor ndPCBA

(part

o.44-10670)

PN: LB MAN CLSERVRev.A


40/52

Welc$11*'

CL 300 SURGTCALLLUMTNAToREPATRARTS rsr

PartNumber

Description

Photo # Bubble# 0uantity

901 5 27W REPLACEMN I LAMP

tB-MAN-1OOW27OW

MANUAL, 1

OOW2TOW

OLARTEC

'l

RM-LBL-023

LABEL,PROTECTIVEARTH

GROUND

'I

A0-10755

BETEL

27A

1

A0-10880

TOP

COVE

R,

LENGTHENED

2

1

A0-10797

EXTERNAL ODULEHOLDER, 7OW

3

1

A 0 - 1 0 7 1 4

SCREW,

AINTED,LS

4

I t t

A0-10768 LABEL,WARNING.LLUMINATOFS

2

5

1

101 -0033 SCREW,832X 3/8,PHPS 2

6

4

101-0022

SCBEW, 6-32X 1/4,PHSS

2

7 8

A0-10907

CHASSIS ASE

2

8

1

01-0068 SEMS,

6-32

5/16,

PHPS 2 9 8

016-0005 X L S , UM P ER , U BB ER ,/ 8

2 1 0

4

101,0062

SEMS, 6.32X 9/16PHPS

2 11 I

207-0007

G U A R D ,

A N ,

2 M M

2 12 2

105-0008 CORD, ETAININGLAMP

2 1 3

208-0016

F U S E ,

A S H E E T

I I

1 2

A0-10904 BACKPANEL

2

1 5

2 1 3 - 0 0 1 9

ROCKEBWITCH,N/OFF,HITE 3

1 6

1

A0-10906

BLOWERRACI..ET

3

1 7 1

A0- 10905

CENTER

BAFFLE 3

1 8

1

44 10670 PCBA, UXILIARY

3

1 9 1

218 003

IGNITOF,70WPI

3

20

1

A0-10864

CABLE,AMP, OK

3 21

1

105-0010 TENSION

WIRE

RETAINER 3 22

4

1 0 1 - 0 0 7 8

SCREW,4-40

1/4, HD,

tT82DG

3 23

1

44-10680 WIREHARNESS,ED/AU)?PS

3

24 1

1 1 2 0 0 1 CABLE IE,SMALL

"

3

2 5

,l

A0-1 81

DUCI NOZZLELOWER,7OW

4

26 1

A 0 - 1 0 8 1 4

STRAEAIR DUCT

4

2 7

'1

u501

7

27OWLAMP SHROUDSUB-ASSEN/LY

4

28

1

u 5 0 1 1 1 27OW DJUSTEDOWER UPPLY

4 29

,l

2 1 3 - 0 0 1 8 SWITCH,

NTERLOCK,

NGL

POLE

4 30

1

1A20012 KEPS, 6_32,

CONICAL

WASHER

4

3 1

3

21

0-0001

LIN

E

FILTER,

.04,

FLANGE 4

32

I

WELCH

ALLYN


41/52

PN:LB-MAN

CLSERV

Rev.A

Part

Number Description Photo# Bubble# 0uantity

1 0 1 - 0 0 5 9

SIMS,

#6-32 1i4PHPS 4

33

2

213-0017

POWER NIRYMODULE LINEFILTER,

F U S D

4

34

101-0084

SCREW,

6 THDFRMG,PHPS

4 35

4

u50123

2 7 O W N T E R N A LO D U L E U BA SSM B 4

36

u501 5 27OWFILTE ASSEMBLY

5

31

101

0061

SCREW, 4-40 1/4,PHPS

5

38

2

u501

27OOW LIGNED LATFORM 5 39

101-0073

SCREW,

8-32

3/4" ,

PHPS

5

4

44-10655

FAN,

ACK, WIRE, 7OW

6 4 1

2

A4-1067

WIREHARN SS, ILTEF/GFOUND

6

44-10673 WIREHARN SS,

WITCH/FILTER 6

A4-1Q67 WIREHARN SS, C/FILTER

6

44

1

09-0006

BUSHING,

PENED/CLOSED,

5OO

6

44 10675 WIREHARNESS,C/SWITCH

6

46

44 1

0465

W I R E , E MT O D I N

6

47 1

44-10676

WIRE HARNESS,FILTER/PS

6

48

1

44-10678 WIREHARNESS,UXTPS

7

A O

1

A4-10677 WIREHARN SS,

ON/OFF/AUX

7 50

1

101-0085

SEMS,

-40X

3/8,

PHPS 7

5 1

4

44-10683 FAN,BLOWER, EFLONWIRE 7

52

1

1 0 1 0 8 3 SCEEW, .40X 1 1/4" ,PHPS,S 7

53

2

106-001 SPACER,

4

UNI

hBD, 114

d,

1l4 l

7

54

2

1

02-0008 NUT,

KEP, -40, HEX

1 55

2

106-001

STANDOFF,

8, 751

7 56

4

102-0001 NUI

HEX

8 57

1

104 0007 WASHER, LAT

I 58

'I

104 0008 WASHER,

ERRATED 8 59

1

1 0 4 - 0 0 1 9 WASHLR,'4

EXILRNAL

OOTF

I

60 2

101-0038

P L U G , 6 / 2 5 8 61 1

1

04-0006 WASHER,OLOR OATED

I

62 1


42/52

Velc$11ytr.

PHoro1

PHoro2

9

11

1-3E

WELCHALLYN


43/52

PHoTo

3

PHoro4

1 7

5

8

30

33 32 34

PN:

LB-MAN LSERV

ev.


44/52

Welc$11ytt*

PHOTo

PHoro

6

WELCHALLYN


45/52

PHoro

7

PHOTo

PN:

LB-MAN LSEBVReV.


46/52

Velc\Allyn.

GLoSSARYoF

TERMS

AC Al ternat ing urrent

COM Found n power onnectors,wi tches, tc . . . ndicat ing ommonwire ermrnatron

DMM Digi ta l

u l t iMeter

Fiber

Opt icBundle

Any

of a

number

f

l ight ransmiss ionevices

haracter izedy useof

mul t ip le,

a i r

h in

strands

f cladded

lass

ibers.Used

o deliver ight ro m

il luminator ox o work area.

Leakage urrent Usual ly speci f ied

maximumamount of

a l lowable urrent o

pass

hrough

solated

electrical omponents

when

subiected

o

very high

electrical

otentials.

LED LightEmit t ing iode

Metal

Hal ide Any

of a

number

f

metal l ic ompounds,sual ly

odideshatareused

n

race

mounts

n

discharge ight sources.

vletalhalidesare incorporatedo

produce

he destredspectral

contentot the l ightsource.

NO Normal ly pen,

Found n swi tches

ndicat ingormal ly pen erminat to n.

PCBoard Pr inted i rcui t oard

PEM PowerEntryModule

FTV

RoomTemperatu re ulcanizing ilicone

TRMS

TrueRootMean

Squared

used o characterize

ccuracy f digital

multFmeters.

VDC Voltage

Direct

Current

Xenon

An

elemental

as

used commonly

used

n l ight ing

roducts.

Used as an

evaporant

suppressant

n ungsten alogen

amps

r

ight miss ionn

gaseous

ischarge

amps.

WELCHALLYN


47/52

FINAL NSPECTIoN

The

purpose

f

preventatrve

arntenances o

pro-act ively

educe r

e l iminate

uture

roblems.

eepinghe ight

sourcen

good

operat ingondi t ion

nsureshat

t wi l l

per form

el iably

ndsafely . very ix

o

twelve

months,

ou

s h o u l d :

NOTE:Perform ypot nd

ground

ont inui tyestson he unrt efore egin ninghe

inal nspect ion.

CL 100SuRGrcArLLUMTNAToR

1.

Set

TIME

o star t .

urn

n he SYSTENiI .egin he f teen

15)

minuteBURN-lN

er iod.

heck

or

he

ol low-

i n g :

.

Drd he

yel low

LED ight r ief ly?

.

Did he amp

star t?Cl ick ing efore he

amp gni tes snormal

10

cl icks r

ess).

o Are he ans unning?

2. Af ter he

f teen

1

) minute urn- innsert thePOWERTESTFIBERntothePort .

Open

he at tenuatorul ly

andmeasurehe ight utput .Rotate

he

proximal

nd o

maximize

ower

output nd

check he ol lowing:

.

Does he connector nsert

smoothly?

.

Does

he attenuatormove smoothly?

.

Does he LrghtOutputmeasure 750mi l l iwat ts?ight utput 375 s

considered

he endof the i feo f

the

amp.

. Turn he systemoff and on again3 more imes. Does t lightabruptly ndproperly?

l f test ing asPASSED,ont inue.f

uni t

a i ls

est ing,roubleshoots

necessary.

CL 3OO URGIcAtLLUMINAToR

IMPORTANTClicking efore he LAMP g nites s normal

10

clicks

or

less).Do not hot re-striken succession.

The LLUMINATORust emainl luminated

ora minimum f for ty- f ive

45)

econds ach imebeforeurning f f .

Wait hirty

(30)

econdsbetween

each

e-strike.

Turn

he

ILLUMINATOR

ff andon aoainhree13)more imes.The LLUMINATORust

emain

l luminatedor a

minimum f for ty j rve

45)

econds ich t rmebefore urning f f Usrng

TIMER,

ai t h i r ty

30)

econds etween

re-st r ikes.

l rck ingef re he LAMP gni tess normal

10

cl icks r ess) . oes t ight

prompt ly

nd

proper ly?

l f test ing asPASSED,ont inue.f uni t a i ls est ing,roubleshoots necessary.

1.

Set

TIME

o star t .

urn

n

ILLUMINATOR.

egin he i f teen

15)

minuteBURN-lN

er iod.

heck

or

he o l

lowrng:

.

Did he

yel low

LED

ight

r iefy?

.

Did he

amp

start?Cl ick ing ef re he amp gni tess normal

10

cl icks r ess) .

.

Are

he

ans unning?

PN:

LB-MAN-CLSEFV

ev.A

1-43


48/52

Welc\ffi*'

2. Af ter

he

i f teen

15)

minute urn- innsert he POWER ESTFIBERnto

he

Port .

Open he at tenuatorul ly

andmeasurehe ight

utput .Rotatehe

proximal

nd

o

maximize

ower

output

ndcheck he

ol lowing:

.

Does he connectornsertsmoothly?

.

Does

he attenuator

move

smoothly?

.

Does he LrghtOutputmeasure

361

umens?

ight utp ut 200 s consideredhe endof the i feof

the

lamp.

WELCHALLYN


49/52

SPEcIFIcATIoNS

Physical

S ize Weight CL100)

Slze

Weight

CL

300)

Space

Requirements

Finsh

Lamp

Lamp

Type

Power Requirements

E ectrical

Amperage

Salety Compliance

5 . 5 "H x 1 1 . 2 5 "W x 1 1 . 2 5 " / 9 . 0 1 b1 4 0 m m H 2 8 6 m m W 2 8 6 m m D / 4 . 0 k 9 )

5 . 5

H x 1 1 . 2 5 " W x 1 2 . 7 5 "

D / 1 ' 1 l b

1 4 0 m m H

2 8 6 m m W 3 2 4 m m D / 5 . 0 k 9 )

Minimum "

(51mm)

i rspace

roundop,backandsides

Painted urfaces

polyuretha

e

'100W

XenonAr c

270WShortArc

DC MetalHal ide

100-240 AC50/60H2

2.5Amps@ 120V

Surgical

l luminator

L

100)

4 Amps

@

120V

(Surgical

l luminatorL 300)

cD.

8737

U12601-1nded,CSAy'CAN-C22.2

o.601-1-M90,

lEC601-1

1988/EN0601- '11990Amend. ,

l E C 6 0 1 - 1 - 2 : 1 9 9 3 / E N0 6 0 1 - 1 - 2 : 1 9 9 3

C l a s s

) , I ST

1 0 0 11 9 9 2 ,

lEC601 -1 :1 96/EN 0601-2-1:1 96

IECClassification

TypeBF,

Class

Continuous

perat ion

PXO

The

CE

markon this

product

ndicates

hat

t has been

ested

o andconforms

with the

provisions

oted

wi th in he 93l42lEEC

edical ev iceDirect ivend89/336EEC

MCdirect ive.

EUContact :

European

egulatory anager

WelchAl lynLtd.

County

Meath,Republ icf l re land

Tel353 46 67700

Fax

353

46

27128

PN:LB MAN

CLSEBV

RCv.


50/52

Welc$11ytt.

THEoRY oF OPERATToN

LIGHT oURcE

TheLightSources onsis t f anenclosure ousing, high ntensi tyamp, ropr ietarypt ical lat form, ser

contro ls nd

ndicators,

nda

power

supply i th contro l lect ronics.

ool ings

provided

ia

nternal

ans. n he

event hat

he fan(s)malfunctions r

if

adequate

ir low is blocked nd/or he

internal emperature f the device

exceedshe engineer ingpeci f icat ions,n

nternalhermal

rotectron

echanism i l lautomat ical lyhuto f f

power

o the

ramp.

f ter

cool rng,

estar the Lrght ources.

REPLAcEMENTAMPS

The ampsare high

pressure,

igh

ntensity

nd

ong ife LightSources.

hey

are

mounted ntoa

patented

amp

l ix turewhich s

designed

o

al low

botheasy nd

apid

xchange

n

he

ie ld s wel las ensur ing

rec ise

|gnment

to the oDticalDlatform.

Powen Suppr-y

wrrH

CoNTRoL

LEcrRoNrcs

All he electricityo the LightSource

s

controlled

hrough he ON/OFF witch.

Power o energize nd operate

he

lamp, ans,and

control

ircuitry s

provided

y a customdesigned,

wattage egulated, witching

power

supply.

Theoperat ional

i fe

of the

amp

and

he amp i fe

ndicator

recontro l led

y a lamp ol tagemoni tor ing

i rcui t

MULT|LtNKn PoRT

ANDMULT|

L|NK*

ExpANSroN oRT

Internal,o both he multi LinkrM

ort

and

Multi LinkrM xpansion ort,are

patented

oupling

pticsan d

mechanics esigned o

produce

he

highestoutput

powers.

nternal

o the

Light

Sources

re ans and

heatsinks

designedo reduceemperatures

t the

opt ical

oupl ing

oints

hereby

minimiz inghe

possib i l i ty

f damage

o

MicroLink@

iber

nd

iberbundles.

1-46

WELCHALLYN


51/52

CL

100

SURGTCAL

LLUMTNAToR

rRcurr

DTAGRAM

100 40vAc

POWER

UPPLYLOCK

IAGBAM

LAI\,4PTERT

OUTPUT

O.ISHUTOWN

INPUT

@ 4VDC

t--r/ |

I I

LAI'/P

"\l

El\,41

FILTEB

&

FUSE

PN:LB MAN CLSERVBCv.

2 [email protected]


52/52

\Velc\ffi*'

CL 3OOSURGICALLLUMINAToR

IRCUIT IAGRAM

- :

= i----.*.

> E

c a - 3

Documents

WelchAllyn CL-300 Surgical Illuminator - Service Manual