ServiceManual

CL 300 Surgicalllluminator
SolarTecSource270

CL 100Surgicalllluminator
SolarTecSource100

WelchAllyn Lighting Products

4 6 1 9J o r d a nR o a d
Skaneateles
Falls,NY 13153-0187

PN: LB-MANCLSERVRev.A

Tableof Contents
------1-1

GENERA
I NL F o R M A T T o N

- - 1-1

T E C H N T CH
AE
L L PI N F o R M A T T o N

-----

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

1-2

WARRANTY

-.----.1-3

SYSTEM
S Y M B o LD E S C R I P T I o N S

-------

1-4

---

--W A R N I N GASN DP R E C A U T I o -N- S

W a r n i n g- - - - - -

1-5
1-5

CautionO P E R A T I NI N
GS T R U C T I o N S

---

1-5

----

1-6
1'6

Conlrols
-'----

PowEO
R N / O FSFw r r c H .

------

F | B EPRo R r
M U L TLI I N K TEMX P A N S I oPNo R T -I N S T A L L A TAI oNNDU S E( o P T I O N A L )
L i c HA
T ] - T E N U A TCTooNNT R o-L- - - L A M PL I F El N D r c A T o R

. - - -- -...-

- 1-8
---1-8

L I G HSTo U R c E
P o w E RS u p p l yw r r HC o N T R oELL E c r R o N r c s
M U L TL| i N K TPMo R T A NM
D U L TLr T N K T
EM
x p A N s r oPNo R T - S E R V T- C E

16
-1-7

---------1-7
-'l-7

P r i n c i p l e sO f O p e r a t i o nR E P L A C E MLEAN
MTP S-

16

-----.

---1-8

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

C L E A N T -N- -G- - -

1-9
--1-9

.-

S U R G T CI LALLU M T N A T o R

1-9

------1-9

M U L TL| T N K E
oN
o R T- - - - - - - T xMp A N s r P

-- 1-10

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

---

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

1-11

- - - - - 1-11
... -'I-12

C L 1 0 0S u R G r c AI L
r LUMTNAToR
C L 1 O OS U R G I C IALLL U I \ , I I N AD
T IoSRA S S E M B-L- Y- T E S T# 1 : B L o W NF U s E s

- - 1-12

TEST
W A T TP O W ESRU P P T Y
# 2 :1 O O
T E S T # 3C:o o L r NFGA N- - -

--------

TEST#4: LED/OVEBTEMP
SWITCH

1-13
.1-13

- - - -' 1.13

T E s r # s :M r c R oL I N K @
F T B ETR
E s r- - T E S T # 6P: o w E RS u p p L yC A L T B R A I o N
C L 1 O OS U R G I C AIL L U M I N A T oDRI S A S S E M B L Y
PoWER
S U P P LRYE M o V A L

--

- -------

1-13
- 1-14

- - - 1.15
- - 1-15

PLATFoRM
EMoVAL

--------

1-16

F R o NBT E Z ERLE M o V A L
REMoVAL
FANDEFLECToR

--------

1-16
1 16

C H A S SFI A
S NR E M o V A L
L E D / O V E R T EHMAPR N E SRSE M o V A L
L A M PC A B L R
E EMoVAL
I N T E R L oS
Cw
K r r c HR E N t o v A L
PoWER
E N T RM
Y O D U LR
EE M o V A L
1
0
0
S
U
R
G
T
C
I
A
L
L
U
M
TNAT
RoERP A TPFA R T L
CL
Sr s r - - C L 3 0 0S U R G T CI LALLU M T N A T o R
C L 3 O OS U R G I C AIL L U M I N A T oDRI S A S S E M B L Y
TEsr#1:BLowN
FusEs
TEST#2: AuxrLrARy
BoARDlNpurTERMTNALS
T E s r # 3C
: o o L r NFGA N- - - T E s r# 4 : L E DO P E R A T o N
TEST#5: MIcRoLINK@
FTBER
TEST
C L 3 O OS U R G I C AILI I U M I N A T o R
DISASSEMBLY
----I N T E R NMAoLD U LREE M o V A- L
PoWERSUPPLY
REMoVAL
(
p
A
R
r
PCBA
N o .A 4 - 1 0 6 7 0R) E M o V A L
l G N r r oR
RE M o V A L
L | N EF T L T ERRE M o V A L
C H A S SF
I SA NR E M o V A L
PowER
E N T RM
Y o D U LR
EE M o V A L
PLATFoRM
EMoVAL
F R o NB
T E Z ERLE M o V A L
B L o w EFRA NR E M o V A. -L
LAMP
C A B LR
E E M o V A -L- - LLUMTNAT
RoERP A TPR
A R T LSr s r - - C L 3 0 0 S U R G T CIA

'- ------- 1-17

-. -.. - 1-17
- --- 1-17
- - - -' 1-18
-. - _ 1-18
-----

1-19

-- - ----'l 25
- - - 1-27
---- 1-21
- - - - 'l-27
127
-----

1-27
- - - 1-2A

.. - 1-29
------129
129
-------

1,30
.--- -- 1-31
-- . - 1-31
---- 1-32

--------

1-33
------ 1-34
----- 1-34

--------1-34
--- 1 35
----- 1-36

G L o S S A RoYF T E R N 4 S
F I N A LI N S P E C T I o N
C L 1 O OS U R G I C IALLL U M I N A T o R
C L 3 O OS U R G I C IALLL U M I N A T o. .R .
SPEcrFlcAroNS
T H E o R Y oO
FP E R A T I o N
L r G HSr o u R c E
R E P L A C E ML E
AN
MTP SP o w E RS u p p L yw r r HC o N T R oELL E c r R o N r c s
M U L TLI I N K TPMo R T A NM
D U L TLr T N K T
EM
x p A N S t oPNo R T - -

------

1-42

-- 1-43
-.. - 1-43
- 1-43
---

1-45

-----

1-46
------1-46

-------1-46
--- - -- 1-46
---------1-46
,I-47

C L 1 O OS U R G I C AI LLL U M I N A T C
oR
I R C U IDTI A G R A M

--- ----

C L 3 O OS U R G I C AILL L U M I N A T oCRI R C U ID
TIAGRAM

. -. - - - - 1-48

GENERALINFoRMATToN
'100
T h eW e l c hA l l y nC L
S u r g i c al l l u m i n a t oarn dt h e W e l c hA l l y nC L 3 0 0 S u r g i c al l l u m i n a t oprr o v i d eb r i l l i a n t
p
h
y
s
i c i aann ds u r g e o nT. h e l a m p sp r o d u c eh i g hi n t e n s i t yl i g h tn e a r l yi d e n t i c at lo t h e s p e c t r u m
i l l u m i n a t i of n
orthe
o f s u n l i g h tS. p e c i afle a t u r e si n c l u d et h e a b i l i t yt o u s e e i t h e ra C o g e n tO p t i c sM i c r oL i n k @F i b e ro r a c o n v e n t i o n a l
f i b e rb u n d l e .

TECHNTCAL
HELPlNFoRrvrATroN
O n l yf u l l yt r a i n e da n d p r o p e r l ye q u i p p e dp e r s o n n esl h o u l dp e r f o r ma l l s e r v i c ea n d r e p a r r su, s r n gq e n u r n e
t a r r a n t ya n dc o u l d
r e p l a c e m e npta r t sa n dc o r r e c p
t r o c e d u r e sF.a i l u r e
t o d o s o w i l l i n v a l i d a tteh e p r o d u c w
performance.
compromiseinstrumentsafety and
R e a da n d u n d e r s t a nadl l s a f e t yw a r n i n g sa n ds e r v i c en o t e sp r i n t e di n t h i sS e r v i c eM a n u a l a n dt h e O p e r a t i n g
, r phone
M a n u a l sp, a r tn u m b e rL B - I V A N - 1 0 0 W 2 7 0lW
f t .h e r ei s a n yd o u b ta b o u ta n y p r e c a u t i oonr p r o c e d u r ef o
h e l p .o r t o o r d e ra d d i t i o n aclo p i e so f t h e O p e r a t i n M
g a n u a lc, o n t a c t :
Customer Service
Welch Allyn, Inc.
4619 Jordan Road. PO Box 187
SkaneatelesFalls,NY 13153-0187USA
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)
W h e n c a l l i n gr,e f e rt o t h e m o d e ln u m b e rs h o w no n t h e d a t al a b e l f, o u n do n t h e b a c ko f y o u rS u r g i c al l l u m i n a t o r .
" T r o u b l e s h o o t i"n g p a g e
T e c h n i c aals s i s t a n cies c o n t a i n e d
in
1 1 o f t h i sm a n u a l .
on

PN: LB-MANCLSERVBev.A

Welc$11ytt'
SeRvrceCENTERS
lf you havean equipmentproblemthat you cannotresolve,you may callthe Welch AllynServiceCenternearest
you for assistance.Technicalservicesupportrs availableby telephoneon norma businessdays at the phone
n u m b e r sl i s t e db e l o w .l f y o u a r e a d v i s e dt o r e t u r na p r o d u c t o W e l c hA l l y nf o r r e p a i ro r r o u t i n em a r n t e n a n c e ,
r i t h t h e s e r v r c ec e n t e .n e a r e syl o u .
s c h e d u l et h e r e D a iw
BEFORERETURNINGA PRODUCTFORREPAIRYOU MUST OBTAINAUTHORIZATIONFROM WELCH
ALLYN. AN RMA (RETURNMERCHANDISEAUTHORIZATION}NUMBERWILL BE GIVENTO YOU BY OUR
SERVICEPERSONNEL.BE SURETO NOTETHIS NUMBER ON THE OUTSIDEOF YOUR SHIPPINGBOX.
RETURNSWITHOUTAN RMA NUMBERWILL NOT BE ACCEPTEDFORDELIVERY.
USA CUSTOMERS

CANADA CUSTOMERS

Welch Allyn, Inc., U.S.A.

4 6 1 9J o r d a nR o a d
, Y 13153-0187
S k a n e a t e l eFsa l l sN
Tel:1-315-685-2993
Fax:315-685-2999

Welch Allyn, Ltd., Canada

'160
M a t h e s o nB l v d .E . ,U n i t# 2
M i s s i s s a u g aC,a n a d aL 4 Z 1 V 4
Tel:905-890-0004
Fax:905-890-0008

INTERNATIONALCUSTOMERS
Welch Allyn, GmbH
Zollerstrasse
24
72417 JunEngen,Germany,
fel: 011-49-7
477-9211-73
Fax.011-49-7477-9271-93

Welch Allyn, Ltd., Singapole

300 BeachRoad,#25-08
The Concourse
Singapore199589
Tel:011 65-291-0882
F a x :0 1 1 - 6 5 - 2 9 1 - 5 7 8 0

Welch Allyn, Ltd., Australia

Metro Center
Unit 5 38 SouthStreet
R y d a l m e r eN, S W2 1 1 6 ,A u s t r a l i a
T e l :0 11 - 6 1 - 2 9 4 - 1 8 3 - 1 5 5
F a x :0 11 - 6 1 - 2 9 4 - 1 8 3 - 6 5 0

Welch Allyn, China

Room708, 22'/ lluang Pi Road,North
CentralPlaza
S h a n g h a2i 0 0 0 0 3
P R .C h i n a
T e l :0 1 1 - 8 6 - 2 1 - 6 3 2 7 9 6 3 1
Fax. O11'86-21-63279632

Welch Allyn, Japan

Bon Marusan8F,3-5-1Kanda
J i n b o - C h oC, h i y o d a - K u
T o k y o1 0 1 - 0 0 5 1
Japan
T e l :0 11 - 8 1 3 - 5 2217 3 9 1
f ax. 0 11-813-3261-7372
LATIN AMERICANCUSTOMERS
MD Intemational
11300 N.W. 41st Street
M i a m i ,F L 3 3 1 7 8U S A
Tel: l-305-669-9003
F a x :1 - 3 0 5 - 6 6 9 - 1 9 7 1

1 2

WELCHALLYN

WARRANTY
W e l c hA l l y nw a r r a n t st h e C L 3 0 0 o r C L 1 0 0S u r g i c al l l u m i n a t owr h e n n e w t o b e f r e e o f d e f e c t si n m a t e r i aal n d
workmanshipand to pertormin accordancewith manufacturer's
specificatrons
when subjectto normaluse and
s e r v i c ef o r a p e r i o do f o n e y e a rf r o m d a t eo f p u r c h a s ter o m W e l c hA l l y no r a n a u t h o r i z eadg e n t .W e l c hA l l y nw i l l
e i t h e rr e p a i ro r r e p l a c ea n y c o m p o n e n tfso u n dt o b e d e f e c t i v eo r a t v a r i a n c e
f r o m m a n u f a c t u r e rs' sp e c l f i c a t i o n s
w i t h i nt h i st i m e a t n o c o s tt o t h e c u s t o m e rl.t s h a l lb e t h e p u r c h a s e r r' se s p o n s i b i l ittoy r e t u r nt h e i n s t r u m e nt to t h e
a u r h o r i z eddi s t n b J t o ra,g e n t .o r s e r v i c er e p r e s e n t a t r v e .
WelchAllynwarrantsthe lampto be free of defectsin materialsand workmanshiptor a periodof 6 monthsfrom
t h e d a t eo f p u r c h a s eT. h i sw a r r a n t yd o e sn o t c o v e rt h e l a m pf o r b r e a k a g o
e r f a i l u r ed u e t o t a m p e r i n gm
, isuse,
n e g l e c ta, c c i d e n t si m
, p r o p e irn s t a l l a t i o m
n ,o d i f i c a t i o n
, i p p i n go, r f r o m i m p r o p em
sh
r aintenance
se
, r v r c eo, r
procedures.
cleaning
Thrswarrantyis void if the instrumentis not used in accordancewith manufacturer's
recommendations
or if
r e q u i r e ds e r v i c ei s p e r f o r m e db y o t h e rt h a nW e l c hA l l y no r a n a u t h o r i z eadg e n t .P u r c h a s d
e a t ed e t e r m r n e s
w a r r a n t yr e q u i r e m e n t sN.o o t h e re x p r e s so r i m p l i e dw a r r a n t yr s g r v e n .

P N :L B M A N C L S E R VF e v .A

Velc$1yt

'

SYSTEM
SYMBoLDEscRtPTtoNs

A
A

A t t e n t i o nR
: e a dO p e r a t i n g
M a n u afl o r W a r n i n g sP, r e c a u t i o nas n
, d I n s t r u c t i o nf so r U s e

Caution- Hot SurfaceArea

Ra^la^a

tr,,c6

ec

lr,4ert orl

250V5A

5A,250V

- Highvoltage
WARNING
is present

Symboo
l n p o w e rs w i t c hi n d i c a t eps o w e ri s o f f w h e n p r e s s e d
S y m b o il n e l e c t r i c ar la t i n gs i g n i f i e A
s C m a i n sp o w e r

+
@
|- ^.*l

|f

H i g hI n t e n s i t yL i g h t

ProtectiveEarthGround

t4__l

Temperature
Storage
Range

Maximum
Storage
Humidity

tr

aPxg

T y p eB F e q u r p m e n tC, l a s sI

Not protectedagainstthe ingressof water

Manufacturedin accordancewith the relevantregulationsand technicalrequirementsof

Japan.

WELCHALLYN

WARNINGS
AND PRECAUTIoNS
e
/-\
l\

WARNING
.
K e e oo u t o l r e a c ho f p a t i e n t .
.
N o t s u i t a b l et o r u s e i n t h e p r e s e n c e
of a flammable
a n e s t h e t im
c i x t u r ew i t h a i r o r w i t h o x y g e no r
n i t r o u so x i d e .
.
Disconnectfrom the patientbeforethe dischargeof a cardiacdefibrillator.
.
E L E C T R I C ASLH O C KH A Z A R DD
. o n o t r e m o v et h e t o o c o v e r
.
.

.
.

.
.
.

r
lA

R o u t i n e ley x a m i n et h e p o w e rc o r da n d p i u g .D o n o t u s e i f i n s p e c t i o rne v e a l sd a m a g eR
. e p l a c eo n l y
with approvedhospitalgradepower cord and plugwith appropriateelectricalrating.
Do not olacethe exooseddistalend of the Micro Link@Fiberor fiber bundleattachedto eithera
headlightor other accessory.Failureto observethese precautionsmay resultin burnsto skin,
c l o t h i n go, r o t h e rm a t e r i ailn a d v e r t e n tpl yl a c e di n f r o n to f t h e M i c r oL i n k @F i b e ro r f i b e rb u n d l e .
H i g he n e r g yr a d i a t e d
l i g h tg u i d e dt h r o u g he n d o s c o p em
s a y g i v er i s et o h i g ht e m p e r a t u r eisn f r o n to f
t h e l i g h to u t l e ta n dt o t h e t i p o t t h e i n s t r u m e n t .
Use care not to pointthe distalend of the fiber or headliqhtdirectlyat the eye when unit is operating.
T h e b r i l l i a nl ti g h to u t p u tf r o m t h e u n i tc a n c a u s ee y e i n j u r yp e r R P 2 7. 1 ( ' 1 9 9 41 9 9 5T h r e s h o l L
dimit
I n d i c e sF, i n adl r a t tM a r c h
V a l u e s{ o r C h e m i c aSl u b s t a n c easn dP h y s i c aAl g e n ta n dB i o l o g i c aElx p o s u r e
3,1995).
Appliedpartsattachedto this equipmentshouldbe approved1) to the MedicalDeviceDirective(93/
TestingLaboratory(UnitedStates),and3) by
42/EEC)(Europe),2) approvedby a NationallyRecognized
(Canada)
a StandardsCouncilof Canadaaccreditedlaboratory
to the appropriatemedicalstandards.
The use of non-approved
componentsmay compromisesafety.
D u r i n gl i { et h r e a t e n i npgr o c e d u r e si t,i s r e c o m m e n d etdo h a v ea b a c k u pL i g h ts o u r c ea n da n a d d i t i o n a l
r e o l a c e m e nl at m o .
m a yc a u s ep r e m a t u r e
T h e l i g h ts o u r c el a m p sa r e h i g h l yp r e s s u r i z e ad n, yd a m a g eo r i m p r o p ehr a n d l i n g
f a i l u r eo r e x p l o s i o n
of the lamp.
The light sourcelampsare hot immediatelyafter use,allow the lampto cool for five (5)minutesafter
peakin the light Sourcesapproximately
60 secondsafterthe LightSourceis
operation.Temperatures
poweredoff.

CAUTION
. Do notplaceanythrng
on topof theLightSource.
Do notstoreliquidabovethe LightSource.
.
.

C l o g g e do r b l o c k e dv e n t sm a yc a u s eL i g h tS o u r c eo v e r h e a t i nagn dw i l l r e s u l ti n t h e r m a sl h u t d o w n .
K e e pt h e L i g h tS o u r c ec l e a ro f a n yo b s t r u c t i o n s .
F u l l yc l o s et h e a t t e n u a t obr e f o r et u r n i n go n t h e L i g h tS o u r c eo r w h e n o p e r a t i o n ablu t n o t i n u s e .

PN: LB-MANCLSERVRev.A

Welc$11yn.
OPERATTNGlNsrRucloNs
CONTROLS

PowERON/OFFswrrcH
l
"Hospital
P l u gh o s p i t agl r a d eP o w e rC o r di n t oa g r o u n d e d" H o s p i t aG
r a d e "o r
U s e " r e c e p t a c lteo e n s u r e
grounding
reliability.
PressMain PowerSwitch ON (l pressedin).
T h e l a m pw i l l c o n t i n u et o o p e r a t eu n t i l t h ep o w e rs w i t c hi s m o v e dt o t h e O F Fp o s i t i o n( O p r e s s e di n ) .l f t h e l a m p
cannotbe startedor stops operatingsee Section8: Troubleshooting.
NOTE:
.
.

l t i s n o r m a tl o h e a rc l i c k i n g( 1 0p u l s e so r l e s s )b e fo r e t h e l a m pi s s t a r t e d .
To insureproperoperation,wait thirty (30)secondsbetween on/off cycles.

F|BERPoRT
To increasethe versatilityand applicability
of use,the LightSourcesare designedto use eithera Micro Link@Fiber
o r a t i b e rb u n d l ev i at h e M u l t iL i n k r MP o r ta n d M u l t iL i n k r ME x p a n s i oP
nort.

Cable Gompatibility
Multi Linkn Port

Table
Multi Link- Expansion Port

Micro Link@
Fiber

KarlStorz

ACMI

Olympus

Wolf, Dyonics

F o rc a b l e sw i t h n o M u l t i L i n k r ME x p a n s i oP
n o r tr e q u i r e d :
1 . C l o s et h e l i g h ta t t e n u a t oor r t u r nt h e L i g h tS o u r c eo f f .

r 6

WELCHALLYN

2 . C o n n e ct h e l n s t r u m e net n d o f t h e M i c r oL i n k @
F i b e ro r f i b e rb u n d l et o t h e i n s t r u m e n t .
, n t i lf u l l ye n g a g e d( s n a ps o u n d )t,h e L r g h tS o u r c ee n d i n t ot h e M u l t iL i n k r MP o r t .
3 . I n s e r tu
4 . T u r no n L i g h tS o u r c e .A d j u s t h e l i g h ta t t e n u a t otro t h e r e q u i r e di l l u m i n a t i ol n
evel.
MULT|L|NK'" ExpANsroNPoRT- lNsrALLATroN
aNo UsE (oproNAL)
CAUTION:

T h e M u l t iL i n k r ME x p a n s i oP
n o r tc o n t a i n so p t i c ael l e m e n t st h a tc a n b e c o m ed a m a g e di f d r o p p e d
or aouseo.

NOTE:

T h e M u l t iL i n k r M
Fiber
E x p a n s i oPn o r tm u s tb e f u l l ye n g a g e di n t ot h e L i g h tS o u r c eb e f o r ei n s e r t i n g
Bundle.

To use the l\4ultiLinkrMExpansionPort performthe followingoperations:

1 . C l o s et h e l i g h ta t t e n u a t oor r t u r nt h e L i g h tS o u r c eo f f .
2 . R e m o v ei,f a n y ,M i c r oL i n k @
F i b e ro r f i b e rb u n d l ef r o m t h e M u l t i L i n k r MP o r t .
3 . I n s e r t h e M u l t iL i n k r ME x p a n s i oP
n o r t ,p r e s sa n dt u r n c l o c k w i s eu n t i li t l o c k si n t op l a c e .
4. Connectthe fiber bundleto the instrument.
5 . I n s e r tu
, n t i lf u l l ye n g a g e dt,h e L i g h tS o u r c ee n d o f t h e f i b e rb u n d l ei n t ot h e M u l t iL i n k r ME x p a n s i oP
no r t .
6 . T u r no n L i g h tS o u r c e .A d j u s t h e l i g h ta t t e n u a t otro t h e r e q u i r e di l l u m i n a t i ol n
evel.
To removethe Multi LinkrMExpansionPort performthe followingoperations:
1 . T u r nt h e L i g h tS o u r c eo f f .
2 . R e m o v et h e f i b e rb u n d l e .
3. Turnl\,4ulti
LinkrMExpansionPortcounter-clockwise
until unlockedand remove.

LrcHTATTENUATToN
CoNTRoL
M o v i n gt h e i l l u m i n a t i ownh e e lu p *

i n " r " u r " . l i g h to u t p u t .M o v i n gt h e w h e e ld o w n -

r e d u c e sr r g n o
t utput.

LAMP LrFElNDrcAToR
A y e l l o w i n d i c a t o rl i g h t l o c a t e do n t h e c o n s o l ew i l l l i g h t w h e n t h e r e i s a p p r o x i m a t e l y5 0 h o u r s
r e m a i n i n go n t h e l a m p . A n e w R e p l a c e m e n tL a m p s h o u l d b e a v a i l a b l ea t t h i s p o i n t . O n c e t h e
r e m a i n i n gh o u r s h a v e b e e n e x h a u s t e dt h e l a m p w i l l t u r n o t f .

PN: LB-MANCLSERVREV.A

Welc\Allyn.
PRINCIPLES
OF OPERATION

LtcHTSouRcE
T h e S u r g i c al l l u m i n a t o rcso n s i s o
t f anenclosure
h o u s i n ga h i g hi n t e n s i t yl a m p ,p r o p r i e t a royp t i c apl l a t f o r mu, s e r
controlsand indicators,and a power supplywith controlelectronics.Coolingis providedvia internalfans. In the
eventthat the fan(s)malfunctionsor if adequateair flow is blockedand/orthe internaltemperatureof the device
exceedsthe engineeringspecifications,
an internalthermalprotectionmechanismwill automatically
shut off
power to the lamp. After cooling,the LightSourcesmay be restarted.

REPLAcEMENT
LAMPs
T h e l a m p sa r e h i g hp r e s s u r eh, i g hi n t e n s i t ya n d l o n gl i f eL i g h tS o u r c e s T
. h e ya r e m o u n t e di n t oa p a t e n t e dl a m p
f i x t u r ew h i c h i s d e s i g n e dt o a l l o wb o t he a s ya n d r a p i de x c h a n g ei n t h e f i e l da s w e l l a s e n s u r i n gp r e c i s ea l i g n m e n t
t o t h e o p t r c apl l a t f o r m .

PowERSupply wrrx CoNTRoLELEcrRoNtcs

All the electricityto the LightSourceis controlledthroughthe ON/OFFswitch. Powerto energizeand operatethe
lamp,tans,and controlcircuitryis providedby a custom designed,wattageregulated,switchingpower supply.
The operationallife of the lamp and lamp life indicatorare controlledby a lamp voltagemonatoring
circuit.

MuLr LtNxn PoRTANDMULT|L|NK* ExpANsroN

PoRT
Internal,to both the Multi LinkrMPortand Multi LinkrMExpansionPort,are patentedcouplingopticsand mechanics
designedto producethe highestoutput powers. Internalto the LightSourcesare fans and heatsinksdesignedto
r e d u c et e m p e r a t u r east t h e o p t i c acl o u p l i n gj o i n t st h e r e b ym i n i m i z i ntgh e p o s s i b i l i toyf d a m a g et o M i c r oL r n k @
F i b e ra n df i b e rb u n d l e s .

1 B

WELCHALLYN

SERVTCE
CLEANTNG
1 . P r i o rt o c l e a n i n gt ,u r nt h e p o w e rs w i t c hO F Ea n dd i s c o n n e cpt o w e rs o u r c ef r o m b o t ht h e L i g h tS o u r c ea n d
t h e w a l lo u t l e t .
2 . C l e a nt h e e x t e r n asl u r f a c e sb y w i p i n gw r t ha c l o t hd a m p e n e dw i t h 1 0 % b l e a c hs o l u t i o nD
. O N O TI M M E R S E .
r

R o u t i n e l iyn s p e c a
t n dc l e a na l l a i ri n t a k e s/ o u t f l o w sa t t h e r e a ro f t h e c h a s s i sf o r l i n to r o t h e rd e b r i s .

F o l l o wt h e m a n u f a c t u r e ri'nss t r u c t i o nwsh e n C l e a n i n tgh e f i b e rb u n d l e so r a c c e s s o r i euss e dw i t h t h e l i g h t

source.

3 . W i p et h e p o w e rc o r dw i t h a c l o t hd a m p e n e dw i t h 1 0 7 ob l e a c hs o l u t i o na n dw a t e r .D O N O TI I V I M E R S E
D .O
N O TR E C O N N E CW
TE T .
4 . D O N O Tw i p e d o w n a n y l e n s e so r w i n d o w s .
5 . D O N O Tp l u gt h e p o w e rs o u r c ei n t oa w a l l o u t l e tu n t i li t i s t h o r o u g h ldyr y .
SURGtcAL
ILLUMtNAToR
T h e c o n s o l em a y b e c l e a n e du s i n ga c l e a ns o f t c l o t hw i t h t h e f o l l o w i n gc l e a n i n g
agents:
E n z y m a t iS
c o l u t i o n( E n z o l )
lsopropylAlcohol
H y d r o g e nP e r o x i d 3
e% USP
2 % Gl u t a r a l d e h y dSeo l u t i o n
Soapand Water
'lOo/o
b l e a c hs o t u t t o a
n n dw a t e r
C A U T I O N : D o n o t s p l a s hc l e a n i n g
a g e n t si n t oa n y o p e n i n g ss,e a m so r e l e c t r i c aclo m p o n e n t s .
MULT|L|NK* ExPANsroN
PoRT
The outsidesurfacesmay be cleanedwith a soft cloth usingthe following:
i s o p r o p yAl l c o h o l
Soapand Water
The glasssurfacesmay be cieanedby the followingmethods:
A cottonswab moistenedwith lsopropylAlcohol
Blow with dry compressedair
NOTE: Use care in cleaningthe opticalsurfacesof the Multi LinkrMExpansionPortto preventscratches.

PN:LB-MANCLSERVRev.A

1-9

'IVelc$;1*.
TooLsREoUIRED
.

"
Slottedscrewdriver,lessthan 6 long

# 1 P h i l l i pS
s c r e w d r i v elre, s st h a n6 " l o n g

# 2 P h i l l i pS
s c r e w d r i v elre, s st h a n6 " l o n g

O p e ne n d w r e n c hs e t - E n g l i s ho r 5 / 1 6 "

N e e d l en o s ep l i e r s

N u t D r i v e rS e t- E n g l i s ho r 3 / 1 6 " , 1 1 4 " , 5 1 1 6 "

N u t D r i v e rS e t- M e t r i co r 1O m m

D e e pw e l l s o c k e ts e t a n dw r e n c h( 2 )- C L 1 0 0S u r g i c al l l u m i n a t o r

N o n - c o n d u c t i vpeo t a d j u s t i n g
t o o l- C L 1 0 0S u r g i c al l l u m i n a t o r

Lightoutputpower meter with head.CoherentLasermate1D or equivalent(meter),HeadModel 1d10- CL

1 0 0S u r g i c al l l u m i n a t o r

Laght
outputmeter- Labsphere
ModelFIMS-400P
or equivalent
thatmeasures
in lumens- CL300Surgical
llluminator

C a I b r a t e oR M S D r g i t aM
l u l t i m e t e (r D M M )

1,10

WELCHALLYN

ThouBLESHoorNG
CL 1o0 SURGTCAL
ILLUMTNAToR

Symptom
L a m pf a i l st o s t a r ta n d
f a n sa r e n o t r un n i n g .

Cause
No power to unit

C h e c kp o w e rs u p p l yc o r da n do u t l e t

Linevoltageis <90 VAC

Referto HospitalEngineering
department
"Test
#1: Blown
Inspect,replaceand retest.Go to
F u s e s "o n p a g e1 2 .

F u s e sb l o w n
Safetyinterlockopen
Power supplyfailure
Lampfailsto start and
f a n sa r e r u n n i n g .

| ^'n^ ^h' '+^ ^al ^t.^.

Lo, r,P r,,urr u, I o, rel

operatingfor a few
m inutesand restartsafter
coolrng.

I n di c a t o rl i g h to n a n d
lampshuts off

Remedy

C h e c ka n dt i g h t e ns l o t t e ds c r e wo n l a m pf i x t u r e
accessdoor
"Test
#2: 100WATTPower Supply"on
Go to
p a g e1 3

L a m pn o t i n l i g h ts o u r c e
( a u d i b lcel i c k i n gh e a r d )

I n s t a lal 1 0 0 Wr e p i a c e m e nl at m p ,m o d e l9 0 1 3 3 .

Defectivelampcable
(discolored,
bent or broken
prongs)
( a u d r b lcel i c k i n gh e a r d )

Reolace
a n d r e t e s tl a m oc a b l e .

Defectivepower supply
(discoloreb
de
, n to r b r o k e n
prongs)
( n oa u d i b l ec l i c k i n gh e a r d )

I n s p e cw
t i r i n ga n di f i t i s f i n e ,r e p l a c ea n dr e t e s t
power supply.

I n a d e q u a taei rf l o w f o r
c o o l i n gL, i g h tS o u r c eo v e r
lemperalUre
F a nf a i l u r e

A i l o w2 " ( 5 1 m m )c l e a r a n caet b a c ko f u n i t ;i n s u r e
vents are cleanand not
that air intake-outflow
blocked.Allow unit to cool and then restart
"
'l
"Test
#3: CoolingFan on page 3.
Go to

l l l u m i n a t oi sr o v e r h e a t i nngo t
d u et o c l e a r a n c e .

Verifyoperationof fans.Cleanfans and internal

componentsof dust.

Lamp rs at the end oi life,but

a m b e rL E Di s i n o p e r a t i v e .

VerifyLED flickerson when it is first turnedon. lf

"Test
not, go to
#4: LED/OvertempSwitch" on
p a g e1 3 .

L a m pl i f ee x c e e d e d .

I n s t a lal 1 0 0 Wr e p l a c e m e nl at m p ,m o d e l9 0 ' 1 3 3 .

L a m pc a b l ed e f e c t r v e .

R e p l a c ei ' p r o n g sa r e d i s c o l o r e db.r o k e no. r b e n t

Powersupplyout of
calibration.

"Test
To go
#6: Power SupplyCalibration"on
p a g e1 4 .

R e p l a c e m e nLta m pw i l l
Lampis not orientedcorrectly Rotatelamp 180' and re-insert
not seat into LightSource
I n c o r r e cRt e p l a c e m e nLta m p I n s t a lal 1 0 0 Wr e p l a c e m e nl at m p ,m o d e l9 0 1 3 3 .

P N :L B - M A NC L S E R VB e v .A

Velc$11yn.
Symptom
Low l i gh t oulpul

F i b e rb u n d l ew i l l n o t
Installin LightSource

"
"
A u d i b l e c l i c k i n go r
a r c i n gs o u n dd u r i n gt h e
l a m pi g n i t i o np r o c e s s

Cause

Remedy

Fiber
D a m a g e dM i c r oL i n k @
o r f i b e rb u n d l e

C h e c ke n d so f M i c r oL i n k @F i b e ro r f i b e rb u n d l e
f o r d a m a g eR
w i t h n e w M i c r oL i n k @
Fiber
. eplace
"Test
o r f i b e rb u n d l eG
. ot o
# 5 : M i c r oL i n k @F i b e r
'13.
T e s t "o n p a g e

Fiberbundlenot connected
correctly.

Re-insertf iber bundlecorrectly.

L a m pn e a re n d o f u s a b l el i f e

l n s t a l l a1 0 0 Wr e p l a c e m e nl at m p ,m o d e l9 0 1 3 3 .

F i l t e ra s s e m b l yo n p l a t f o r m
contamrnated.

C l e a no r r e p l a c ef i l t e ra s s e m b l ya s n e c e s s a r y .

Minors dirty.

Cleanmirrors.

B r o k e nm i r r o r s .

Replaceplatform.

M i s a l i g n em
d i r r o r s( p o s s i b l e
if unit suffersdamage)

lf abovestepsfail to improveoutput, replaceand

retestplatform.

Dirtyor damagedinternal
mooute.

Inspect,clean,and replaceif necessary.

"Operating
Instructions"
on page6
Usecompatible
bundle
design

N o t a c o m p a t i b l fei b e rb u n d l e See

"Operatrng
I n s t r u c t r o n so"n p a g e6

I n s t a l l / F e m o vMeu l t i L i n k r M
ExpansionPort

See

Multi LinkrMExpansionPort
installed

RemoveMulti LinkrMFxpansionPort

No problem

Normaloperation

CL lOOSURGICAL
ILLUMINAToR
DISASSEMBLY
NOTE: For all tests, remove9 screws from top cover.
NOTE: Do not operateunit with the top cover removedfor more than 5 minutesor the unit will overheat.
TEST#1: BLowN FUsEs
The purposeof this test is to determinethe sourceof a short circuitcausingfusesto blow. Referto the Block
D i a g r a mo n p a g e4 7 .
Replaceand retestthe fuses. lf unit functionsnormally,inspectfuses that were blown. lf solderis meltingout of
the end of the fuse and the glassis not blackened,removeand replacethe power entry module.Thisfault occurs
when the prongof the fuse holdermakespoor contactwith the fuse. The prongwill look discoloredand pitted
where it contactsthe fuse.

WELCHALLYN

l f t h e f u s eb l o w sa g a r nI,n s p e ctth e p o w e rs u p p l ya n dt h e w i r i n gt o r d a m a g e do r b u r n tc o m p o n e n t sR. e m o v ea n d

replaceany visuallydefectivecomponents.
l f v i s u a Il n s p e c t i odno e sn o t y i e l da n ye v i d e n c eo f d a m a g er, e m o v ea n d r e p l a c ep o w e rs u p p l ya n d r e t e s t .
IEST#2: lOOWATT PowERSUPPTY
V e r i f yo p e r a t i n vgo l t a g ei s p r e s e n ot n p o w e rs u p p l yi n p u tt e r m i n a l sC. o n n e c m
t e t e ra n ds e t t o v o l t sA C t o J 1 a n d
J 2 t e r m i n a l sW
. h e n p o w e ri s a p p l i e dt o t h e u n i t ,v e r i f yt h e o p e r a t i n vgo l t a g ei s d i s p l a y e od n t h e m e t e r .N O T E :
Verifythe lampaccessdoor is closed.
lf voltageis present,repraceand retestpower supply.
l f v o l t a g ei s n o t p r e s e n ti,n s p e ct h e f u s e s ,w i r i n g ,p o w e re n t r ym o d u l e l,i n ef i l t e r a
, n d i n t e r l o c sk w i t c h .
TEST#3: CooLINGFAN
The purposeof this test ls to verifythe operattonof the lampcoolingtan.
V i s u a l l iyn s p e c ft o r a b r o k e nt a n .W h e nt h e u n i t i s p o w e r e du p , l o o kf o r a f a n n o t t u r n i n g l.f f o u n d ,r e m o v et o p
c o v e ra n di n s p e c ft a n .R e p l a c e
a n y b r o k e nf a n s .
lf fan is inoperativeand not broken,measureusingDMM set for VoltsDC for 12VDCon fan connector.
.

lf voltageis present,replaceand retestfan.

lf voltageis not present,replaceand retestpower supply.

IEST#4: LED/OVERTEMP
SwITcH
The purposeof this test is to veriiy properoperationof the LED.
Visuallyinspectthat LED/overtempswitch harnessis connectedto the power supply.Verifycontinuityof wiring
a n d L E Dw i t h D M M s e t t o t h e D i o d eS c a l e D
. M M s h o u l dr e a d= . 7 V D C .
.

l f t h e D M M r e a d i n gd o e sn o t m a t c h ,r e p l a c ea n d r e t e s t h e L E Dh a r n e s s

l f D M M r e a d i n gm a t c h e sa b o v e ,r e p l a c ea n d r e t e s t h e p o w e rs u p p t y .

TEST#5: MIcRo LINK@FIBERlEsT

The purposeof this test is to verifythe operationof the Micro Link@Fiber.
W i t h t h e i l l u m i n a t oorn , c o n n e c t h e f i b e ra n dt h e h e a d l i g h O
t . v e ra d i s t a n c eo f a t l e a s tf i v et e e t ,a d j u s t h e s p o t
d r a m e t et'o t h e l a r g e sst t z e .
.

l f t h e i n t e n s i t yo f l i g h ti s n o t c o n s i s t e ntth r o u g h o utth e l i g h ts p o ta n dr o t a t i n gt h e d i s t a e
l n d c o n n e c t odr o e s
n o t c a u s et h e s h a p et o c h a n g et,h e h e a d l i g hi ts t h e m o s t l i k e l yc a u s eo f t h e f a u l t

l f t h e i n t e n s i t yi s n o t c o n s i s t e nwt i t h a l t e r n a t i nlgi g h ta n dd a r kr i n g sp r e s e n tt,h e f i b e ri s b r o k e na t t h e d i s t a l

O v e rt h e s a m ed i s t a n c ea, d j u s t h e h e a d l i g ht to t h e s m a l l e sdt i a m e t e sr p o t .A t t h i s a d j u s t m e n t h
, e h e a d l i g hi ts
f o c u s e dl.t a n y s p o t i r r e g u l a r i t i e
a sr e p r e s e n th, o l dt h e h e a d l i g hstt e a d yw h i l er o t a t i n gt h e d i s t a e
l nd(black)
connector.

PN: LB-MAN-CLSEBV
Rev.A

1,13

Welc\Allyn'
.

lf the locationof the defectsmove,removethe fiber,cleanthe end with distilledwater,reconnectthe unit,and

test. Replacethe fiber if detectsare still present.

lf the locationof the defectsremainstationary,

the fault is within the headlight.

TEST#6: PowERSUPPLY
CAL|BRAT|oN
The purposeof this test is to verifythe operationof the power supply.
Applypower to unit,once the lamp lights,connectthe DIVIV(setto volts DC)to the lampcablewires on the
p o w e rs u p p l yT. h e p o s i t i v el e a do f D M M t o t h e H V + t e r m i n aol n t h e p o w e rs u p p l ya n dt h e n e g a t i v el e a do f t h e
D M M t o t h e L a m pR e t u r n- t e r m i n aol n t h e p o w e rs u p p l yW
. A R N I N GD: o n o t c o n n e c tD I V Mt o w i r e sp r i o rt o
t u r n i n gt h e u n i to n .W h e n t h e l a m pi g n i t e st,h e r ei s a p p r o x i m a t e2l y5 k Vo n t h e t e r m i n a l w
s h i c hc o u l dd a m a g et h e
D M M . M o n i t o rt h e v o l t a g ed i s p l a y eodn t h e f l u k ew h e n t h e L E Df i r s tt u r n so n .V e r i f yt h e v o l t a g ei s b e t w e e n1 7 . 0 0
and18.00v.
'

lf the voltageis less than 17.00VDC,removeand replacethe power supplyor returnthe unit for recalibration.

l f t h e v o l t a g ei s b e t w e e n1 7 . 0 0 V D C
a n d 1 8 V D Cr, e m o v ea n d r e p l a c et h e l a m pf i x t u r e .
o

lt the voltageis more than 18.00DC,contactthe Welch AllynTechnicalServicesDepartmentat

1-315-685-2993or 1 315-685-4233,
7:00am-3:00pm(EST).

WELCHALLYN

ILLUMTNAToRDrsAssEMBLy
CL 100 SURGTCAL
PowERSUPPLY
REMoVAL
'l

. Bemovethe 9 screwssecurinqthe toDcoverand removethe cover.

2 . R e m o v et h e 3 s c r e w sf r o m t h e b o t t o ms i d eo f t h e b a c kp a n e .
3 . D i s c o n n e cwt i r e sf r o m J 1 a n dJ 2 o n t h e p o w e rs u p p l v D
. i s c o n n e cf at n c o n n e c t ofrr o m J 4 .
4.

Removethe 2 screwsfrom the bottom chassis,securingthe centerbaffle(seefigurebelow).

lC"

Screws
s e c u r i n gc e n t e r
baffleto bottom
c h a s sr s

w
5 . R e m o v et h e n u t t h a ts e c u r e st h e c e n t e rb a f f l et o t h e b a c kp a n e l .
6 . Pullbackpanelout and move to the platformside of the chassisto garnaccessto the backof the power
supply.

PN: LB MAN'CLSERVRev.A

1 1 5

Welc$;1yt '
7 . Removethe two white lampcablewires and disconnectthe 4 wire connector.Removethe supplyand baffle.
8 . Removethe 4 screws from the cornersof the power supply.Removesupply.
9 . Reinstallatio
i snt h e r e v e r s ep r o c e s sw i t h t h e b r o w nw i r e g o i n gt o J 1 a n dt h e b l u ew i r e g o i n gt o J 2 . T h e l o n g e r
of the two lampcablewires attachesto the (+) lamp HV terminaland the shorterwire attachesto the (-)lamp
"
r e t u r n .R e f e rt o P h o t o8 " o n p a g e2 4 t o c o n n e c t h e H V + a n d l a m pr e t u r n- t e r m i n a l sa s s h o w n .
PLATFoR'U
REMovAL
'L

Remove9 screwssecuringtop coverand removethe cover.Removethe 5 screws securingthe front bezelto

t h e b o t t o mc h a s s i sa n d p u l lf r o n tp a n e lo u t f r o m c h a s s i sR
. e m o v et h e l a m pf r o m t h e p l a t f o r m .

2. Removethe 2 screws from the fan deflectorassemblv.

3. Removethe 4 screwsf rom the cornersof the platform.
4. As necessary,removethe 2 screwsfrom the f ilterassembly.
. einstallatio
5 . R e m o v et h e p l a t f o r mR
i snt h e r e v e r s ep r o c e s sI.n s t a l l t h ef r o n tb e z e a
l n d c h e c kf o r p r o p e r
movementof attenuator.Loosenplatformscrewsand repositronas necessary.
FRONT
BEZELREMoVAL
1. Remove9 screwssecuringtop coverand removethe cover.Removethe 5 screwssecuringthe front bezelto
t h e b o t t o mc h a s s i sa n d p u l lf r o n tp a n e lo u t f r o m c h a s s i s .
2. Removewires from power switch notingwire localions.Pushon switch from the insideto removethe switch
from the bezel.
3. Usinga sharpknife,removethe blackRry from the LED wires where it mountsto the tront bezel.Once
removed,applyacetoneto the LEDandthe front bezelto weakenthe glue bondand removethe LEDfrom the
front bezel.
4. Installationis the reverseprocess.To attachthe LED,ensureboth paneland LED surfacesare clean.Use
superglue,loctite430 to mount the LED.Use RTVsealantDow Corning737 to sealthe LED,preventingany
l i g h tf r o m t h e i l l u m i n a t opra s s i n gt h r o u g h .
FANDEFLECTOR
REMOVAL
1. Remove9 screws securingtop coverand removethe cover.
2 . R e m o v et h e 5 s c r e w ss e c u r i n g
t h e f r o n tb e z e lt o t h e b o t t o mc h a s s i sa n d p u l l f r o n tp a n e lo u t f r o m c h a s s i s .

3 . Removethe overtempswitch f rom the fan deflector.

4 . Carefullyremovethe heat shrinktubingfrom the fan wiring harness.
5 . Disconnectthe connectorand removeit from the power supply.
6. Installationis the reverseprocesswith installingnew heat shrinktubingover fan connector.

WELCHALLYN

CHAssrsFANREMovAL
T. Remove9 screws securingtop coverand removethe cover.Remove4 screws securingthe fan to the back
pane.
2 . R e m o v eh e a ts h r i n kt u b i n gf r o m t h e f a n c o n n e c t o rD. i s c o n n e catn d r e m o v et h e w i r e t i e sf r o m t h e h a r n e s sa t
t h e p l a t f o r mm o u n t s .R e m o v et h e f a n .
3.

Installation
is the reverseprocess.

LED/OVERTEMP
HARNESS
REMovAL
1. Remove9 screwssecuringtop coverand removethe cover.Removethe 5 screwssecuringthe front bezelto
l ut fromchassis.
t h e b o t t o mc h a s s i sa n d p u l l t r o n tp a n e o
2. Removethe overtempswitch from the fan deflectorassembly.Removethe wire tie f rom the overtempswitch
harnessat the platform.
Usinga sharpknife,removethe blackRTVfrom the LED wires where it mountsto the front bezel.Once
removed,applyacetoneto the LEDand the front bezelto weakenthe glue bondand removethe LEDfrom the
front bezel.
4.

Removethe 3 wire ties and removethe harness.

5.

lnstallationis the reverseprocess.To attachthe LED,ensureboth the paneland the LED surfacesare clean.
( l o c t i t e4 3 0 )t o m o u n tt h e L E D .U s e R T Vs e a l a n(tD o wC o r n i n g7 3 7 )t o s e a lt h e L E Dp r e v e n t i n g
U s es u p e r g l u e
a n y l i g h tf r o m t h e i l l u m i n a t ot or p a s st h r o u g hS
. e ef i g u r eb e l o wf o r r o u t i n go f w i r e s .

LAMPCABLEREMovAL
1. RemoveI screwssecuringthe top coverand removethe cover.Removethe 3 screwsfrom the bottom of the
. l i d eb a c kp a n e tl o t h e s i d e .
b a c kp a n e l .R e m o v et h e n u t s e c u r i n gc e n t e rb a f f l et o t h e b a c kp a n e l S

PN: LB-MAN-CLSERV
Rev.A

117

Welc\ffiytt.
2 . R e m o v et h e n u t f r o m t h e w i r e t i e c l a m ps e c u n n gt h e l a m pc a b l et o t h e b o t t o mc h a s s i sR
. e m o v et h e l a m p
cablefrom the power supplyand removethe cable.
3 . I n s t a l l a t i oi sn t h e r e v e r s ep r o c e s sw i t h t h e l o n g e rc a b l ew r r eg o i n gt o t h e H V +t e r m i n aol n t h e p o w e rs u p p l y
a n d c o n n e c t i n tgh e s h o r t e rw i r e t o t h e L a m pR e t u r n- t e r m i n a lV. i e wt h e u n i tf r o m t h e r e a ra n dc o m p a r et h e
"Photo
H V + a n dt h e L a m pR e t u r n- a r e c o n n e c t e d
8 " o n p a g e2 4 .
a s s h o w ni n
INTERLoCK
SwtrcH REMovAL
1. Removethe 9 screws securinothe toDcoverand removethe cover.
2 . D i s c o n n e ct th e w i r e st r o m t h e i n t e r l o c sk w i t c h .
3. Removethe two nuts from the interlockswitch and remove.
4. Instaliationis the reverseprocess,connectingthe wires to the terminalsmarkedCOM and NO.
PowERENTRYMoDULEREMoVAI
1. Remove9 screwssecuringthe top coverand removethe cover.Removethe 3 screwsfrom the bottom of the
backpanel.Bemovethe nut securingcenterbaffleto the backpanel.

2 . R e m o v et h e 4 s c r e w ss e c u r i n gt h e c h a s s i sf a n . R e m o v et h e w i r e sf r o m P E M .
3 . Removethe two nuts securingthe PElvlto the back panel.Removethe PEM.
4.

lnstallationis the reverseprocesswith the tollowingrequirements:

.

The starwasher is locatedbetweenthe PEM flangeand the paintedsurfaceside of the back panel.
The flat washer is installedon the other side of the paneland is securedwith the nut.
Rotatethe screw so that you can later installthe power cord retainer.
The brown wire is connectedto the terminalmarkedas P on the PEM.The blue wire is connectedto the
t e r m i n am
l a r k e da s N o n t h e P E N /T] .h e g r e e nw i r e f r o m t h e b a c kp a n e li s c o n n e c t e d
t o t h e g r o u n dt e r m i n a lo n t h e P E M .

r 1B

WELCHALLYN

CL 100 SuRGrcArILLUMTNAToR
REpAtR
PARTSLtsr

PartNumber
90133
LB-MAN.1OOW27OW
A0-10756
A0-10768

Description

Photo #

Bubble#

Ouantity

l OOWREPLACEMENT LAMP
'l

MANUAL,1OOW2TOW
SOLARTEC
PANEL,
BOTTOIV,
27OW
L A B E LW
, A R N I N GI,L L U I V I N A T O R S

'l

1
12

PAINTED,
SCREW,
XLS
SCREW,
#8-32X 3/8,PHPS
scREW,#6-32X 1/4,PHSS
XLS,BUIVPER,RUBBER,
5/8

2
3

10 1- 0 0 6 8

S E M S ,# 6 - 3 2X 5 i 1 6 P H P S

A0-10683

2
2

A0-10721

TOEXLSCHASSIS
COVER,
KAPTON
TAPE,
IOP COVER,
XLS

A 0 - t0 8 2 8

,]OOW
P A N E LF, R O N TS, O L A R T E C

10

u50087
u50081
u50085
u50075

l O O WI N T E R N AM
L O D U L EA S S E M B L Y

3
3
3
3

1 t

12
13

14

15

to

17

3
3

18
'19

20

21

1
1
4

A0-10714
1 0 10 0 3 3

101-0022
016-0005

A 0 - 1 0 71
A0-10856

213-0017
102-0012
44-10650
A4-10647
A0-10746

l O O WF A ND E F L E C T OARS S E M B L Y
l O O WF I L T R
E ASSEMBLY
l O O WA L I G N E DP L A T F O R M
F A N ,C H A S S I SX, L S

PANEL,BACKWAVEPATTERN
POWERENTRYMODULE/LINEFILTER,
FUSED
KEPS,#6.32,W/CONICAL
WASHEB
WtREHARNESS,
l OOW
ON/OFF,
POWER
SUPPLY
XLS
OVERTEMP/LED
SW]TCH
ASSEMBLY

A0-10712

B A F F L EC, E N T E RX,L S

A0-'r0843

F O A M ,I G NT O R

101-0062

'l

S E M S ,# 6 3 2 X 9 / 1 6P H P S

22
40
23

207-0007

, 2MM
G U A R DF, A N 9

24

105-0008

C O R D ,R E T A I N I NC
GL A M P

r06-0011

S T A N D O F#F8, , . 7 5 1

208-0016

F U S E5, A S H E E TI I I

44-10465

W I R EP, E MT OD I N

101-0073

S C R E W#, 8 - 3 2X 3 / 4 " , P H P S

010-0016

TUBING,
HEATSHRINK
3/4" BLACK

I010061

4 ,H P S
S C R E W#, 4 - 4 0 X 1 1 P

25
26
27
28
29
30
31
32

1 0 10 0 3 8

PN: LB-MAN.CLSERV
ReV.A

PLUG,6/25

4
2
1
4
z.za
4
1

Welc$11*.
Part Number

Photo #

Bubble#

Ouantity

W A S H E H ,C O L O H C O A I I I )

33

104-0008
104-0007
102-0001

W A S H E RS, E F R A T E D

W A S H E RF, L A T

NUT,HEX

104-0019

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

A0-10864

LAMP,
CABLE,
3OK

C A B L ET I E ,S M A L L4 "

104 0006

112-0001

124

Description

35
36
31
38
39

2
1

WELCHALLYN

PHoro1

--.
(' lc"
,,

<-;-2

5
- =---|'

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

a.--.-r

PHOTO2

P N :L B M A N C L S E R VB E v A
.

1-21

Welc$;1*'
PHoTo3

19
12
10
11

14 18 17 15
PHoTo4
21

WELCHALLYN

PHoTo5

23
?4

PHoTo6

31
30

PN: LB-MAN-CLSERV
Rev.A

Welc\ffi*'
PHoro7

PHoTo8

WELCHALLYN

CL 300 SuRGrcAr
ILLUMTNAToR

Symptom
L a m pf a i l st o s t a r ta n d
f a n sa r e n o t r u n n i n g .

Cause
N o p o w e rt o u n i t

C h e c fp o w e rs u p p l yc o r da 1 do u t l e l

Linevoltageis <90 VAC

R e f e rt o H o s p i t aEl n g i n e e r i ndge p a r t m e n t

F u s e sb l o w n

Inspect,replaceand retest.Go to
"
F u s e s o n p a g e2 7 .

Satetyinterlockopen

C h e c ka n dt i g h t e ns l o t t e ds c r e wo n l a m pf i x t u r e
a c c e s sd o o r
"Test
G ot o
# 2 : A u x i l i a rB
y o a r dI n p u tT e r m i n a l s
p
a
g
e
27
an

Powersupplyor auxiliary
boardtailure
L a m pf a i l st o s t a r ta n d
t a n sa r e r u n n i n g .

Lamp shutsoff after

operatingfor a few
m Inutes and restarts

I n d i c a t ol r g h to n a n d
l a m ps h u t so f f

Remedy

"Test
#1: Blown

L a m pn o t i n l i g h ts o u r c e
( a u d i b lcel i c k i n gh e a r d )

I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 .

D e f e c t i v el a m pc a b l e
(discoloreb
de
, n to r b r o k e n
prongs)
( a u d i b l cel i c k i n gh e a r d )

Replace
a n d r e t e s tl a m pc a b l e .

Defectivepower supply
(discolored,
bent or broken
prongs)
( n oa u d i b l ec l i c k i n gh e a r d )

Inspectwiringand if it is fine, replaceand retest

power supply.

l n a d e q u a taei rf l o w f o r
c o o l i n gL, i g h tS o u r c eo v e r
IemperaTUre

A l l o w2 " ( 5 1 m m )c l e a r a n caet b a c ko f u n i t ,i n s u r e
vents are cleanand not
that air intake-outflow
blocked.Allow unit to cool and then restart

F a nf a i l u r e

Goto

l l l u m i n a t oi sr o v e r h e a t i nngo t
d u et o c l e a r a n c e .

Verifyoperationof fans.Cleanfans and internal

componentsof dust.

L a m pi s a t t h e e n d o f l i i e ,b u t
a m b e rL E Di s i n o p e r a t i v e .

VerifyLED flickerson when it is first turned on. lf

"
not, go to "Test f4 LED Operatron on page27.

L a m pl i f ee x c e e d e d .

I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 .

Lampcabledelective.

B e p l a c ei f p r o n g sa r e d i s c o l o r e db,r o k e n o, r b e n t .

"Test
# 3 . C o o l i n gF a n " o n p a g e2 7 .

R e p l a c e m e nLta m pw i l l
Lampis not orientedcorrectly R o t a t el a m p1 8 0 "a n dr e - i n s e r t
not seat into LightSource
l n c o r r e cR
t e p l a c e m e nLta m p I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 .

PN. LB-MAN-CLSERV
Rev.A

Welc\ffiyr..
Symptom
Low light output

Cause

Remedy

Filterassemblyon platform
contamrnated.

Cleanor replacefiltersas necessary.

Mirrorsare dirty.

C l e a ntnemrrrors.

Broken
mirrors.

Replaceplatform.

(possible l f a b o v es t e p sf a i l t o i m p r o v eo u t p u t ,r e p l a c ea n d
Misaligned
mirrors
if unitsuffersdamage)
retestplatform.
D a m a g e dM i c r oL i n k @F i b e r
o r f i b e rb u n d l e

F i b e ro r f i b e rb u n d l e
C h e c ke n d so f M i c r oL i n k @
f or damage.Replacewith new Micro Link@Fiber
"Test
#5: Micro Link@Fiber
or fiber bundle.Go to
Test" on page28.

Fiberbundle not connected

correctly.

Be-insertf iber bundlecorrectly.

L a m pn e a re n d o f u s a b l el i f e
F i b e rb u n d l ew i l l n o t
i n s t a liln L i g h tS o u r c e

" clicking
"
Audible
or
arcrng
soundduringthe
process
lampignition

I n s t a lal 2 7 0 W r e p l a c e m e nl at m p ,m o d e l9 0 1 2 5 .
"Operating
N o t a c o m p a t r b lfei b e rb u n d l e S e e
I n s t r u c t i o n so"n p a g e6
U s ec o m p a t i b l b
e u n d l ed e s i g n
"Operatrng
Install/Remove
I n s t r u c t r o n so"n p a g e6
Multi LinkrM
See
ExpansionPort
Multi LinklMExpansionPort

B e m o v eM u l t i L i n k r ME x p a n s i oP
nort

No problem

Normaloperation

W E L C HA L L Y N

CL 300 SURGTGAL
ILLUMTNAToRDrsAssEMBLy
NOTE: Forall tests, remove9 screwsfrom top cover.
N O T E : D o n o t o p e r a t eu n i tw i t h t h e t o p c o v e rr e m o v e df o r m o r et h a n5 m i n u t e so r t h e u n r tw i l l o v e r h e a t .
lEsT #1: BLowNFUsEs
T h e p u r p o s eo f t h i st e s t i s t o d e t e r m i n e
t h e s o u r c eo f a s h o r tc i r c u i tc a u s i n gf u s e st o b l o w .R e f e rt o t h e B l o c k
D i a g r a mo n p a g e4 8 .
R e p l a c ea n d r e t e s t h e f u s e s .l f u n i tf u n c t i o n sn o r m a l l yi ,n s p e cftu s e st h a tw e r e b l o w n .l f s o l d e ri s m e l t i n go u t o f
t h e e n d o f t h e f u s ea n dt h e g l a s si s n o t b l a c k e n e dr e
, m o v ea n d r e p l a c et h e p o w e re n t r ym o d u l eT. h i sf a u l to c c u r s
when the prongof the fuse holdermakespoor contactwith the tuse.The prongwill look discoloredand pitted
where it contactsthe fuse.
l f v i s u a il n s p e c t i odno e sn o t y i e l da n ye v i d e n c eo f d a m a g er, e m o v eJ 2 a n dJ 3 f r o m a u x i l i a rbyo a r d( b l u ea n db r o w n
w i r e st h a tc o n n e c tP C B Aa u x ii a r yb o a r dt o t h e p o w e rs u p p l yR
f u s e sa n dt u r n s y s t e mo n . R e m o v ep o w e r
. eplace
a n d i n s p e c ft u s e s
.

l f t h e f u s e sa r e b l o w n ,r e m o v ea n d r e p l a c et h e P C B Aa u x i l i a rbyo a r d( p a r tn o .A 4 - 1 0 6 7 0 ) .

l f f u s e sa r et i n e ,r e m o v ea n d r e p l a c et h e p o w e rs u p p t y .

TEsr#2: AuxtLtARyBoARDlNpur TERM|NALS

V e r i t yo p e r a t i n vg o l t a g ei s p r e s e n ot n a u x i l i a rbyo a r di n p u tt e r m r n a l sC. o n n e c m
t e t e ra n ds e t t o v o l t sA C t o J 1 a n d
J 4 t e r m r n a l sW. h e n p o w e ri s a p p l i e dt o t h e u n i tt h e o p e r a t i n vg o l t a g ev, e r i f yi t i s d i s p l a y e od n t h e m e t e r .N O T E :
Verifvthe lamoaccessdoor is closed.
lf voltageis present,replaceand retestauxiliaryboard.
lf voltageis not present,inspectthe fuses,wiring,power entry module,linefilter,and interlockswitch.
N O T E : l f l a m pi s n o t o n a n dv o l t a g ei s p r e s e n tc, h e c ki f t h e p o w e rs u p p l yi s d e f e c t i v e .
lEsr #3: CooUNGFAN
T h e p u r p o s eo f t h i st e s t i s t o v e r i t yt h e o p e r a t i o o
n f t h e l a m pc o o l i n gf a n .
V i s u a l l iyn s p e c ft o r a b r o k e nf a n .W h e nt h e u n i ti s p o w e r e du p , l o o kt o r a f a n n o t t u r n i n g l.f f o u n d ,r e m o v et o p
c o v e ra n d i n s p e cfta n . R e p l a c e
a n yb r o k e nf a n s
'l2VDC
l f f a n i s i n o p e r a t i vaen dn o t b r o k e n m
, e a s u r eu s r n gD M M s e t f o r V o l t sD Cf o r
o n f a n c o n n e c t o r sJ ,l T i s { o r
t h e l a m pf a n ( e x h a u s ta)n dJ 1 0 1 o rt h e p o w e rs u p p l y( i n t a k e ) .
.

lf voltageis present,replaceand retestfan.

lf vo tage is not present,replaceand re-testauxilraryboard.

IEST#4: LED OPERATIoN

The purposeof this test is to verifyproperoperationof the LED.
V i s u a l l iyn s p e c t h a tJ 1 i s c o n n e c t e d
t o t h e a u x i l i a rbyo a r d V
. e r i f yc o n t r n u i tovf w i r i n ga n d L E Dw i t h D M M s e t t o
t h e D i o d eS c a l e D
. M M s h o u l dr e a d= . 7 V D C .

P N :L B M A N - C L S E R R
V e v .A

Welc$1yn.
.

l f t h e D M M r e a d i n gd o e sn o t m a t c h ,r e p l a c ea n d r e t e s t h e L E Dh a r n e s s .

f D M M r e a d i n gm a t c h e sa b o v e ,r e p l a c ea n d r e t e s t h e a u x i l i a rbyo a r d .

TEST#5: MIcRo LINK@FIBERTEST

The purposeof this test is to verifythe operationof the Micro Link@Fiber.
W i t h t h e i l l u m i n a t oorn , c o n n e c t h e f i b e ra n dt h e h e a d l i g h O
t . v e ra d i s t a n c eo i a t l e a s tf i v ef e e t ,a d j u s t h e s p o t
d i a m e t etro t h e l a r g e sst i z e .
.

l f t h e i n t e n s i t yo f l i g h ti s n o t c o n s i s t e ntth r o u g h o utth e l i g h ts p o ta n dr o t a t i n gt h e d i s t a e
l n d c o n n e c t odr o e s
n o t c a u s et h e s h a p et o c h a n g et,h e h e a d l i g hi ts t h e m o s t l i k e l yc a u s eo Jt h e f a u l t .

l f t h e i n t e n s i t yi s n o t c o n s i s t e nwt i t h a l t e r n a t i nlgi g h ta n dd a r kr i n g sa r e p r e s e n tt,h e b r o k e nf i b e ri s b r o k e na t

t h e d r s t ael n d .

O v e rt h e s a m ed i s t a n c ea, d j u s t h e h e a d l i g ht to t h e s m a l l e sdt i a m e t e sr p o t .A t t h i sa d l u s t m e n t h
, e h e a d l i g hits
f o c u s e d l.f a n ys p o t i r r e g u l a r i t i e
a sr e p r e s e n th, o l dt h e h e a d l i g hst t e a d yw h i l er o t a t i n gt h e d i s t a l e n d( b l a c k )
connector.
.

lf the locationof the defectsmove,removethe fiber,cleanthe end with distilledwater,reconnectthe unit,and

test. Replacethe fiber if defectsare still present.

lf the locationof the defects remainstationary,

the fault is within the headlight.

WELCHALLYN

ILLUMTNAToR
CL 300 SURGICAL
DrsAssEMBLy
NOTE: All servicingrequiresremovalof the top cover.Removethe 9 screwsand removethe cover.
INTERNAL
MODULE
REMovAL
1 . R e m o v et h e t o p c o v e r .
2 . R e m o v et h e f r o n tb e z e b
l y r e m o v i n gt h e 5 s c r e w ss e c u r i n g
t h e f r o n tb e z e tl o t h e b o t t o mc h a s s i s .
3 . P u l lt h e i n t e r n am
l o d u l eo u t o f t h e p l a t f o r ma s s e m b l y .
4.

Installationis the reverseprocesswith the flat edgeson the gray portionof the internalmodulealignedso rt
l n dt h e b l a c kd o t i n t h e g r a yp l a s t i ct o t h e b o t t o mr i g h t .
w i l l f t i n t ot h e r e c e s s e d
a r e ao f t h e f r o n tp a n e a

PowERSUPPLY
REMovAL
1 . B e m o v et h e t o p c o v e r .
2. Removethe front bezelby removingthe 5 screws securingthe front bezelto the bottom chassis.
3 . R e m o v et h e a i r d u c ts t r a pa n da i r d u c t .
4 . R e m o v et h e 5 w i r e sf r o m t h e P C B Aa u x i l i a rbyo a r d( p a r tn o .A 4 - 1 0 6 7 0 ) .
5. Removethe 7 wires f rom the power supply.
NOTEP
: u l lo r p r yt h e w i r e ss t r a i g hut p . R o c k i n g
t h e w i r e t o r e m o v ei t f r o m t h e p o w e rs u p p l ym a yd a m a g et h e
t e r m l n a l ' s o l d e rj o i n to n t h e p o w e rs u p p l yb o a r d .
P u l io r p r yw i r e t e r m i n asl t r a i g hut p .
Do not rockto remove.

U s e b e n tt i Dn e e d l en o s eo l i e r st o o r v t h e t e r m i n aol f f .T h e h a n d l eo f a s c r e w d r i v ei rs u s e da s t h e f u l c r u m .

PN: LB-MAN-CLSERV
ReV.A

TVelc$1*.
6 . R e m o v et h e 4 s c r e w sf r o m t h e p o w e rs u p p l ya n dp u l l t h es u p p l yo u t o f t h e f r o n tt o r e m o v e .
7. Installationis the reverseprocesswith the wires locatedas forrows:
.

P 1 o n p o w e rs u p p l yt o J b o n P C B A( p a r tn o .A 4 - 1 0 6 7 0-)r e dw i r e

P 2 A - U s e dt o c o n f r g u r teo 2 3 0 vo p e r a t i o n
o n l y- N O T U S E D

P 2 o n p o w e rs u p p l yt o J 4 o n P C B A( p a r rn o .4 4 - 1 0 6 7 0-) b r o w nw i r e

P 3 o n p o w e rs u p p l y t o J l o n P C B A( p a r tn o .4 4 1 0 6 7 0 ) b l u e w i r e

P4 on power supply- blackwire from red/blackpair- housedin tubing

P 5 o n p o w e rs u p p l y- r e d w i r e f r o m r e d / b l a cpka i r- h o u s e di n t u b i n g

P 1 1o n p o w e rs u p p l y- r e d o r w h i t e w i r e f r o m r e d / b l a cpka i r( t h t nw i r e p a i r )

P12 on power supply- blackwire from red/blackparr(thinwire pair)

PCBA (PARrNo. 44-10670) REMovaL

'1.

Removepower as notedabove.

2. Notthe location
a n d r e m o v ec o n n e c t o rfsr o m J 6 , J 7 , J 9 , J 1 0 ,J 11, a n dJ 1 2 .
3. Usinga short#1 screwdriver,removethe 4 screwsfrom the cornersof PCBA(partno. A4-10670)and remove
PCBA.
4 . I n s t a l l a t i oi sn t h e r e v e r s ep r o c e s sU
. s et h e b l o c kd i a g r a m sa s n e c e s s a rtyo r e c o n n e ctth e w i r e s .S e ef i g u r e
below for properwire routing.

WELCHALLYN

IGNIToR
REMovAL
1 . R e m o v et h e t o p c o v e r .
t e 2 l a m pc a b l ew i r e sa n dt h e r e d a n d b l a c kw i r e sf r o m t h e i g n i t o rN
. o t et h e w i r e l o c a t i o n s .
2 . D i s c o n n e ct h
3. Remove4 screws,securingrgnitormoduleto the centerbaffle.Screwsare locatedon the other side of the
centerbaffle.
4.

Installation
is the reverseprocess.NOTE:becausethe screwdriverwill not directlyreachthe lower screws,
I n s t a l l i nagn dr e m o v i n gt h e s c r e w sl n t ot h e i g n i t o tr o t a p t h e h o l e sp r i o rt o i n s t a l l i ntgh e i g n i t o ri n t h e u n i tw i l l

5 . R e c o n n e ct th e w i r e sa s f o l l o w s{ s e ef i g u r ef o r o r i e n t a t i o n ) .
.

R e dw i r e t o t h e l o w e rc e n t e rm o s tt e r m i n a l .

Blackwire to the lower outermosttermina.

- l a m pc a b l ew i r e t o t h e t o p l e f t t e r m i n a(l s h o r t ew
r ire).
+ l a m pc a b l ew i r e t o t h e t o p r i g h tt e r m i n alll o n g e w
r ire).

LINE FILTERREMOVAL
1.

R e m o v et h e t o p c o v e r .

PN: LB MAN CLSERVREv.A

Welc$1ytt'
2 . R e m o v et h e s c r e w ss e c u r i n gt h e c e n t e rb a f f l et o t h e b a c kp a n e la n dt h e b o t t o mc h a s s i s( s e ef i g u r eb e l o w ) .
X L SR u b b e rB u m p e r

Hexheadscrew
securingcenter
batfleto sideof
bottomcnassts

rentdr baffleto
bottomchassis

Screw securing
centerbaffleto
b a c kp a n e l

3. Removethe wires from both ends of the linefilter.Note locationof wires.

4. Removethe 2 screws securingthe linefilter and remove.
5. Installationis the reverseprocesswith the followingrequirements:
.

The end of the filter with 3 terminalsis on the platformside of the centerbaffle.

The green (ground)wire goes to the terminaldirectlymountedto the metalsurtace.

The bluewires go to the terminalsnearestthe fans on both ends.The brown wires go to the centermost
termrnals.

CHAssrsFANREMovAL
'1
. Removethe top cover.
2. Removethe 4 screwssecuringthe fan and the wire guard.NOTE:to removethe fan from the lampside of the
u n i t ,r e m o v et h e f a n o n t h e p o w e rs u p p l ys i d e .T o r e m o v et h e l a m pf a n ,p u s ht h e s p l i tg r o m m e tt h r o u g ht h e
center baffle,then pull the wires out of the grommet.
3. Disconnectthe fan connectorfrom the PCBAAuxiliaryboard(partno. A4-10670)and remove.

WELCHALLYN

4. InstalatlonisthereverseprocesswithJ11forthefanonthelampsrdeandJl0forthefanonthe
s u p p l ys i d e .R o u t et h e w i r e sa s s h o w ni n f i g u r e sb e l o w .
W i r e B o u t i n go n l g n i t o ra n d P C B A
( p a r tn o .4 4 - 1 0 6 7 0 )

C h a s s i sF a nW r r eR o u t i n g

T h el a b eo
l n t h e l a m ps i d ef a n f a c e so u t ,t h e l a b e o
l n t h e p o w e rs u p p l ys i d ef a c e si n ( s e ef i g u r eb e l o w ) .

POWER
ENTRYMoDULEREMoVAL
T . R e m o v et h e t o p c o v e r .
2. Removethe 3 screws securingthe backpanelto the bottom chassisand the 1 screw back panelto center
baffle.

3 . R e m o v et h e 3 w i r e t e r m i n a l sf r o m p o w e re n t r ym o d u l e .
4.

Move backpanelas necessaryto gainaccessto nuts securingthe PEM (powerentry module).

5.

R e m o v en u t sf r o m t h e P E Ma n dr e m o v em o d u l e .

PN: LB-MAN.CLSERV
ReV.A

Welc$11yr..
6. Installation
is the reverseprocesswith the followingrequirements.
.

The lockwasher is insertedbetweenthe PEIV1

and the paintedside of the back panel.

The flat washeris insertedbetweenthe non-paintedside of the back paneland the nut.

T h e g r e e n( g r o u n dw) i r e i s c o n n e c t e d
t o t h e t e r m i n a l s o l d e r eddi r e c t l yt o t h e m e t a ls u r f a c eT. h e b l u ew i r e
is connectedto the terminallabeledN and the brown wire to the terminalmarkedP

PLATFoRM
REMoVAL
'1
. Removethe top coverand removethe lamp.
2. Removethe front bezelby removingthe 5 screwsthat secureit to the bottom chassis.Removethe internal
mooute.
3. Removethe two screws from the air duct strapand removethe duct.
4. Removethe 4 screws securingthe plat{orm.
5 . R e m o v et h e l a m ps h r o u df r o m t h e p l a t f o r m .
6 . R e m o v et h e p l a t f o r ma n dt h e t h e r m i s t oar s s e m b l yf r o m J 1 2 .
7. Installation
is the reverseprocess.When installingthe platform,verifythat the shroudduct,the strap,andthe
internalmoduleare installed.Reattachthe front bezeland checkfor attenuatorwheel alignment.
.

Botatethe wheel acrossits adjustmentrangeand if the wheel movesfreely,continue,if it does not move
freely,loosenthe platformscrewsand repositionthe platformso the wheel rotatesfreely.

FRoNTBEZELREMoVAL
1. Removethe top cover.
2. Removethe 5 screws, securingthe front bezelto the bottom chassis.
3. Notingthe wire locations,removethe wires from the power switch. Pushout the power switch.
4. Usinga sharpknife,removethe blackRW from the LED.Once removed,applyacetoneto the areabetween
t h e L E Da n dt h e f r o n tp a n e tl o l o o s e nt h e q l u eb o n d .R e m o v et h e L E D .
5. Installationis the reverseprocesswith the LED gluedto the front panelusingLoctite430 or equivalent.Once
s e t ,a p p l yo p a q u es e a l a n tD
, o w C o r n i n g7 3 7 o r e q u i v a l e ntto, t h e a r e aa r o u n dt h e L E Dt o p r e v e n tl i g h tf r o m
t h e i l l u m i n a t opra s s i n gt h r o u g ht h e L E D .
BLowERFANREMovAL
1 . R e m o v et h e t o p c o v e r .
2. Removethe front bezelas describedoreviouslv.
3 . R e m o v et h e a i r d u c t s t r a pa n d d u c ta s d e s c r i b e d
above.

I -34

WELCHALLYN

4 . R e m o v ee l e c t r i c aclo n n e c t oJr g f r o m P C B A( p a r tn o .4 4 - 1 0 6 7 0 ) .
5 . R e m o v et h e 2 n u t s ,s c r e w s ,a n ds p a c e r st h a t m o u n tt h e b l o w e rf a n t o t h e b l o w e rb r a c k e t .
6 . i n s t a l l a t i oi n
s t h e r e v e r s ep r o c e s sw i t h t h e f o l l o w i n gr e q u i r e m e n t s :
.

Spacera
s r ei n s t a l l eo
d n t h e s c r e w sb e t w e e nt h e b r a c k eat n dt h e f a n .

LAMPCABLEREMoVAL
I

R e m o v et h e t o p c o v e r .

2 . O p e nt h e l a m pa c c e s sd o o r ,o p e nt h e l a t c h a
, n dd i s c o n n e ccta b l e .
3 . D i s c o n n e ct h
t e l a m pc a b l ew i r e sf r o m t h e i g n i t o r .
4

P u l ll a m oc d b l eo u t t h r o u g l t-h e l a ' n pa c c e s sd o o r .

5 . I n s t a l l a t i oi sn t h e r e v e r s ep r o c e s sw i t h t h e f o l l o w i n gr e q u i r e m e n t s .
.

B e m o v et h e n y l o nw i r e t i e f r o m t h e l a m pc a b l e .
Feedthe wires throughthe spacebetweenthe linefilter andthe centerchassis.
Connectthe shorterwire to the top left terminalon the ignitor.Connectthe longerwire to the top, right
t e r m i n a lI.n s t a ltlh e t e r m i n a l sb e t w e e nt h e t w o f l a t w a s h e r s( s e ef i g u r ef o r w i r e r o u t i n g ) .
W i r e R o u t i n go n l g n r t oar n d P C B A
( p a r tn o .4 4 - 1 0 6 7 0 )

PN: LB MAN CLSERVRev.A

Welc$11*'
CL 300 SURGTCAL
ILLUMTNAToR
REPATR
PARTSLrsr

Part Number

Description

9 0 12 5

2 7 W RE P L A C E M
tN I LAMP

Photo # Bubble#

'l

t B - M A N - 1 O O W 2 7 O W MANUAL,1OOW2TOWSOLARTEC

A0-10880

LABEL,PROTECTIVE
EARTHGROUND
BETEL27A
TOPCOVER, LENGTHENED

A0-10797

RM-LBL-023
A0-10755

A0-10714

0uantity

'I

1
1

EXTERNAL
MODULEHOLDER,27OW

2
3

S C R E WP
, A I N T E DX, L S

Itt

101-0033
101-0022
A0-10907

SCREW,
#8 32 X 3/8,PHPS
CHASSIS
BASE

2
2
2
2

10 1 - 0 0 6 8

S E M S ,# 6 - 3 2X 5 / 1 6 ,P H P S

016-0005

X L S ,B U M P E RR, U B B E R5,/ 8

10

S E M S ,# 6 . 3 2X 9 / 1 6 P H P S

11

, 2MM
G U A R DF, A N 9

12
13

CORD,RETAINING
CLAMP

2
2

F U S E5, A S H E E TI I I

A0-10904

B A C KP A N E L

15

213-0019

ROCKEB
SWITCH,
WHITE
ON/OFF,

2
3
3
3
3
3
3
3
3
3
3
4

26

27

u 5 0 11 7
u50111

DUCI NOZZLE
BLOWER,
27OW
STRAEAIR DUCT
27OWLAMP SHROUDSUB-ASSEN/
BLY
27OWADJUSTED
POWER
SUPPLY

28

29

213-0018

S W I T C HI,N T E R L O C K
S,N G LP O L E

30

1A20012

K E P S#, 6 _ 3 2W
, C O N I C A LW A S H E R

31

210-0001

L I NE F I L T E R6,. 0 4 , F L A N G E

32

A0-10768

101,0062
207-0007
105-0008
208-0016

A0-10906
A0- 10905

L A B E LW
, A R N I N GI.L L U M I N A T O F S
S C B E W#, 6 - 3 2X 1 / 4 ,P H S S

BLOWER
BRACI..ET
CENTERBAFFLE

44 10670

PCBAA
, UXILIARY

2 1 80 0 0 3

I G N I T O F2, 7 0 W P I

A0-10864
101-0078

CABLE,
LAMP,3OK
TENSIONWIRE RETAINER
X 1/4,FHD,StT82DG
SCREW,4-40

44-10680

W I R EH A R N E S SL,E D / A U ) ? P S

105-0010

1 1 20 0 0 1
A 0 - 10 8 12
A0-10814

C A B L ET I E ,S M A L L4 "

2
16

17

18

19

20
21
22
23

24
25

1
4

1
1
,l
1
'1

1
,l

WELCHALLYN

PartNumber

Description

Photo# Bubble#

101-0059

S I M S , # 6 - 3 2X 1 i 4 P H P S

33

213-0017

P O W E RE N I R YM O D U L E/ L I N EF I L T E R ,
F U SE D

34

101-0084

S C R E W#, 6 T H D F R M G ,P H P S

35

u50123
u50125

2 7 O WI N T E R N AM
L O D U L ES U BA S S M B

27OWFILTER ASSEMBLY

36
31

S C R E W#, 4 - 4 0X 1 / 4 ,P H P S

38

27OOW
A L I G N E DP L A T F O R M

39

S C R E W#, 8 - 3 2X 3 / 4 " , P H P S

101-0061

u 5 0 115
101-0073

0uantity
2

2
4

A4-10672

FAN,BACK,
3 WIRE,27OW
WIREHARN
ESS,FILTEF/GFOUND

44-10673

W I R EH A R NE S S ,S W I T C H / F I L T E R

A 4 - 1 Q 647

W I R EH A R NE S S A
, C/FILTER

109-0006

B U S H I N GO, P E N E D / C L O S E.D
5O
, O

44 10675

W I R EH A R N E S SA,C / S W I T C H

46

47

44-10655

44 10465

W I R E ,P E MT O D I N

41

6
44

44-10676

WIRE HARNESS,FILTER/PS

48

44-10678

W I R EH A R N E S SA,U X T P S

AO

A4-10677

W I R EH A R NE S S ,O N / O F F / A U X

50

S E M S ,4 - 4 0X 3 / 8 ,P H P S

51

44-10683

F A N ,B L O W E RT, E F L O NW I R E

52

1 0 10 0 8 3

S C E E W4, . 4 0X 1 1 / 4 " , P H P SS, S

53

1 0 6 - 0 051

S P A C E Rf 4
, U N I h B D , 1 1 4o d , 1 l 4 l

54

102-0008

NUT,KEP,4-40, HEX

55

2
2

1 0 6 - 0 01

#8
STANDOFF
, ,.751

56

NUI HEX

57

WASHER,FLAT

58

59

60

PLUG,6/25

61

WASHER,
COLOR
COATED

62

101-0085

102-0001
104 0007
104 0008
104-0019

101-0038
104-0006

PN: LB-MANCLSERVRev.A

W A S H E RS, E R R A T E D
W A S H L Rt,' 4 E X I L R N A LT O O T F

'I

Velc$11ytr.
PHoro1

PHoro2

11

1-3E

WELCHALLYN

PHoTo3

t8

25

17

PHoro4

30 33 32 34

P N :L B - M A NC L S E R VR e v .A

Welc$11ytt*
PHOTo5

PHoro6

WELCHALLYN

PHoro7

PHOTo8

P N :L B - M A NC L S E B VR e VA
.

Velc\Allyn.
GLoSSARY oF TERMS
AC

A l t e r n a t i nC
g urrent

COM

g o m m o nw i r e t e r m r n a t r o n
F o u n do n p o w e rc o n n e c t o r ss,w i t c h e se, t c . . .i n d i c a t i nC

DMM

D i g i t aM
l ultiMeter

F i b e rO p t i cB u n d l e

A n y o f a n u m b e ro f l i g h tt r a n s m i s s i odne v i c e sc h a r a c t e r i z ebdy u s e o f m u l t i p l eh, a i rt h i n

strandsof claddedglassfibers.Usedto deliverlightfrom illuminatorbox to work area.

Leakage
Current

U s u a l l ya s p e c i f i e dm a x i m u ma m o u n t o f a l l o w a b l ec u r r e n tt o p a s s t h r o u g hi s o l a t e d
electricalcomponentswhen subiectedto very high electricalpotentials.

LED

L i g h tE m i t t i n gD i o d e

M e t a lH a l i d e

A n y o f a n u m b e ro f m e t a l l i c o m p o u n d su, s u a l l yi o d i d e st h a ta r e u s e di n t r a c ea m o u n t si n
dischargelight sources.lvletalhalidesare incorporatedto producethe destredspectral
contentot the light source.

NO

N o r m a l l yO p e n ,F o u n do n s w i t c h e si n d i c a t i nngo r m a l l yo p e nt e r m i n a t t o n .

P CB o a r d

P r i n t e dC i r c u i B
t oard

PEM

P o w e rE n t r yM o d u l e

FTV

RoomTemperature
Vulcanizing
Silicone

TRMS

accuracyof digitalmultFmeters.
True Root Mean Squared- usedto characterize

VDC

Voltage-DirectCurrent

Xenon

An elementag
l a s u s e d c o m m o n l yu s e d i n l i g h t i n gp r o d u c t s .U s e d a s a n e v a p o r a n t
s u p p r e s s a ni nt t u n g s t e nh a l o g e nl a m p so r l i g h te m i s s i o ni n g a s e o u sd i s c h a r g lea m p s .

WELCHALLYN

FINAL INSPECTIoN
T h e p u r p o s eo f p r e v e n t a t r vmea r n t e n a n crest o p r o - a c t i v erl ye d u c eo r e l i m i n a t e
f u t u r ep r o b l e m sK. e e p i n g
the light
g
o
o
d
s o u r c ei n
o p e r a t i n cgo n d i t i o n
e n s u r e st h a ti t w i l l p e r f o r mr e l i a b l ay n ds a f e l yE
. v e r ys i xt o t w e l v em o n t h s y, o u
should:
N O T E :P e r f o r mh y p o ta n dg r o u n dc o n t i n u i ttye s t so n t h e u n r tb e f o r eb e g i n n i n tgh e f i n a li n s p e c t i o n .
CL 100SuRGrcAr
ILLUMTNAToR
. h e c kf o r t h e f o l l o w 1 . S e t T I M Et o s t a r t .T u r no n t h e S Y S T E NB
i Ie
. g i nt h e f i f t e e n( 1 5 )m i n u t eB U R N - l Np e r i o dC
ing:
.

D r dt h e y e l l o wL E D l i g h tb r i e f l y ?

D i dt h e l a m ps t a r t ?C l i c k i n gb e f o r et h e l a m pi g n i t e sr s n o r m a l( 1 0c l i c k so r l e s s ) .

A r e t h e f a n sr u n n i n g ?

2 . A f t e rt h e f i f t e e n( 15 ) m i n u t eb u r n - i ni n s e r t t h eP O W E R T E S T F I B Ei R
n t o t h e P o r t .O p e nt h e a t t e n u a t of ru l l y
a n d m e a s u r et h e l i g h to u t p u t .R o t a t et h e p r o x i m ael n d t o m a x i m i z ep o w e ro u t p u ta n dc h e c kt h e f o l l o w i n g :
.

Doesthe connectorinsertsmoothly?

Doesthe attenuatormove smoothly?

D o e st h e L r g h tO u t p u tm e a s u r e> 7 5 0 m i l l i w a t t s L
? i g h to u t p u t< 3 7 5 i s c o n s i d e r etdh e e n d o f t h e l i f eo f
the lamp.

Turnthe system off and on again3 more times. Does it lightabruptlyand properly?

l f t e s t i n gh a sP A S S E Dc,o n t i n u el.f u n i tf a i l st e s t i n gt,r o u b l e s h o oats n e c e s s a r y .

CL 3OOSURGIcAt
ILLUMINAToR
IMPORTANTClickingbeforethe LAMP ignitesis normal(10 clicksor less).Do not hot re-strikein succession.
( 4 5 )s e c o n d se a c ht i m e b e f o r et u r n i n go f f .
T h e I L L U M I N A T Om
Ru s tr e m a i ni l l u m i n a t efdo r a m i n i m u mo f f o r t y - f i v e
Wait thirty (30)secondsbetween eachre-strike.
T u r nt h e I L L U M I N A T OoRf f a n do n a o a i nt h r e e1 3 )m o r et i m e s .T h e I L L U M I N A T Om
R u s t r e m a i ni l l u m i n a t efdo r a
m i n i m u mo f f o r t y j r v e( 4 5 )s e c o n d se i c h t r m eb e f o r et u r n i n go f f. U s r n ga T I M E R w
, a i tt h i r t y( 3 0 )s e c o n d sb e t w e e n
r e - s t r i k e sC. l r c k i n bg e fo r e t h e L A M Pi g n i t e si s n o r m a (l 1 0c l i c k so r l e s s ) D
. o e si t l i g h tp r o m p t l ya n dp r o p e r l y ?
l f t e s t i n gh a sP A S S E Dc,o n t i n u el.f u n i tf a i l st e s t i n g t, r o u b l e s h o oats n e c e s s a r y .
. h e c kf o r t h e f o l
1 . S e tT I M Et o s t a r t .T u r no n I L L U M I N A T O R
B.e g i nt h e f i f t e e n( 1 5 )m i n u t eB U R N - l Np e r i o dC
lowrng:
.

D i dt h e y e l l o wL E Dl i g h tb r i e lfy ?

D i dt h e l a m ps t a r t ?C l i c k i n gb e fo r e t h e l a m pi g n i t e si s n o r m a (l 1 0c l i c k so r l e s s ) .

A r e t h e f a n sr u n n i n g ?

PN: LB-MAN-CLSEFV
Rev.A

1-43

Welc\ffi*'
2 . A f t e rt h e f i f t e e n( 1 5 )m i n u t eb u r n - i ni n s e r t h e P O W E RT E S TF I B E Ri n t ot h e P o r t .O p e nt h e a t t e n u a t ofru l l y
a n d m e a s u r et h e l i g h to u t p u t .R o t a t et h e p r o x i m ael n d t o m a x i m i z ep o w e ro u t p u ta n dc h e c kt h e f o l l o w i n g :
.

Doesthe connectorinsertsmoothly?

Doesthe attenuatormove smoothly?

D o e st h e L r g h tO u t p u tm e a s u r e> 3 6 1 l u m e n s ?L i g h to u t p u t< 2 0 0 i s c o n s i d e r etdh e e n do f t h e l i f eo f t h e

lamp.

WELCHALLYN

SPEcIFIcATIoNS
Physical
x 2 8 6 m m Wx 2 8 6 m m D / 4 . 0 k 9 )
" x 1 1 . 2 5 "D / 9 . 0 1(b1 4 0 m m H
S i z e/ W e i g h t( C L1 0 0 ) 5 . 5 " H x 1 1 . 2 5 W
"
(140mmH
x 2 8 6 m m Wx 3 2 4 m m D / 5 . 0 k 9 )
S l z e/ W e i g h t( C L3 0 0 ) 5 . 5 H x 1 1 . 2 5 " W x 1 2 . 7 5 "D / 11. ' 1 l b
e r o u n dt o p ,b a c ka n ds i d e s
SpaceRequirements M i n i m u m2 " ( 5 1 m m )a i r s p a c a
ne
Paintedsurfaces- polyuretha

F i ni s h
Lamp

'100W
XenonArc
2 7 0 WS h o r tA r c D C M e t a lH a l i d e

LampType

Power Requirements
Electrical

100-240VAC50/60H2

Amperage

2 . 5 A m p s@ 1 2 0 V( S u r g i c al lll u m i n a t oCr L 1 0 0 )
' 1 2 0 V( S u r g i c a l
4 A m p s@
l l l u m i n a t oCr L 3 0 0 )

Salety Compliance
U12601-2
1 n d e d , C S A y ' C A N - C 2N
2 .o2. 6 0 1 - 1 - M 9 0 ,

cD.

6 0 6 0 1 -:' 1 9 9 0A m e n d .2 ,
l E C 6 0 1 -:11 9 8 8 / E N
s ) ,J I ST 1 0 0 1: 1 9 9 2 ,
l E C 6 0 1 - 1 - 2 : 1 9 9 36/0E6N0 1 - 1 - 2 : 1 9( 9C3l a s B

78737

l E C 6 0 12 - 18 : 19 9 6 / E N6 0 6 0 1 - 2 -81: 19 9 6

IECClassification
TypeBF,Classl
lPXO
Operation
Continuous
The CE mark on this productindicatesthat it has beentestedto and conformswith the provisionsnoted
E M Cd i r e c t i v e .
M e d i c aD
l e v i c eD i r e c t i v a
e n d8 9 / 3 3 6 E E C
w i t h i nt h e 9 3 l 4 2 l E E C
y anager
Eu r o p e a nR e g u l a t o rM
EUContact:
W e l c hA l l y nL t d .
C o u n t yM e a t h ,R e p u b l i oc f l r e l a n d
Tel353 46 67700
Fax353 46 27128

P N :L B M A N C L S E B VR C vA
.

Welc$11ytt.
THEoRY oF OPERATToN
LIGHT
SoURcE
T h e L i g h tS o u r c e sc o n s i s o
t f a n e n c l o s u r eh o u s i n ga, h i g hi n t e n s i t yl a m p ,p r o p r i e t a royp t i c apl l a t f o r mu, s e r
i
n
d
i
c
a
t
o
r
s
,
c o n t r o l sa n d
a n da p o w e rs u p p l yw i t h c o n t r oel l e c t r o n i c sC.o o l i n gi s p r o v i d e dv i a i n t e r n af la n s .I n t h e
event that the fan(s)malfunctionsor if adequateair flow is blockedand/orthe internaltemperatureof the device
n echanism
w i l l a u t o m a t i c a lsl yh u to f f
l r o t e c t r om
e x c e e d st h e e n g i n e e r i nsgp e c i f i c a t i o nasn, i n t e r n atlh e r m a p
. f t e rc o o l r n gr,e s t a r t h e L r g h tS o u r c e s .
p o w e rt o t h e r a m p A
REPLAcEMENT
LAMPS
The lampsare high pressure,high intensityand long life Light Sources.They are mountedinto a patentedlamp
l i x t u r ew h i c h i s d e s i g n e dt o a l l o wb o t he a s ya n d r a p i de x c h a n g ei n t h e f i e l da s w e l l a s e n s u r i n gp r e c i s ea | g n m e n t
to the oDticalDlatform.
Powen Suppr-ywrrH CoNTRoLELEcrRoNrcs
All the electricityto the LightSourceis controlledthroughthe ON/OFFswitch. Powerto energizeand operatethe
lamp,fans,and controlcircuitryis providedby a customdesigned,wattageregulated,switchingpower supply.
d y a l a m pv o l t a g em o n i t o r i n cgi r c u i t
T h e o p e r a t i o n al i lf eo f t h e l a m pa n dt h e l a m pl i f ei n d i c a t oar r e c o n t r o l l e b
PoRT
MULT|LtNKn PoRTANDMULT|L|NK* ExpANSroN
Internal,to both the multi LinkrMPort and Multi LinkrMExpansionPort,are patentedcouplingopticsand
mechanicsdesignedto producethe highestoutput powers.Internalto the LightSourcesare fans and heatsinks
d e s i g n e dt o r e d u c et e m p e r a t u r east t h e o p t i c acl o u p l i n g
J o i n t st h e r e b ym i n i m i z i ntgh e p o s s i b i l i toyf d a m a g et o
M i c r oL i n k @F i b e ra n df i b e rb u n d l e s .

1-46

WELCHALLYN

ILLUMTNAToR
CL 100 SURGTCAL
CrRcurr DTAGRAM

POWER
DIAGBAM
SUPPLY
BLOCK
@]4VDC
100240vAc

El\,41
FILTEB

&
FUSE

t--r/
|
I I LAI'/P
I

"\l

LAI\,4P
ATERT
OUTPUT
O.I SHUT
DOWN
INPUT
2 VDC@0.6A

PN:LB MAN CLSERVBCv.A

\Velc\ffi*'
CL 3OOSURGICAL
ILLUMINAToR
CIRCUIT
DIAGRAM

-:

>

c a - 3

= i----.*.

148

WELCHALLYN