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8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
1/52
Service
Manual
CL300Surgical l luminator
SolarTec ource270
CL100Surgicall luminator
SolarTec ource
100
WelchAllyn Lighting Products
4619
ordan
Road
Skaneatelesalls,NY 131
3-0187
PN:LB-MANCLSERVRev.A
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Table
f Contents
G E N E R A LN F o R M A T T o N
- - - - - - 1 - 1
TECHNTCALELP NFoRMATToN
- -
1-1
S E R V I C EE N T E R S
- - - -
- - - - -
1 - 2
W A R R A N T Y
- . - - - - . 1 - 3
S Y S T E MY M B o L E S C R I P T I o N S
- - - - - - -
1 - 4
W A R N I N G SN D R E C A U T I o N S
- - - -
- - -
1 - 5
W a r n i n g
- - - - -
1 - 5
C a u t i o n -
- - -
1 - 5
O P E R A T I N GN S T R U C T I o N S
- - - -
1 - 6
Conlro ls
1 '6
P o w E R
N / O F F
w r r c H .
- ' - - - -
1 6
F | B E Ro R r - - - - - - 1 6
MULTI INKTMXPANSIoN
oRT-
NSTALLATIoN
NDUSE
oPTIONAL)
. - - - - - . . . - -1-7
L i c H T ] - T E N U A T T o N
o N T R o L
- - - -
- - - - - - - - - 1 - 7
LAMP IFENDrcAToR
- ' l -7
Pr inc ip les f Operat ion
-
1-8
L I G H To U R c E
- - - 1 - 8
R E P L A C E M E N TA M P S
- - - - - . - - - 1 - 8
PowER upplywrrHCoNTRoLLEcrRoNrcs
--- -
-1-8
M U L T | i N K T Mo R T A N DU L T rT N K T Mx p A N s r o No R T
-
- - - - - - - - - 1 - 8
S E R V T C E
- - - - - - - - -
1 - 9
C L E A N T N G
- - - - -
1 - 9
S U R G T C A LL L U M T N A T o R
. -
- - 1 - 9
M U L T |
T N K T M
x p A N s r o No R T
- - - - - - -
- - - - - - 1 - 9
T o o L SR E o U I R E D
- -
1 - 1 0
T R o U B L E S H o o T N G
- - - -
- - -
1 - 1 1
CL 100SuRGrcArLLUMTNAToR
- - - - -
1-11
CL 1OO URGICALLLUI\ , I INAToRISASSEMBLY
- - -
. . . - ' I -12
TEST
1: BLoWN
UsEs
-
- -
1-12
T E S T
2 :
1 O O A T T
P O W E RU P P T Y
- - - - - - - -
1 - 1 3
T E S T # 3 :o o L r N GA N
- -
. 1 - 1 3
TEST
4:
LED/OVEBTEMPWITCH
.
- - - - '
1.13
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T E s r # s :M r c R o I N K @T B E RE s r
- - - - - -
- -
1 - 1 3
TEST#6: owER uppLy ALTBRAIoN
---- - -
1-14
CL 1OO URGICALLLUMINAToRISASSEMBLY
- - -
1.15
PoWERUPPLYEMoVAL
- -
1-15
P L A T F o R ME M o V A L
- - - - - - - -
1 - 1 6
F R o N TE Z E LE M o V A L
- - - - - - - -
1 - 1 6
FAN
DEFLECToREMoVAL 1 16
C H A S S I S
A N E M o V A L
' - - - - - - - -
1 - 1 7
LED/OVERTEMPARNESSEMoVAL
-.
- . .
-
1-17
LAMP ABLE EMoVAL
- - - -
1-17
INTERLoCK
wrrcH
RENtovAL
- - -
- '
1-18
PoWER NTRY ODULEEMoVAL
-.
- _
1-18
CL
100SURGTCALLLUMTNAToREPATF
ARTSrsr
-- -
- - - - -
1 -19
C L 3 0 0
S U R G T C A LL L U M T N A T o R
- - - - - - - ' l
2 5
CL 3OOSURGICALLLUMINAToRISASSEMBLY
- - -
1-27
T E s r # 1 : B L o w Nu s E s
- - - -
1 - 2 1
TEST 2: AuxrLrARy oARDNpurTERMTNALS
- - - -
' l-27
T E s r # 3 :
o o L r N G
A N
- - -
1 2 7
TEsr
#4:
LED
OPERAToN
---- -
1-27
TEST
5:
MIcRoLINK@ TBEREST
- - -
1-2A
CL 3OO
SURGICAL
IIUMINAToR
ISASSEMBLY
.. -
1-29
I N T E R N A Lo D U L EE M o V A L
- - - - -
- - - - - - 1 2 9
PoWER
UPPLYEMoVAL
129
P C B A
p A R r
o .A 4 - 1 0 6 7 0 )
E M o V A L
- - - - - - -
1 , 3 0
l G N r r o R
E M o V A L
. - - - - -
1 - 3 1
L|NE
TLTER
EMoVAL
-
- -
. -
1-31
CHASSISANREMoVAL
-- - -
1-32
P o w E R N T R Y o D U L EE M o V A L
- - - - - - - -
1 - 3 3
P L A T F o R ME M o V A L
- - - - - -
1 - 3 4
F R o N T E Z E LE M o V A L
- - - - -
1 - 3 4
B L o w E RA N E M o V A L
-
- - - - - - - - 1 - 3 4
L A M P A B L EE M o V A L
- - -
- - -
1 3 5
CL
300SURGTCALLLUMTNAToREPATRARTSrsr
-- -
- - - - -
1-36
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G L o S S A R YF T E R N 4 S
- - - - - -
1 - 4 2
FINALNSPECTIoN
--
1-43
CL 1OO URGICALLLUMINAToR
-. .
-
1-43
CL3OO URGICALLLUMINAToR
. .
-
1-43
SPEcrFlcAroNS
---
1-45
T H E o R Y o FP E R A T I o N - - - - - 1 - 4 6
L r G H ro u R c E
- - - - - - 1 - 4 6
R E P L A C E M E N TA M P S
- - - - - - - 1 - 4 6
PowER
uppLy rrHCoNTRoLLEcrRoNrcs
--- - - -
1-46
M U L T I
I N K T Mo R T A N DU L T rT N K T Mx p A N S t o No R T
- - - - - - - - - - 1 - 4 6
C L 1 O O U R G I C A LL L U M I N A T o R
I R C U I T
I A G R A M
- - - - - - -
, I - 4 7
CL 3OO
SURGICAL
LLUMINAToR
IRCUIT
IAGRAM
.
-. - - - -
1-48
8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
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GENERAL
NFoRMATToN
TheWelch
Al lynCL
100
Surgical
l luminator
nd he WelchAl lynCL 300Surgicall luminator
rov ide
r i l l iant
i l luminat ionor he
physic ian
nd
surgeon. he amps
roduce
igh ntensi tyight ear lydent ical
o the spectrum
of
sunl ight .
pecia l
eaturesnclude
he abi l i tyo useei ther CogentOpt icsMicroLink@ iber r a convent ional
f ber
bundle.
TECHNTCALELPNFoRrvrATroN
Only
ul ly
ra ined nd
proper ly
quipped
ersonnel
hould
erform
l lserv ice nd eparrs,srng
enurne
replacement
arts
nd
correct
rocedures.
a i lure
o do so
wi l l nval idate
he
product
arranty
ndcould
compromise nstrument af ty and
performance.
Read ndunderstandl lsafetywarnings ndserv ice otes
pr inted
n hisServ ice anualandhe
Operat ing
Manuals,
ar t
number
B-IVAN-100W270W.
f
there s anydoubtabout ny
precaut ion
r
procedure,
or
phone
help. r o
order ddi t ionalopies f the Operat ing anual , ontact :
Customer Service
Welch Allyn, Inc.
4619Jordan
Road.
PO
Box 187
SkaneatelesFalls,NY 13153-0187 SA
Telephone: 1-315-685-2993o1
1-866-801-8428
FAX: 1-315-685-2999
Techncial Assistance
Telephone:
1-315-685-4233,7:00am-3:00pm(EST)
Whencal l ing,efer o the modelnumber hown
on
he data abel ,oundon he
backof
your
Surgicall luminator .
Technicalss is tances
contained
n
"Troubleshoot ing
on
page
11
of
th ismanual .
PN:LB-MAN
CLSERV
Bev.A
8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
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Welc$11ytt'
SeRvrce
ENTERS
lf
you
havean equipment
problem
hat
you
cannot esolve,
ou
may
call he
Welch
AllynServiceCenternearest
you
or
assistance.
echnical
ervice upport s
available y telephone n norma
business
ays
at the
phone
numbersis ted
elow. f
you
areadvisedo return
product
o WelchAl lyn or repai r
r
rout ine
marntenance,
schedulehe
reDair
i th
he servrce ente.nearesl
ou.
BEFORE
ETURNING PRODUCT
FORREPAIR OU
MUST OBTAINAUTHORIZATION ROMWELCH
ALLYN.AN RMA
(RETURN
MERCHANDISE
UTHORIZATION} UMBERWILL
BE GIVENTO YOU BY OUR
SERVICEPERSONNEL.
E
SURE
TO
NOTETHIS NUMBERON THE
OUTSIDEOF YOUR SHIPPINGBOX.
RETURNSWITHOUT
AN RMA NUMBER
WILL NOT BE ACCEPTED ORDELIVERY.
USA
CUSTOMERS
CANADA
CUSTOMERS
Welch Allyn, I nc.,
U.S.A.
Welch Allyn, Ltd.,
Canada
4619
ordanRoad
'160
Matheson lvd.E. ,Uni t#2
Skaneateles
al ls ,
Y 13153-0187
Miss issauga,
anada 4Z1V4
Tel:1-315-685-2993 Tel:
905-890-0004
Fax:
15-685-2999
Fax:
905-890-0008
INTERNATIONAL
USTOMERS
Welch
Allyn, GmbH
Welch Allyn,
Ltd., Singapole
Zollerstrasse 4
300 BeachRoad, 25-08
72417
JunEngen,Germany,
The
Concourse
fel:
011-49-7
77
9211-73
Singapore 99589
Fax.011-49-7477-9271-93
Tel:011 65-291-0882
Fax:
11-65-291-5780
WelchAllyn, Ltd.,
Australia
Welch Allyn,
China
Metro Center Room708, 22'/ lluang Pi Road,North
Unit5 38 SouthStreet
Central
Plaza
Rydalmere, SW
2116,Austra l ia
Shanghai00003
Tel :
11-61-294-183-155
PR.China
Fax:
11-61-294-183-650
Tel :
11-86-21-63279631
Fax. O11'86-21
6327
9632
Welch
Allyn, Japan
Bon Marusan
F,3-5-1Kanda
Jinbo-Cho,hiyoda-Ku
Tokyo
01-0051
Japan
Tel :
11-813-5217391
f ax.011 813-32617372
LATINAMERICAN
CUSTOMERS
MD Intemational
1
1300 N.W.41
st Street
Miami ,
FL33178USA
Tel:
-305-669-9003
Fax: -305-669-1971
1 2
WELCH
ALLYN
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WARRANTY
Welch
Al lynwarrantshe CL300or CL 100
Surgical
l luminatorhen new to
be
ree
of defects
n mater ia l
nd
workmanship
nd o
pertorm
n
accordance ith
manufacturer's
pecificatrons hen subject o normaluse and
serv iceor
a
per iod
f one
year rom
dateof
purchase
romWelchAl lynor an author izedgent .WelchAl lynwi l l
e i ther
epai r
r replace nycomponentsound o be defect ive r
at
var iancerommanufacturer 's
pecl f icat ions
wi th in
his imeat
no
cost o the customer.t shal l e he
purchaser 's
esponsib i l i tyo return he nstrumento the
aurhor izedis tnbJtor ,gent .
r serv ice
epresentatrve.
WelchAllyn
warrants he lamp o be free of defects n materials nd workmanshipor a
period
of 6
months rom
the
dateof
purchase.
hiswarranty oesnotcover he amp or breakager a i lure ue o tamper ing, isuse,
neglect , cc idents,mpropernsta l lat ion,odi f icat ion,
h ipping,r rom mproper a intenance,ervrce,r
c leaning
rocedures.
Thrs
warranty s void f the instrument s not
used
n
accordance
ith manufacturer'secommendations
r
if
requi red
erv ices
performed
y other hanWelchAl lyn r anauthor izedgent .Purchaseate
determrnes
warrantyequi rements.o
otherexpress r mpl ied arranty s
grven.
PN:LB MAN
CLSERV ev.
A
8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
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Velc$1yt
'
SYSTEMYMBoL EscRtPTtoNs
aPxg
Attent ion: ead
Operat ing anualor Warnings, rec aut ions,nd nstruct ionsor Use
Caution
Hot
SurfaceArea
Ra^la^a t r , ,c6 ec l r ,4er t or l
250V
5A
WARNINGHigh ol tages
present
Symbol n
power
swi tch ndicates
ower
s of f when
pressed
Symbol
n
electr icalat ing igni f ies C mains
ower
High ntensi ty
ight
Protective arth
G
ound
Storage
emperature
ange
Maximum torage umidi ty
Type
BFequrpment, lass
Not
protected
gainst he
ingress
f
water
Manufactured
n accordance ith the relevant egulations nd
echnical
equirements
f
Japan.
A
A
A
5 A , 2 5 0 V
A
I
+
@
| - ^ .* l
| |f l
t4__l
@
tr
WELCHALLYN
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WARNINGS ND PRECAUTIoNS
e
WARNING
/-\
l \
. Keeo ut o l reach f pat ient .
PN:LB-MAN
CLSERV
Rev.A
.
Notsui tableor use n
he
presence
f a f lammable nesthet ic ix ture i th a i ror
wi th
oxygen r
n i t rous
xide.
.
Disconnectrom the
patient
before he discharge f a cardiac efibri l lator.
.
ELECTRICAL
HOCK
AZARD. o not remove he oo cover
.
Rout inelyxaminehe
power
ordand
piug.
Do not
use
f nspect ioneveals
amage.
eplace nly
with approved ospital
rade
power
cordand
plug
with appropriate lectrical
ating.
.
Do not olace he exoosed istalend of the
Micro
Link@
Fiber
or
fiber
bundleattached o either
a
headlight
r otheraccessory.
ailure
o observe hese
precautions
may result n burns o skin,
c loth ing,
r other
mater ia lnadvertent ly
laced
n rontof the MicroLink@ iber r
iber
bundle.
.
High
energy
adiatedight
uided
hrough ndoscopes
ay
give
ise o h igh emperaturesn ront
of
the ight ut let nd o the ipot the nstrument.
.
Use care
not
to
point
he distalend of the
fiber
or
headliqht
irectly
t the eye when unit s operating.
The
br i l l iant
ight
utput
om
he uni tcancause ye
njury
er
RP27 1
( '1994
995Threshold imi t
ValuesorChemical ubstancesndPhysical
gent
nd
Biologicalxposurendices, inal
rat t
March
3 , 1 9 9 5 ) .
.
Applied
parts
attached o this equipment
hould
be
approved ) o the MedicalDeviceDirective
93/
42/EEC)
Europe),
) approved y a Nationally
ecognized esting
aboratory
United
States),
nd
3) by
a Standards ouncil f Canada ccredited
aboratory
Canada)
o the appropriate
edical tandards.
The
use of
non-approved
omponents
may compromise afety.
.
Dur ingi {e
hreatening
rocedures,
t s recommendedo have backup ight ource ndanaddi t ional
reolacementamo.
. The ight ourceamps rehighly ressur ized,nydamage r mproper andl ing aycause remature
fa i lure r explos ion f the
amp.
.
The ight
source
amps
are
hot immediately
fter use,
allow he lamp o cool or five
(5)
minutesafter
operation.
emperatures
eak
n the lightSources pproximately 0 seconds fter he LightSource s
powered
off.
r
CAUTION
lA
.
Donot
place
nythrngn opof heLight ource. o
not
store
iquid
bovehe
Light ource.
.
C logged r b locked ents
may
cause ightSource verheat ingnd
wi l l resul t n hermal
hutdown.
Keep
he LightSource lear
f any
obstruct ions.
.
Ful ly
lose he at tenuator
efore urning n he LightSource r whenoperat ionalut not
n
use.
8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
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Welc$11yn.
OPERATTNGNsrRucloNs
CONTROLS
PowERON/OFF wrrcH
Plug ospi ta l
rade
Power
Cord nto
a
grounded
Hospi ta l
Grade" r
"Hospi ta l
Use"
receptac le
o ensure
grounding
el iabi l i ty .
Press
Main Power
Switch ON
(l
pressed
n).
The ampwi l l
cont inueo operate nt i l the
power
wi tch
s moved
o the OFF
posi t ion
O
pressed
n). f
the
amp
cannot
be startedor stops operating
ee Section : Tro ubleshooting .
NOTE:
.
l t is normal
o hear l ick ing
10
pulses
r ess) ef re he amp s s tar ted.
. To nsureproperoperation, ait thirty(30) econdsbetweenon/offcycles.
F|BER oRT
To ncrease
he
versatility
nd
applicabilityf use, he LightSources redesigned
o use eithera
Micro
Link@
iber
or a t iberbundle ia he Mul t i
L inkrM ortandMul t iL inkrM
xpansion
ort .
Cable Gompatibility Table
For
ables i th no Mul t iL inkrM
xpansionort equi red:
1.
Close
he ight
t tenuator r u rn
he
Light
Source f f .
Multi Linkn Port
Multi Link-
ExpansionPort
MicroLink@ iber
Karl
Storz ACMI
Olympus
Wolf Dyonics
r 6
WELCHALLYN
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2.
Connecthe
nstrument
ndof the
MicroLink@ iber r iberbundle o the nstrument.
3.
Insert ,
nt i l u l lyengaged
snap
ound),he Lrght ource nd
nto
he
Mul t i
L inkrM
ort .
4. Turn n L ight
Source.
Adjust he ight
t tenuatoro
the requi redl luminat ionevel .
MULT|L|NK'" ExpANsroN oRT lNsrALLATroNNo
UsE
(oproNAL)
CAUTION: TheMul t iL inkrM xpansionort onta ins
pt ical
lementshat
can
become
amaged
f
dropped
or
aouseo.
NOTE: TheMul t i
L inkrM xpansion
ortmust
be
ul ly
ngaged
nto
he LightSource efore
nsert ing iber
Bundle.
Touse he l\4ulti inkrM xpansion ortperform he followingoperations:
1.
Close he ight t tenuatorr turn h e LightSource f f .
2. Remove,f
any,
Micro
Link@
iber
r
iber
bundle
rom
he
Mul t i
L inkrM
ort .
3. Inserthe Mul t iL inkrM
xpansion
ort ,
ress
nd urnc lockwise nt i l
t locks nto
place.
4.
Connect he fiberbundle o the instrument.
5. Insert , nt i l u l lyengaged,
he
Light
Source
nd
of
the iberbundlento he Mul t iL inkrM xpansionort .
6. Turn n L ight
Source.
Adjust
he
ight
t tenuatoro the
requi redl luminat ionevel .
To remove
he Multi LinkrM xpansion ort
perform
he followingoperations:
1 . Turn
he LightSource f f .
2. Remove
he
iber
bundle.
3. Turn
\,4ulti
inkrM xpansion
ort
counter-clockwisentilunlocked nd remove.
LrcHTATTENUATToN
oNTRoL
Moving he l luminat ionheelup * in"r"ur" . l ight utput .Moving he wheeldown
-
reducesrgnt utput .
LAMP LrFE NDrcAToR
A
yel low
ndicator ight ocated n the conso lewi l l l igh twhen there s approx imate ly 0 hours
remain ing
n the
lamp. A
new
Replacement amp
shouldbe ava i lab le t th is
po in t .
Once he
remain ing
ourshave been exhausted he lamp w i l l tu rn o t f .
PN:
LB-MANCLSERV
REV.
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Welc\Allyn.
PRINCIPLES F OPERATION
LtcHT ouRcE
The
Surgical
l luminators
onsis t
f anenclosure ousing high
ntensi tyamp,
ropr ietary
pt ical
lat form,
ser
controls
nd
ndicators,
nd a
power
supply
with
controlelectronics.Cooling
s
provided
ia nternal ans. In
the
event
hat the
fan(s)
malfunctions
r
if adequate
ir
low is
blocked
nd/or he internal emperature
f
the
device
exceeds he engineering
pecifications,n nternal hermal
protection
mechanismwill automaticallyhut off
power
o the
lamp. After
cooling, he Light
Sources
may
be
restarted.
REPLAcEMENTAMPs
The amps rehigh
pressure,
igh
ntensi ty nd ong i feLightSources. heyaremounted ntoa
patented
amp
f ix ture
hich s designedo
al lowbotheasyand apid xchange
n
he
ie ld
as
wel l
as ensur ing
rec ise
l ignment
to the optrcal lat form.
PowER
Supply
wrrx
CoNTRoLELEcrRoNtcs
All
he electricityo the LightSource s
controlledhrough he ON/OFF witch.
Power
o energize nd
operate
he
lamp, ans,and control
ircuitry s
provided
y a customdesigned,wattage egulated, witching
power
supply.
The
operational
ife
of the lamp
and
amp ife ndicator
re controlled
y
a
lampvoltagemonatoring
ircuit.
MuLr
LtNxn PoRT NDMULT| |NK* ExpANsr oN oRT
Internal,
o both he Multi LinkrM ort
and
Multi
LinkrM xpansion
ort,
are
patented
oupling pticsand
mechanics
designed o
produce
he highestoutput
powers.
Internalo the LightSources re ansand heatsinks esigned o
reduce
emperaturest the opt ical
oupl ing
oints
hereby
minimiz ing
he
possib i l i ty
f damageo
MicroLrnk@
Fiber nd berbundles.
1 B
WELCH
ALLYN
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SERVTCE
CLEANTNG
1. Pr ior
o c leaning,urn he
power
wi tchOFEanddisconnect
ower
ource
rom
both h e LightSource nd
the wal lout let .
2.
Cleanhe external ur faces y wip ingwrtha c lothdampened i th 10%
bleach olut ion. O NOT
MMERSE.
r
Rout inelynspect
ndclean l la i r
ntakes
out lowsat he rear
f the chassis
or int
or otherdebr is .
.
Fol low he manufacturer 'snstruct ionshenCleaning
he
iber
bundles r accessor iessedwi th he ight
source.
3.
Wipe
he
power
ordwi th a c lothdampened i th 107o
leach olut ion nd
water.
DO
NOT IVIMERSE.
O
NOTRECONNECT
ET.
4.
DO NOTwipedownany e nses r windows.
5.
DO NOT
plug
he
power
sourcentoa wal lout let nt i l t s horoughly
ry.
SURGtcALLLUMtNAToR
The
consolemaybe c leaned s ing c lean of tc lothwi th
he
ol lowing
leaning gents:
Enzymat ic o lut ion
Enzol )
lsopropyl
lcohol
Hydrogen
eroxide
% USP
2% G utaraldehyde
olut ion
Soapand Water
' lOo/o
bleach otut ton
nd
water
CAUTION: Do notsplash leaninggents nto
any
openings,
eams r e lectr icalomponents.
MULT| |NK* ExPANsroNoRT
The outside urfacesmay
be cleaned
with
a soft cloth using he
following:
isopropyl lcohol
Soap
and
Water
The
glass
surfacesmay be cieaned y the followingmethods:
A cottonswab moistenedwith lsopropyl lcohol
Blow with
dry compressed ir
NOTE: Us e care n
cleaninghe optical
urfaces
f the
Multi
LinkrM xpansion
ort
o
prevent
cratches.
PN:LB-MAN LSERV ev.
1 - 9
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'IVelc$;1*.
TooLsREoUIRED
.
Slotted crewdriver,ess
han6
"
long
.
#1 Phi l l ips
crewdr iver,ess han
6"
long
.
#2 Phi l l ips
crewdr iver,ess han
6"
long
.
Open
end
wrench
et- Engl ish r 5/16"
.
Needle ose
pl iers
.
Nut Dr iver et Engl ish
r 3/16" ,114",5116"
.
Nut Dr iver
et
Metr ic
or 1Omm
.
Deepwel l
socket etand
wrench
2)
CL
100
Surgicall luminator
.
Non-conduct ive
ot
adjust ingool CL
100
Surgicall luminator
.
Lightoutput
power
meterwith head.
Coherent asermate D or equivalent
meter),
HeadModel 1d10
CL
100
Surgical
l luminator
.
Laght utputmeter Labsphere odelFIMS-400P
r equivalenthatmeasuresn umens
CL300Surgical
llu-
minator
o
CaIbrateo
MS
Drgi ta l u l t imeter
DMM)
1 , 1 0
WELCHALLYN
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ThouBLESHoorNG
CL 1o0 SURGTCALLLUMTNAToR
Symptom Cause
Remedy
Lamp ai ls o s tar t nd
fansarenot running.
No
power
o unit Check
ower
upply
ordandout let
Line
voltage s
8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
16/52
Symptom Cause Remedy
Lo w
l ig t ou lpu l
DamagedMicroLink@ iber
or berbundle
Check ndsof MicroLink@ iber r iberbundle
for
damage.
eplace i t h new MicroLink@ iber
or iberbundle. o o
"Test
#5: MicroLink@ iber
Test"on
page
13.
Fiber
bundle
not connected
correctly.
Re-insert berbundle orrectly.
Lampnear
endof usable
i fe
lnsta l la 00W eplacementamp,model 0133.
Fi l ter
ssembly n
plat form
contamrnated.
Clean r replacei l ter ssembly s necessary.
Minors dirty.
Clean i rrors.
Brokenmirrors. Replace
latform.
Misal igned i r rors
possib le
if
unit suffersdamage)
lf abovesteps ail o improveoutput, eplace nd
retest
platform.
Dirty
or damaged
nternal
mooute.
Inspect, lean,and replace f necessary.
Fiber
undle
wi l l not
Installn LightSource
Not
a compat ib le
berbundle
See
Operat ing
Instruct ions"n
page
Use ompatib leundle esign
Insta l l /Femove
ul t iL inkrM
Expansion ort
See
Operatrng
Instructrons"
n
page
6
Multi
Lin
rMExpansion ort
insta l led
RemoveMulti LinkrM
xpansion
or t
Audib le
c l ick ingor
arc ing
ound
ur ing
he
lamp
gni t ion
rocess
No
problem
Normal
operation
Velc$11yn.
CL lOOSURGICALLLUMINAToRISASSEMBLY
NOTE: For all ests, emove9 screws rom top cover.
NOTE: Do not operateunit
with
the top cover emoved
or
more han 5 minutesor the unit
will
overheat.
TEST 1: BLowN
FUsEs
The
purpose
of this est is to determine he sourceof a short circuit ausing uses o blo w. Refer o the Block
Diagram n
page
7.
Replace
nd
retest he fuses. f
unit
unctionsnormally,nspect uses hat were blown. f solder s meltingout of
the end of the
fuse
and he
glass
s not blackened,
emove
and
replace
he
power
entry
module.This ault
occurs
when
he
prong
of the fuse holdermakes
poor
contactwith
the
fuse.The
prong
will lookdiscolored nd
pitted
where t contacts he fuse.
WELCHALLYN
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l f
the
use
blowsagarn,nspect
he
power
supply nd he wi r ing or
damaged r burnt omponents. emove
nd
replace
ny
visually
efective omponents.
l f v isual
nspect ion
oes
not
y ie ld
nyevidence
f damage,emove nd eplace
ower
upply
nd etest .
IEST#2: lOOWATT PowERSUPPTY
Veri fy perat ingol tages
present
n
power
upply nput
erminals . onnectmeter nd
set
o vol tsAC
o J1 and
J2 erminals . hen
power
s
appl iedo the uni t , er i fy he
operat ing
ol tage
s displayedn the meter.NOTE:
Verify he lamp
accessdoor s closed.
lf voltage s
present,
eprace
nd retest
power
supply.
l f vol tages not
present ,
nspecthe
uses,
wi r ing,
ower
entrymodule,ine i l ter ,
nd
nter lock
wi tch.
TEST 3: CooLINGFAN
The
purpose
f this est ls to verify
he operatton f the lamp
cooling
an.
Visual ly
nspector a broken an.
When he uni t s
powered
p,
ook or
a fan not urning.f found, emove
op
cover nd nspectan.
Replace ny
broken
ans.
lf fan is inoperative
nd not broken,measure
usingDMM set for VoltsDC or 12VDC
n
fan
connector.
.
lf
voltage s
present,
eplace nd retest an.
.
lf voltag e s not
present,
eplace
nd
retest
power
supply.
IEST#4: LED/OVERTEMPwITcH
The
purpose
f
this
est
is
to veri iy
proper
operation
f the LED.
Visuallynspect hat LED/overtempwitch harness s connectedo the powersupply. erifycontinuity f wiring
andLEDwith DMM
set o the Diode
Scale.
MM
should ead
=
.7VDC.
.
l f
the DMM reading oesnot
match,
eplace
nd etest
he
LEDharness
r
l f
DMM reading atches
bove, eplace nd etest
he
power
uppty.
TEST 5: MIcRo
LINK@
IBEREsT
The
purpose
f this est is to verify
he operation f the Micro Link@ iber.
Wi th
he
l luminator
n,connecthe iberand
he
headl ight .
vera d is tance f at east ive eet ,
adjust he spot
dramete '
o the
argest
tze.
.
l f
the ntensi ty f l ight s not
consis tenthroughouthe ight
potand otat inghe dis ta l ndconnector oes
not
cause he shape o change,
he
headl ight
s he most ikely
ause f the
aul t
.
l f
the ntensi tys not
consis tent i th a l ternat ingight
nddark
ings
resent ,
he iber s broken
t the d is ta l
Over he samedistance, d just
he
headl ight
o the smal lest
iameter pot .At th isadjustment ,he headl ights
focused.
t anyspot r regular i t ies
re
present ,
o ld
he
headl ight
teady hi le otat ing
he
dista l
nd
black)
connector.
PN:
LB-MAN-CLSEBV ev.A
1 , 1 3
8/19/2019 WelchAllyn CL-300 Surgical Illuminator - Service Manual
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Welc\Allyn'
.
l f
the
location
f the
defectsmove, emove he fiber,
lean he
end
with
distilled ater, econnect
he unit,an d
test. Replace
he fiber f
detectsare still
present.
.
l f the location f the defects emainstationary,he fault s within he headlight.
TEST 6: PowER
SUPPLY AL|BRAT|oN
The
purpose
of this est is
to
verify
he operation
f the
power
supply.
Apply
power
o unit,once
he
lamp
ights, onnect
he DIVIV
set
o volts DC)
o the lamp
cable
wires
on the
power
upply. he
posi t ive
ead
f DMM
to the
HV+
erminal n
the
power
upply nd he negat iveead
f the
DMM to
the LampReturn
terminal n the
power
supply.WARNING: o not
connectDIVM o wi res
pr ior
o
turninghe
uni ton.When he amp gni tes,
here s
approximately5kV n he
erminals h ichcould amage
he
DMM. Moni tor
hevol tage
isplayedn he ukewhen
he LED i rs t urns
on.Ver i fyhevol tages
between
7.00
and18.00v.
'
l f the voltage s less
han 17.00VDC,emove
and replace
he
power
supply
or
return
he unit or recalibration.
l f the vol tage
s between 7.00VDC
nd18VDC,emove
nd
eplace
he amp ix ture.
o
lt the voltage s more
han 18.00DC,
ontact he WelchAllynTechnical
ervicesDepartment
t
1-31
-685-2993 r 1
315-685-4233,:00am-3:00pm(EST).
WELCHALLYN
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CL
100
SURGTCAL
LLUMTNAToR
rsAssEMBLy
PowERSUPPLY EMoVAL
'l
. Bemove he 9 screwssecurinq he
toD
cover
and
remove
he
cover.
2. Removehe 3 screws rom he
bot tom
ide
of the back
pane.
3. Disconnect
i res rom
J1 andJ2 on he
power
upplv.
isconnect
an
connector
rom
J4.
4. Remove
he
2
screws
rom
the bottom chassis, ecuring he centerbaffle
see
igure
below).
Screws
secur ing enter
baffle o bottom
chasss
l C "
o o
w
5 .
6 .
Remove
he
nut hat
secureshe center af f le o the back
panel .
Pull
back
panel
out and move o the
platform
ide
of the chassi s o
garn
access o the backof the
power
supply.
PN:
LB
MAN'CLSERVRev.
A
1 1 5
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Remove he two white lampcablewires and disconnect
he
4 wire
connector.
emove
he supplyand baff
e.
Remove h e 4
screws
rom
the corners f the
power
supply.Remove upply.
Reinsta l lat ions he reverse
rocess
i th
he
brownwire
going
o J1 and he blue
wire
going
o J2.
The onger
of the two
lamp
cable
wires
attaches o the
(+)
amp
HV erminaland he shorterwire attaches o the
(-)
amp
return.Refer o
"
Photo "
on
page
4
o connect he
HV+
and
amp eturn
terminals s shown.
PLATFoR'UEMovAL
'L
Remove
9 screwssecuring op coverand remove he cover.Remove he 5 screwssecuringhe front bezel o
the bot tom hassis nd
pul l
ront
panel
ut
rom
chassis .
emove
he
amp rom
he
plat form.
2. Remove he 2 screws rom
the
fan deflector
ssemblv.
3. Remove he
4
screws
rom
the cornersof
the
platf
rm.
4. As necessary,emove he 2
screws
rom
the
f lter
assembly.
5. Removehe
plat form.
einsta l lat ions he reverse
rocess.
nsta l l theront
bezel ndcheck
or
proper
movement
of attenuator. oosen
platform
screwsand repositron s necessary.
FRONT EZEL EMoVAL
1.
Remove9 screwssecuringop coverand remove he
cover.
Remove
he 5 screwssecuring he
front
bezel o
the bot tom hassis nd
pul l
ront
panel
ut romchassis .
2. Remove
wires
rom
power
switchnotingwire localions. ushon
switch
rom
the
inside
o
remove he
switch
from
the bezel.
3. Usinga sharpknife,
emove
he blackRry from the LEDwires where t mounts
o
the tront
bezel.
Once
removed,
pplyacetone o the LEDand he front bezel o weaken he
glue
bond
and
remove he LED rom he
front bezel.
4. Installations
the
reverse
process.
o
attach he LED,ensureboth
panel
and LEDsurfaces re clean.Use
superglue,octite430 to mount
he
LED.
Use
RTV
ealantDow Corning 37 o seal he LED,
preventing
ny
l ight rom he l luminator
assing
hrough.
FANDEFLECTOREMOVAL
1.
Remove9 screwssecuring
op
cover
and
remove
he cover.
8.
9 .
Welc$;1yt
'
7 .
2 .
3 .
4 .
5 .
Remove
he 5 screws ecur inghe
ront
bezel o the bot tom hassis nd
pul l f ront anel
ut romchassis .
Remove he overtempswitch rom the fan
def
ector.
Carefully
emove
he
heat
shrink ubing
rom
the
fan
wiring harness.
Disconnect
he connector nd
remove t
from the
power
supply.
6.
Installations
the
reverse
process
with
install ing ew heatshrink ubingover an connector.
WELCHALLYN
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4 .
5 .
CHAssrs
FANREMovAL
T. Remove
9 screwssecuring op cover
and
remove
he cover.
Remove
screwssecuring he
fan to
the back
p a n e .
2. Remove eat
shr inkubing rom he an
connector .
isconnect
nd
emove
he
wire
ies
rom he harness
t
the
plat form
mounts.Remove
he an.
3. Installations the reverse
process.
LED/OVERTEMPARNESSEMovAL
1. Remove
screwssecuring op coverand remove he
cover.
Remove
he 5 screws
securing he front
bezel o
the bot tom hassis nd
pul l t ront anel
ut romchassis .
2.
Remove
he overtemp witch rom he fan
def
ector
assembly.
emove
he wire ie
f rom
he overtemp witch
harness t the platf rm.
Usinga sharp
knife, emove
he blackRTV rom the LEDwires where t mounts
o
the front bezel.Once
removed,
pplyacetone o the LEDand
he
ront
bezel o
weaken
he
glue
bondand
remove
he
LED rom
he
front bezel.
Remove he
3
wire
ties and
remove
he harness.
lnstallations
the reverse
process.
o attach
he
LED,
ensureboth he
panel
and he
LED
surfaces
re
clean.
Usesuperglue
loct i te
30)
o
mount
he LED.UseRTV ealant
Dow
Corning 37) o seal he LED
prevent ing
any
ight rom
he l luminatoro
pass
hrough.
ee
igure
elow
or rout ing
f
wi res.
LAMP
CABLE
EMovAL
1. Remove screwssecuring
he op coverand
remove
he cover.Remove he 3 screws
rom
the bottomof the
back
anel .
Removehe nut secur ing
enter af f le o the back
panel .
l ide ack
panel
o
the s ide.
PN:
LB-MAN-CLSERV ev.A 1 1 7
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2.
3 .
4 .
Welc\ffiytt.
2.
Remove
he
nut rom
he wire ie c lamp ecunnghe
amp
cable o the bot tom hassis .
emovehe amp
cable
rom
the
power
supplyand remove he cable.
3. Insta l lat ions he reverse rocess i th he onger ablewrregoing o the HV+ erminal n he powersupply
andconnect inghe shorter i re o the LampReturn terminal .
iew
he uni t
rom
he
rear
ndcompare
he
HV+
and he
LampReturn are
connected s shown
n
"Photo
8" on
page
24.
INTERLoCKwtrcH REMovAL
1. Remove he 9 screws securino he toDcoverand
remove
he cover.
2. Disconnecthe wi res rom he nter lockwi tch.
3. Remove he two nuts rom the interlock witchand remove.
4. Instaliations
the reverse
process,
onnectinghe
wires
o the terminals
marked
COM and
NO.
PowERENTRYMoDULEREMoVAI
1.
Remove
9 screwssecuring he top coverand
remove
he cover.
Remove
he 3 screws
rom
the
bottom of the
back
panel.
Bemove
he
nut securing enterbaffle o the back
panel.
Remove
he
4
screws ecur inghe chassis
an.Remove
he
wires rom PEM.
Remove he two nuts securing he PElvl o the ba ck
panel.
Remove he
PEM.
lnstallations the rever se
process
with the tollowing equirements :
.
The starwasher s locatedbetween he PEM langeand he
painted
urface ideof the back
panel.
The
lat
washer s installed
n the othersideof the
panel
and
s
secured
with
the
nut.
Rotate he screw
so
that
you
can
ater nstall he
power
cord etainer.
The
brown
wire is
connected o
the terminalmarked
as
P on the PEM.The bluewire is connected o th e
terminalmarked s N on he PEN/] .he
green
wire rom he back
panel
s connectedo the
ground
ermi-
nalon he
PEM.
r 1 B WELCHALLYN
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CL
100
SuRGrcArLLUMTNAToREpAtR
ARTS tsr
Part
Number
Description
Photo #
Bubble
#
Ouantity
9 0 1 3 3 l OOWREPLACEMENT LAMP
LB-MAN.1OOW27OW
MANUAL,
1OOW2TOW
OLARTEC
'l
A0-10756
PANEL, OTTOIV,
7OW
1 1
'l
A0-10768
LABEL,WARNING,LLUIVINATORS
1
2
1
A0-1
71
4
SCREW,
AINTED,
LS
1
3
1 2
101
0033
SCREW,8-32
3/8,PHPS
1 4
4
101-0022
scREW,
6-32
1/4,
PHSS
1 5
2
016-0005 XLS,
UIV ER, UBBER,
/8
1 6 4
1
1
0068
SEMS,
6-32
5i
16
PHPS
1
1
I
A0-10683
COVER,OEXLSCHASSIS 2
8 1
A0-107
1 KAPTONAPE,
OP
COVER,LS 2
9
1
A0-t
0828 PANEL,
RONT,
OLARTEC
]OOW
3
1 0 1
u50087
l OOWNTERNAL
ODULE SSEMBLY
3
1 t
1
u50081
l OOW ANDEFLECTOR
SSEMBLY
3 12
1
u50085
l OOW ILTE
ASSEMBLY
3
1 3
1
u50075
l
OOW LI GNED LATFORM
3
1 4
1
A0-1071
FAN,
CHASSIS,LS
3 1 5
1
A0-10856
PANEL,
BACKWAVEPATTERN
3
t o
1
213-0017 POWERENTRYMODULE/LINE ILTE ,
FUSED
3
1 7
'l
102-0012
KE S,
6.32,W/CONICAL
ASHEB
3
1 8
4
44-10650
WtRE
ARNESS,
N/OFF,OOW
3
'19
1
A4-10647
POWER
UPPLYLS
4
20
1
A0-10746
OVERTEMP/LED
W]TCHSSEMBLY 4
21 1
A0-10712
B A F F L E ,
E N T E R ,
L S
4
22
1
A0-'r0843
F O A M ,
GN
O R
4
40
1
1 0 1 - 0 0 6 2
SEMS, 6
32
X
9/16
PHPS
5
23
4
207
0007
G U A R D ,
A N ,
2 M M
5 24 1
105-0008 CORD,RETAININGLAMP 5
25
I
r06-0011
S T A N D O F F ,8 , . 7 5 1
5
26
4
208-0016
F U S E ,
AS H E E TI I
6
27
2
44-10465
WIRE, EM
ODIN
6
28 1
101-0073
SCREW, 8-32
3/4" , PHPS
6
29 4
0 1 0 - 0 0 1 6
TUBING,
EAT HRINK
/4"
BLACK
6
30 z . z a
I 0 1
0 0 6 1
SCREW,
4-40X114,HPS
6
31 4
1010038
PLUG,6 /25
7
32 1
PN:
LB-MAN.CLSERV eV.
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Welc$11*.
Part
Number
Description Photo # Bubble
# Ouantity
104
0006
WASHEH,COLOH
COAI I )
7 33 1
1 4-0008
WASHER, EFRATED 7 1
104-0007
WASHER, LAT 7
35
1
102-0001
NUT,HEX
7
36
1
104-0019
W A S H E R ,4 t X I t R N A I
T O O T H
7 31 2
A0-10864
CABLE,
AMP,
OK
8 38
1
1 12-0001
C A B L E
I E ,
M A L L
"
8
39
8
1 2 4
WELCHALLYN
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PHoro1
PHOTO
--.
( '
lc"
, ,
< - ; - 2
c
5
=---|'
e
- / ) .
"t-.......-o
a.--.-r
PN:LB MAN
CLSERV
Ev.
1-21
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Welc$;1*'
PHoTo
1 9
1 2
1 0
1 1
PHoTo4
1 4 1 8 1 7 1 5
2 1
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23
?4
PHoTo
5
PHoTo6
3 1
30
PN:LB-MAN-CLSERV ev.A
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Welc\ffi*'
PHoro7
PHoTo8
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CL 300 SuRGrcArLLUMTNAToR
Symptom Cause
Remedy
Lamp ai ls
o s tar tand
fansarenot running.
No
power
o un i t Checf
power
supply orda1dout le l
Linevoltage s
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Welc\ffiyr..
Symptom
Cause
Remedy
Low lightoutput Filter
assembly n
platform
contamrnated.
Cleanor re place iltersas necessary.
Mirrorsare dirty. Clean
ne
mrrrors.
Broken i rrors.
Replace
latform.
Misal ignedirrors
possible
if
unitsuffers amage)
l f above
teps
ai l to mprove utput , eplace nd
retest
platform.
Damaged icro
Link@
iber
or berbundle
Check ndsof MicroLink@
iber
r
iber
bundle
f or damage.Replace ith new Micro Link@
iber
or
fiber
bundle.Go o
"Test
#5:
Micro Link@
iber
Test"
on
page
28 .
Fiber
bu
ndle
not connected
correctly.
Be-insert berbundle
orrectly.
Lamp
near
endof usable
i fe
Insta l l 270W eplacementamp,model90125.
Fiber
undle
i l l not
insta l l
n L ightSource
Not
a compatrb le
iber
bund le See
Operat ing
Instruct ions"n
page
6
Usecompat ib leundle es ign
Install/Remove
ulti LinkrM
Expansion ort
See
Operatrng
Instructrons"
n
page
6
Multi LinklMExpansion ort Be moveMul t iL inkrM
xpansion
ort
Audiblecl ickingor
arcrngound ur inghe
lampgnit ion
rocess
Noproblem
Normaloperation
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CL
300
SURGTGALLLUMTNAToR rsAssEMBLy
NOTE:
For
all ests, remove9
screws
rom
top cover.
NOTE: Do notoperate n i twi th he op cover emovedor more han5 minutes r he unrtwi l loverheat .
lEsT#1:
BLowNFUsEs
The
purpose
f th is est s o determinehe source f a short
i rcui t
ausinguses
o blow.
Refer
o the Block
Diagram n
page
8.
Replace
nd etest he uses. f uni t unct ions ormal ly ,nspectuses
hatwereblown. f solders mel t ing
ut of
the endof
the
use
and he
glass
s
not b lackened,emove nd eplace
he
power
entry
module. h is
aul toccurs
when
the
prong
of the fuse holdermakes
poor
contact
with
the
tuse.
The
prong
will lookdiscolored
nd
pitted
where t contacts
he fuse.
l f v isualnspect ion
oesnot
y ie ld
nyevidence f damage,
emove
2 andJ3 romauxi l iaryoard
blue
ndbrown
wires
hatconnect
CBA
uxi ary
oard
o the
power
supply. eplace
uses
and urnsystem n. Remove
ower
and nspectuses
.
l f
the
uses
areblown,
emove
nd
eplace
he PCBA
uxi l iaryoard
part
o .A4-10670).
.
l f fusesare ine, emove
nd
eplace
he
power
uppty.
TEsr#2:
AuxtLtARyBoARDNpur TERM|NALS
Veri ty perat ingol tages
present
n auxi l iaryoardnput ermrnals. onnectmeter
andset
o vol ts
AC o J1 and
J4
termrnals.
hen
power
s appl iedo the uni t
he operat ing
ol tage, er i fy
t
is
displayedn he meter.NOTE:
Verifv he lamo
accessdoor
s
closed.
lf voltage s
present,
eplace
nd retestauxiliary
oard.
lf voltage s
not
present,
nspect he fuses,wiring,
power
entry
module,
ine ilter,and nterlock witch.
NOTE: f
lamp s not
on and
vol tages
present ,
heck
f
he
power
upplys defect ive.
lEsr #3:
CooUNGFAN
The
purpose
f th is est s o ver i ty
he operat ionf the
amp
ool ing
an.
Visual lynspector
a brokenan.When he uni t s
powered
p,
ook or
a
fan not
urning.
f found,
emoveop
cover nd nspectan.Replace ny
broken
ans
l f fan s noperat ive
ndnotbroken,measure
srngDMM set
or Vol ts
DC or
l2VDC
on anconnectors,
l
T s or
the amp an
(exhaust)
ndJ101or he
power
upply
intake).
.
lf voltage s
present,
eplace nd retest an.
.
lf vo age s not
present,
eplace
nd
re-test
auxilrary oard.
IEST
#4:
LED OPERATIoN
The
purpose
f
this
est is to
verify
proper
operation f the LED.
Visual lynspecthatJ1 is
connectedo the auxi l iaryoard. er i fy ontrnui tv
f
wi r ing
nd
LEDwith
DMM set o
the
Diode
Scale. MM should ead
=
.7VDC.
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Welc$1yn.
.
l f the DMM r eading
oes
not match, eplace
nd etest he LED
harness.
.
f
DMM
reading atches
bove, eplace nd etest
he
auxi l iary
oard.
TEST 5: MIcRo LINK@ IBER EST
The
purpose
of this est is to verify he
operation f the
Micro
Link@
Fiber.
Wi th
he
l luminator
n,connect he iberand he headl ight . vera d is tance i at east ive eet ,adjust he spot
diametero the argest
ize.
.
l f the
ntensi ty
f
l ight
s not consis tent
hroughouthe
ight
potand
otat ing
he dis ta l ndconnector oes
not
cause he shape o change,he headl ights
he
most ikely
ause
J he aul t .
.
l f the ntensi tys notconsis tent i th
al ternat ing
ight
nddark
ings
re
present ,
he broken
iber s
broken
t
the d
sta l
nd.
Over he samedistance,djust he headl ighto the smal lest iameter pot .At th isadlustment ,he headl ights
focused.f
anyspot r regular i t iesre
present ,
o ld
he
headl ight
teady
whi le otat inghe
dista lend
black)
connector.
.
l f the location f the defectsmove, emove
he
fiber,
lean he end
with
distilled
water, econnect
he unit,an d
test.
Replace
he fiber f defectsare sti l l
present.
.
l f
the
location
f the defects emain
stationary,he
fault s within he headlight.
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CL 300 SURGICAL
LLUMTNAToR
rsAssEMBLy
NOTE: All servicing equires emoval
f the
top cover.Remove he 9 screwsand
remove
he cover.
INTERNALODULE EMovAL
1. Remove
he op cover.
2. Removehe rontbezel
y
removing
he
5 screws ecur inghe rontbezel o the bot tom hassis .
3. Pul l he nternal odule ut of the
plat form
ssembly.
4.
Installation
s the reverse
process
with the
flat
edgeson the
gray
portion
of the
internalmodule
aligned o
rt
wi l l t in to
he
recessed
rea f the
ront
panel
nd he
black ot n he
grayplast ic
o the bot tom ight .
PowERSUPPLY EMovAL
1. Bemove
he op cover.
2. Remove he front bezel
by
removing
he
5 screwssecuring he front bezel o the botto m chassis.
3. Removehe ai rductst rap ndai rduct .
4.
Removehe 5 wi res rom he PCBA
uxi l iary
oard
par t
o.A4-10670).
5.
Remove
he 7
wires
rom the
power
supply.
NOTE: u l l
r
pry
he wires t ra ight p.
Rocking
he
wire o remove t om he
power
upplymaydamagehe
termlnal 'solder
oint
on he
power
upply oard.
Pul i r
pry
wire erminal t ra ight p.
Do
not rock
o
remove.
Usebent iDneedle ose
ol iers
o
orv
he erminal f f .
Thehandle
f a screwdr iver
s
usedas he ulcrum.
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TVelc$1*.
6. Remove
he 4
screws
rom
he
power
upply nd
pul l the
supply ut of the ront
o
remove.
7.
Installations
the reverse
rocess
with
the
wires ocated
s forrows:
.
P1
on
power
upply o Jb
on
PCBA
par t
o.A4-10670)red
wire
.
P2A- Used
o confrgure
o 230voperat ion n ly
NOTUSED
.
P2
on
power
upply o J4
on
PCBA
parr
o.44-10670)
brownwire
.
P3
on
power
upplytoJ l
on PCBA
par t
o.44
10670) b luewire
.
P4
on
power
supply
blackwire from red/black
air
housed
n tubing
o
P5on
power
upply red
wire om ed/black
ai r
housedn
ubing
.
P11on
power
supply red
or
whi te
wire rom red/black
ai r
th tn
wire
pai r)
.
P12
on
power
supply blackwire from red/black
arr
thin
wire
pair)
PCBA
(PARr
No. 44-10670)
REMovaL
'1.
Remove
power
as noted
above.
2. Not
he
ocat ion
nd
emove
onnectors
romJ6,J7,
J9,J
10,
J
1
1 andJ12.
3. Usinga short#1
screwdriver,emove
he 4 screws rom
the corners f PCBA
part
no. A4-10670)
nd remove
PCBA.
4.
Insta l lat ions
he reverse
rocess.
se
he block iagrams s necessary
o
reconnect
he wi res.
See
igure
below
or
proper
wire routing.
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IGNIToR EMovAL
1. Remove
he op cover.
2.
Disconnect
he 2
lamp
ablewiresand he
red
andblack
wires om
he
gni tor .
ote he
wire ocat ions.
3.
Remove
screws,securing gnitor
module
o the centerbaffle.Screwsare
ocated
n the othersideof the
center
baff
e.
Installations
the
reverse
rocess.
NOTE:
because
he screwdriver ill not
directly
each he lower screws,
Insta l l ing
nd emovinghe screws nto he gni toro tap he
holes
r io r
o insta l l inghe
gni tor
n he uni twi l l
Reconnect
he
wires
as
ol lows
see
igure or
or ientat ion).
.
Redwire o the ower entermost erminal .
.
Blackwire
to the
lower
outermost ermina
4 .
5 .
-
lampcablewire o the op ef t erminal
shorter
i re) .
+ lampcablewire o the op r ight erminal
longer
i re) .
LINE FILTERREMOVAL
1. Remove he top cover .
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CLSERV
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2. Remove he screws
ecur inghe center af f le o the back
panel
nd he
bot tom
hassis
see
igure e low).
XLSRubber umper
Welc$1ytt'
Hexhead
crew
secu
ing
center
batfleo sideof
bottom nassts
a
rentdr baffle o
bottom hassis
a
Screwsecuring
centerbaffle o
back
panel
3. Remove he wires rom both ends
of
the l ine i l ter.Note ocation f wires.
4. Remove he 2 screws
securing he
line i l ter
and
remove.
5.
Installations he reverse
rocess
with the
following equirements:
.
The
end of the fi l terwith 3 terminals s on the
platform
ideof the centerbaffle.
.
The
green
ground)
ire
goes
o the terminaldirectly
mounted o the metalsurtace.
.
The bluewires
go
to the terminals
nearest
he
fans
on both ends.
The brown wires
go
to the centermost
termrnals.
CHAssrs
FANREMovAL
'1
. Remove
he top cover.
2. Remove he 4 screwssecuring he fan and he wireguard.NOTE: o remove he fan rom he lampsideof the
uni t , emovehe anon the
power
supply
ide. o emove he amp
an,
push
he spl i t
grommet
hroughhe
centerbaffle, hen
pull
he
wires
out of
the
grommet.
3. Disconnecthe
fan
connector rom the PCBAAuxil iary oard
part
no.
A4-10670) nd
remove.
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4 . I n s t a l a t l o n i s t h e r e ve r s e p r o c e s s w i t h J 1 1f o r t h e f a n o n t h e l a m p s r d e a nd J l 0 f o r t h e f a n o n t h
supply ide.Route
he wiresas shown n igures
elow.
Wire Bout ing
n gni tor ndPCBA
(part o.44-10670) Chassis anWrreRout ing
The abel
n the amp
ide
an aces
ut , he abel n the
power
upply
ide
aces n
(see
igure
elow).
POWER NTRY
oDULEREMoVAL
T. Removehe op cover.
2. Remove
he 3 screwssecuring he
back
panel
o the
bottom
chassis nd he
1
screw back
panel
o center
baff e.
Remove
he 3 wi re erminalsrom
power
entrymodule.
Move
back
panel
as necessary
o
gain
access o
nuts
securing he
PEM
(power
entrymodule).
Remove uts rom
he PEMand emovemodule.
3.
4 .
5 .
PN:
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Welc$11yr..
6. Installations
the
reverse
process
with the following equ irements.
.
The
ock
washer s inserted
between he
PEIV1
nd he
painted
ideof the back
panel.
.
The lat
washer s inserted etween
he
non-painted
ideof the back
panel
and he nut.
o
The
green
ground)
i re s
connectedo the erminalsolderedi rect lyo the metal ur face. hebluewire
is connected
o the terminal abeledN
and he brown
wire
to the terminalmarkedP
PLATFoRMEMoVAL
'1
.
Remove he top cover
and
remove
he lamp.
2. Remove
he front bezelby removing
he 5 screws hat secure t to the bottomchassis.Remove he internal
mooute.
3. Remove he two screws rom the air duct strapand remove he duct.
4. Remove he 4
screws securing he
plat{orm.
5. Removehe ampshroud om
he
plat form.
6.
Remove
he
plat form
nd
he hermistor ssemblyromJ12.
7. Installations
he
reverse
rocess.
When installing
he
platform,
erify hat he shroudduct, he strap,and he
internalmodule
are
nstalled.
eattachhe front bezel
and check
or
attenuator
wheel
alignment.
.
Botate
he
wheel
across ts adjustment angeand f
the
wheel moves reely,
ontinue,f
it
does
not
move
freely, oosen he platformscrewsand repositionhe platform o the wheel rotates reely.
FRoNT
EZEL EMoVAL
1.
Remove he top cover.
2. Remove
he 5 screws,
securing he
front
bezel o th e bottom chassis.
3. Noting he wire locations,
emove he wires rom
the
power
switch.
Push
out the
power
switch.
4.
Usinga sharpknife, emove
he black
RW from
the LED.Once emoved, pplyacetone o the areabetween
the LEDand
he
ront
panel
o loosenhe
qlue
bond.Removehe LED.
5. Installations the reverseprocesswith the LEDglued o the frontpanelusingLoctite430 or equivalent. nc e
set ,apply paque
ealant , ow Corning 37or equivalent ,o the
area
round
he
LED o
prevent
ight rom
the l luminator
assing
hrough
he LED.
BLowER ANREMovAL
1. Remove
he op cover.
2. Remove
he
front
bezelas
described reviouslv.
3. Removehe ai rductst rap
ndductas descr ibedbove.
I
-34
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4.
Remove lectr icalonnector
g
from PCBA
part
o .44-10670).
5. Removehe 2 nuts,
crews, ndspacershat
mount
he blower an o the
blower racket .
6 .
insta l lat ion
s he reverse
rocess
i th
he
ol lowingequi rements:
.
Spacers re nsta l led
n he screws etween he bracket nd he an.
LAMP
CABLE
EMoVAL
I Removehe
op cover.
2. Open he amp
access oor, p en he
atch,
nddisconnectable.
3. Disconnect
he ampcablewires rom he gni tor .
4 Pul l amocdble ut hrougl -he a 'np ccess oor.
5. Insta l lat ions
he
reverse
rocess
i th
he
ol lowing
equi rements.
.
Bemove he ny lonwire
ie
rom
he
amp
able.
Feed he wires hrough
he spacebetween he
line ilter
and he centerchassis.
Connect he shorterwire to the top left erminalon the ignitor.
Connect he
longerwire
to the top, right
terminal .nsta l lhe erminals etween
he
wo f latwashers
see
igure or
wire
out ing).
WireRout ing
n gnrtor ndPCBA
(part
o.44-10670)
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Welc$11*'
CL 300 SURGTCALLLUMTNAToREPATRARTS rsr
PartNumber
Description
Photo # Bubble# 0uantity
901 5 27W REPLACEMN I LAMP
tB-MAN-1OOW27OW
MANUAL, 1
OOW2TOW
OLARTEC
'l
RM-LBL-023
LABEL,PROTECTIVEARTH
GROUND
'I
A0-10755
BETEL
27A
1
A0-10880
TOP
COVE
R,
LENGTHENED
2
1
A0-10797
EXTERNAL ODULEHOLDER, 7OW
3
1
A 0 - 1 0 7 1 4
SCREW,
AINTED,LS
4
I t t
A0-10768 LABEL,WARNING.LLUMINATOFS
2
5
1
101 -0033 SCREW,832X 3/8,PHPS 2
6
4
101-0022
SCBEW, 6-32X 1/4,PHSS
2
7 8
A0-10907
CHASSIS ASE
2
8
1
01-0068 SEMS,
6-32
5/16,
PHPS 2 9 8
016-0005 X L S , UM P ER , U BB ER ,/ 8
2 1 0
4
101,0062
SEMS, 6.32X 9/16PHPS
2 11 I
207-0007
G U A R D ,
A N ,
2 M M
2 12 2
105-0008 CORD, ETAININGLAMP
2 1 3
208-0016
F U S E ,
A S H E E T
I I
1 2
A0-10904 BACKPANEL
2
1 5
2 1 3 - 0 0 1 9
ROCKEBWITCH,N/OFF,HITE 3
1 6
1
A0-10906
BLOWERRACI..ET
3
1 7 1
A0- 10905
CENTER
BAFFLE 3
1 8
1
44 10670 PCBA, UXILIARY
3
1 9 1
218 003
IGNITOF,70WPI
3
20
1
A0-10864
CABLE,AMP, OK
3 21
1
105-0010 TENSION
WIRE
RETAINER 3 22
4
1 0 1 - 0 0 7 8
SCREW,4-40
1/4, HD,
tT82DG
3 23
1
44-10680 WIREHARNESS,ED/AU)?PS
3
24 1
1 1 2 0 0 1 CABLE IE,SMALL
"
3
2 5
,l
A0-1 81
DUCI NOZZLELOWER,7OW
4
26 1
A 0 - 1 0 8 1 4
STRAEAIR DUCT
4
2 7
'1
u501
7
27OWLAMP SHROUDSUB-ASSEN/LY
4
28
1
u 5 0 1 1 1 27OW DJUSTEDOWER UPPLY
4 29
,l
2 1 3 - 0 0 1 8 SWITCH,
NTERLOCK,
NGL
POLE
4 30
1
1A20012 KEPS, 6_32,
CONICAL
WASHER
4
3 1
3
21
0-0001
LIN
E
FILTER,
.04,
FLANGE 4
32
I
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ALLYN
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PN:LB-MAN
CLSERV
Rev.A
Part
Number Description Photo# Bubble# 0uantity
1 0 1 - 0 0 5 9
SIMS,
#6-32 1i4PHPS 4
33
2
213-0017
POWER NIRYMODULE LINEFILTER,
F U S D
4
34
101-0084
SCREW,
6 THDFRMG,PHPS
4 35
4
u50123
2 7 O W N T E R N A LO D U L E U BA SSM B 4
36
u501 5 27OWFILTE ASSEMBLY
5
31
101
0061
SCREW, 4-40 1/4,PHPS
5
38
2
u501
27OOW LIGNED LATFORM 5 39
101-0073
SCREW,
8-32
3/4" ,
PHPS
5
4
44-10655
FAN,
ACK, WIRE, 7OW
6 4 1
2
A4-1067
WIREHARN SS, ILTEF/GFOUND
6
44-10673 WIREHARN SS,
WITCH/FILTER 6
A4-1Q67 WIREHARN SS, C/FILTER
6
44
1
09-0006
BUSHING,
PENED/CLOSED,
5OO
6
44 10675 WIREHARNESS,C/SWITCH
6
46
44 1
0465
W I R E , E MT O D I N
6
47 1
44-10676
WIRE HARNESS,FILTER/PS
6
48
1
44-10678 WIREHARNESS,UXTPS
7
A O
1
A4-10677 WIREHARN SS,
ON/OFF/AUX
7 50
1
101-0085
SEMS,
-40X
3/8,
PHPS 7
5 1
4
44-10683 FAN,BLOWER, EFLONWIRE 7
52
1
1 0 1 0 8 3 SCEEW, .40X 1 1/4" ,PHPS,S 7
53
2
106-001 SPACER,
4
UNI
hBD, 114
d,
1l4 l
7
54
2
1
02-0008 NUT,
KEP, -40, HEX
1 55
2
106-001
STANDOFF,
8, 751
7 56
4
102-0001 NUI
HEX
8 57
1
104 0007 WASHER, LAT
I 58
'I
104 0008 WASHER,
ERRATED 8 59
1
1 0 4 - 0 0 1 9 WASHLR,'4
EXILRNAL
OOTF
I
60 2
101-0038
P L U G , 6 / 2 5 8 61 1
1
04-0006 WASHER,OLOR OATED
I
62 1
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PHoro2
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GLoSSARYoF
TERMS
AC Al ternat ing urrent
COM Found n power onnectors,wi tches, tc . . . ndicat ing ommonwire ermrnatron
DMM Digi ta l
u l t iMeter
Fiber
Opt icBundle
Any
of a
number
f
l ight ransmiss ionevices
haracter izedy useof
mul t ip le,
a i r
h in
strands
f cladded
lass
ibers.Used
o deliver ight ro m
il luminator ox o work area.
Leakage urrent Usual ly speci f ied
maximumamount of
a l lowable urrent o
pass
hrough
solated
electrical omponents
when
subiected
o
very high
electrical
otentials.
LED LightEmit t ing iode
Metal
Hal ide Any
of a
number
f
metal l ic ompounds,sual ly
odideshatareused
n
race
mounts
n
discharge ight sources.
vletalhalidesare incorporatedo
produce
he destredspectral
contentot the l ightsource.
NO Normal ly pen,
Found n swi tches
ndicat ingormal ly pen erminat to n.
PCBoard Pr inted i rcui t oard
PEM PowerEntryModule
FTV
RoomTemperatu re ulcanizing ilicone
TRMS
TrueRootMean
Squared
used o characterize
ccuracy f digital
multFmeters.
VDC Voltage
Direct
Current
Xenon
An
elemental
as
used commonly
used
n l ight ing
roducts.
Used as an
evaporant
suppressant
n ungsten alogen
amps
r
ight miss ionn
gaseous
ischarge
amps.
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FINAL NSPECTIoN
The
purpose
f
preventatrve
arntenances o
pro-act ively
educe r
e l iminate
uture
roblems.
eepinghe ight
sourcen
good
operat ingondi t ion
nsureshat
t wi l l
per form
el iably
ndsafely . very ix
o
twelve
months,
ou
s h o u l d :
NOTE:Perform ypot nd
ground
ont inui tyestson he unrt efore egin ninghe
inal nspect ion.
CL 100SuRGrcArLLUMTNAToR
1.
Set
TIME
o star t .
urn
n he SYSTENiI .egin he f teen
15)
minuteBURN-lN
er iod.
heck
or
he
ol low-
i n g :
.
Drd he
yel low
LED ight r ief ly?
.
Did he amp
star t?Cl ick ing efore he
amp gni tes snormal
10
cl icks r
ess).
o Are he ans unning?
2. Af ter he
f teen
1
) minute urn- innsert thePOWERTESTFIBERntothePort .
Open
he at tenuatorul ly
andmeasurehe ight utput .Rotate
he
proximal
nd o
maximize
ower
output nd
check he ol lowing:
.
Does he connector nsert
smoothly?
.
Does
he attenuatormove smoothly?
.
Does he LrghtOutputmeasure 750mi l l iwat ts?ight utput 375 s
considered
he endof the i feo f
the
amp.
. Turn he systemoff and on again3 more imes. Does t lightabruptly ndproperly?
l f test ing asPASSED,ont inue.f
uni t
a i ls
est ing,roubleshoots
necessary.
CL 3OO URGIcAtLLUMINAToR
IMPORTANTClicking efore he LAMP g nites s normal
10
clicks
or
less).Do not hot re-striken succession.
The LLUMINATORust emainl luminated
ora minimum f for ty- f ive
45)
econds ach imebeforeurning f f .
Wait hirty
(30)
econdsbetween
each
e-strike.
Turn
he
ILLUMINATOR
ff andon aoainhree13)more imes.The LLUMINATORust
emain
l luminatedor a
minimum f for ty j rve
45)
econds ich t rmebefore urning f f Usrng
TIMER,
ai t h i r ty
30)
econds etween
re-st r ikes.
l rck ingef re he LAMP gni tess normal
10
cl icks r ess) . oes t ight
prompt ly
nd
proper ly?
l f test ing asPASSED,ont inue.f uni t a i ls est ing,roubleshoots necessary.
1.
Set
TIME
o star t .
urn
n
ILLUMINATOR.
egin he i f teen
15)
minuteBURN-lN
er iod.
heck
or
he o l
lowrng:
.
Did he
yel low
LED
ight
r iefy?
.
Did he
amp
start?Cl ick ing ef re he amp gni tess normal
10
cl icks r ess) .
.
Are
he
ans unning?
PN:
LB-MAN-CLSEFV
ev.A
1-43
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Welc\ffi*'
2. Af ter
he
i f teen
15)
minute urn- innsert he POWER ESTFIBERnto
he
Port .
Open he at tenuatorul ly
andmeasurehe ight
utput .Rotatehe
proximal
nd
o
maximize
ower
output
ndcheck he
ol lowing:
.
Does he connectornsertsmoothly?
.
Does
he attenuator
move
smoothly?
.
Does he LrghtOutputmeasure
361
umens?
ight utp ut 200 s consideredhe endof the i feof
the
lamp.
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SPEcIFIcATIoNS
Physical
S ize Weight CL100)
Slze
Weight
CL
300)
Space
Requirements
Finsh
Lamp
Lamp
Type
Power Requirements
E ectrical
Amperage
Salety Compliance
5 . 5 "H x 1 1 . 2 5 "W x 1 1 . 2 5 " / 9 . 0 1 b1 4 0 m m H 2 8 6 m m W 2 8 6 m m D / 4 . 0 k 9 )
5 . 5
H x 1 1 . 2 5 " W x 1 2 . 7 5 "
D / 1 ' 1 l b
1 4 0 m m H
2 8 6 m m W 3 2 4 m m D / 5 . 0 k 9 )
Minimum "
(51mm)
i rspace
roundop,backandsides
Painted urfaces
polyuretha
e
'100W
XenonAr c
270WShortArc
DC MetalHal ide
100-240 AC50/60H2
2.5Amps@ 120V
Surgical
l luminator
L
100)
4 Amps
@
120V
(Surgical
l luminatorL 300)
cD.
8737
U12601-1nded,CSAy'CAN-C22.2
o.601-1-M90,
lEC601-1
1988/EN0601- '11990Amend. ,
l E C 6 0 1 - 1 - 2 : 1 9 9 3 / E N0 6 0 1 - 1 - 2 : 1 9 9 3
C l a s s
) , I ST
1 0 0 11 9 9 2 ,
lEC601 -1 :1 96/EN 0601-2-1:1 96
IECClassification
TypeBF,
Class
Continuous
perat ion
PXO
The
CE
markon this
product
ndicates
hat
t has been
ested
o andconforms
with the
provisions
oted
wi th in he 93l42lEEC
edical ev iceDirect ivend89/336EEC
MCdirect ive.
EUContact :
European
egulatory anager
WelchAl lynLtd.
County
Meath,Republ icf l re land
Tel353 46 67700
Fax
353
46
27128
PN:LB MAN
CLSEBV
RCv.
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THEoRY oF OPERATToN
LIGHT oURcE
TheLightSources onsis t f anenclosure ousing, high ntensi tyamp, ropr ietarypt ical lat form, ser
contro ls nd
ndicators,
nda
power
supply i th contro l lect ronics.
ool ings
provided
ia
nternal
ans. n he
event hat
he fan(s)malfunctions r
if
adequate
ir low is blocked nd/or he
internal emperature f the device
exceedshe engineer ingpeci f icat ions,n
nternalhermal
rotectron
echanism i l lautomat ical lyhuto f f
power
o the
ramp.
f ter
cool rng,
estar the Lrght ources.
REPLAcEMENTAMPS
The ampsare high
pressure,
igh
ntensity
nd
ong ife LightSources.
hey
are
mounted ntoa
patented
amp
l ix turewhich s
designed
o
al low
botheasy nd
apid
xchange
n
he
ie ld s wel las ensur ing
rec ise
|gnment
to the oDticalDlatform.
Powen Suppr-y
wrrH
CoNTRoL
LEcrRoNrcs
All he electricityo the LightSource
s
controlled
hrough he ON/OFF witch.
Power o energize nd operate
he
lamp, ans,and
control
ircuitry s
provided
y a customdesigned,
wattage egulated, witching
power
supply.
Theoperat ional
i fe
of the
amp
and
he amp i fe
ndicator
recontro l led
y a lamp ol tagemoni tor ing
i rcui t
MULT|LtNKn PoRT
ANDMULT|
L|NK*
ExpANSroN oRT
Internal,o both he multi LinkrM
ort
and
Multi LinkrM xpansion ort,are
patented
oupling
pticsan d
mechanics esigned o
produce
he
highestoutput
powers.
nternal
o the
Light
Sources
re ans and
heatsinks
designedo reduceemperatures
t the
opt ical
oupl ing
oints
hereby
minimiz inghe
possib i l i ty
f damage
o
MicroLink@
iber
nd
iberbundles.
1-46
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CL
100
SURGTCAL
LLUMTNAToR
rRcurr
DTAGRAM
100 40vAc
POWER
UPPLYLOCK
IAGBAM
LAI\,4PTERT
OUTPUT
O.ISHUTOWN
INPUT
@ 4VDC
t--r/ |
I I
LAI'/P
"\l
El\,41
FILTEB
&
FUSE
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CL 3OOSURGICALLLUMINAToR
IRCUIT IAGRAM
- :
= i----.*.
> E
c a - 3