LS200 Procedure Light Service Manual
Contents
1. Mobile Stand 9 106119 9 Screw SHCS 2 5 Not Shown Mobile Stand 10 106105 2 Lockwasher Hel 1 4 x 20 Not Shown Used to Secure Item 8 Reference Figure 441146 Repair BOM 44210 REPAIR or 44250 REPAIR Page 7 6 Repair Parts Catalog L eee s EN KE tw meen Y Q s 2 TU am br de 1 si LELE A SIRES FO OE ROUTED Tunu ASSEMBIT A 1MDICATIOD BT MODELS 2 ALL MARDBADE FOR THiS ASSENGLT DRAVING MAS OMITTED site aumeres LOCATION BLER MOTER HUTS CHTEM 11 TO DE TOROUED 4 54 5 18 605 FORCE TO BOTATE TO BE 8 ILES 2 105 FORCE TO BE WEASURCO FROu 80 IN e TORO TO ROTANG TO BC 22 50 26 15 m TOROVI TO BL MEASURLO FROM o TO tai 3709 TOSQUL TO MOTAIC TO OE 17 4 26 3 1 05 CCS TORQUE 10 BE MLASURID rg Ing 3109 103 un 13200 ASSIMBLI AVSTAAL IA va b tdifude Ores on band ad 18 186240 200 eg Rac 18280 AMYL YAR Tri BH TEU e or fmi8 pe SOtm L32060 ASSEMBLY DOMESTIC rece bosas sasar tost Grann 1506 v tatt pm PR E 3 1 KU nom y na SECTION ASSINE 17 152048 FINAL aie tt 14 LA TIN L wrearee ML 1 SEE BC tail 6 OA OA GN l SSG 2 Q AN 22. 17 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING F TRANSFORMER ASSEMBLY amp TOCHECK FOR DEFECTIVE TRANSFORMER MEASURE input 120V 60HZ AND OUTPUT 12 6 VAC 2 VAC 5 Amps SEE DWG 441048 LOW OUTPUT INDICATES A DEFECTIVE TRANSFORMER HOWEVER EVEN A GOOD TRANSFORMER WILL PRODUCE LOW OUTPUT IF INPUT VOLTAGE IS BELOW REQUIREMENTS MEASURE BOTH LIGHT INTENSITY IS PROPORTIONAL TO CURRENT PASSING THROUGH THELAMP FILAMENT F 1 REMOVE BACK HOUSING DISCONNECTLS200 FROM MAINS REMOVE TRANSFORMER ASSEMBLY FROM POLE OF MOBILE STAND IF SO EQUIPPED REMOVE FOUR SCREWS AND REMOVE BACK HOUSING F 2 REMOVE OLD TRANSFORMER DISCONNECT FIVE 5 TRANSFORMER WIRES FROM POWER CONNECTOR AND SECONDARY CABLE GRAY CORD REMOVE TRANSFORMER STRAPS BY UNSCREWING FOUR PHILLIPS HEAD SCREWS LIFT TRANSFORMER OUT OF FRONT HOUSING F 3 INSTALL REPLACEMENT TRANSFORMER ALIGN TRANSFORMER WITH WIRES DOWN WITH THREE 3 PRIMARY WIRES TOWARDS THE POWER CONNECTOR THESE WIRES MUST PASS BETWEEN THE RIBS OF THE TRANSFORMER SUPPORT ALIGN STRAPS SO THAT HOLES IN STRAPS MATCH WITH HOLES IN TRANSFORMER SECURE THE TRANSFORMER WITH TWO STRAPS AS SHOWN ON ASSEMBLY DRAWING 441019 AND FOUR STRAP HOLDING SCREWS TIGHTEN SCREWS F 4 RESTORE ELECTRICAL CONNECTIONS CONNECT SPADE CONNECTORS OF TRANSFORMER PRIMARY WIRES TO TERMINALS OF POWER CONNECTOR AS SHOWN IN ASSEMBLY DRAWING BUNDLE THE THREE LINE SIDE WIRES TOGETHER
3. Late Ma 994 ES200 TASK LIGAT SCHEMATICS LAMP1 12 20 TRANSFORMER ISOLATED STEP DOWN LINE F1 Ti POWER SWITCH LAMP2 12V 20W NEUTRAL 120 60 HZ DPST LAMP3 12v eow GROUND DOMES LAMP1 12 20W TRANSFORMEA ISOLATEO STEP DOWN UINE F4 y POWER SWITCH LAMP 12v 20W 00 mA 1 NEUTRAL 240 VAC SO HZ av 7 DPST LAMP3 12V 20W GROUND INTERNATIONAL NOTES 1 OACAD FILENAME 44104BB1 SCH WELCH ALLYN INC SCHEMATIC 441046881 SCH LIBRARY 44104681 LIB PLOT 44194884 PLT ae i pr SE Title LS200 TASK LIGHT ELECTRICAL SCHEMATICS EE E PPAQ GN DATE 18 94 441048 APPENDIX The following items or their equivalent are required for the complete repair and testing of the LS200 Halogen Light E e he 13 14 15 COMMON TOOLS Description Screwdriver Phillips 1 Screwdriver Phillips 2 Screwdriver 7 32 5 5mm Flat Blade Strain relief tool HEYCO no 29 Pliers long nose 51 Pliers crimping Klein 1005 Pliers slip joint Channel Lock 420 Wire cutter Xcelite 107CG Wire stripper Xcelite 105SCG Hex key set Volt Ohm Meter with input impedance above I megohm EX BECKMAN 330 Alligator test leads kit Open end wrench 15 60 degree 15 16 Heat shrink gun 3 8 Nut driver SPECIAL WELCH ALLYN TOOLS Spring tensioning
4. WITH THREE TABS OVER THREE RECESSES IN THE LAMP HOUSING ALIGN TABS ON BEZEL WITH TABS ON LAMP HOUSING PLACE THE TETHER ONTO THE THREADED ROD OF THE CENTRAL BRACE THREAD THE NUT ONTO THE THREADED ROD AND TIGHTEN HAND TIGHT THREAD THE HANDLE ONTO THE THREADED ROD UNTIL IT CONTACTS THE BEZEL TIGHTEN THE HANDLE SLIGHTLY UNTIL THE BEZEL IS FIRMLY IN PLACE A 4 VERIFY REPAIR PLUG LS200 INTO MAINS AND TURN SWITCH TO ON POSITION ALL THREE LAMPS SHOULD BE LIT TURN OFF ALL LAMPS MUST TURN OFF TECHNICIAN NOTES 13 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING B HALOGEN LAMP REMOVAL AND REPLACEMENT R amp R PN 06400 OSRAM 44860sp or 44860nsp 12V 20W 12 degree spread DO NOT TOUCH HOT LAMP WARNING ALLOW LAMP TO COOL OFF FOR AT LEAST 20 MINUTES BEFORE TOUCHING LAMP OR SURROUNDING METAL PARTS NOTE REFER TO LAMP CHANGING DIAGRAMS IN OWNERS MANUAL 44118ML B 1 UNPLUG LS200 AND REMOVE BEZEL REMOVE POWER CORD FROM A C POWER SOURCE TURN THE UNIT FOR EASY ACCESS TO THE HANDLE AND UNSCREW HANDLE COUNTER CLOCKWISE LET THE BEZEL SWING AWAY TO EXPOSE LAMPS AND LAMP SOCKETS THE BEZEL WILL BE SUSPENDED BY THE TETHER DO NOT TOUCH HOT LAMP OR METAL PARTS NEAR LAMPS B 2 REMOVE LAMP AFTER A COOLING DOWN PERIOD OF AT LEAST 20 MINUTES LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET PULL THE LAMP HOLDING LEVER TOWARD THE BACK OF THE UNIT
5. Welch PN 06400 defective failed open switch CHECK voltage across switch pole pairs in closed position If full transformer voltage 1 present then the switchis OPEN electrically REPLACE defective switch TEST defective transformer primary or secondary windings or defective or failed OPEN thermal protection device in transformer primary winding for international LS200 CHECK for continuity in transformer primary winding REPLACE if non resetting type does not reset upon cooling OPEN circuit in power connector REPLACE defective component power cord damaged REPLACE cord COMPLAINT CONDITION Light output is very INDEX FAILURE CAUSE LS200 ELECTRICAL CAUSE CORRECTIVE ACTION Wrong lamp s voltage rating above low all lamps lit 12 volts REPLACE with PN 06400 lamp s not properly aligned in holder INSPECT ADJUST bezel not installed properly CHECK AND ALIGN three clear round sections of bezel directly over the lamps dirty glass filters on bezel assembly CLEAN defective transformer MEASURE secondary voltage at transformer input 120V 60HZ output 12 6 VAC 2 VAC 5 Amps OR at lamp holder 12 0 3 See drawing 441048 Low output indicates defective transformer However even a good transformer will have low output when provided with low input voltage MEASURE both voltages Light intensitv is proportional
6. plus how to do it technique statement before starting the repair or practice Training for the LS200 should consist of detailed demonstrations of required repair tasks practice LS200 S using repair tooling and materials Assess skill development through observation of trainee practice on actual equipment Set up sessions to allow the trainee to practice the use of the diagnostic repair adjustment and re testing procedures found in this manual The ability of the technician to develop and retain new skills 1 in great part dependent on well prepared training exercises Each trainee must have the opportunity to practice the procedure s after it has been demonstrated by the instructor More detailed background product information is found in the APPENDIX section and as such will be a critical element in comprehensive service training program for technicians IMPORTANT Welch Allyn part numbers and M material numbers appearing in this manual are for the purpose of familiarizing new technicians with Welch Allyn documentation conventions Order replacement parts as always by referencing your latest bill of materials parts catalog and assembly drawings Part number changes product updates or new test procedures should be noted on the appropriate page of this manual by the manual owner Notices announcing these changes should be attached to PRODUCT UPDATES APPENDIX WEAR EYE PROTECTION WHEN SER VICING THIS PRODUCT SAFE SERVIC
7. EE Ti UPPAT ASSEMBLE DOMESTIC LEG CONAECTOR iA BLACE me ee IEC COMRECTOR GREEN TECLONW Cutout VIKE WHITE LI C8 pre I ALA HARDWARE FOR HIS ASSIMBLT HAS BEEN OMITTED ITEM NUMBERS LOCATION BiA f HAVE BEEN MOTED OutPut FIRE BLACA FESTER Wei Aah av ees KO PIRES TO BE LOCATED 1 THIS AREA SEE TABLE FOR CONNECTION DETAILS SCREBS TO 6 TOROUED TO 2022 Im L BS SCREWS BE TORQUED 2022 6 165 ATEM i TIC RAP TO BE LOCATED tm 1 5 AREA OUTPUT CABLE FROM ARM ASSEMBLY 10 ROUTED TMROUGMH 11 8 STRAIN ALL IEF AND COMMECT EO AS tmDICATED ASS T POPE SUPPLI h ee ET 5 NW TAT a ee EE E ly To APPENDIX WIRING DIAGRAM SCHEMATIC 15200 schematic dwg 441048 wiring diagram dwe 441114 39 ry D PR eg APPAQVA Wi a MN k LS200 EXAM LIGHT WIRING DIAGRAM FUSES DOMESTIC 1 250v INTER O 54 250V LAMP RED QUICK CONNECTS 4 WAY CONNECTOR DETACHABLE POWER CASLE fe Fe OUTPUT CABLE AWG 16 2 Sw LAMP macro mora t l d I POWER PLUG IEC L TRANSFORMER ISOLATED 20W WELCH ALLYN INC ORCAD FILE 44141441 SCH Q g Title RELEASED PRODUCTION Document Number DATE 441114
8. OPERATION CONNECT A C POWER SOURCE AND VERIFY THAT ALL THREE LAMPS ILLUMINATE TECHNICIAN NOTES 25 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING J JOINT 3 amp 1 REMOVE LOWER REMOVE TWO FLAT HEAD PHILLIPS SCREWS NEAREST JOINT 3 ADJUSTABLE JOINT AND SLIDE LOWER ARM OFF OF HINGE BRACKET J 2 REMOVE STRAP FROM HINGE BRACKET UNSCREW NUT FROM STUD USE SLIP JOINT PLIERS TO PULL AND LIFT STRAP FROM STUD J 3 UNSCREW HINGE FROM UPPER ARM UNSCREW TWO FLAT HEAD PHILLIPS SCREWS IN UPPER ARM NEAREST HINGE REMOVE HINGE JOINT FROM UPPER ARM BEING CAREFUL NOT TO CATCH THE END OF THE STRAP ON PARTS OF THE HINGE JOINT J 4 DISASSEMBLE HINGE IF NECESSARY REMOVE JOINT KNOB AND BOLT REMOVE THE NON TWIST BRACE NTB AND NYLON WASHERS REMOVE ALL HINGE PARTS J 5 INSTALL NEW HINGE SEGMENTS PLACE LOCTITE PRIMER 770 M30391 ONTO JOINT BEARINGS PRIOR TO ASSEMBLY AND ALLOW TO DRY UNTIL A DULL FINISH RETURNS TO PART APPLY TWO DROPS OF LOCTITE 403 M30372 TO HINGE BRACKETS ON SURFACE WHERE BEARINGS MATE ADHERE THE BEARINGS TO THE HINGE BRACKETS POSITION THE PARTS ON THE BENCH WITH THE OPEN SIDE OF THE HINGE BRACKETS FACING YOU AND THE HINGE BRACKET WITH THE STUD ON YOUR LEFT HAND SIDE J 6 INSERT PIVOT BOLT SCREW THE GOAL POST ONTO THE MANDREL PLACE THE MANDREL WITH FRICTION WASHER ON BOTTOM INTO THE CENTER OF THE ASSEMBLY PLACE THE NON TWIST BRACE NTB SQUARE CUT OUT ON TOP AND O
9. PROPERLY THE LIGHT HOUSING WILL STAY IN POSITION WHEN RELEASED K 11 TEST TO VERIFY SAFE AND PROPER OPERATION PERFORM STEP J 9 PERFORM HY POT TEST PER A 02861 END CABLER amp R JOINT 4 UNIVERSAL CONNECTOR amp 1 REMOVE CONNECTOR BLOCK REFER TO DRAWING 441009 FOR ASSEMBLY REMOVE SET SCREW AND TWO PHILLIPS HEAD SCREWS FROM LOWER END OF SHORT ARM REMOVE THE END CAP CONNECTOR PLATE UNIVERSAL CONNECTOR BRAKE ONE FLAT SPRING AND CONNECTOR BLOCK AND TWO NYLINERS L 2 REASSEMBLE CONNECTOR BLOCK UNIVERSAL CONNECTOR ASSEMBLY PLACE NYLINERS AT EACH END OF THE CONNECTOR BLOCK BORE PLACE ONE END CAP ONTO THE UNIVERSAL CONNECTOR PLACE THE UNIVERSAL CONNECTOR INTO THE CONNECTOR BLOCK BORE PLACE THE BRAKE MATERIAL AND ONE FLAT SPRING CURVED SIDE UP OVER OPENING IN THE CONNECTOR BLOCK L 3 SECURE BLOCK TO SHORT ARM TUBE WITH TWO SCREWS FIRST INSTALL THE PHILLIPS SCREW CLOSEST TO THE END OF THE ARM AND TIGHTEN IT TO MINIMUM OF 15 INCH LBS THEN INSTALL AND TIGHTEN THE SECOND AND LAST SCREW AND TIGHTEN IT TO THE SAME TORQUE L 4 INSTALL SET SCREW AND ADJUST JOINT 4 SET SCREW INSTALL SET SCREW WITHOUT LOCTITE THREAD INTO HOLE PLACE THE COMPLETED UNIT ON A TWO DEGREE FROM VERTICAL MOUNTING ADJUST THE LONG ARM TO A HORIZONTAL POSITION ROTATE LS200 TO THE HIGHER OF THE TWO STOPS VERY SLOWLY LOOSEN SET SCREW UNTIL THE LS200 STARTS TO MOVE TOWARDS THE LOWER STOP STOP AND TURN THE SCREW CLOCK
10. TIGHTEN wall bracket option is not secure ATTACH to wall at stud with approved screws only joint 3 knob too loose TIGHTEN pole is loose on mobile stand REASSEMBLE according to instructions ALIGN the small metal post in the stand with the hole in the pole 10 COMPLAINT CONDITION Light head wobbles Power supply wobbles Mobile stand is difficult to LS200 is noisv when articulated LS200 makes clicking sound when upper arm 1 raised and or lowered INDEX FAILURE CAUSE LS200 MECHANICAL CAUSE CORRECTIVE ACTION clear plastic cover on front of light head is not put on properly REFER to lamp replacement instructions to VERIFY that plastic cover tabs are aligned with those on the white plastic light housing REMOVE and RE INSTALL clear plastic cover power supply attachment points are not secure TIGHTEN this connection by PUSHING the power supply housing down onto the mounting screws as far as it will go casters are locked UNLOCK casters when moving unit wheel s are bound up with foreign material such as string CLEAR obstruction some type of cleaning agent or solvent may have gotten into joint s ALLOW it to dry and DO NOT LUBRICATE foreign material has built up in the joint WIPE material out of joints the heat shrink tubing over the spring is not in place REPOSITION to eliminate sound strap attached to spring is interfering with mandrel assembly Replace strap a
11. UNTIL LEVER IS ALMOST VERTICAL REMOVE THE EXPIRED LAMP AND RETURN THE LEVER TO ITS FORMER POSITION CAUTION WEAR A PROTECTIVE GLOVE WHEN REMOVING FRACTURED LAMPS REMOVE BROKEN LAMP FRAGMENTS FROM THE LAMP HOUSING B 3 REPLACE WITH NEW LAMP PN 06400 RETURN THE LAMP HOLDING LEVER TO ITS ORIGINAL POSITION NOTE HOLD THE LAMP ON THE OUTSIDE SURFACES ONLY FINGER GREASE OR OTHER CONTAMINANTS WILL DARKEN THE QUARTZ ENVELOPE CAUSING DISCOLORATION AND PREMATURE FAILURE OF THE REPLACEMENT LAMP VERIFY PROPER ALIGNMENT OF PINS IN LAMP SOCKET PRESS DOWN INTO FULL ENGAGEMENT WITH LAMP SOCKET LAMP WILL SNAP INTO PLACE B 4 INSTALL BEZEL ALIGN THE TABS ON THE BEZEL WITH THE TABS ON THE LAMP HOUSING AND MAKE SURE THAT THE THREE CLEAR WINDOWS IN THE BEZEL LINE UP WITH LAMPS WHILE HOLDING BEZEL IN PLACE WITH ONE HAND SCREW THE HANDLE ONTO THE THREADED SHAFT TIGHTEN THE HANDLE UNTIL IT IS FIRMLY IN PLACE B 5 TEST TO VERIFY SAFE OPERATION CONNECT TO POWER SOURCE PLACE THE POWER SWITCH IN THE ON POSITION ALLOW NEW LAMPS TO OPERATE FOR FIVE MINUTES TO BURN IN 14 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING C FUSES TWO R amp R DOMESTIC 1A 250V PN 236706 3907 INTERNATIONAL 0 5A 250V PN 236706 3114 CAUTION IFANLS200 HAS BEEN RETURNED FOR FUSE REPLACEMENT DO NOT JUST REPLACE FUSES AND PLUG IN TO TEST INSTEAD 1 LOCATE AND ELIMINATE THE SHORT CIRCUIT BY TESTING TRANSFORMER OR WIRING DETERMINE TH
12. WITH A WIRE TIE CONNECT SECONDARY TRANSFORMER WIRES TO CABLE F 5 ATTACH BACK HOUSING OF POWER SOURCE MAKE SURE THE STRAIN RELIEF AND IEC CONNECTOR ARE IN PLACE PLACE THE COVER ONTO THE POWER SUPPLY HOUSING BEING CAREFUL NOT TO PINCH WIRES BETWEEN THE CASES FASTEN WITH FOUR 4 SCREWS F 6 TEST TO VERIFY SAFE OPERATION CONNECT LS200 TO POWER SOURCE AND VERIFY THAT ALL THREE LAMPS ARE LIT CONDUCT HI POT TEST PER A 02861 TECHNICIAN NOTES 18 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING G LAMP HOLDER R amp R G 1 REMOVE BEZEL DANGER ALSO REFER TO PG 8 OPERATING INSTRUCTIONS PN441118 1ML PUT POWER SWITCH IN OFF POSITION AND REMOVE POWER CORD CONNECTOR FROM A C POWER SOURCE LAY UNIT DOWN WITH HANDLE UP UNSCREW HANDLE COUNTER CLOCK WISE REMOVE NUT TETHER AND BEZEL ASSEMBLY DO NOT TOUCH HOT LAMPS OR HOT LAMP HOLDERS l GLASS AND METAL COMPONENTS RETAIN HEAT EVEN AFTER LAMPS ARE OFF SEVERAL MINUTES G 2 REMOVE COOL LAMP S AFTER COOLING DOWN PERIOD OF AT LEAST 20 MINUTES LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET PULL THE LAMP HOLDING LEVER TOW ARD THE BACK OF THE UNIT UNTIL LEVER IS ALMOST VERTICAL REMOVE EXPIRED LAMP G 3 REMOVE OLD LAMP HOLDER FROM LAMP HOLDER UNSCREW THREE SCREWS CUT THE LAMP HOLDER WIRES AS CLOSE TO THE LAMP HOLDER AS POSSIBLE LIFT OLD LAMP HOLDER OUT OF LAMP HOUSING G 4 ATTACH REP
13. to current passing through lamp filament glass is damaged REPLACE glass angle bracket bent REPLACE angle bracket lamps are defective or damaged REPLACE lamps COMPLAINT CONDITION Illumination is intermittent light flickers as arm 15 articulated Customer should send LS200 to Welch Allyn for service Switch produces arc or flash when operated Customer should send LS200 to Welch Allyn for service Fails Dielectric strength Lamps blow very quickly less than 30 seconds incorrect bulbs INDEX FAILURE CAUSE LS200 ELECTRICAL CAUSE CORRECTIVE ACTION loose connections defective wiring or lamp s not seated fully in holder TROUBLESHOOT RESTORE connections REPLACE defective parts switch 18 defective or wiring connections are loose intermittent TROUBLESHOOT REPLACE switch connectors transformer has electrical insulation failure current leak REPLACE transformer transformer output voltage 1 too high Find cause ex wrong transformer input voltage too high TECHNICIAN NOTES INDEX FAILURE CAUSE LS200 MECHANICAL DEFINITIONS To simplify text numbers are used for the names of the joints on the LS200 See figure I on page 9 This page of information 1 for referencing the joints on the LS200 and giving general description of required adjustments This page is not service instructions JOINT NUMBER DESCRIPTION Yoke Housing joint seen The crescent shaped part is t
14. AED MIRE TO BE CORMICTED TO POSITION ZA COSRECT ONE WITE WIRE OF THE OUTPUT CABLE FROM Tat TO POSTt Om Oe Tut OnOff S ITCn LITEM F CONECT OnE BLACH WIRI OF Int OUTPUT CABLE FROM Twf ARM aSSEwBL Tr POSITiOs I OG tal Omsore Seitcm itta 91 STEM 19 RAPI BE LOCATED TrESE s e ma 6 U Qal 18 EACH acl A a p 1 Ice Bill kent PI mast nganan 19 FOODS A RO in ulan wes a 47800 10 44181 na At CMLONT I Ges GE EE im hos ig aa 209 56 daan ets Wie 1 5 2 F 4 L i tis Meter i on 12 1 f tt Jaman om 2106 f c fame Mn EU ELJ Po p ADEL 00 p 14 vw gt 481 10 text TES ra CALL wi n RIO k gadd la K A a 2 PLCS 4 y Y 7Y r 7a r t 4 lei S OM scare o 500 R al Ft d gt n A H och t TO SS SECTION ates ie Jala ony SCALE 000 lt H N SCA 504 EH LE l ES EE TABLE SECTHON voy CARES FROM THE TRANSFONMER ITEM DOG 3068 POSTA SUPPLT AUSTRALIA Supi VI AO TOLGA aga ETTE mn YM
15. AND TIGHTEN TWO SCREWS I 13 INSTALL STRAIN RELIEF CAREFULLY REMOVE ANY CABLE SLACK THAT MAY BE PRESENT IN THE LONG ARM GENTLY PULL THE CABLE AT THE STRAIN RELIEF HOLE WHILE HOLDING ON TO THE BLACK AND WHITE WIRES AT THE YOKE DON T LET THESE SLIP BACK DOWN INTO THE HOLE IN THE STUD INSTALL STRAIN RELIEF USING STRAIN RELIEF TOOL 2 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING I YOKE amp CONTINUED I 14 ATTACH LAMP HOUSING ASSEMBLY TO YOKE APPLY LUBRICANT DOW CORNING 7 RELEASE COMPOUND M11175 TO THE CONTACT SURFACES BETWEEN THE YOKE AND LAMP HOUSING FULLY ENGAGE THE LAMP HOUSING IN THE YOKE INSERT PIVOT BOLTS THROUGH YOKE WITH FLAT SIDE OF BOLT ALIGNED WITH FLAT OF CENTRAL BRACE SECURE THE LAMP HOUSING WITH THE FOLLOWING ITEMS ASSEMBLED IN SEQUENCE AS LISTED FOR EACH PIVOT BOLT IST INSTALL ONE 1 SPACER GRAY WASHER 2ND INSTALL ONE 1 WAVE WASHER 3RD APPLY LOCTITE 242 WA M 30338 TO ONE HALF OF 5 15 16 NUT THREADS 4TH ONE 15 16 NUT TIGHTEN NUTS EQUALLY UNTIL ONE THREAD IS VISIBLE ON THE BOLT ROTATE THE LAMP HOUSING ASSEMBLY BY PULLING WITH A FORCE GAUGE AT THE TOP OF THE CENTER BOLT ADJUST NUT TIGHTNESS UNTIL A READING OF BETWEEN 1 0 TO 3 0 LBS IS OBTAINED 15 INSTALL THE LAMP HOLDERS AND RESTORE CONNECTIONS FASTEN LAMP HOLDERS TO LAMP HOUSING USING THREE 6 PHILLIPS HEAD SCREWS FEED WIRES THROUGH THE YOKE CHANNEL PIVOT BOLTS AND UNDER THE CENTRAL BRAC
16. BLY amp CONTINUED 6 REMOVE CENTRAL BRACE UNSCREW FOUR 4 PHILLIPS HEAD SCREWS AND REMOVE THE BRACKET FROM THE LAMP HOUSING REMOVE LAST BOTTOM LAMP HOLDER 7 ATTACH EXISTING LAMP HOLDERS AND CENTRAL BRACE ATTACH BOTTOM LAMP HOLDER WITH 3 PHILLIPS HEAD SCREWS MAKE SURE THAT WIRES ARE ROUTED ACCORDING TO ABOVE DRAWING TEMPORARILY ATTACH REMAINING TWO LAMP HOLDERS WITH ONLY ONE SCREW EACH ATTACH FOUR WAY CONNECTORS ATTACH CENTRAL BRACE WITH FOUR PHILLIPS SCREWS IF A NEW CENTRAL BRACE IS BEING INSTALLED ALONG WITH THE NEW LAMP HOUSING ATTACH A NEW WARNING LABEL WITH THE SAME ORIENTATION AS THE ORIGINAL 8 ATTACH LAMP HOUSING ASSEMBLY TO YOKE FULLY ENGAGE THE LAMP HOUSING IN THE YOKE INSERT PIVOT BOLTS THROUGH YOKE WITH FLAT SIDE OF BOLT ALIGNED WITH FLAT OF CENTRAL BRACE SECURE THE LAMP HOUSING WITH THE FOLLOWING ITEMS ASSEMBLED IN SEQUENCE AS LISTED FOR EACH PIVOT BOLT IST INSTALL ONE 1 SPACER GRAY MATERIAL WASHER 2ND INSTALL ONE 1 WAVE WASHER 3RD APPLY LOCTITE 242 WA M 30338 TO ONE HALF OF 5 15 16 NUT THREADS 4TH ONE 15 16 NUT TIGHTEN NUTS EQUALLY UNTIL ONE THREAD IS VISIBLE ON THE BOLT ROTATE THE LAMP HOUSING ASSEMBLY BY PULLING WITH A FORCE GAUGE AT THE TOP OF THE CENTER BOLT ADJUST NUT TIGHTNESS UNTIL A READING OF BETWEEN 1 0 TO 3 0 LBS IS OBTAINED 9 INSTALL THE LAMP HOLDERS AND RESTORE CONNECTIONS FASTEN LAMP HOLDERS TO LAMP HOUSING USING THREE 6 PHILLIPS HEAD S
17. CREWS FEED WIRES THROUGH THE YOKE CHANNEL PIVOT BOLTS AND UNDER THE CENTRAL BRACE GENTLY PULL ON THE BLACK AND WHITE CABLE WIRES AS THEY ENTER LAMP HOUSING TO REMOVE ANY SLACK THAT MIGHT BE PRESENT WHERE THEY PASS THROUGH THE HOLLOW CRESCENT OF THE YOKE WHEN SLACK IS REMOVED PRESS WIRES INTO NOTCHES IN THE CRESCENT OR THE FOAM INSERT WILL NOT FIT PROPERLY INSTALL FOAM IN YOKE ATTACH WELCH ALLYN LOGOS IN RECESSES OVER PIVOT BOLTS AND ALIGNED WITH PARTING LINE IN YOKE H 10 INSTALL SWITCH LAMPS AND BEZEL CRIMP TWO FEMALE QUICK CONNECTS PN 106130 8 ONTO THE BLACK AND WHITE POWER WIRES PRESS SWITCH INTO CUTOUT OF LAMP HOUSING ATTACH WIRES TO SWITCH AND INSTALL WIRE TIES PER DWG 441013 INSTALL LAMPS AND BEZEL SEE B 3 THROUGH 4 21 CAUTION DISCONNECT 15200 FROM POWER BEFORE SERVICING amp 1 NO gt On ON Oo O REMOVE LAMP HOUSING REFER TO SECTION H 1 H 4 AND H 5 ON PAGE 20 BUT LEAVE TWO RED WIRES ATTACHED TO THE SWITCH SINCE IT IS NOT BEING REMOVED REMOVE LOWER ARM REMOVE TWO FLAT HEAD PHILLIPS SCREWS NEAREST JOINT 3 ADJUSTABLE JOINT AND SLIDE LOWER ARM OFF OF HINGE BRACKET REMOVE STRAP FROM HINGE BRACKET UNSCREW 3 8 NUT FROM STUD USE SLIP JOINT PLIERS TO PULL AND LIFT STRAP FROM STUD THIS WILL RELIEVE TENSION ON 2 YOKE SCREWS AND PERMITS DISASSEMBLY OF SPRING BRACKET FROM YOKE STUD REMOVE STRAIN RELIEF COMPRESS STRAIN RELIEF WITH HEYCO TOOL AND REMOV
18. E DISCONNECT power cord from A C power source before initial disassembly of LS200 Light OBSER VE cautions warnings in owners manual and printed on the product itself COMPLY with all safety codes and practices for this type of product COMPLY with all safety regulations at your work place PERFORM all recommended Welch Allyn service test procedures to assure the LS200 meets all requirements safely and reliably EXAMINE AND REPAIR OR REPLACE as required any and all worn or questionable wiring components connections connectors warning labels insulation and other items necessary for the continued safe operation of this product DO NOT TOUCH halogen lamps or nearby parts during or immediately after operation WAIT AT LEAST TWENTY MINUTES 20 MIN BEFORE TOUCHING HALOGEN LAMPS OR METAL NEAR THE LAMP S VERY HIGH TEMPERATURES will cause severe burns Fractured or broken lamps may cause injury To prevent cuts REMOVE such lamps by HOLDING them with a cloth or wear work gloves WEAR SAFETY GLASSES DO NOT LOOK DIRECTLY AT TOUCH OR SPRAY LIT halogen lamps QUALITY SERVICE MODIFY your SERVICE Manual by notating changes and revisions of part numbers and procedures Enter this information on the appropriate page and include a copy of the notification in your Appendix Product Updates READ AND UNDERSTAND customer comments and complaints on accompanying documentation P O or other correspondence IF AN INJURY OR IL
19. E GENTLY PULL ON THE BLACK AND WHITE CABLE WIRES AS THEY ENTER LAMP HOUSING TO REMOVE ANY SLACK THAT MIGHT BE PRESENT WHERE THEY PASS THROUGH THE HOLLOW CRESCENT OF THE YOKE WHEN SLACK IS REMOVED PRESS WIRES INTO NOTCHES IN THE CRESCENT OR THE FOAM INSERT WILL NOT FIT PROPERLY INSTALL FOAM IN YOKE ATTACH WELCH ALLYN LOGOS IN RECESSES OVER PIVOT BOLTS AND ALIGNED WITH PARTING LINE IN YOKE I 16 INSTALL BEZEL CRIMP TWO FEMALE QUICK CONNECTS PN 106130 8 ONTO THE BLACK AND WHITE POWER WIRES ATTACH WIRES TO SWITCH AND INSTALL WIRE TIES PER DWG 441013 INSTALL LAMPS AND BEZEL SEE B 3 THROUGH 4 17 INSTALL SET SCREW AND ADJUST JOINT 2 SET SCREW PLACE ONE DROP OF LOCTITE 222 M 30375 TO SET SCREW AND THREAD INTO HOLE PLACE UNIT IN UPRIGHT POSITION AND ROTATE JOINT 2 TO THE STOP VERY SLOWLY LOOSEN SET SCREW UNTIL THE LIGHT HOUSING ROTATES DOWNWARD STOP AND TURN THE SCREW CLOCKWISE 1 4 TURN ROTATE THE LIGHT HOUSING TO THE STOP AND RELEASE IF THE SET SCREW IS ADJUSTED PROPERLY THE LIGHT HOUSING WILL STAY IN POSITION WHEN RELEASED 24 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING I YOKE amp CONTINUED I 18 TEST JOINTS WITH THE 1 5200 IN AN UPRIGHT POSITION CYCLE THE ARM UP AND DOWN THREE TO FIVE TIMES CHECK FORT AN Y BINDING OF THE JOINT WITH THE ARM AT 45 DEGREES CHECK FOR DROOP WITH THE ARM ALL THE WAY DOWN AT THE 90 DEGREE POSITION CHECK FOR SPRINGBACK TEST TO VERIFY SAFE
20. E CAUSE OF THE PROBLEM IF POSSIBLE ex LINE SURGE WHAT 5 IF ANY WERE DAMAGED 2 RESTORE THE CIRCUIT SPECIFICATIONS BEFORE REPLACING FUSE AND ENERGIZING S LOCATE AND ELIMINATE SHORT CIRCUITS LINE TO LINE LINE TO GROUND BEFORE CONNECTING LS200 TO MAINS INSPECT WIRE INSULATION AND COMPONENTS FOR BURN AND SMOKE MARKS REPLACE ALL DAMAGED COMPONENTS TO RESTORE CIRCUIT TO SPECIFICATIONS INSPECT TRANSFORMER ASSEMBLY FIRST 1 REMOVE FUSE DRAWER DISCONNECT 15200 FROM POWER SOURCE REMOVE POWER CORD FROM UNIT POWER CORD RECEPTACLE INSERT THE FLAT BLADE OF A SMALL SCREWDRIVER 1 8 INTO SLOTS ON SIDES OF THE FUSE DRAWER PRY BOTH LATCHES AND SLIDE THE FUSE DRAWER OUT OF THE RECEPTACLE C 2 REMOVE FUSES FROM FUSE DRAWER PULL BOTH FUSES FROM FUSE DRAWER AND VERIFY THAT ONE OR BOTH ARE ELECTRICALLY BLOWN NOTE THE FUSE RATING THIS IS IMPORTANT SINCE THE FUSES MAY HAVE BLOWN BECAUSE THEIR AMP RATING WAS BELOW THE REQUIRED AMP RATING FOR THIS PRODUCT THUS THE FUSES WERE AT FAULT NOT THE 15200 CIRCUITS FUSES OF THE PROPER RATING BE INSTALLED AND THE LAMP TURNED ON FOR FUNCTIONAL CHECK FUSES CAN BE CHECKED VISUALLY FOR OPEN FILAMENT CONTINUITY CAN BE CHECKED WITH AN ANALOG OR DIGITAL VOLT OHM METER D V O M OPEN BLOWN FUSES HAVE INFINITE RESISTANCE SYMBOL INDICATES OPEN LEADS FOR MANY DIGITAL VOLT OHM METERS C 3 INSTALL NEW FUSES IN FUSE DRAWER INSER
21. E FRONT HOUSING BE CAREFUL NOT TO PINCH WIRES ON SECONDARY SIDE WHILE CLOSING HOUSING POSITION THE COVER ONTO THE POWER SUPPLY HOUSING AND FASTEN IT WITH FOUR SCREWS D 5 TEST TO VERIFY SAFE OPERATION CONNECT 15200 TO POWER SOURCE AND VERIFY THAT ALL THREE LAMPS ARE LIT CONDUCT HI POT TEST PER A 02861 TECHNICIAN NOTES 16 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING POWER SWITCH amp IT IS NOT NECESSARY DISASSEMBLE THE LAMP HOUSING REPLACE THE SWITCH E 1 REMOVE SWITCH APPLY SMALL PIECE OF MASKING TAPE TO THE LAMP HOUSING ALONG THE EDGES OF THE SWITCH TO PROTECT THE SURFACE FINISH OF HOUSING DURING SWITCH REMOVAL PULL THE OLD SWITCH OUT OF THE LIGHT HOUSING BY PRYING UPWARDS AT THE END OF THE SWITCH WITH A THIN EDGE SUCH AS A PUTTY KNIFE E 2 DISCONNECT WIRES FROM SWITCH UNPLUG ALL FOUR 4 WIRES FROM THE BOTTOM OF THE SWITCH E 3 INSTALL NEW SWITCH ATTACH WIRES AND PRESS SWITCH INTO LAMP HOUSING MAKING SURE THAT THE LAMP SYMBOL ON THE TOP OF THE SWITCH IS TOWARDS THE WORD WELCH OF THE WELCH ALLYN NAME ON THE FRONT OF THE HOUSING THESE WIRES CONDUCT A C CURRENT AND AS SUCH MAY BE ATTACHED TO THE SWITCH IN EITHER POSITION REFER TO ASSEMBLY DRAWING NO 441013 E 4 VERIFY REPAIR CONNECT 15200 TO POWER SOURCE AND OPERATE THE SWITCH APPROXIMATELY 5 TIMES TO DETERMINE THAT THE SWITCH IS OPERATING PROPERLY VERIFY THAT ALL THREE LAMPS LIGHT TECHNICIAN NOTES
22. E SCREWS TIGHTENED TO 18 IN LBS MINIMUM LINE UP THE BOSS ON THE PIN WITH THE LENGTHWISE AXIS OF THE ARM PLACE LOCTITE ONTO THE THREADS OF THE SET SCREW AND INSERT IT INTO THE THREADED HOLE ON THE END OF THE ARM TIGHTEN THE SET SCREW 18 IN LBS MINIMUM 30 WALL MOUNT BRACKET ASSEMBLY CONTINUED 7 ATTACH THE ARM TO WALL PLATE INSERT FOUR SCREWS INTO BRACKET THROUGH REAR OF WALL PLATE AND TIGHTEN TO 25 IN LBS MINIMUM TECHNICIAN NOTES 31 APPENDIX EXPLODED VIEW OF LS200 WITH PARTS LEGEND 32 Section 7 Lighting Nos 44200 44202 44204 44206 LS 200 Procedure Light Introduced September 1994 e el ran beer s emas Jaen 1 WM MM WD KEES 106124 18 8 x 125 Self Tapping Screw 44206 441015 506 Reference Figure 441144 Repair BOM 44200 REPAIR or appropriate Repair BOM Transformer Housing with Label Assy 44202 441015 512 761076 2 Detachable Power Cord 5 7 10 11 12 13 13 14 15 17 18 19 Repair Parts Catalog Page 7 5 Section 7 Lighting LS2007 Mobile Stand No 44250 LS200 Wall Mount No 44210 Introduced September 1994 441112 502 Wall Mount Hardware Kit Mobile Stand 2 441112 501 Mobile Stand Hardware Kit Mobile Stand 5 485642 l Caster with Brake Mobile Stand 6 485642 1 Caster without Brake Mobile Stand Pole
23. E STRAIN RELIEF FROM LONG ARM UNSCREW YOKE SET SCREW AT JOINT 2 USE FLAT BLADE SCREWDRIVER TO UNSCREW YOKE SET SCREW REMOVE YOKE FROM JOINT 2 UNSCREW TWO FLAT HEAD PHILLIPS SCREWS FROM UPPER ARM AT YOKE JOINT WHILE FEEDING CABLE BACK OUT OF YOKE PULL YOKE OUT OF JOINT 2 WHEN CONNECTOR PLATE IS ACCESSIBLE REMOVE IT FROM CONNECTOR BLOCK YOKE STUD ASSEMBLY TWO FLAT SPRINGS BRAKE MATERIAL AND NYLINERS WILL COME OUT OF CONNECTOR BLOCK REMOVE END CAPS REMOVE CABLE FROM YOKE GENTLY PULL WIRES OUT OF YOKE DISCARD YOKE ASSEMBLE CONNECTOR BLOCK TO END OF NEW YOKE SNAP ONE OF THE END CAPS ONTO THE YOKE PLACE A SECOND END CAP ONTO STUD FACING OTHER END CAP INSERT NYLINERS TO EACH END OF CONNECTOR BLOCK BORE FEED THE BLACK WHITE WIRES THROUGH STUD INTO YOKE PLACE THE STUD PORTION OF THE YOKE INTO THE CONNECTOR BLOCK PLACE THE STRAP SPRING CONNECTOR PLATE ASSEMBLY ONTO THE CONNECTOR BLOCK YOKE ASSEMBLY PLACE THE BRAKE MATERIAL AND TWO FLAT SPRINGS CURVED SIDE UP INTO THE OPENING IN THE CONNECTOR BLOCK POSITION THE CONNECTOR PLATE OVER THE CONNECTOR BLOCK YOKE STUD ASSEMBLY WITH THE ROTATIONAL STOP OF THE STUD ENGAGED WITH THE CONNECTOR PLATE 22 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING I YOKE amp CONTINUED I 10 SLIDE CONNECTOR BLOCK YOKE STUD CONNECTOR PLATE INTO THE UPPER ARM TUBE ALIGN THE KEY EXTRUSION OF THE INTERIOR OF THE UPPER ARM WITH THE
24. KEY WAY OF THE CONNECTOR BLOCK MAKE SURE THE END OF THE GRAY CABLE IS PULLED ALL THE WAY INTO THE YOKE SO THAT THE CABLE INSULATION IS VISIBLE WHERE THE SHAFT JOINS THE CRESCENT I 11 SECURE CONNECTOR BLOCK TO LONG ARM TUBE WITH TWO SCREWS FIRST INSTALL THE PHILLIPS SCREW CLOSEST TO THE YOKE AND TIGHTEN IT TO A MINIMUM OF 15 INCH LBS THEN INSTALL AND TIGHTEN THE SECOND AND LAST SCREW AND TIGHTEN IT TO THE SAME TORQUE THESE YOKE SCREWS AT JOINT 2 MUST BE TIGHTENED BEFORE TENSIONING THE SPRING STRAP TO PREVENT SCREW HOLES FROM BECOMING MISALIGNED BECAUSE OF SPRING TENSION DO NOT INSTALL SET SCREW AT THIS TIME 12 INSTALL LOWER ARM UNIVERSAL JOINT ASSEMBLY ATTACH STRAP TO STUD USING TOOL T 12686 INSTALL AND TIGHTEN NUT CAUTION MAKE SURE YOUR FINGERS ARE AWAY FROM THE HINGE AREA BEFORE PRESSING THE SHORT ARM ALL THE WAY ONTO THE HINGE BRACKET THERE IS THE RISK OF PINCHING FINGERS IF THE ARM IS PRESSED ON WHILE HOLDING THE MANDREL DOWN THE MANDREL DOES NOT NEED TO BE HELD DOWN SLIDE THE LOWER ARM SHORT ARM ONTO THE HINGE BRACKET UNTIL IT IS APPROXIMATELY 1 4 AWAY FROM CONTACTING THE MANDREL HOLD THE LONG ARM DOWN AND LIFT THE SHORT ARM UP APPROXIMATELY 45 DEGREES WHILE HOLDING IT IN THAT POSITION PRESS THE MANDREL DOWN AND RELEASE IT IT WILL STAY IN POSITION WITHOUT HOLDING IT SO THAT IT CAN FIT INSIDE OF THE SHORT ARM REMOVE YOUR FINGER FROM THE MANDREL AREA AND SLIDE THE SHORT ARM ON AS FAR AS IT WILL GO INSTALL
25. LACEMENT LAMP HOLDER TO LAMP HOUSING CONNECT REPLACEMENT LAMP HOLDER WIRES TO OLD WIRES USING BUTT SPLICES PN 488377 KEEPING WIRES OUT FROM UNDER THE LAMP HOLDER POSITION LAMP HOLDER OVER THREE THREADED BOSSES IN LAMP HOUSING MAKE SURE THAT THE WIRES DO NOT INTERFERE WITH THE LAMP CHANGING LEVERS INSERT AND TIGHTEN THREE SCREWS INSTALL LAMP G 5 INSTALL BEZEL ASSEMBLY FOLLOW INSTRUCTIONS IN SECTION B 4 PG 14 TO ATTACH THE BEZEL ASSEMBLY TO THE LS200 G 6 TEST TO VERIFY SAFE OPERATION CONNECT TO A C POWER SOURCE AND ILLUMINATE LAMP LET THE UNIT STAY ON FOR FIVE MINUTES TO VERIFY PROPER OPERATION TECHNICIAN NOTES 19 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING H LAMP HOUSING PN 441023 1 R amp 1 REMOVE BEZEL UNPLUG LS200 AND REMOVE HANDLE ALSO REFER TO OPERATING INSTRUCTIONS PN 441118 1ML REMOVE POWER CORD FROM A C POWER SOURCE LS200 DOWN WITH HANDLE FACING UP UNSCREW THE HANDLE COUNTER CLOCK WISE REMOVE HANDLE UNSCREW THE TETHER RETAINING NUT AND REMOVE THE TETHER REMOVE BEZEL DANGER DO NOT TOUCH HOT LAMPS OR HOT LAMP HOLDERS GLASS AND METAL COMPONENTS RETAIN HEAT EVEN AFTER THE LAMPS HAVE BEEN TURNED OFF SEVERAL MINUTES H 2 REMOVE COOL LAMPS AFTER COOLING DOWN PERIOD OF AT LEAST 20 MINUTES LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET PULL THE LAMP HOLDING LEVER TOW ARD THE BACK OF THE UNIT U
26. LNESS TO PATIENT OR USER OR HAZARDOUS MALFUNCTION HAS OCCURRED OR IS SUSPECTED DO NOT DISASSEMBLE REASSEMBLE ALTER OR REPAIR THE PRODUCT IN ANY WAY INSTEAD GIVE THE UNIT AND ALL ACCOMPANYING PAPERWORK TO YOUR REPAIR SUPERVISOR Appropriate action per approved Welch Allyn policy will be taken When performing acomplete inspection LOOK for missing parts product defects damage tampering unsafe condition of wiring or any component ENTER all findings and test data along with repair status in the appropriate file Most of the repairs can be performed on a foam covered work bench Place the LS200 in holding fixture for repairs Take all actions to prevent scratching the bezel INDEX FAILURE CAUSE COMPLAINT CONDITION Less than 3 lamps light None of the lamps illuminate SWITCH IS ON POWER CORD PLUGGED IN WARNING ALLOW LAMPS TO COOL FOR at least 20 MINUTES LS200 ELECTRICAL CAUSE CORRECTIVE ACTION lamp is burned out REPLACE PN 06400 lamp not seated correctly SEAT lamp 3 lamps are wired in parallel lamp socket defective REPLACE no voltage at A C source TRY other power outlet RESTORE power power cord loose RESTORE connections fuse s blown CHECK for short to ground or other high current path such as a line to line short RESTORE circuit to specifications prior to energizing LS200 REPLACE fuses burned out lamps CHECK lamps are they correct part for this Light REPLACE lamp
27. NE NYLON WASHER ON THE BOTTOM SIDE OVER THE ENTIRE JOINT ASSEMBLY THE TAB ON THE NTB SHOULD ENGAGE WITH THE HINGE BRACKET INSERT A SCREWDRIVER THROUGH ASSEMBLY AND ALIGN PARTS REMOVE SCREWDRIVER AND INSERT PIVOT BOLT THROUGH ASSEMBLY ENSURE THAT THE SQUARE ON THE PIVOT BOLT COMPLETELY ENGAGES WITH THE SQUARE OF THE NTB TIGHTEN KNOB ONTO BOLT J 7 INSTALL JOINT ASSEMBLY SLIDE JOINT ASSEMBLY INTO THE UPPER ARM WHILE ROUTING STRAP UNDER THE MANDREL ATTACH THE JOINT TO THE UPPER ARM WITH TWO PHILLIPS SCREWS 26 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING J JOINT 3 amp CONTINUED J 8 INSTALL LOWER ARM UNIVERSAL JOINT ASSEMBLY ATTACH STRAP TO STUD USING TOOL T 12686 INSTALL AND TIGHTEN NUT CAUTION MAKE SURE YOUR FINGERS ARE AWAY FROM THE HINGE AREA BEFORE PRESSING THE SHORT ARM ALL THE WAY ONTO THE HINGE BRACKET THERE IS THE RISK OF PINCHING FINGERS IF THE ARM IS PRESSED ON WHILE HOLDING THE MANDREL DOWN THE MANDREL DOES NOT NEED TO BE HELD DOWN SLIDE THE LOWER ARM SHORT ARM ONTO THE HINGE BRACKET UNTIL IT IS APPROXIMATELY 1 4 AWAY FROM CONTACTING THE MANDREL HOLD THE LONG ARM DOWN AND LIFT THE SHORT ARM UP APPROXIMATELY 45 DEGREES WHILE HOLDING IT IN THAT POSITION PRESS THE MANDREL DOWN AND RELEASE IT IT WILL STAY IN POSITION WITHOUT HOLDING IT SO THAT IT CAN FIT INSIDE OF THE SHORT ARM REMOVE YOUR FINGER FROM THE MANDREL AREA AND SLIDE THE SHORT ARM ON AS FAR AS IT WILL GO INS
28. NTIL LEVER IS ALMOST VERTICAL REMOVE EXPIRED LAMP H 3 UNSCREW TWO LAMP HOLDERS NEAR PIVOT BOLTS TOP HOLDERS MARK LAMP HOLDERS 1 2 3 REPLACE IN SAME POSITIONS REMOVE THREE SCREWS ON EACH OF THE TWO LAMP HOLDERS ADJACENT TO THE POWER SWITCH THESE 2 LAMP HOLDERS WILL REMAIN IN THE LAMP HOUSING ATTACHED TO THE WIRES UNTIL THE LAST LAMP HOLDER AT THE BOTTOM OF THE LAMP HOUSING BOTTOM LAMP HOLDER IS REMOVED DO NOT CUT ANY OF THE LAMP HOLDER WIRES OR SPLICES UNSCREW BOTH OF THE 4 WAY CONNECTORS H 4 REMOVE SWITCH UNPLUG ALL FOUR 4 WIRES FROM THE BOTTOM OF THE SWITCH AND CUT OFF THE SPADE CONNECTORS ON THE BLACK AND WHITE WIRES ONLY CUT RIGHT AT THE CONNECTOR THESE TWO WIRES ARE THE 12 VOLT SUPPLY FOR THE LAMPS SQUEEZE DETENTS TOGETHER ON THE BACK OF THE SWITCH AND REMOVE SWITCH FROM LAMP HOUSING REMOVE FOAM RUBBER INSERT FROM THE YOKE INSERT SMALL SCREWDRIVER IN THE YOKE RECESS NEAR THE PIVOT PUSH THE WA LOGO PLATE OUT OF THE PIVOT RECESS PUSH THE BLACK AND WHITE POWER WIRES OUT OF THE LAMP HOUSING THROUGH PIVOT BOLTS H 5 REMOVE YOKE PIVOT BOLTS AND HARDWARE UNSCREW 15 16 NUTS FROM YOKE PIVOT BOLTS NUTS HAVE LOCTITE 242 ON THEM REMOVE SPACER AND WAVE WASHER ALIGN FLAT OF THE PIVOT BOLT WITH THE FLAT IN THE HOLE D HOLE IN THE BRACKET PRESS BOLTS OUT OF LAMP HOUSING REMOVE LAMP HOUSING FROM YOKE 20 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING H H H H LAMP HOUSING ASSEM
29. SERVICE MANUAL 15200 Procedure Light MODELS 44200 Domestic Copyright 1995 Welch Allyn Co 4341 State Street Road P O Box 220 Skaneateles Falls NY 13153 0220 Originator RJS ECN 5 29347 10 94 44202 44204 44206 44210 44250 Europe U K Australia Wall Mount Mobile Stand SERVICE MANUAL 441147 REV A 9 94 1 TABLE OF CONTENTS FORWARD SAFE SERVICE INDEX ELECTRICAL FAILURE CAUSE CORRECTIVE ACTION MECHANICAL FAILURE CAUSE CORRECTIVE ACTION INDEX REMOVAL REPLACEMENT amp PROCEDURES REMOVAL REPLACEMENT PROCEDURES APPENDIX SERVICE PARTS LIST AND DIAGRAM WIRING DIAGRAM SCHEMATIC TOOLS COMMON amp SPECIAL PRODUCT UP DATES PRODUCT DESCRIPTION 13 31 AA BB FORWARD This SERVICE MANUAL provides technical assistance to Welch Allyn repair technicians for diagnosing repairing and testing the WELCH ALLYN LS200 PROCEDURE LIGHT The manual e main content areas cover troubleshooting step by step repair adjustment and re test procedures The repair TASK procedures R amp Removal and Replacement are written to provide quick and easy reference for repair technicians of different experience levels Required specifications and materials are listed at each step where applicable When reading this manual for the first time have an LS200 readily available for reference and practice Read each complete repair step on what to do task statement
30. T TWO FUSES IN THE RECESSES IN THE FUSE DRAWER REPLACE BOTH FUSES EVEN WHEN ONE IS NOT BLOWN MELTED THROUGH ALIGN THE TAB ON THE BOTTOM OF THE FUSE DRAWER WITH THE SLOT IN THE POWER CORD RECEPTACLE EVENLY INSERT THE FUSE DRAWER INTO HOUSING UNTIL ITS DETENTS LATCH C 4 TEST TO VERIFY SAFE CONNECT 15200 TO POWER SOURCE AND VERIFY THAT ALL THREE LAMPS ARE LIT CONDUCT HI POT TEST PER A 02861 15 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING D IEC CONNECTOR amp D 1 REMOVE BACK HOUSING DISCONNECT 15200 FROM MAINS IF MOUNTED ON MOBILE STAND DETACH TRANSFORMER ASSEMBLY FROM POLE REMOVE FOUR SCREWS AND REMOVE BACK HOUSING D 2 REMOVE IEC CONNECTOR DISCONNECT THREE WIRES FROM THE TERMINALS ON THE BACK OF THE IEC CONNECTOR POWER RECEPTACLE LIFT IEC CONNECTOR OUT OF THE FRONT HOUSING RE USE THE OLD FUSE TRAY IF IT IS NOT DAMAGED NEW FUSES OF THE CORRECT RATING SHOULD BE USED D 3 INSTALL REPLACEMENT IEC CONNECTOR ALIGN REPLACEMENT POWER RECEPTACLE WITH THE GROUND CENTER TERMINAL AT THE BOTTOM OF THE HOLE IN THE CHASSIS PRESS RECEPTACLE INTO HOUSING CUTOUT CONNECT WIRES PER ASSEMBLY DRAWING CONNECT THE BLACK WIRES TO THE IEC CONNECTOR AT FI AND F2 THE CENTER TERMINAL IS THE GROUND TERMINAL CONNECT THE GREEN WITH YELLOW STRIPE GROUND WIRE TO THE GROUND TERMINAL D 4 ATTACH BACK HOUSING OF POWER SOURCE MAKE SURE THE STRAIN RELIEF AND IEC CONNECTOR ARE IN THE NOTCHES IN TH
31. TALL AND TIGHTEN TWO SCREWS J 9 TEST TO VERIFY SAFE AND PROPER OPERATION WITH THE LS200 IN AN UPRIGHT POSITION CYCLE THE ARM UP AND DOWN THREE TO FIVE TIMES CHECK FOR ANY BINDING OF THE JOINT WITH THE ARM AT 45 DEGREES CHECK FOR DROOP WITH THE ARM ALL THE WAY DOWN AT THE 90 DEGREE POSITION CHECK FOR SPRINGBACK CONNECT TO A C POWER SOURCE AND VERIFY ALL THREE LAMPS ILLUMINATE TECHNICIAN NOTES 21 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING K amp 1 REMOVE JOINT 3 MAIN HINGE WITH FOLLOW INSTRUCTIONS IN SECTION 1 1 THROUGH 1 4 ON PG 25 K 2 REMOVE BEZEL FOLLOW INSTRUCTIONS IN SECTION A 1 AND A 2 ON PG 13 K 3 DISCONNECT CABLE FROM POWER SOURCE REMOVE FOUR SCREWS TO OPEN TRANSFORMER HOUSING DISCONNECT CABLE FROM TRANSFORMER K 4 DISCONNECT CABLE FROM LONG ARM REMOVE STRAIN RELIEF WITH HEYCO TOOL 29 CUT CONNECTORS FROM BOTH ENDS OF THE CABLE PULL FOAM OUT OF YOKE AND PULL WIRES OUT OF YOKE REFER TO SECTION 1 5 AND 1 6 TO REMOVE YOKE FROM ARM AND TO OBTAIN ACCESS TO THE CABLE REMOVE CABLE FROM THE ASSEMBLY BY PULLING FROM THE STRAIN RELIEF HOLE K 5 INSTALL NEW CABLE IN LONG ARM PLACE THE CABLE END WITH LONGER LEADS IN THROUGH THE STRAIN RELIEF HOLE OF THE LONG ARM AND OUT THROUGH THE OTHER END OF THE ARM TUBE PLACE CORD TUBE OVER THE CABLE AND INTO THE ARM SEPARATE THE LONG LEADS PLACE THE ELECTRICAL CABLE THROUGH THE CONNECTOR BLOCK YOKE ASSEMBL
32. WISE 1 4 TURN ROTATE THE LS200 TO THE STOP AND RELEASE IF THE SET SCREW IS ADJUSTED PROPERLY THE LIGHT HOUSING WILL STAY IN POSITION WHEN RELEASED 29 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING MOBILE STAND DISASSEMBLY ASSEMBLY 1 CASTERS PRY THE CASTERS OUT USING TOOL DESIGNED FOR 486 MOBILE STAND 2 POLE REMOVAL UNSCREW THE HEX HEAD SCREW UNDER THE BASE 3 BASE LEGS UNSCREW TWO CAP SCREWS AT EACH END OF THE BASE WALL MOUNT DISASSEMBLY REFER DRAWING 441007 1 REMOVE MOUNT BRACKET FROM WALL PLATE REMOVE FOUR SCREWS AND REMOVE BRACKET FROM PLATE 2 REMOVE CLAMP BUSHING BOTTOM OF MOUNT BRACKET REMOVE SET SCREW FROM ASSEMBLY THIS SCREW WAS INSTALLED WITH LOCTITE REMOVE THREE HEX HEAD CAP SCREWS FROM CLAMP BUSHING AND REMOVE 3 REMOVE PIN AND WASHERS TAP OUT PIN SPRING WASHERS BUSHINGS WILL COME OUT REASSEMBLE WALL MOUNT SEE DRAWING 441014 4 INSTALL WASHERS AND NYLINER PLACE NYLINERS INTO THE MOUNT BRACKET PLACE NYLON WASHER OVER THE NYLINER THEN TWO SPRING WASHERS CONVEX SIDES TOGETHER AND ANOTHER NYLON W ASHER 5 INSTALL PIN SLIDE THE MOUNT ARM INTO THE ASSEMBLY AND INSERT NYLON WASHER BETWEEN THE ARM AND BRACKET PLACE THE CLAMP BUSHING AND ANOTHER NYLINER INTO THE MOUNT BRACKET ASSEMBLY AND LINE UP HOLES DROP PIN INTO THE ASSEMBLY WITH THE MOUNT ARM PERPENDICULAR TO THE MOUNT BRACKET 6 SECURE ARM WITH SET SCREW SECURE WITH THRE
33. Y PULL THE WIRE UP THROUGH THE YOKE UNTIL THE INSULATION CAN BE SEEN IN THE YOKE THE INSULATED PORTION WILL END AT THE EXIT POINT OF THE WIRES IMPORTANT CHECK THE POSITION OF THE CABLE IN THE ARM CABLE SHOULD RUN UNDER THE SPRING STRAP ASSEMBLY CORD TUBE SHOULD COVER THE CABLE ALL THE WAY DOWN TO THE STRAIN RELIEF PULL CABLE TO REMOVE SLACK AND SECURE WITH STRAIN RELIEF K 6 ATTACH YOKE TO ARM REFER TO SECTIONS l 8 THROUGH 1 11 K 7 RESTORE CONNECTIONS AND ATTACH BEZEL REFER TO SECTIONS H 9 AND H 10 FOLLOW INSTRUCTIONS IN SECTION A 3 PAGE 13 TO REPLACE BEZEL K 8 INSTALL HINGE ASSEMBLY AND SHORT ARM ASSEMBLY REFER TO SECTION J 7 AND J 8 ON PAGES 26 27 TO ATTACH THE HINGE JOINT 3 15200 REFER TO SECTION J PG 27 TO ATTACH THE SHORT ARM ASSEMBLY TO LS200 K 9 RESTORE WIRING CONNECTIONS IN TRANSFORMER HOUSING CRIMP CONNECTORS PN 106134 2 ONTO TRANSFORMER END OF CABLE RECONNECT TO SECONDARY CONNECTORS ON TRANSFORMER FOLLOW STEP F 5 TO CLOSE HOUSING 28 CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING K amp 10 INSTALL SET SCREW AND ADJUST PLACE ONE DROP OF LOCTITE 222 M 30375 TO SET SCREW AND THREAD INTO HOLE PLACE UNIT IN UPRIGHT POSITION AND ROTATE JOINT 2 TO THE STOP VERY SLOWLY LOOSEN SET SCREW UNTIL THE LIGHT HOUSING ROTATES DOWNWARD STOP AND TURN THE SCREW CLOCKWISE 1 4 TURN ROTATE THE LIGHT HOUSING TO THE STOP AND RELEASE IF THE SET SCREW IS ADJUSTED
34. cap screws underneath wall mount bracket INDEX FAILURE CAUSE 1 5200 MECHANICAL NZ CNS COMPLAINT CONDITION Joints are stiff Excessive resistance to movement at below listed joint s 1 2 3 4 5 2 4 3 1 LS200 does not maintain position Generally at 5 joint Unit sways or wobbles Entire arm and light head wobbles these are customer items INDEX FAILURE CAUSE LS200 MECHANICAL CAUSE CORRECTIVE ACTION foreign matter in joint DISASSEMBLE CLEAN REASSEMBLE ADJUST set screw too tight for 2 4 LOOSEN and ADJUST per instructions in owners manual arm adjustment knob is too tight LOOSEN to RESTORE desired holding pivot nuts too tight LOOSEN nuts intended joint friction other than joint 1 which is supposed to be lubricated possibly compromised by lubrication DISASSEMBLE CLEAN REPLACE brake washers in affected joints and components of joint 43 DO NOT LUBRICATE joints Only joint 1 requires lubrication with Dow Corning 7 release compound Welch 11175 set screw at 2 is loose or missing TIGHTEN REPLACE set screw at 4 is loose or missing TIGHTEN REPLACE wall bracket is not mounted per instructions CHECK with a level REMOUNT within 2 degrees of level per instructions in owners manual cap head screws are loose or missing mounting option attachment screw is loose or missing INSTALL screw and
35. he yoke It holds the I joint lamp housing This is a technician adjustable friction joint Adjust friction to keep lamp housing in position when moved Tighten loosen lamp housing 15 16 nut on pivot bolt Secure this nut with Loctite 242 M30338 REMOVE flakes of Loctite which may be in lamp housing This is the only joint that is lubricated Dow Corning 7 release compound M11175 Yoke arm joint eg The yoke is attached to the upper long f 2 joint arm at the voke arm joint 2 User can adjust this friction joint by tightening or loosening slotted set screw in arm near joint This set screw is secured with Loctite 4222 M30375 To replace components of joint f 2 remove short arm See sect I Arm joint The two arm sections are joined at the adjustable 3 joint arm joint User can adjust this friction joint bv tightening or loosening the black knob To replace or repair it you must remove the lower arm and release spring tension See sect J Universal connector DEN The lower short arm attaches to the mounting 4 joint option pole or wall mount at the universal connector joint User can adjust this friction joint by tightening or loosening the slotted set screw in the arm near this joint Do not use Loctite on this set screw Mount arm joint The mount arm attaches to the wall mount bracket 5 joint at the mount arm joint This joint is not adjustable Disassembled by removing 3
36. nd any other worn parts in joint 3 REASSEMBLE according to instructions in section K END LS200 MECHANICAL TROUBLESHOOTING TECHNICIAN NOTES 11 INDEX REMOVAL AND REPLACEMENT amp PROCEDURES CAUTION DISCONNECT 15200 FROM A C POWER SOURCE BEFORE SERVICING TO AVOID ELECTRICAL SHOCK HAZARD Component Page A Bezel assembly 13 B Halogen lamps 14 C Fuses ee ee 15 D IEC connector 16 E Power switch 17 F Transformer 18 G Lamp holder 19 H Lamp housing 20 21 I Yoke gt 22 25 J Joint 3 Main hinge 26 27 K Cable I we ee 28 29 L Joint 4 Universal connector 29 M Mobile stand 30 N Wallmount GO LxI I 30 31 TECHNICIAN NOTES CAUTION DISCONNECT 15200 FROM POWER SOURCE BEFORE SERVICING A BEZEL ASSEMBLY R amp R PN 441145 501 CAUTION ALLOW HOT LAMPS TO COOL FOR 20 MINUTES BEFORE REMOVING BEZEL A 1 UNPLUG LS200 AND REMOVE HANDLE ALSO REFER TO OPERATING INSTRUCTIONS PN 441118 1ML REMOVE POWER CORD FROM A C POWER SOURCE LAY LS200 DOWN WITH HANDLE FACING UP UNSCREW THE HANDLE COUNTER CLOCKWISE REMOVE HANDLE UNSCREW THE TETHER RETAINING NUT AND REMOVE THE TETHER A 2 REMOVE BEZEL SLIDE THE BEZEL OFF OF THE THREADED ROD A 3 REPLACE BEZEL INSPECT LAMPS REFLECTORS SHROUD BEZEL AND GLASS FOR SMUDGES AND DUST CLEAN BEFORE REASSEMBLING DO NOT USE SOLVENTS TO CLEAN BEZEL PUT BEZEL OVER LIGHT HOUSING
37. s switched by Double Pole Single Throw DPST switch The transformer 15 energized whenever the power cord is plugged into an active AC outlet when fuse drawer contains two good fuses Please refer to the Owner s Manual PN 441118 1ML Set Up and operation to become familiar with the LS200 This product is designed and manufactured to strict specifications and safety regulations for medical products and should be serviced by Welch Allyn trained technicians only 44
38. tool Chatillion gage Holding fixture for arm and Support fixture for Luminaire Front transformer housing nest Tinnerman clip tool Two degree tilt universal connector fixture MATERIALS DESCRIPTION Loctite 4242 USED ON PIVOT NUT INSIDE LUMINAIRE Loctite 4222 USED ON LONG ARM SET SCREW Loctite 4403 Loctite Primer 4770 ITEMS 3 AND 4 USED ON JOINT 3 MAIN HINGE Dow Corning 7 release compound USED ON CONTACT SURFACES BETWEEN YOKE AND LUMINAIRE T 12686 T 7047 2 T 13403 T 12930 T 12643 T 13414 W A Part M30338 M30375 M30372 M30391 11175 42 APPENDIX DD PRODUCT UP DATES FILE ALL UP DATES IN THIS SECTION MAKE THE APPROPRIATE CHANGES IN THE MANUAL PERTAINING TO THESE UP DATES 43 APPENDIX EE PRODUCT DESCRIPTION LS200 PROCEDURE LIGHT The LS200 is a halogen procedure light with two mounting options mobile stand and wall mount Itis used for routine medical examinations and as such can be positioned in variety of positions The light housing is manufactured of injection molded plastic which minimizes surface temperature Light is provided three quartz halogen lamps rated at 12 volts and 20 Watts each The power source for LS200 is standard A C for the country it is sold into Two power sources are available for the LS200 Domestic 120 VAC 60 Hz and International 240 VAC 50Hz The secondary or lamp voltage is 12 VAC All models use the same 20 watt halogen lamp PN 06400 Lamp current i
39. w 22 N y TA gt ne LASS ss EG GR pj NE SECTION H H SECTION SCALE 1 000 SCALE 1 500 SECTION c D A Ne SSSI IS gt Ws 777777 REA LI VELLE See Vi L AN M Y BOTLS SECTION W W BOTH ENDS UNLESS NOTED SCALE 1 000 AN 3CAEW ITEM 11 TO ASSEMBLED WOLE BEFORE 255661126 SOLE B dch Kei TO GE IOROQ D TO 13 TO 20 18083 ool scacw TO BE 1080410 TO 3 152 3 8 B3 fN to BE TORDUED TO 34 3 10 185 AN COBO BE ROUTED THRU AS MOICATED BT mOD S FOR IMIS ROJE ALL NARDWABE FOR AMC HOLT MAE BEER OMITTID LOCATIONS and 1 nyuki s Sits hl A LIES 19 TO BE SNRUBN OVER iis T AmD ING LUD OF ITEN a3 SHOWN e mut 10 TOGQULB TO 13 20 18 18 SCREW TOROULD 4 1 1 63 1 ROTES o o SA sA N i 441013 u UD W a Em nm TE ow ie Gb et ab dad 1 SER met af rem GM s GE e DD Ro db ei er item 10 READ D R CTtON a SCREWS TO BE TOROUED TO 621 1871 05 08653 TO B 1OROUID TO 04 187105 3 sA CORRECT AED SINE FOM Inf ELECTRICAL ASSEMBLE IUJLM 2 POSITION ia OG taf Ow OfF ALL WARDHANI AUD ELECTRICAL WIRING SOM 1813 AZZOMBLI DAARING MAS BELE 0 LOCAVYIOB amp TEN NUMSLSS navi BEEN NOTID 3WiTCN 14T M OF tet OTER
Download Pdf Manuals
Related Search