Service Manual
Contents
1. Wireless 1 Service Manual Keeler 2415 P 7012 Removing the PCB 1 Carefully release the 4 clips retaining the PCB 30 taking care to lift the opposite side to the LED first Do Not adjust the potentiometers on the PCB they are set when the PCB is manufactured Issue A 07 07 2008 Page 5 Wireless 1 Service Manual Keeler 2415 P 7012 Control Box 1 Remove 4 off M2 5 x 10 Pozi Csk Screws 31 2 The Control Box can now be removed from the Headband Issue A 07 07 2008 Page 6 Wireless 1 Service Manual Keeler 2415 P 7012 Replacements Battery Contacts 1 2 Take the Housing Cover 13 Remove 1 off M1 6 Nuts 21 with 2 off M1 6 Washers 29 from each contact Remove 1 off Solder Tag 17 from each contact From the other side of the Housing Cover 13 remove 2 off M1 6 x 6 Pan Head Screw from each Nut Plate 23 and remove the Battery Contact 10 Fit the replacement Battery Contact 10 using 2 off M1 6 x 6 Pan Head Screw screwed from the front of the Housing Cover 13 Ensure that when the screws are tightened the Battery Contact 10 moves freely in its cut out Refit the Solder Tags 17 using 1 off M1 6 Washer 29 and 1 off M1 6 Nut 21 Issue A 07 07 2008 Page 7 Wireless 1 Service Manual Keeler 2415 P 7012 Microswitch PCB This section also covers replacement of the earlier Microswitch actuator which was an integral plastic finger on the Control Box This has been replaced by2. Keeler Wireless 1 Headband amp Charger Service Manual d ALWAYS READ THE INSTRUCTIONS A HALMA GROUP COMPANY Keeler Limited Clewer Hill Road Windsor Berks United Kingdom SL4 4AA Tel No 44 0 1 753 857177Fax No 44 0 1 753 830247 Issue A 07 07 2008 2415 P 7012 Keeler Wireless 1 Service Manual 2415 P 7012 CONTENTS Introduction Service Principles 1 Precautions 3 Headband 4 Disassembly 4 Open the Control Unit 4 Removing the PCB 5 Control Box 6 Replacements 7 Battery Contacts 7 Microswitch PCB 8 Headband 9 Control PCB 10 Reassembly 11 Control Box Wiring 11 Fit Comfort Pad 12 Fit Control Box 12 Fit Control PCB 13 Fit Housing Cover 13 Fit Control Knob 14 Spares 15 Spare Parts List 16 Headband Spares 17 Charger 18 Disassembly 18 Reassembly 18 Spare Parts List 19 Issue A 07 07 2008 Wireless 1 Service Manual Keeler 2415 P 7012 Introduction This manual covers servicing of both the Wireless 1 Headband and Wireless 1 Charger unit There are 2 versions of Headband The only difference is the method of connection to the Indirect Optics either directly wired into the Dimmer or by plug into the Dimmer unit Service Principles Where a sub assembly is specified the individual parts are not available as the assembly of the sub assembly involves the use of specific tooling jigs and adhesives Issue A 07 07 2008 Page 1 Wireless 1 Service Manual Keeler 2415 P 7012 Tools Require
3. a new Control Box and separate Microswitch Plunger If the Control Box has the integral actuator a Control Box Upgrade kit will be required 1299 P 7103 The current Microswitch PCB cannot be fitted to the earlier Control Box 1 Unsolder the Black and Blue wires from the Microswitch PCB 3 2 Remove the Microswitch PCB 3 by removing 1 off M2 x 5 Pozi Pan head Screw 2 and 1 off M2 Washer 8 3 Check if there is a separate Plunger If not an Upgrade Kit will be required 4 Check that the Microswitch Plunger 4 is in place 5 Fit the replacement Microswitch PCB using 1 off M2 x 5 Pozi Pan head Screw 2 and 1 off M2 Washer 8 6 Re solder the Black and Blue wires Pee BLUE RP1L 06473 gt 120mm LONG BLACK SOLDER WIRES TO P C B PADS SWITCH P C B Issue A 07 07 2008 Page 8 Wireless 1 Service Manual Keeler 2415 P 7012 Headband 1 Carefully remove the Comfort Pad 9 Double sided adhesive tape is applied during assembly to retain the pad in place until the Control Box is fitted 2 Remove 1 off M4 x 25 Pozi Screw 34 from the Headband Adjuster 35 joining it to the Extension Bar 15 3 It will now be possible to remove both sides of the Headband from the Mounting Plate 14 4 Feed both side of the replacement Headband into the Mounting Plate 5 Fit the Adjuster 35 through the back of the Mounting Plate 14 and fit it to the Extension Bar 15 with 1 off M4 x 25 Pozi Screw 34 6 Mesh
4. al Service Technical Service Keeler Ltd Clewer Hill Road Windsor Berks SL4 4AA Phone 44 0 1753 827110 Fax 44 0 1753 827114 Issue A 07 07 2008 Page 15 Keeler Spare Parts List ltem 1 oN O FP O DPD 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 Part No SP72 00001 SP12 05002 EP39 19822 EP39 19988 SP72 00003 EP39 70232 WP12 01007 EP39 15573 EP29 05664 EP29 05680 EP19 02365 EP29 05672 EP39 19021 EP79 10403 EP79 07618 EP79 10358 EP79 10374 2099 P 5010 NP11 60000 1299 P 7163 EP39 15602 SP11 65001 SP11 65002 SP70 80024 EP79 40899 WP11 61017 1945 P 5007 SP72 50002 EP39 19005 Issue A 07 07 2008 Description M2 x Csk PT Screw M2 x 5 Pozi Pan Hd Screw Microswitch PCB Microswitch Plunger M2 x 4 Pozi Pan Hd Screw Strain Relief Clamp M2 Washer Comfort Pad Battery Contact Adjusting Knob Housing Cover Mounting Plate Extension Bar Spring Solder Tag Knob Cap Ferrite bead Mk2 Headband Assy M1 6 Hexagon Nut Control Box Upgrade Kit Nut Plate M1 6 x 4 Screw M1 6 x 6 Pan Hd Screw No 8B x 12 7 Pan Head Screw Cable Tie M1 6 Washer Control PCB Assy M2 5 x 10 Screw Detent Plate Wireless 1 Service Manual 2415 P 7012 Page 16 Wireless 1 Service Manual Keeler 2415 P 7012 33 1202 P 5832 Cable Form 1299 P 7155 Fixings Marked above Headband Spares Item Part No Description TECHX HB1 Adjusting Knob Set TECHX HB2 Comfo
5. d Most of the tools required will be in standard electro mechanical toolkit Issue A 07 07 2008 Page 2 Wireless 1 Service Manual Keeler 2415 P 7012 Precautions Care should be taken to carry out any repair work on a clean soft surface to minimise damage to the outside of the unit Solvents should not be used for cleaning Anti static precautions must be used when servicing the electronic components in this product Issue A 07 07 2008 Page 3 Wireless 1 Service Manual Keeler 2415 P 7012 Headband Disassembly It is easier to work if the Optics Assembly and Browbar are removed by unscrewing the 2 knobs attaching the Browbar to the Headband and unplugging the cable from the Dimmer Block If the Control Unit is permanently wired to the Dimmer Block it is not recommended to disconnect the cable but to carefully protect the Optics Assembly whilst carrying out servicing The first level of disassembly is required for most repairs Open the Control Unit 1 Carefully using a sharp blade remove the Knob Cap 18 2 Remove the Screw 26 from the centre of the Adjusting Knob 12 3 Remove the Adjusting Knob 12 and the Detent Plate 32 4 Remove 8 off M2 x 8 Csk PT Screw 1 Note that these screws are fitted parallel to the ends of the Control Box 22 not perpendicular to the surface of the Housing Cover 13 5 The inside of the Control Unit is now exposed Contact B v 1 cost a ye Issue A 07 07 2008
6. d above Page 19
7. he screws holding the Control Box to the Mounting Plate RED ROUTED UNDER PCR 1 hi SS al SOLDER BOTH BLACK WIRES TO THIS CONTACT CONTACT 5 mi SOLDER BOTH RED iH WRES TO THIS Ls e 9 Issue A 07 07 2008 Page 11 Wireless 1 Service Manual Keeler 2415 P 7012 Fit Comfort Pad 1 Apply 2 pieces of Double Sided Adhesive Tape to the Mounting Plate 14 as shown 2 Ensure that the Headband Adjuster 35 is tightly fitted to the Extension Bar 15 3 Fit the Comfort Pad 9 from the rear of the Headband so that the edges fold over the front of the Mounting Plate with the bosses poking through the holes in the Pad and stick the Pad temporarily to the Mounting Plate S Fit Control Box 1 Offer the Control Box 22 to the Headband Assy ensuring that it is correctly orientated and that the Comfort Pad 9 is clear of the bosses on the Mounting Plate 2 Secure the Control box 22 to the Mounting Plate 14 with 4 off M2 5 x 10 Pozi Csk PT Screws 31 Issue A 07 07 2008 Page 12 Wireless 1 Service Manual Keeler 2415 P 7012 Fit Control PCB 1 Offer the Control PCB 30 into the Control Box by putting the LED into its hole first then pushing the PCB home until the retainers at each end cl
8. ick over the PCB 2 Fit the Foam Pad 5 over the outside face of the Control PCB if not already fitted Fit Housing Cover 1 Check that the wiring loom and Ferrite Beads are correctly placed as shown in Control Box Wiring above and that all wires are clear of the screw bosses 2 Fit the Spring 16 to the Control Box 3 Fit the Housing Cover 13 to the Control Box 22 and secure with 8 off M2 x 8 Pozi Csk PT Screws 1 Issue A 07 07 2008 Page 13 Wireless 1 Service Manual Keeler 2415 P 7012 Fit Control Knob 1 Itis important that the Headband adjustment is set up equally on both sides 2 Push the Extension Bar in and pull the Headband sides apart 3 Release the Extension Bar and move the Headband sides slightly together until the Adjuster meshes with the sides and the Extension Bar moves into position to have the Control Knob fitted 4 Place the Detent Plate 82 over the 2 pegs on the Housing Cover 13 5 Fit the Control Knob 12 over the Extension Bar 15 and secure it with 1 off M4 x 13 Pozi Pan head PT Screw 26 Ensure the screw is fully home by pressing on the Adjuster through the Comfort Pad 6 Fit the Knob Cap 18 Issue A 07 07 2008 Page 14 Keeler Wireless 1 Service Manual 2415 P 7012 Spares Spare parts can be supplied in accordance with the following list The parts indicated with are only available as part of a Fixings kit Current prices for spare parts are available from Technic
9. ing of the Adjuster with the Headband will be adjusted after the Control Box has been fitted Gy 2 positions Issue A 07 07 2008 Page 9 Wireless 1 Service Manual Keeler 2415 P 7012 Control PCB 1 Carefully unsolder 1 1 1 off Red wire and 1 off Black wire going to the fixed contacts in the Control Box 1 2 10ff each Red Yellow Brown and Blue wires from the Cableform to the Dimmer Block and Microswitch PCB 2 Solder the Cableform and Control Box wiring to the replacement Control PCB as shown below before fitting the PCB to the Control Box 1202 P 5832 EP79 40899 TWIST 1945 P 5007 WIRES FERRITE BEAD a TE a v Ee SSS Tr YELLO SSP Rw BLUE lt RPI1 06473 PLU BLACK 120mm LONG aq eee SOLDER WIRES TO P C B PADS SWITCH P C B BLACK lt RPL1 06406 EE RED RPI 06465 Go Y f TWIST WIRES G9 WIRES AROUND FERRITE BEAD ONCE EACH RED 250mm D DETAIL A Ss CONTACT A POS RED 3mm E SCHEMATIC WIRING DIAGRAM EP79 07618 FOR DETAILS OF WIRE ROUTING 2 SEE DETAIL B Do Not Adjust the 2 Potentiometers on the PCB These are adjusted during manufacture of the PCB Issue A 07 07 2008 Page 10 Wireless 1 Service Manual Keeler 2415 P 7012 Reassembly Control Box Wiring 1 Check that the wiring in the Control Box is as shown below and that the Ferrite beads 19 are correctly in place on the wiring Do not fit the Control PCB at this stage as access is required to fit t
10. rt Sleeve Set TECHX HB3 Browbar Knob Set Issue A 07 07 2008 Page 17 Wireless 1 Service Manual Keeler 2415 P 7012 Charger Disassembly Remove 4 off M3 x 10 Pozi Pan head PT Screws 7 Lift off the Back 10 Remove 5 off M3 x 8 Pozi Pan head PT Screws 6 Lift out the PCB 5 zee eos Reassembly 1 Check the Charger Front 2 Earlier versions were equipped with integral plastic springs These have been replaced by Metal Springs 4 If the plastic springs have failed an upgrade kit will be required This includes the Cover 2 2 off Springs 4 Screws 1 and Washers 3 2 Check the Spring Contacts 8 soldered to the PCB They should be perpendicular to the PCB 5 3 Offer the PCB 5 to the Front Cover 2 ensuring that all 4 Spring Contacts 8 fit through their relative cut outs 4 Secure the PCB 5 using 5 off M3 x 8 Pozi Pan head PT Screws 6 5 Offer the Back 10 to the main assembly and secure it with 4 off M3 x 10 Pozi Pan head PT Screws 7 Issue A 07 07 2008 Page 18 Keeler Spare Parts List ltem 1 N O oO A WO PD oO Part No SP12 05002 1945 P 7012 WP12 01007 EP39 19996 1941 P 5342 SP73 00002 SP73 00003 EP19 02381 1945 P 7010 Issue A 07 07 2008 Wireless 1 Service Manual 2415 P 7012 Description M2 x 5 Pozi Pan Head Screw Charger Front Assy M2 Washer Metal Spring PCB Assembly M3 x 8 Pozi Pan Head Screw M3 x 10 Pozi Pan Head Screw Back Fixings Marke
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