- Frank`s Hospital Workshop
Contents
1. 1 7 Principles Of Operation 1 8 LIGHT SOURCE 1 8 REPLACEMENT LAMPS 1 8 POWER SUPPLY WITH CONTROL ELECTRONICS 1 8 MULTI LINK PORT AND MULTI LINK EXPANSION PORT 1 8 SERVICE 1 9 CLEANING 1 9 SURGICAL ILLUMINATOR 1 9 MULTI LINK EXPANSION PORT 1 9 TOOLS REQUIRED 1 10 TROUBLESHOOTING 1 11 CL 100 SURGICAL ILLUMINATOR 1 11 CL 100 SURGICAL ILLUMINATOR DISASSEMBLY 1 12 TEST 1 BLOWN FUSES 1 12 TEST 2 100 WATT POWER SUPPLY 1 13 TEST 3 COOLING FAN 1 13 TEST 4 LED OVERTEMP SWITCH2. 1 43 CL 300 SURGICAL ILLUMINATOR 1 43 SPECIFICATIONS 1 45 THEORY OF OPERATION 1 46 LIGHT SOURCE 1 46 REPLACEMENT LAMPS 1 46 POWER SUPPLY WITH CONTROL ELECTRONICS 1 46 MULTI LINK PORT AND MULTI LINK EXPANSION PORT 1 46 CL 100 SURGICAL ILLUMINATOR CIRCUIT DIAGRAM 1 47 CL 300 SURGICAL ILLUMINATOR CIRCUIT DIAGRAM 1 48 GENERAL INFORMATION The Welch Allyn CL 100 Surgical Illuminator and the Weich Allyn CL 300 Surgical tiluminator provide brilliant illumination for the physician and surgeon The lamps produce high intensity light nearly identical to the spectrum of sunlight Special features include the ability to use either a Cogent Optics Micro Link Fiber or a conventional fiber bundle TECHNICAL HELP INFORMATION Only fully trained and properly equipped personnel should perform all service and repairs using genuine replacement parts and correct procedures Failure to do so will invalidate the product warranty and could compromise instrument safety and performance
3. WelchAllyn Service Manual CL 300 Surgical Illuminator SolarTec Source 270 CL 100 Surgical Illuminator SolarTec Source 100 Welch Allyn Lighting Products 4619 Jordan Road Skaneateles Falls NY 13153 0187 PN LB MAN CLSERV Rev A Table of Contents GENERAL INFORMATION 1 1 TECHNICAL HELP INFORMATION 1 1 SERVICE CENTERS 1 2 WARRANTY 1 3 SYSTEM SYMBOL DESCRIPTIONS 1 4 WARNINGS AND PRECAUTIONS 1 5 Warning 1 5 1 5 OPERATING INSTRUCTIONS 1 6 Controls 1 6 POWER ON OFF SWITCH 1 6 FIBER PORT 1 6 MULTI LINKTM EXPANSION PORT INSTALLATION AND USE OPTIONAL 17 LIGHT ATTENUATION CONTROL 1 7 LAMP LIFE INDICATOR
4. 1 27 TEST 4 LED OPERATION 1 27 TEST 5 MICRO LINK FIBER TEST 1 28 CL 300 SURGICAL ILLUMINATOR DISASSEMBLY 1 29 INTERNAL MODULE REMOVAL 1 29 POWER SUPPLY REMOVAL 1 29 PCBA PART 4 10670 REMOVAL 1 30 IGNITOR REMOVAL 1 31 LINE FILTER REMOVAL 1 31 CHASSIS FAN REMOVAL 1 32 POWER ENTRY MODULE REMOVAL 1 33 PLATFORM REMOVAL on mene eee R eS 1 34 FRONT BEZEL REMOVAL 9 1 34 BLOWER FAN REMOVAL 1 34 LAMP CABLE REMOVAL 1 35 CL 300 SURGICAL ILLUMINATOR REPAIR PARTS LIST 1 36 GLOSSARY OF TERMS oS sth et tess eae ss 1 42 FINAL INSPECTION 1 43 CL 100 SURGICAL ILLUMINATOR
5. FILTER 3 17 1 102 0012 KEPS 86 32 W CONICAL WASHER 3 18 4 A4 10647 POWER SUPPLY XLS 4 20 1 A0 10746 OVERTEMP LED SWITCH ASSEMBLY 4 21 1 A0 10712 BAFFLE CENTER XLS 4 22 1 A0 10843 FOAM IGNITOR 4 40 1 101 0062 SEMS 86 32 X 9 16 PHPS 5 23 4 207 0007 GUARD FAN 92MM 5 24 1 105 0008 CORD RETAINING CLAMP 5 25 106 0011 STANDOFF 8 75L 5 26 4 208 0016 FUSE 5A SHEET III 6 27 2 A4 10465 WIRE PEM TO DIN 6 28 1 101 0073 SCREW 48 32 X 3 4 5 6 29 4 010 0016 TUBING HEAT SHRINK 3 4 BLACK 6 30 2 25 101 0061 SCREW 4 40X1 4 PHPS 6 31 4 101 0038 PLUG 6 25 7 32 1 PN LB MAN CLSERV Rev A 1 19 WelchAllyn Part Number Description Photo Bubble Quantity 104 0006 WASHER COLOR COATED 7 33 1 104 0008 WASHER SERRATED 7 34 1 104 0007 WASHER FLAT 7 35 1 102 0001 NUT HEX 7 36 1 104 0019 WASHER 4 EXTERNAL TOOTH 7 37 2 A0 10864 CABLE LAMP 30K 8 38 17 112 0001 CABLE TIE SMALL 4 8 39 8 1 20 WELCH ALLYN 1 gt 2 t P 2 LB MAN CLSERV Rev 1 21 WelchAllyn 3 13 14 18 17 PHOTO 4 122 WELCH ALLYN 5 6 PN LB MAN CLSERV Rev WelchAllyn PHOTO 7 TZ yc Te 8 1 24 WELCH ALLYN CL 300 SuRGICAL ILLUMINATOR Symptom Cause Remedy Lamp fails to start and f
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7. 1 13 TEST 5 MICRO LINK FIBER TEST 1 13 TEST 6 POWER SUPPLY CALIBRATION 1 14 CL 100 SURGICAL ILLUMINATOR DISASSEMBLY 1 15 POWER SUPPLY REMOVAL 1 15 PLATFORM REMOVAL 1 16 FRONT BEZEL REMOVAL 1 16 FAN DEFLECTOR REMOVAL 9 1 16 CHASSIS FAN REMOVAL 1 17 LED OVERTEMP HARNESS REMOVAL 1 17 LAMP CABLE REMOVAL 1 17 INTERLOCK SWITCH REMOVAL 1 18 PowER ENTRY MODULE REMOVAL 1 18 CL 100 SURGICAL ILLUMINATOR REPAIR PARTS LIST 1 19 CL 300 SURGICAL ILLUMINATOR 1 25 CL 300 SURGICAL ILLUMINATOR DISASSEMBLY 1 27 TEST 1 BLOWN FUSES 1 27 TEST 2 AUXILIARY BOARD INPUT TERMINALS 1 27 TEST 3 COOLING FAN
8. Protective Earth Ground Storage Temperature Range Maximum Storage Humidity Type BF equipment Class Not protected against the ingress of water Manufactured in accordance with the relevant regulations and technical requirements of Japan WELCH ALLYN WARNINGS AND PRECAUTIONS WARNING A Keep out of reach of patient Not suitable for use in the presence of a flammable anesthetic mixture with air or with oxygen or nitrous oxide Disconnect from the patient before the discharge of a cardiac defibrillator ELECTRICAL SHOCK HAZARD Do not remove the top cover Routinely examine the power cord and plug Do not use if inspection reveals damage Replace only with approved hospital grade power cord and plug with appropriate electrical rating Do not place the exposed distal end of the Micro Link Fiber or fiber bundle attached to either a headlight or other accessory Failure to observe these precautions may result in burns to skin clothing or other material inadvertently placed in front of the Micro Link Fiber or fiber bundle High energy radiated light guided through endoscopes may give rise to high temperatures in front of the light outlet and to the tip of the instrument Use care not to point the distal end of the fiber or headlight directly at the eye when unit is operating The brilliant light output from the unit can cause eye injury per RP 27 1 1994 1995 Threshold Limit Values for Chemical Substances and Physical A
9. housed in tubing red wire from red black pair housed in tubing P11 on power supply red or white wire from red black pair thin wire pair P12 on power supply black wire from red black pair thin wire pair PCBA PART A4 10670 REMOVAL 1 Remove power as noted above 2 Not the location and remove connectors from J6 J7 J9 J10 J11 and J12 3 Using a short 1 screwdriver remove the 4 screws from the corners of PCBA no 4 10670 and remove PCBA 4 Installation is the reverse process Use the block diagrams as necessary to reconnect the wires See figure below for proper wire routing 1 30 WELCH ALLYN REMOVAL 1 Remove the top cover 2 Disconnect the 2 lamp cable wires and the red and black wires from the ignitor Note the wire locations 3 Remove 4 screws securing ignitor module to the center baffle Screws are located on the other side of the center baffle 4 Installation is the reverse process NOTE because the screwdriver will not directly reach the lower screws installing and removing the screws into the ignitor to tap the holes prior to installing the ignitor in the unit will make the task easier 5 Reconnect the wires as follows see figure for orientation e Red wire to the lower center most terminal Black wire to the lower outermost terminal lamp cable wire to the top left terminal shorter wire e lamp cable wire to the top right termina
10. longer wire LiNE FiLTER REMOVAL 1 Remove the top cover PN LB MAN CLSERV Rev 131 WelchAllyn 2 Remove the screws securing the center baffle to the back panel and the bottom chassis see figure below XLS Rubber Bumper 2 p 3 screws securing center baffle to bottom chassis Hex head screw 7 s securing center baffle to side of i bottom chassis Screw securing center baffle to back panel 3 Remove the wires from both ends of the line filter Note location of wires 4 Remove the 2 screws securing the line filter and remove 5 Installation is the reverse process with the following requirements The end of the filter with 3 terminals is on the platform side of the center baffle The green ground wire goes to the terminal directly mounted to the metal surface The blue wires go to the terminals nearest the fans on both ends The brown wires go to the center most terminals CHASSIS FAN REMOVAL 1 Remove the top cover 2 Remove the 4 screws securing the fan and the wire guard NOTE to remove the fan from the lamp side of the unit remove the fan on the power supply side To remove the lamp fan push the split grommet through the center baffle then pull the wires out of the grommet 3 Disconnect the fan connector from the PCBA Auxiliary board part no A4 10670 and remove 132 WELCH ALLYN 4 Installation is the reverse process with J11 for the fan on t
11. 1 Remove 9 screws securing the top cover and remove the cover Remove the 3 screws from the bottom of the back panel Remove the nut securing center baffle to the back panel Slide back panel to the side PN LB MAN CLSERV Rev A 1 17 WelchAllyn Remove the nut from the wire tie clamp securing the lamp cable to tne bottom chassis Remove the lamp cable from the power supply and remove the cable Installation is the reverse process with the longer cable wire going to tne HV terminal on the power supply and the shorter wire to the Lamp Return terminal View the unit from the rear and compare the HV and the Lamp Return are connected as shown in Photo 8 on page 24 INTERLOCK SWITCH REMOVAL 1 2 3 4 Remove the 9 screws securing the top cover and remove the cover Disconnect the wires from the interlock switch Remove the two nuts from the interlock switch and remove Installation is the reverse process connecting the wires to the terminals marked COM and NO Power ENTRY MODULE REMOVAL 1 Remove 9 screws securing the top cover and remove the cover Remove the 3 screws from the bottom of the back panel Remove the nut securing center baffle to the back panel Remove the 4 screws securing the chassis fan Remove the wires from PEM Remove the two nuts securing the PEM to the back panel Remove the PEM installation is the reverse process with the following requirements e star washe
12. 2 1993 EN 60601 1 2 1993 Class B JIS T 1001 1992 777 1EC601 2 18 1996 EN 60601 2 18 1996 IEC Classification Type BF Class Continuous Operation IPXO within the 93 42 EEC Medical Device Directive and 89 336 directive EU Contact European Regulatory Manager Welch Allyn Ltd County Meath Republic of Ireland Tel 353 46 67700 Fax 353 46 27128 mark this product indicates that it has been tested to and conforms with the provisions noted PN LB MAN CLSERV Rev 1 45 WelchAllyn THEORY OF OPERATION LIGHT SOURCE The Light Sources consist of an enclosure housing a high intensity lamp proprietary optical platform user controls and indicators and a power supply with control electronics Cooling is provided via internal fans In the event that the fan s malfunctions or if adequate air flow is blocked and or the internal temperature of the device exceeds the engineering specifications an internal thermal protection mechanism will automatically shut off power to the lamp After cooling restart the Light Sources REPLACEMENT LAMPS The lamps are high pressure high intensity and long life Light Sources They are mounted into a patented lamp fixture which is designed to allow both easy and rapid exchange in the field as well as ensuring precise alignment to the optical platform SUPPLY WITH CONTROL ELECTRONICS All the electricity to the Light Source is controlled through the ON OF
13. Install a 300W replacement lamp model 90133 Defective lamp cable discolored bent or broken prongs audible clicking heard Defective power supply discolored bent or broken prongs no audible clicking heard Lamp shuts off after operating for a few minutes and restarts after cooling Inadequate air flow for cooling Light Source over temperature Fan failure Replace and retest lamp cable Inspect wiring and if it is fine replace and retest power supply Allow 2 51mm clearance at back of unit insure that air intake outflow vents are clean and not blocked Allow unit to cool and then restart Go to Test 3 Cooling Fan on page 13 lluminator is overheating not due to clearance Verify operation of fans Clean fans and internal components of dust Lamp is at the end of life but amber LED is inoperative b Verify LED flickers on when it is first turned on If not go to Test 4 LED Overtemp Switch on page 13 Indicator light on and Lamp life exceeded Install a 100W replacement lamp model 90133 lamp shuts off Lamp cable defective Replace if prongs are discolored broken or bent Power supply out of calibration To go Test 6 Power Supply Calibration on page 14 Replacement Lamp will Lamp is not oriented correctly Rotate lamp 180 and re insert not seat into Light Source ncorrect Replacement
14. PHPS 5 40 4 A4 10655 FAN BACK 3 WIRE 270W 6 41 2 A4 10672 WIRE HARNESS FILTER GROUND 6 42 1 4 10673 WIRE HARNESS SWITCH FILTER 6 43 1 4 10674 WIRE HARNESS AC FILTER 6 44 1 109 0006 BUSHING OPENED CLOSED 500 6 45 1 A4 10675 WIRE HARNESS AC SWITCH 6 46 1 A4 10465 WIRE PEM TO DIN 6 47 1 4 10676 WIRE HARNESS FILTER PS 6 48 1 4 10678 WIRE HARNESS AUX PS 7 49 1 A4 10677 WIRE HARNESS ON OFF AUX 7 50 1 A4 10683 FAN BLOWER TEFLON WIRE 7 52 1 101 0083 SCREW 4 40 X 1 1 4 PHPS SS 7 53 2 06 0015 SPACER 4 UNTHRD 1 4 od 1 41 7 54 2 02 0008 NUT 4 40 HEX 7 55 2 06 0011 STANDOFF 8 75L 7 56 4 02 0001 NUT HEX 8 57 1 104 0007 WASHER FLAT 8 58 1 04 0008 WASHER SERRATED 8 59 1 04 0019 WASHER 4 EXTERNAL TOOTH 8 60 2 01 0038 PLUG 6 25 8 61 1 104 0006 WASHER COLOR COATED 8 62 1 PN LB MAN CLSERV Rev A 1 37 WelchAllyn 1 2 1 38 WELCH ALLYN 4 LB MAN CLSERV Rev 20 18 19 25 36 17 28 29 35 31 30 33 3234 WelchAltyn PHOTO 5 PHOTO 6 1 40 WELCH ALLYN 7 8 PN LB MAN CLSERV 61 WelchAllyn GLOSSARY OF TERMS AC COM DMM Fiber Optic Bundle Leakage Current LED Metal Halide NO PC Board PEM RTV TRMS VDC Xenon 1 42 Alternating Current Found on power connectors switches etc indicating Common wire
15. Read and understand all safety warnings and service notes printed in this Service Manual and the Operating Manuals part number LB MAN 100W270W If there is any doubt about any precaution or procedure for phone help or to order additional copies of the Operating Manual contact Customer Service Welch Allyn Inc 4619 Jordan Road PO Box 187 Skaneateles Falls NY 13153 0187 USA Telephone 1 315 685 2993 or 1 866 801 8428 FAX 1 315 685 2999 Techncial Assistance Telephone 1 315 685 4233 7 00am 3 00pm EST When calling refer to the model number shown on the data label found on the back of your Surgical llluminator Technical assistance is contained in Troubleshooting on page 11 of this manual PN LB MAN CLSERV Rev A 14 Welch Allyn SERVICE CENTERS If you have an equipment problem that you cannot resolve you may call the Welch Allyn Service Center nearest you for assistance Technical service support is availabie by telephone on normal business days at the phone numbers listed below If you are advised to return a product to Welch Allyn for repair or routine maintenance schedule the repair with the service center nearest you BEFORE RETURNING A PRODUCT FOR REPAIR YOU MUST OBTAIN AUTHORIZATION FROM WELCH ALLYN AN RMA RETURN MERCHANDISE AUTHORIZATION NUMBER WILL BE GIVEN TO YOU BY OUR SERVICE PERSONNEL BE SURE TO NOTE THIS NUMBER ON THE OUTSIDE OF YOUR SHIPPING BOX RETURNS WITHOUT AN RMA NUMBER WILL NOT BE ACCEPTED
16. adjust the headlight to the smailest diameter spot At this adjustment the headlight is focused If any spot irregularities are present hold the headlight steady while rotating the distal end black connector PN LB MAN CLSERV Rev A 143 Welch Allyn lt e If the location of the defects move remove the fiber clean the end with distilled water reconnect the unit and test Replace the fiber if defects are still present lf the location of the defects remain stationary the fault is within the headlight TEST 6 POWER SUPPLY CALIBRATION The purpose of this test is to verify the operation of the power supply Apply power to unit once the lamp lights connect the DMM set to volts DC to the lamp cable wires on the power supply The positive lead of DMM to the terminal on the power supply and the negative lead of the DMM to the Lamp Return terminal on the power supply WARNING Do not connect DMM to wires prior to turning the unit on When the lamp ignites there is approximately 25 on the terminals which could damage the DMM Monitor the voltage displayed on the fluke when the LED first turns on Verify the voltage is between 17 00 18 00 If the voltage is less than 17 00VDC remove and replace the power supply or return the unit for recalibration If the voltage is between 17 00VDC and 18VDC remove and replace the lamp fixture the voltage is more than 18 00DC contact the Welch Allyn Technical Servi
17. engaged into the Light Source before inserting Fiber Bundle To use the Multi Link Expansion Port perform the following operations 1 Close the light attenuator or turn the Light Source off 2 Remove if any Micro Link Fiber or fiber bundle from the Multi Link Port 3 Insert the Multi Link Expansion Port press and turn clockwise until it locks into place 4 Connect the fiber bundle to the instrument 5 Insert until fully engaged the Light Source end of the fiber bundie into the Multi Link Expansion Port 6 Turn on Light Source Adjust the light attenuator to the required illumination level To remove the Multi Link Expansion Port perform the following operations 1 Turn the Light Source off 2 Remove the fiber bundle 3 Turn Multi Link Expansion Port counter clockwise until unlocked and remove LiGHT ATTENUATION CONTROL Moving the illumination wheel up increases light output Moving the wheel down 7 reduces light output LAMP LiFE INDICATOR A yellow indicator light located on the console will light when there is approximately 50 hours remaining on the lamp A new Replacement Lamp should be available at this point Once the remaining hours have been exhausted the lamp will turn off PN LB MAN CLSERV Rev A 17 WelchAllyn PRINCIPLES OF OPERATION LiGHT SOURCE The Surgical llluminators consist of an enclosure housing a high intensity lamp proprietary optical platform user controls an
18. termination Digital Meter Any of a number of light transmission devices characterized by use of multiple hair thin strands of cladded glass fibers Used to deliver light from illuminator box to work area Usually a specified maximum amount of allowable current to pass through isolated electrical components when subjected to very high electrical potentials Light Emitting Diode Any of a number of metallic compounds usually iodides that are used in trace amounts in discharge light sources Meta halides are incorporated to produce the desired spectral content of the light source Normally Open Found on switches indicating normaily open termination Printed Circuit Board Power Entry Module Room Temperature Vulcanizing Silicone True Root Mean Squared used to characterize accuracy of digital muiti meters Voltage Direct Current An elemental gas used commonly used in lighting products Used as an evaporant suppressant in tungsten halogen lamps or light emission in gaseous discharge lamps WELCH ALLYN FINAL INSPECTION The purpose of preventative maintenance is to pro actively reduce or eliminate future problems Keeping the light Source in good operating condition ensures that it will perform reliably and safely Every six to twelve months you should NOTE Perform hypot and ground continuity tests on the unit before beginning the final inspection CL 100 SuRGICAL ILLUMINATOR 1 Set TIME to start Turn on the SYSTEM
19. ASE 2 8 1 101 0068 SEMS 46 32 X 5 16 PHPS 2 9 8 016 0005 XLS BUMPER RUBBER 5 8 2 10 4 101 0062 SEMS 86 32 X 9 16 PHPS 2 11 8 207 0007 GUARD FAN 92MM 2 a gt 105 0008 CORD RETAINING CLAMP 2 13 208 0016 FUSE 5A SHEET III 1 14 2 0 10904 BACK PANEL 2 15 1 213 0019 ROCKER SWITCH ON OFF WHITE 3 16 1 A0 10906 BLOWER BRACKET 3 17 i 0 10905 CENTER BAFFLE 3 18 1 4 10670 PCBA AUXILIARY 3 19 1 218 0003 IGNITOR 270 WPI 3 20 1 A0 10864 CABLE LAMP 30K 3 21 1 105 0010 TENSION WIRE RETAINER 3 22 4 101 0078 SCREW 4 40 X 1 4 FHD SLT 82DG 3 23 1 4 10680 WIRE HARNESS LED AUX PS 3 24 1 112 0001 CABLE TIE SMALL 4 3 25 1 1 0 10812 DUCT NOZZLE BLOWER 270W 4 26 1 0 10814 STRAP AIR DUCT 47 27 1 U50117 270W LAMP SHROUD SUB ASSEMBLY 4 28 1 050111 270W ADJUSTED POWER SUPPLY 4 29 1 213 0018 SWITCH INTERLOCK SNGL POLE 4 30 1 102 0012 KEPS 46 32 W CONICAL WASHER 4 31 3 210 0001 LINE FILTER 6 0A FLANGE 4 32 1 1 36 WELCH ALLYN Part Number Description Photo Bubble Quantity 101 0059 SEMS 86 32 X 1 4 PHPS 4 s 2 518077 POWER ENTRY MODULE LINE FILTER 4 d 1 101 0084 SCREW 6 THD FRMG PHPS 4 35 4 U50123 270W INTERNAL MODULE SUB ASSMB 4 36 1 050125 270W FILTER ASSEMBLY 5 37 1 101 0061 SCREW 4 40 X 1 4 PHPS 5 38 2 050115 2700W ALIGNED PLATFORM 5 39 1 101 0073 SCREW 88 32 X 3 4
20. Begin the fifteen 15 minute BURN IN period Check for the follow ing Did the yellow LED light briefly Did the lamp start Clicking before the lamp ignites is normal 10 clicks or less the fans running 2 After the fifteen 15 minute burn in insert the POWER TEST FIBER into the Port Open the attenuator fully and measure the light output Rotate the proximal end to maximize power output and check the following s Does the connector insert smoothly Does the attenuator move smoothly Does the Light Output measure gt 750 milliwatts Light output lt 375 is considered the end of the life of the lamp e Turn the system off and on again 3 more times Does it light abruptly and properly If testing has PASSED continue If unit fails testing troubleshoot as necessary CL 300 SURGICAL ILLUMINATOR IMPORTANT Clicking before the LAMP ignites is normal 10 clicks or less Do not hot re strike in succession The ILLUMINATOR must remain illuminated for a minimum of forty five 45 seconds each time before turning off Wait thirty 30 seconds between each re strike Turn the ILLUMINATOR off and on again three 3 more times The ILLUMINATOR must remain illuminated for a minimum of forty five 45 seconds each time before turning off Using a TIMER wait thirty 30 seconds between re strikes Clicking before the LAMP ignites is normal 10 clicks or less Does it light promptly and properly If testing has PASSED contin
21. F switch Power to energize and operate the lamp fans and control circuitry is provided by a custom designed wattage regulated switching power supply The operational life of the lamp and the lamp life indicator are controlled by a lamp voltage monitoring circuit MULTI LINK PORT AND MULTI LINK EXPANSION PORT Internal to both the multi Link Port and Multi Link Expansion Port are patented coupling optics and mechanics designed to produce the highest output powers Internal to the Light Sources are fans and heatsinks designed to reduce temperatures at the optical coupiing joints thereby minimizing the possibility of damage to Micro Link Fiber and fiber bundles 1 46 WELCH ALLYN CL 100 SuRGICAL ILLUMINATOR CIRCUIT DIAGRAM POWER SUPPLY BLOCK DIAGRAM FAULT CT BA 14VDC 100 240VAC FILTER VOLTAGE HV amp REGULATOR REGULATOR IGNITOR rq FUSE THERMAL SWITCH 100C NC LAMP ALERT CONTROLLER OUTPUT SHUT DOWN INPUT 2 VDC 0 8A PN LB MAN CLSERV Rev A 1 47 WelchAllyn CL 300 SURGICAL ILLUMINATOR CIRCUIT DIAGRAM on 34 dw 30 0N3 an 0 901 bv GHYOA Agvnixv 2 7 Dn ur
22. FOR DELIVERY USA CUSTOMERS Welch Allyn Inc U S A 4619 Jordan Road Skaneateles Falls NY 13153 0187 Tel 1 315 685 2993 Fax 315 685 2999 NTERNATIONAL TOM Welch Allyn GmbH Zollerstrasse 2 4 72417 Jungingen Germany Tel 011 49 7477 9271 73 Fax 011 49 7477 9271 93 Welch Allyn Ltd Australia Metro Center Unit 5 38 South Street Rydaimere NSW 2116 Australia Tel 011 61 294 183 155 Fax 011 61 294 183 650 Welch Allyn Japan Bon Marusan 3 5 1 Kanda Jinbo Cho Chiyoda Ku Tokyo 101 0051 Japan Tel 011 813 5212 7391 Fax 011 813 3261 7372 LATIN AMERICAN CUSTOMERS MD Internationa 11300 N W 41st Street Miami FL 33178 USA Tel 1 305 669 9003 Fax 1 305 669 1971 NA TOMER Welch Allyn Ltd Canada 160 Matheson Blvd E Unit 2 Mississauga Canada L4Z 1V4 Tel 905 890 0004 Fax 905 890 0008 Welch Allyn Ltd Singapore 300 Beach Road 25 08 The Concourse Singapore 199589 Tel 011 65 291 0882 Fax 011 65 291 5780 Welch Allyn China Room 708 227 Huang Pi Road North Central Plaza Shanghai 200003 PR China Tel 011 86 21 63279631 Fax 011 86 21 63279632 WELCH ALLYN WARRANTY Welch Allyn warrants the CL 300 or CL 100 Surgical Illuminator when new to be free of defects in material and workmanship and to perform in accordance with manufacturer s specifications when subject to normal use and service for a period of one year from date of purchase from Welch Allyn or an aut
23. ISASSEMBLY NOTE For all tests remove 9 screws from top cover NOTE Do not operate unit with the top cover removed for m TEST 1 BLOWN FUSES ore than 5 minutes or the unit will overheat The purpose of this test is to determine the source of a short circuit causing fuses to blow Refer to the Block Diagram on page 47 Replace and retest the fuses If unit functions normally inspect fuses that were blown If solder is melting out of the end of the fuse and the glass is not blackened remove and replace the power entry module This fault occurs when the prong of the fuse holder makes poor contact with the fuse The prong will look discolored and pitted where it contacts the fuse WELCH ALLYN If the fuse blows again inspect the power supply and the wiring for damaged or burnt components Remove and replace any visually defective components If visual inspection does not yield any evidence of damage remove and replace power supply and retest TEST 2 100 WATT Power SuPPLY Verify operating voltage is present on power supply input terminals Connect meter and set to volts AC to J1 and J2 terminals When power is applied to the unit verify the operating voitage is displayed on the meter NOTE Verify the lamp access door is closed If voltage is present replace and retest power supply If voltage is not present inspect the fuses wiring power entry module line filter and interlock switch TEST 3 COOLING FAN The purpose o
24. J12 7 Installation is the reverse process When installing the platform verify that the shroud duct the strap and the internal module are installed Reattach the front and check for attenuator wheel alignment Rotate the wheel across its adjustment range and if the wheel moves freely continue if it does not move freely loosen the platform screws and reposition the platform so the wheel rotates freely BEZEL REMOVAL 1 Remove the top cover 2 Remove the 5 screws securing the front bezel to the bottom chassis 3 Noting the wire locations remove the wires from the power switch Push out the power switch 4 Using a sharp knife remove the black RTV from the LED Once removed apply acetone to the area between the LED and the front panel to loosen the glue bond Remove the LED 5 Installation is the reverse process with the LED glued to the front panel using Loctite 430 or equivalent Once set apply opaque sealant Dow Corning 737 or equivalent to the area around the LED to prevent light from he illuminator passing through the LED BLOWER FAN REMOVAL 1 Remove the top cover 2 Remove the front bezel as described previously 3 Remove the air duct strap and duct as described above 1 34 WELCH ALLYN 4 Remove electrical connector J9 from part no 4 10670 5 Remove the 2 nuts screws and spacers that mount the blower fan to the blower bracket 6 installation is the reverse process w
25. Lamp Install a 100W replacement lamp model 90133 PN LB MAN CLSERV Rev A WelchAllyn Symptom Cause Remedy Low light output Damaged Micro Link Fiber or fiber bundle Check ends of Micro Link Fiber or fiber bundle for damage Replace with new Micro Link Fiber or fiber bundle Go to Test 5 Micro Link Fiber Test on page 13 Fiber bundle not connected correctly Re insert fiber bundle correctly Lamp near end of usable life Install a 100 replacement lamp model 90133 Filter assembly on platform contaminated Clean or replace filter assembly as necessary Mirrors dirty Clean mirrors Broken mirrors Replace platform Misaligned mirrors possible if unit suffers damage emn If above steps fail to improve output replace and retest platform Dirty or damaged internal module Fiber bundle will not install in Light Source Not a compatible fiber bundle Install Remove Multi Link Expansion Port Multi Link Expansion Port installed Inspect clean and replace if necessary See Operating Instructions on page 6 Use compatible bundle design See Operating Instructions on page 6 Remove Multi Link Expansion Port Audible clicking or arcing sound during the lamp ignition process No problem Normal operation CL 100 SuRGICAL ILLUMINATOR D
26. WELCH ALLYN SERVICE CLEANING 1 Prior to cleaning turn the power switch OFF and disconnect power source from both the Light Source and the wall outlet 2 Clean the external surfaces by wiping with a cloth dampened with 1096 bleach solution DO NOT IMMERSE e Routinely inspect and clean all air intakes out flows at the rear of the chassis for lint or other debris Follow the manufacturer s instructions when Cleaning the fiber bundles or accessories used with the light source 3 Wipe the power cord with a cloth dampened with 10 bleach solution and water DO NOT IMMERSE DO NOT RECONNECT WET 4 DO NOT wipe down any lenses or windows 5 DO NOT plug the power source into a wail outlet until it is thoroughly dry SURGICAL ILLUMINATOR The console may be cleaned using a clean soft cloth with the following cleaning agents Enzymatic Solution Enzol Isopropyl Alcohol Hydrogen Peroxide 3 USP 2 Glutaraldehyde Solution Soap and Water 10 bleach solution and water CAUTION Do not splash cleaning agents into any openings seams or electrical components MULTI LINK EXPANSION PORT The outside surfaces may be cleaned with a soft cloth using the following Isopropyl Alcohol Soap and Water The glass surfaces may be cleaned by the following methods cotton swab moistened with Isopropyl Alcoho Blow with dry compressed air NOTE Use care in cleaning the optical surfaces of the Multi Link Expansion Port to prevent scrat
27. ans are not running No power to unit Check power supply cord and outlet Line voltage is 90 VAC Refer to Hospital Engineering department Fuses blown Inspect replace and retest Go to Test 1 Blown Fuses on page 27 Safety interlock open Check and tighten slotted screw on lamp fixture access door Power supply or auxiliary board failure Go to Test 2 Auxiliary Board Input Terminals on page 27 Lamp fails to start and fans are running Lamp not in light source audible clicking heard Install a 270W replacement lamp model 90125 Defective lamp cable discolored bent or broken prongs audible clicking heard Replace and retest lamp cable Defective power supply discolored bent or broken prongs audible clicking heard Inspect wiring and if it is fine replace and retest power supply Lamp shuts off after operating for a few minutes and restarts after cooling inadequate air flow for cooling Light Source over temperature Allow 2 51mm clearance at back of unit insure that air intake outflow vents are clean and not biocked Allow unit to cool and then restart Fan failure lluminator is overheating not due to clearance Go to Test 3 Cooling Fan on page 27 Verify operation of fans Clean fans and internal components of dust amber LED is inoperative Lamp is at the end of life but Verify LED flickers on when it is
28. bility Press Main Power Switch ON I pressed The lamp will continue to operate until the power switch is moved to the OFF position O pressed in If the lamp cannot be started or stops operating see Section 8 Troubleshooting NOTE normal to hear clicking 10 pulses or less before the lamp is started insure proper operation wait thirty 30 seconds between on off cycles FiBER PORT To increase the versatility and applicability of use the Light Sources are designed to use either a Micro Link Fiber or a fiber bundle via the Multi Link Port and Multi Link Expansion Port Cable Compatibility Table Multi Link Port Multi Link Expansion Port Micro Link Fiber c Karl Storz 0 Olympus Wolf Dyonics ar For cables with no Multi LinkTM Expansion Port required 1 Close the light attenuator or turn the Light Source off 1 6 WELCH ALLYN 2 Connect the instrument end of the Micro Link Fiber or fiber bundle to the instrument 3 Insert until fully engaged snap sound the Light Source end into the Multi Link Port 4 Turn on Light Source Adjust the light attenuator to the required illumination level MULTI LINK EXPANSION PORT INSTALLATION AND USE OPTIONAL CAUTION The Multi Link Expansion Port contains optical elements that can become damaged if dropped or abused NOTE The Multi Link Expansion Port must be fully
29. ces Department at 1 315 685 2993 or 1 315 685 4233 7 00am 3 00pm EST 1 14 WELCH ALLYN CL 100 SURGICAL ILLUMINATOR DISASSEMBLY POWER SUPPLY REMOVAL 1 Remove the 9 screws securing the top cover and remove the cover 2 Remove the 3 screws from the bottom side of the back panel 3 Disconnect wires from J1 and J2 on the power supply Disconnect fan connector from J4 4 Remove the 2 screws from the bottom chassis securing the center baffle see figure below Screws 9 securing center ge baffle to bottom chassis 5 Remove the nut that secures the center baffle to the back panel 6 Pull back panel out and move to the platform side of the chassis to gain access to the back of the power supply M PN LB MAN CLSERV Rev A 1 15 WelchAllyn 7 Remove the two white lamp cable wires and disconnect the 4 wire connector Remove the supply and baffle Remove the 4 screws from the corners of the power supply Remove supply Reinstallation is the reverse process with the brown wire going to J1 and the blue wire going to J2 The longer of the two lamp cable wires attaches to the lamp HV terminal and the shorter wire attaches to the lamp return Refer to Photo 8 on page 24 to connect the HV and lamp return terminals as shown PLATFORM REMOVAL 1 Remove 9 screws securing top cover and remove the cover Remove the 5 screws securing the front bezel to the bottom chassis and pull front panel out from chassi
30. ches PN LB MAN CLSERV Rev A 1 9 WelchAllyn TOOLS REQUIRED e Slotted screwdriver less than 6 long 1 Phillips Screwdriver less than 6 long 2 Phillips Screwdriver less than 6 long Open end wrench set English or 5 16 Needle nose pliers Driver Set English or 3 16 1 4 5 16 e Driver Set Metric or 10mm Deep well socket set and wrench 2 CL 100 Surgical llluminator Non conductive pot adjusting tool CL 100 Surgical llluminator e Light output power meter with head Coherent Lasermate 1D or equivalent meter Head Model 1d10 CL 100 Surgical llluminator Light output meter Labsphere Model FIMS 400P or equivalent that measures in lumens CL 300 Surgical Ilu minator Calibrated RMS Digital Multimeter DMM 1 10 WELCH ALLYN TROUBLESHOOTING CL 100 SURGICAL ILLUMINATOR Symptom Cause Remedy Lamp fails to start and No power to unit Check power supply cord and outlet fans are not running Line voltage is lt 90 VAC Refer to Hospital Engineering department Fuses blown Inspect repiace and retest Go to Test 1 Blown Fuses on page 12 Safety interlock open Check and tighten slotted screw on lamp fixture access door Power supply failure Go to Test 2 100 WATT Power Supply page 13 Lamp fails to start and fans are running Lamp not in light source audible clicking heard
31. d indicators and a power supply with control electronics Cooling is provided via internal fans In the event that the fan s malfunctions or if adequate air flow is blocked and or the internal temperature of the device exceeds the engineering specifications an internal thermal protection mechanism will automatically shut off power to the lamp After cooling the Light Sources may be restarted REPLACEMENT LAMPS The lamps are high pressure high intensity and long life Light Sources They are mounted into a patented lamp fixture which is designed to allow both easy and rapid exchange in the field as well as ensuring precise alignment to the optical platform POWER SUPPLY WITH CONTROL ELECTRONICS All the electricity to the Light Source is controlled through the ON OFF switch Power to energize and operate the lamp fans and control circuitry is provided by a custom designed wattage regulated switching power supply The operational life of the lamp and lamp life indicator are controlled by a lamp voltage monitoring circuit Mutt LINK PORT AND MULTI LINK EXPANSION PORT Internal to both the Multi Link Port and Multi Link Expansion Port are patented coupling optics and mechanics designed to produce the highest output powers Internal to the Light Sources are fans and heatsinks designed to reduce temperatures at the optical coupling joints thereby minimizing the possibility of damage to Micro Link Fiber and fiber bundles 18
32. e replace and retest the auxiliary board TEST 5 MICRO LINK FIBER TEST The purpose of this test is to verify the operation of the Micro Link Fiber With the illuminator on connect the fiber and the headlight Over a distance of at least five feet adjust the spot diameter to the largest size e If the intensity of light is not consistent throughout the light spot and rotating the distal end connector does not cause the shape to change the headlight is the most likely cause of the fault f the intensity is not consistent with alternating light and dark rings are present the broken fiber is broken at the distal end Over the same distance adjust the headlight to the smallest diameter spot At this adjustment the headlight is focused If any spot irregularities are present hold the headlight steady while rotating the distal end black connector f the location of the defects move remove the fiber clean the end with distilled water reconnect the unit and test Replace the fiber if defects are still present e If the location of the defects remain stationary the fault is within the headlight 1 28 WELCH ALLYN CL 300 SuRGICAL ILLUMINATOR DISASSEMBLY NOTE All servicing requires removal of the top cover Remove the 9 screws and remove the cover INTERNAL MODULE REMOVAL 1 Remove the top cover 2 Remove the front bezel by removing the 5 screws securing the front bezel to the bottom chassis 3 Pull the internal modu
33. f this test is to verify the operation of the lamp cooling fan Visually inspect for a broken fan When the unit is powered up look for a fan not turning If found remove top cover and inspect fan Replace any broken fans If fan is inoperative and not broken measure using DMM set for Volts DC for 12VDC on fan connector lf voltage is present replace and retest fan f voltage is not present replace and retest power supply TEST 4 LED OVERTEMP SWITCH The purpose of this test is to verify proper operation of the LED Visually inspect that LED overtemp switch harness is connected to the power supply Verify continuity of wiring and LED with DMM set to the Diode Scale DMM should read 7VDC If the DMM reading does not match replace and retest the LED harness If DMM reading matches above replace and retest the power supply TEST 5 MICRO LINK FIBER TEST The purpose of this test is to verify the operation of the Micro Link Fiber With the illuminator on connect the fiber and the headlight Over a distance of at least five feet adjust the spot diameter to the largest size lf the intensity of light is not consistent throughout the light spot and rotating the distal end connector does not cause the shape to change the headlight is the most likely cause of the fault lf the intensity is not consistent with alternating light and dark rings present the fiber is broken at the distal end Over the same distance
34. first turned on If not go to Test 4 LED Operation on page 27 Indicator light on and lamp shuts off Lamp life exceeded Install a 270W replacement lamp model 90125 Lamp cable defective Replace if prongs are discolored broken or bent Replacement Lamp will not seat into Light Source Lamp is not oriented correctly Rotate lamp 180 and re insert ncorrect Replacement Lamp Install 270W replacement lamp model 90125 PN LB MAN CLSERV Rev 1 25 WelchAllyn Symptom Cause Remedy Low light output Filter assembly on platform contaminated Clean or replace fiiters as necessary Mirrors are dirty Clean the mirrors Broken mirrors Replace platform Misaligned mirrors possible if unit suffers damage if above steps fail to improve output replace and retest platform Damaged Micro Link Fiber or fiber bundie Check ends of Micro Link Fiber or fiber bundle for damage Replace with new Micro Link Fiber or fiber bundle Go to Test 5 Micro Link Fiber Test on page 28 Fiber bundle will not install in Light Source Audible clicking or arcing sound during the Multi Link Expansion Port lamp ignition process 1 26 Fiber bundie not connected correctly Re insert fiber bundle correctly Lamp near end of usable life Install a 270W replacement lamp modei 90125 Not a co
35. gent and Biological Exposure Indices Final draft March 3 1995 Applied parts attached to this equipment should be approved 1 to the Medical Device Directive 93 42 EEC Europel 2 approved by a Nationally Recognized Testing Laboratory United States and 3 by a Standards Council of Canada accredited laboratory Canada to the appropriate medical standards The use of non approved components may compromise safety During life threatening procedures it is recommended to have a backup Light source and an additional replacement lamp The light source lamps are highly pressurized any damage or improper handling may cause premature failure or explosion of the lamp The light source lamps are hot immediately after use allow the lamp to cool for five 5 minutes after operation Temperatures peak in the light Sources approximately 60 seconds after the Light Source is powered off CAUTION Do not place anything on top of the Light Source Do not store liquid above the Light Source Clogged or blocked vents may cause Light Source overheating and will result in thermal shutdown Keep the Light Source clear of any obstructions Fully close the attenuator before turning on the Light Source or when operational but not in use PN LB MAN CLSERV Rev A 15 WelchAllyn OPERATING INSTRUCTIONS NTROL POWER ON OFF SWITCH Plug hospital grade Power Cord into a grounded Hospital Grade or Hospital Use receptacle to ensure grounding relia
36. he lamp side J10 for the fan on the power supply side Route the wires as shown in figures below Wire Routing on Ignitor and PCBA part no A4 10670 Chassis Fan Wire Routing POWER ENTRY MODULE REMOVAL 1 Remove the top cover 2 Remove the 3 screws securing the back panel to the bottom chassis and the 1 screw back panel to center baffle 3 Remove the 3 wire terminals from power entry module 4 Move back panel as necessary to gain access to nuts securing the PEM power entry module 5 Remove nuts from the PEM and remove module PN LB MAN CLSERV Rev A 1 33 WelchAllyn 6 Installation is the reverse process with the following requirements lock washer is inserted between the PEM and the painted side of the back panel e flat washer is inserted between the non painted side of the back panel and the nut The green ground wire is connected to the terminal soldered directly to the metal surface The blue wire is connected to the terminal labeled and the brown wire to the terminal marked P PLATFORM REMOVAL 1 Remove the top cover and remove the lamp 2 Remove the front bezel by removing the 5 screws that secure it to the bottom chassis Remove the internal module 3 Remove the two screws from the air duct strap and remove the duct 4 Remove the 4 screws securing the platform 5 Remove the lamp shroud from the platform 6 Remove the platform and the thermistor assembly from
37. horized agent Welch Allyn will either repair or replace any components found to be defective or at variance from manufacturer s specifications within this time at no cost to the customer It shall be the purchaser s responsibility to return the instrument to the authorized distributor agent or service representative Welch Allyn warrants the lamp to be free of defects in materials and workmanship for a period of 6 months from the date of purchase This warranty does not cover the lamp for breakage or failure due to tampering misuse neglect accidents improper installation modification shipping or from improper maintenance service or cleaning procedures This warranty is void if the instrument is not used in accordance with manufacturer s recommendations or if required service is performed by other than Welch Allyn or an authorized agent Purchase date determines warranty requirements No other express or implied warranty is given PN LB MAN CLSERV Rev A 1 3 WelchAllyn SYSTEM SYMBOL DESCRIPTIONS gt E gt gt ol gt M s lt o 01 E gt Attention Read Operating Manual for Warnings Precautions and instructions for Use Caution Hot Surface Area Replace Fuse as Marked 250V 5A WARNING High voltage is present Symbol on power switch indicates power is off when pressed Symbol in electrical rating signifies AC mains power High Intensity Light
38. ing voltage is present on auxiliary board input terminals Connect meter and set to volts AC to J1 and J4 terminals When power is applied to the unit the operating voltage verify it is displayed on the meter NOTE Verify the lamp access door is closed If voltage is present replace and retest auxiliary board If voltage is not present inspect the fuses wiring power entry module line filter and interlock switch NOTE If lamp is not on and voltage is present check if the power supply is defective TEST 3 COOLING FAN The purpose of this test is to verify the operation of the lamp cooling fan Visually inspect for a broken fan When the unit is powered up look for a fan not turning If found remove top cover and inspect fan Replace any broken fans If fan is inoperative and not broken measure using DMM set for Volts DC for 12VDC on fan connectors J11 is for the lamp fan exhaust and J10 for the power supply intake if voltage is present replace and retest fan If voltage is not present replace and re test auxiliary board Test 4 LED OPERATION The purpose of this test is to verify proper operation of the LED Visually inspect that J1 is connected to the auxiliary board Verify continuity of wiring and LED with DMM set to the Diode Scale DMM should read 7VDC PN LB MAN CLSERV Rev 127 WelchAllyn If the DMM reading does not match replace and retest the LED harness e If DMM reading matches abov
39. ith the following requirements Spacers are installed on the screws between the bracket and the fan LAMP CABLE REMOVAL 1 Remove the top cover 2 Open the lamp access door open the latch and disconnect cable 3 Disconnect the lamp cable wires from the ignitor 4 Pull lamp cable out through the lamp access door 5 Installation is the reverse process with the following requirements e Remove the nylon wire tie from the lamp cable Feed the wires through the space between the line filter and the center chassis Connect the shorter wire to the top left terminal on the ignitor Connect the longer wire to the top right terminal Install the terminals between the two flat washers see figure for wire routing Wire Routing on ignitor and PCBA part no A4 10670 PN LB MAN CLSERV Rev 1 85 WelchAllyn CL 300 SURGICAL ILLUMINATOR REPAIR PARTS LIST Part Number Description Photo Bubble Quantity 90125 27W REPLACEMENT LAMP 1 LB MAN 100W270W MANUAL 100W 270W SOLARTEC 1 RM LBL 023 LABEL PROTECTIVE EARTH GROUND 1 0 10755 BEZEL 270 1 1 1 0 10880 TOP COVER LENGTHENED 1 2 1 0 10797 EXTERNAL MODULE HOLDER 270W 1 3 1 0 10714 SCREW PAINTED XLS 1 4 18 0 10768 LABEL WARNING ILLUMINATORS 2 5 1 101 0033 SCREW 88 32 X 3 8 PHPS 2 6 4 101 0022 SCREW 86 32 X 1 4 PHSS 2 7 8 0 10907 CHASSIS B
40. k tubing from the fan wiring harness Disconnect the connector and remove it from the power supply Installation is the reverse process with installing new heat shrink tubing over fan connector WELCH ALLYN CHASSIS FAN REMOVAL 12 3 Remove 9 screws securing top cover and remove the cover Remove 4 screws securing the fan to the back panel Remove heat shrink tubing from the fan connector Disconnect and remove the wire ties from the harness at the platform mounts Remove the fan Installation is the reverse process LED OVERTEMP HARNESS REMOVAL 1 Remove 9 screws securing top cover and remove the cover Remove the 5 screws securing the front bezel to the bottom chassis and pull front panel out from chassis Remove the overtemp switch from the fan deflector assembly Remove the wire tie from the overtemp switch harness at the platform Using a sharp knife remove the black RTV from the LED wires where it mounts to the front bezel Once removed apply acetone to the LED and the front bezel to weaken the glue bond and remove the LED from the front bezel Remove the 3 wire ties and remove the harness installation is the reverse process To attach the LED ensure both the panel and the LED surfaces are clean Use superglue loctite 430 to mount the LED Use RTV sealant Dow Corning 737 to seal the LED preventing any light from the illuminator to pass through See figure below for routing of wires LAMP CABLE REMOVAL
41. le out of the platform assembly 4 Installation is the reverse process with the flat edges on the gray portion of the internal module aligned so it will fit into the recessed area of the front panel and the black dot in the gray plastic to the bottom right Power SUPPLY REMOVAL 1 Remove the top cover 2 Remove the front bezel by removing the 5 screws securing the front bezel to the bottom chassis 3 Remove the air duct strap and air duct 4 Remove the 5 wires from the PCBA auxiliary board part no 4 10670 5 Remove the 7 wires from the power supply NOTE Pull or pry the wires straight up Rocking the wire to remove it from the power supply may damage the terminal s solder joint on the power supply board Pull or pry wire terminal straight up Do not rock to remove Use bent tip needle nose pliers to pry the terminal off The handle of a screwdriver is used as the fulcrum PN LB MAN CLSERV Rev 1 29 WelchAllyn 6 Remove the 4 screws from the power supply and pull the supply out of the front to remove 7 Installation is the reverse process with the wires located as follows P1 on power supp P2A Used to con P2 on power supp P3 on power supp P4 on power supp P5 on power supp y to J5 on PCBA part no A4 10670 red wire igure to 230v operation only NOT USED y to J4 on PCBA part no A4 10670 brown wire to J1 on part A4 10670 blue wire black wire from red black pair
42. mpatible fiber bundle Install Remove Multi LinkTM Expansion Port See Operating Instructions on page 6 Use compatible bundle design See Operating Instructions on page 6 No problem Remove Multi Link M Expansion Port Normal operation WELCH ALLYN CL 300 SURGICAL ILLUMINATOR DISASSEMBLY NOTE For all tests remove 9 screws from top cover NOTE Do not operate unit with the top cover removed for more than 5 minutes or the unit will overheat TEST 1 BLOWN FUSES The purpose of this test is to determine the source of a short circuit causing fuses to blow Refer to the Block Diagram on page 48 Replace and retest the fuses If unit functions normally inspect fuses that were blown If solder is melting out of the end of the fuse and the glass is not blackened remove and replace the power entry module This fault occurs when the prong of the fuse holder makes poor contact with the fuse The prong will look discolored and pitted where it contacts the fuse If visual inspection does not yield any evidence of damage remove J2 and J3 from auxiliary board blue and brown wires that connect PCBA auxiliary board to the power supply Replace fuses and turn system on Remove power and inspect fuses e If the fuses are blown remove and replace the PCBA auxiliary board part no A4 10670 If fuses are fine remove and replace the power supply TEST 2 AUXILIARY BOARD INPUT TERMINALS Verify operat
43. r is located between the PEM flange and the painted surface side of the back panel The flat washer is installed on the other side of the panel and is secured with the nut Rotate the screw so that you can later install the power cord retainer brown wire is connected to the terminal marked as P on the PEM The blue wire is connected to the terminal marked as N on the PEM The green wire from the back panel is connected to the ground termi nal on the PEM WELCH ALLYN CL 100 SURGICAL ILLUMINATOR REPAIR PARTS LIST Part Number Description Photo Bubble Quantity 90133 TOOW REPLACEMENT LAMP 1 LB MAN 100W270W MANUAL 100W 270W SOLARTEC 1 A0 10756 PANEL BOTTOM 270W 1 1 1 A0 10768 LABEL WARNING ILLUMINATORS 1 2 1 A0 10714 SCREW PAINTED XLS 1 3 12 101 0033 SCREW 48 32 X 3 8 PHPS 1 4 4 101 0022 SCREW 86 32 X 1 4 PHSS 1 5 2 016 0005 XLS BUMPER RUBBER 5 8 1 6 4 101 0068 SEMS 86 32 X 5 16 PHPS 1 7 8 A0 10683 COVER XLS CHASSIS 2 8 1 A0 10727 KAPTON TAPE TOP COVER XLS 2 9 1 0 10828 PANEL FRONT SOLARTEC 100W 3 10 1 U50087 100W INTERNAL MODULE ASSEMBLY 3 11 1 U50081 100W FAN DEFLECTOR ASSEMBLY 3 12 1 050085 100W FILTER ASSEMBLY 3 13 1 U50075 100W ALIGNED PLATFORM 3 14 1 0 10711 FAN CHASSIS XLS 3 15 1 0 10856 PANEL BACK WAVE PATTERN 3 16 1 213 0017 POWER ENTRY
44. s Remove the lamp from the platform Remove the 2 screws from the fan defiector assembly Remove the 4 screws from the corners of the platform As necessary remove the 2 screws from the filter assembly Remove the platform Reinstallation is the reverse process Install the front bezel and check for proper movement of attenuator Loosen platform screws and reposition as necessary FRONT BEzEL REMOVAL 1 Remove 9 screws securing top cover and remove the cover Remove the 5 screws securing the front to the bottom chassis and pull front panel out from chassis Remove wires from power switch noting wire locations Push on switch from the inside to remove the switch from the bezel Using a sharp knife remove the black RTV from the LED wires where it mounts to the front bezel Once removed apply acetone to the LED and the front bezel to weaken the glue bond and remove the LED from the front bezel Installation is the reverse process To attach the LED ensure both panel and LED surfaces are clean Use supergiue loctite 430 to mount the LED Use sealant Dow Corning 737 to seal the LED preventing any light from the illuminator passing through FAN DEFLECTOR REMOVAL 1 2 Remove 9 screws securing top cover and remove the cover Remove the 5 screws securing the front bezel to the bottom chassis and pull front panel out from chassis Remove the overtemp switch from the fan deflector Carefully remove the heat shrin
45. ue If unit fails testing troubleshoot as necessary 1 Set TIME to start Turn on ILLUMINATOR Begin the fifteen 15 minute BURN IN period Check for the fol lowing e the yellow LED light briefly _ Did the lamp start Clicking before the lamp ignites is normal 10 clicks or less e Are the fans running PN LB MAN CLSERV Rev A 1 43 WelchAllyn 2 After the fifteen 15 minute burn in insert the POWER TEST FIBER into the Port Open the attenuator fully and measure the light output Rotate the proximal end to maximize power output and check the following Does the connector insert smoothly e Does the attenuator move smoothly Does the Light Output measure gt 361 lumens Light output 200 is considered the end of the life of the lamp 144 WELCH ALLYN SPECIFICATIONS Physical Size Weight CL 100 5 5 Hx 11 25 11 25 D 9 0lb 140mmH x 286mmW x 286mmD 4 0kg Size Weight CL 300 5 5 Hx 11 25 12 75 D 11 1lb 140mmH x 286mmW x 324mmD 5 0kg Space Requirements Minimum 2 51mm airspace around top back and sides Finish Painted surfaces polyurethane Lamp Lamp Type 100W Xenon Arc 270W Short Arc DC Metal Halide Power Requirements Electrical 100 240 VAC 50 60Hz Amperage 2 5 Amps 120V Surgical Illuminator CL 100 4 Amps 120V Surgical llluminator CL 300 Safety Compliance UL2601 1 2nd ed CSA CAN C22 2 No 601 1 90 1 601 1 1988 60601 1 1990 Amend 2 n IEC601 1
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