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Welch Allyn LS100 Service Manual
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Welch Allyn LS100 Service Manual

Halogen light
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WA
WELCH ALLYN
4341 State Street Road
P.O. Box 220
Skaneateles Falls, NY 13153-0220
WELCH ALLYN
LS100 HALOGEN LIGHT
SERVICE MANUAL
Technical Service Dept:
Telephone: 315 685-4445
Fax:
315 685-4653
1

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Summary of Contents for Welch Allyn LS100

  • Page 1 WELCH ALLYN LS100 HALOGEN LIGHT SERVICE MANUAL WELCH ALLYN 4341 State Street Road P.O. Box 220 Skaneateles Falls, NY 13153-0220 Technical Service Dept: Telephone: 315 685-4445 Fax: 315 685-4653...
  • Page 2 SERVICE MANUAL FOR: WELCH ALLYN LS100 HALOGEN LIGHT MODELS: 44100...Domestic 44110...Wall/Table mount Copyright 1994, Welch Allyn Co. 4341 State Street Road P.O. Box 220 Skaneateles Falls, NY 13153-0220 Originator: Richard Settembre cad file name:440082B.WP5 ECN# 5-29487 SERVICE MANUAL 440088 REV.B...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS FORWARD - - - - - - - - - - - - - - - - - - - - - - - - - - 3 SAFE SERVICE - - - - - - - - - - - - - - - - - - - - - - - 4 INDEX: FAILURE/CAUSE - - - - - - - - - - - - - - - - - - - 5 - 6 INDEX: REMOVAL/REPLACEMENT (R &...

  • Page 4: Forward

    Required specifications and materials are listed at each step where applicable. When reading this manual for the first time, have an LS100 readily available for reference and practice. Read each complete repair step on what to do (task statement), plus how to do it (technique statement) before starting the repair or practice.

  • Page 5: Safe Service

    *** SAFE SERVICE *** DISCONNECT power cord from A.C. power source before initial disassembly of LS100 Light. OBSERVE cautions / warnings in owners manual and printed on the product itself. COMPLY with all safety codes and practices for this type of product.

  • Page 6: Index: Failure/Cause

    ..lamp is of too high wattage,(over 22 watts) and is overloading transformer. INSTALL correct lamp. Lamp is intermittent when LS100 is touched or moved ..loose connection in wiring or lamp is loose in lamp socket. RESTORE connections/REPLACE socket.
  • Page 7 Fails leakage current testing ..replace the entire transformer/power cord assembly. LS100 WALL / TABLE MOUNT TROUBLESHOOTING No light output ..broken lamp (broken pins, filament, glass envelope,) REPLACE lamp..defective switch (failed open), replace switch.

  • Page 8: Index: Removal/Replacement (R & R) Procedures

    INDEX: REMOVAL AND REPLACEMENT (R & R) PROCEDURES CAUTION : DISCONNECT LS100 FROM A.C. POWER SOURCE BEFORE SERVICING TO AVOID ELECTRICAL SHOCK HAZARD Component: Page: Halogen Lamp Power Switch Transformer/Power Cord Assembly- 10-11 Bezel 11-13 Reflector 13-14 Light Cap Hinge 'Stand-off'...

  • Page 9: Removal/Replacement Procedures

    POSITION. TEST BY TRYING TO OPEN LIGHT CAP WITHOUT DEPRESSING TABS. LIGHT CAP SHOULD NOT OPEN. 5. VERIFY REPAIR CONNECT LS100 TO POWER SOURCE AND TURN LIGHT ON. ALLOW NEW LAMP TO OPERATE AT LEAST FIVE MINUTES TO 'BURN IN'.
  • Page 10 PN----* * part number for country of use, see parts list in catalog. REMOVE BASE MOUNT PLATE PN440035-501 UNPLUG THE A.C. POWER CORD AND PLACE THE LS100 IN A HORIZONTAL POSITION. UN-SCREW FIVE (5) FASTENERS (1/4- 20) PN106140-1 STARTING WITH THE CENTER FASTENER. IT IS...
  • Page 11 BASEPLATE.IF NECESSARY, TRIM/CUT OFF EXCESS TRANSFORMER SECONDARY WIRE TO REDUCE THE LENGTH OF UNNECESSARY WIRE WHICH WILL BE PUT BACK INTO BASE OF LS100. IF YOU CUT OFF TOO MUCH WIRE, THERE WILL BE INSUFFICIENT ROOM BETWEEN THE BASE AND THE BASEPLATE TO GET YOUR HANDS IN TO CRIMP ON THE CONNECTORS.
  • Page 12 INSPECT THAT NO WIRES WILL BE TRAPPED BETWEEN POLE BOTTOM AND BASE PLATE. INSERT AND TORQUE CENTER FASTENER TO 37 INCH/LBS +/- 2 INCH/LBS. VERIFY REPAIR CONNECT LS100 TO APPROPRIATE A.C. POWER OUTLET AND ILLUMINATE LAMP FOR APPROXIMATELY 15 MINUTES. OBSERVE FOR ILLUMINATION, NO EXCESSIVE HEAT OR A.C.
  • Page 13 LIGHT HOUSING AS SHOWN IN FIG. 2a BELOW. DETENT TABS ON THE BEZEL ARE IN AN UP/DOWN/LEFT/RIGHT ORIENTATION. BY STARTING OUT THIS WAY, THE WELCH ALLYN LABEL WILL BE 'RIGHT-SIDE-UP' AS SHOWN, AFTER THE BEZEL COUNTER-CLOCKWISE AND LOCKED IN IS ROTATED 45 DEGREES PLACE.
  • Page 14 BEZEL (R & R) CONTINUED CONTINUED BEZEL TO THE PRESS GENTLY AND EVENLY TO INTERLOCK THE SEE FIG. 2 b. LIGHT HOUSING. ROTATE BEZEL COUNTER-CLOCKWISE APPROXIMATELY 45 DEGREES. THREE CLICKS WILL BE HEARD AS EACH OF THE THREE SETS OF ALLYN LOGO SHOULD...
  • Page 15 REFLECTOR (R & R) CONTINUED REPLACE REFLECTOR VERIFY THAT ALL WIRES ARE ON THE SWITCH SIDE OF THE LIGHT HOUSING AND WILL NOT BE PINCHED OR CUT WHEN REFLECTOR IS PRESSED INTO PLACE. ALIGN REFLECTOR TO ITS ORIGINAL POSITION AND PRESS IT FIRMLY AND EVENLY INTO THE LIGHT HEAD.
  • Page 16 CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING HINGE STANDOFF (R & R) PN440022-1 REMOVE LAMP REMOVE BEZEL REMOVE REFLECTOR REMOVE LIGHT CAP DISCONNECT WIRES DISCONNECT BOTH WHITE LAMP SOCKET WIRES FROM: a)SWITCH, b)SECONDARY WIRE. REMOVE HINGE STANDOFF/LAMP SOCKET ASSEMBLY FROM...
  • Page 17 USED ON THE 'O' RINGS OF THE ROTATION STOP HEAD AT THE TOP OF THE GOOSENECK. REFER TO WIRING DIAGRAM IN APPENDIX BB. VERIFY REPAIR CONNECT LS100 TO POWER SOURCE AND TURN ON. TEST FOR ROTATION AND ROTATION-STOP WITH NO SQUEAKING. ------------------------------------------------------------------ ------------------------------------------------------------------...
  • Page 18 UNSCREW FASTENER PN106119-3 FROM THE LOWER END OF THE GOOSENECK CONNECTOR AND PULL THE SLEEVE INSERT OFF. REASSEMBLE GOOSENECK ASSEMBLY (DO NOT CONNECT GOOSENECK TO POLE IF LS100 WILL BE PACKED FOR SHIPPING) REPLACE O-RINGS PN106108-7 AND PN482038 ON GOOSENECK AND SLEEVE INSERT.
  • Page 19 INSERT WIRES UP AND THROUGH GOOSENECK ASSEMBLY AND ATTACH NEW CRIMP CONNECTORS PN483308. REFER TO WIRING DIAGRAM IN APPENDIX BB. VERIFY REPAIR ILLUMINATE LS100. FLEX GOOSENECK. CHECK FOR ROTATION STOP WITH NO SQUEAKING SOUND AND SMOOTH OPERATION. ------------------------------------------------------------------ ------------------------------------------------------------------ BASE POLE PN440033 (R &...
  • Page 20 SAVE GROMMET FOR REASSEMBLY IF IT IS IN GOOD CONDITION. REASSEMBLE (DO NOT CONNECT GOOSENECK TO POLE IF THE LS100 MUST BE PACKED FOR SHIPPING BACK TO THE CUSTOMER) PUT GROMMET OVER SECONDARY WIRES AND INSERT IT INTO THE WIRE HOLE IN THE POLE.
  • Page 21 USE CLOSED END 'CRIMP' CONNECTORS PN711036. STRIP, CRIMP, AND INSPECT FOR BARE WIRE CONDUCTORS. INSTALL NEW STRAIN RELIEF. RE-ASSEMBLE LIGHT HEAD AND TEST LS100 TO "A" SPECS IN APPENDIX. REPLACE TRANSFORMER FUSE. THE DOMESTIC (U.S.A.) TRANSFORMER MODEL #________ HAS A REPLACEABLE 5 AMP FUSE SOLDERED IN SERIES WITH THE SECONDARY WINDING AT THE TERMINALS.THE INTERNATIONAL TRANSFORMER...
  • Page 22 VERIFY REPAIR CONNECT LS100 TO APPROPRIATE A.C. POWER OUTLET AND ILLUMINATE LAMP. PERFORM APPROPRIATE 'A' TESTS. CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING. BEFORE REPLACING TRANSFORMER, REFER TO THE TROUBLESHOOTING SECTION TO DETERMINE IF THE FUSE(S) HAVE BECOME OPEN OR IF THE TRANSFORMER WINDINGS HAVE FAILED.
  • Page 23 VERIFY REPAIR. ILLUMINATE LS100. BEND GOOSENECK. CHECK FOR ROTATION STOP WITH NO CONTINUAL SQUEAKING SOUND AND SMOOTH OPERATION. TABLE BRACKET ASSEMBLY. REMOVE THREADED ROD AND KNOB. GENTLY PULL THE SWIVEL PAD UPWARDS AND TURN THE HREADED ROD CLOCKWISE TO UNSCREW THE PAD FROM ITS LEFT HANDED (REVERSE) THREADS.
  • Page 24 APPENDIX AA EXPLODED VIEW OF LS100 WITH PARTS LEGEND DRAWING # 440045, 440120...
  • Page 26 APPENDIX CC REPAIR VERIFICATION TEST PROCEDURES Perform the following test procedures after repairs have been made and prior to returning the LS100 to the customer. PERFORM THE FOLLOWING WELCH ALLYN TESTS. COPIES OF TESTS ARE INCLUDED IN THIS APPENDIX. Domestic -- A 02477...
  • Page 27 APPENDIX DD PACKAGING FOR SHIPMENT REPACK AS SHOWN: wrap bubble-pack material...
  • Page 28 APPENDIX EE SAFETY / ADVISORY LABELS Part No.: Description: --------- ------------ 440030-1 Label, Bezel 440056-1 Label, Brazil 747041 Warning Tag 440061 Cap Trim Label 440087 Lamp Insertion Label 440041-3 Label, Halogen, Domestic 747042-2 Service Label 440050-1 Label, Europe 440052-1 Label, United Kingdom 440054-1 Label, Australia...
  • Page 29 APPENDIX EE CONTINUED S E R V I C E LABEL ( ( POLE BASE) CAUTION LABEL (BASE PLATE) ELECTRIC SHOCK HAZARD, 00 NOT DISASSEMBLE IN- STRUMENT REFER SERVIC- ING TO OUALIFIED SERVICE PERSONNEL. SKANEATELES FALLS. N.Y. 13153 U . S . A I N P U T 24A/ I 20V~60Hz LAMP INSERTION LABEL...
  • Page 30 APPENDIX FF The following items or their equivalent are required for the complete repair and testing of the LS100 Halogen Light: COMMON TOOLS: Item: Description: Catalog #:1. Screwdriver: Phillips #1* cat. #2501 Screwdriver: Phillips #2* cat. #2502 Spanner Insert: Magna #41780 **** cat.
  • Page 31 APPENDIX FF CONTINUED Illuminance meter: MINOLTA T-1, Item# 1519-206 Minolta Corp.,101 Williams Drive, Ramsey, NJ, (201)825-4000 SUPPLIES: Item:Description: W/A Part #: Dow 111 grease (gooseneck bottom) PN M11379 MolyKote 33 grease (gooseneck top) PN M11041 Locktite #262-31 PN M30328 (Transformer) Cover (to base) rivets PN 106125-1 Transformer (to cover) rivets PN 106125-2...
  • Page 32 APPENDIX GG PRODUCT UP-DATES FILE ALL UP-DATES IN THIS SECTION. MAKE THE APPROPRIATE CHANGES IN THE MANUAL PERTAINING TO THESE UP-DATES.
  • Page 33 The light housing is manufactured of injection molded plastic which minimizes surface temperature. The power source for the LS100 is standard A.C. for the country it is sold into. Different source voltages and frequencies are accommodated by manufacturing the LS100 with either of two basic transformers, and the appropriate plug configuration.