Welch Allyn CL 300 Service Manual
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Welch Allyn CL 300 Service Manual

Surgical illuminator
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Service Manual
CL 300 Surgical Illuminator
SolarTec Source 270
CL 100 Surgical Illuminator
SolarTec Source 100
Welch Allyn Lighting Products
4619 Jordan Road
Skaneateles Falls, NY 13153-0187
PN: LB-MAN-CLSERV Rev. A

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Summary of Contents for Welch Allyn CL 300

  • Page 1 Service Manual CL 300 Surgical Illuminator SolarTec Source 270 CL 100 Surgical Illuminator SolarTec Source 100 Welch Allyn Lighting Products 4619 Jordan Road Skaneateles Falls, NY 13153-0187 PN: LB-MAN-CLSERV Rev. A...
  • Page 2 New Release 0-1013 8/20/02 D. Rutan Drawings, illustrations, and/or part numbers contained in this document are for reference purposes only. For current revisions call the Welch Allyn Customer Service phone number listed in “Service Centers” on page 2 of this manual.

  • Page 3: Table Of Contents

    Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 ENERAL NFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1...
  • Page 4 ARTS CL 300 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25...
  • Page 5 LLUMINATOR CL 300 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43...

  • Page 7: General Information

    ENERAL NFORMATION The Welch Allyn CL 100 Surgical Illuminator and the Welch Allyn CL 300 Surgical Illuminator provide brilliant illumination for the physician and surgeon. The lamps produce high intensity light nearly identical to the spectrum of sunlight. Special features include the ability to use either a Cogent Optics Micro Link® Fiber or a conventional fiber bundle.

  • Page 8: Service Centers

    ERVICE ENTERS If you have an equipment problem that you cannot resolve, you may call the Welch Allyn Service Center nearest you for assistance. Technical service support is available by telephone on normal business days at the phone numbers listed below. If you are advised to return a product to Welch Allyn for repair or routine maintenance, schedule the repair with the service center nearest you.

  • Page 9: Warranty

    ARRANTY Welch Allyn warrants the CL 300 or CL 100 Surgical Illuminator when new, to be free of defects in material and workmanship and to perform in accordance with manufacturer’s specifications when subject to normal use and service for a period of one year from date of purchase from Welch Allyn or an authorized agent. Welch Allyn will either repair or replace any components found to be defective or at variance from manufacturer’s specifications...

  • Page 10: System Symbol Descriptions

    Protective Earth Ground +49 C Storage Temperature Range -20 C Maximum Storage Humidity Type BF equipment, Class I Not protected against the ingress of water IPXØ Manufactured in accordance with the relevant regulations and technical requirements of Japan. WELCH ALLYN...

  • Page 11: Warnings And Precautions

    ARNINGS AND RECAUTIONS WARNING • Keep out of reach of patient. • Not suitable for use in the presence of a flammable anesthetic mixture with air or with oxygen or nitrous oxide. • Disconnect from the patient before the discharge of a cardiac defibrillator. •...

  • Page 12: Operating Instructions

    Cable Compatibility Table Multi Link™ Port Multi Link™ Expansion Port ® Micro Link Fiber Karl Storz ACMI Olympus Wolf, Dyonics For cables with no Multi Link™ Expansion Port required: 1. Close the light attenuator or turn the Light Source off. WELCH ALLYN...

  • Page 13: Multi Link ™ Expansion Port - Installation And Use ( Optional )

    ® 2. Connect the instrument end of the Micro Link Fiber or fiber bundle to the instrument. 3. Insert, until fully engaged (snap sound), the Light Source end into the Multi Link™ Port. 4. Turn on Light Source. Adjust the light attenuator to the required illumination level. ™...

  • Page 14: Principles Of Operation

    Internal to the Light Sources are fans and heatsinks designed to ® reduce temperatures at the optical coupling joints thereby minimizing the possibility of damage to Micro Link Fiber and fiber bundles. WELCH ALLYN...

  • Page 15: Service

    ERVICE LEANING 1. Prior to cleaning, turn the power switch OFF, and disconnect power source from both the Light Source and the wall outlet. 2. Clean the external surfaces by wiping with a cloth dampened with 10% bleach solution. DO NOT IMMERSE. •...

  • Page 16: Tools Required

    Light output power meter with head. Coherent Lasermate 1D or equivalent (meter), Head Model 1d10 - CL 100 Surgical Illuminator • Light output meter - Labsphere Model FIMS-400P or equivalent that measures in lumens - CL 300 Surgical Illu- minator •...

  • Page 17: Troubleshooting

    ROUBLESHOOTING CL 100 S URGICAL LLUMINATOR Symptom Cause Remedy Lamp fails to start and No power to unit Check power supply cord and outlet fans are not running. Line voltage is <90 VAC Refer to Hospital Engineering department Fuses blown Inspect, replace and retest.

  • Page 18: Cl 100 Surgical Illuminator

    This fault occurs when the prong of the fuse holder makes poor contact with the fuse. The prong will look discolored and pitted where it contacts the fuse. 1-12 WELCH ALLYN...

  • Page 19: Test #2: 100 Watt Power Supply

    If the fuse blows again, inspect the power supply and the wiring for damaged or burnt components. Remove and replace any visually defective components. If visual inspection does not yield any evidence of damage, remove and replace power supply and retest. #2: 100 WATT P OWER UPPLY...

  • Page 20: Test #6: Power Supply Calibration

    If the voltage is less than 17.00VDC, remove and replace the power supply or return the unit for recalibration. If the voltage is between 17.00VDC and 18VDC, remove and replace the lamp fixture. • If the voltage is more than 18.00DC, contact the Welch Allyn Technical Services Department at 1-315-685-2993 or 1-315-685-4233, 7:00am-3:00pm(EST). 1-14...

  • Page 21: Cl 100 S Urgical Illuminator Disassembly

    CL 100 S URGICAL LLUMINATOR ISASSEMBLY OWER UPPLY EMOVAL 1. Remove the 9 screws securing the top cover and remove the cover. 2. Remove the 3 screws from the bottom side of the back panel. 3. Disconnect wires from J1 and J2 on the power supply. Disconnect fan connector from J4. 4.

  • Page 22: Platform Removal

    4. Carefully remove the heat shrink tubing from the fan wiring harness. 5. Disconnect the connector and remove it from the power supply. 6. Installation is the reverse process with installing new heat shrink tubing over fan connector. 1-16 WELCH ALLYN...

  • Page 23: Chassis Fan Removal

    HASSIS EMOVAL 1. Remove 9 screws securing top cover and remove the cover. Remove 4 screws securing the fan to the back panel. 2. Remove heat shrink tubing from the fan connector. Disconnect and remove the wire ties from the harness at the platform mounts.

  • Page 24: Interlock Switch Removal

    The brown wire is connected to the terminal marked as P on the PEM. The blue wire is connected to the terminal marked as N on the PEM. The green wire from the back panel is connected to the ground termi- nal on the PEM. 1-18 WELCH ALLYN...

  • Page 25: Cl 100 Surgical Illuminator Repair Parts List

    CL 100 S URGICAL LLUMINATOR EPAIR ARTS Part Number Description Photo # Bubble # Quantity 90133 100W REPLACEMENT LAMP LB-MAN-100W270W MANUAL, 100W/270W SOLARTEC A0-10756 PANEL, BOTTOM, 270W A0-10768 LABEL, WARNING, ILLUMINATORS A0-10714 SCREW, PAINTED, XLS 101-0033 SCREW, #8-32 X 3/8, PHPS 101-0022 SCREW, #6-32 X 1/4, PHSS 016-0005...
  • Page 26 Part Number Description Photo # Bubble # Quantity 104-0006 WASHER, COLOR COATED 104-0008 WASHER, SERRATED 104-0007 WASHER, FLAT 102-0001 NUT, HEX 104-0019 WASHER, #4 EXTERNAL TOOTH A0-10864 CABLE, LAMP, 30K 112-0001 CABLE TIE, SMALL 4” 1-20 WELCH ALLYN...
  • Page 27 HOTO HOTO PN: LB-MAN-CLSERV Rev. A 1-21...
  • Page 28 HOTO 14 18 17 15 HOTO 1-22 WELCH ALLYN...
  • Page 29 HOTO HOTO PN: LB-MAN-CLSERV Rev. A 1-23...
  • Page 30 HOTO HOTO 1-24 WELCH ALLYN...

  • Page 31: Cl 300 Surgical Illuminator

    CL 300 S URGICAL LLUMINATOR Symptom Cause Remedy Lamp fails to start and No power to unit Check power supply cord and outlet fans are not running. Line voltage is <90 VAC Refer to Hospital Engineering department Fuses blown Inspect, replace and retest. Go to “Test #1: Blown Fuses”...
  • Page 32 Use compatible bundle design Install/Remove Multi Link™ See “Operating Instructions” on page 6 Expansion Port Multi Link™ Expansion Port Remove Multi Link™ Expansion Port Audible “clicking” or No problem Normal operation arcing sound during the lamp ignition process 1-26 WELCH ALLYN...

  • Page 33: Cl 300 S Urgical Illuminator Disassembly

    CL 300 S URGICAL LLUMINATOR ISASSEMBLY NOTE: For all tests, remove 9 screws from top cover. NOTE: Do not operate unit with the top cover removed for more than 5 minutes or the unit will overheat. #1: B LOWN USES The purpose of this test is to determine the source of a short circuit causing fuses to blow.

  • Page 34: Est Icro Ink Iber Est

    If the location of the defects move, remove the fiber, clean the end with distilled water, reconnect the unit, and test. Replace the fiber if defects are still present. • If the location of the defects remain stationary, the fault is within the headlight. 1-28 WELCH ALLYN...

  • Page 35: Cl 300 S Urgical Illuminator Disassembly

    CL 300 S URGICAL LLUMINATOR ISASSEMBLY NOTE: All servicing requires removal of the top cover. Remove the 9 screws and remove the cover. NTERNAL ODULE EMOVAL 1. Remove the top cover. 2. Remove the front bezel by removing the 5 screws securing the front bezel to the bottom chassis.

  • Page 36: Pcba ( Part No . A4-10670) Removal

    3. Using a short #1 screwdriver, remove the 4 screws from the corners of PCBA (part no. A4-10670) and remove PCBA. 4. Installation is the reverse process. Use the block diagrams as necessary to reconnect the wires. See figure below for proper wire routing. 1-30 WELCH ALLYN...

  • Page 37: Ignitor Removal

    GNITOR EMOVAL 1. Remove the top cover. 2. Disconnect the 2 lamp cable wires and the red and black wires from the ignitor. Note the wire locations. 3. Remove 4 screws, securing ignitor module to the center baffle. Screws are located on the other side of the center baffle.

  • Page 38: Hassis An Emoval

    To remove the lamp fan, push the split grommet through the center baffle, then pull the wires out of the grommet. 3. Disconnect the fan connector from the PCBA Auxiliary board (part no. A4-10670) and remove. 1-32 WELCH ALLYN...

  • Page 39: Power Entry Module Removal

    4. Installation is the reverse process with J11 for the fan on the lamp side and J10 for the fan on the power supply side. Route the wires as shown in figures below. Wire Routing on Ignitor and PCBA Chassis Fan Wire Routing (part no.

  • Page 40: Platform Removal

    Dow Corning 737 or equivalent, to the area around the LED to prevent light from the illuminator passing through the LED. LOWER EMOVAL 1. Remove the top cover. 2. Remove the front bezel as described previously. 3. Remove the air duct strap and duct as described above. 1-34 WELCH ALLYN...

  • Page 41: Lamp Cable Removal

    4. Remove electrical connector J9 from PCBA (part no. A4-10670). 5. Remove the 2 nuts, screws, and spacers that mount the blower fan to the blower bracket. 6. Installation is the reverse process with the following requirements: • Spacers are installed on the screws between the bracket and the fan. ABLE EMOVAL 1.

  • Page 42: Cl 300 Surgical Illuminator Repair Parts List

    CL 300 S URGICAL LLUMINATOR EPAIR ARTS Part Number Description Photo # Bubble # Quantity 90125 27W REPLACEMENT LAMP LB-MAN-100W270W MANUAL, 100W/270W SOLARTEC RM-LBL-023 LABEL, PROTECTIVE EARTH GROUND A0-10755 BEZEL 270 A0-10880 TOP COVER, LENGTHENED A0-10797 EXTERNAL MODULE HOLDER, 270W...
  • Page 43 Part Number Description Photo # Bubble # Quantity 101-0059 SEMS, #6-32 X 1/4 PHPS POWER ENTRY MODULE / LINE FILTER, 213-0017 FUSED 101-0084 SCREW, #6 THD FRMG, PHPS U50123 270W INTERNAL MODULE SUB-ASSMB U50125 270W FILTER ASSEMBLY 101-0061 SCREW, #4-40 X 1/4, PHPS U50115 2700W ALIGNED PLATFORM 101-0073...
  • Page 44 HOTO HOTO 13 14 1-38 WELCH ALLYN...
  • Page 45 HOTO HOTO 32 34 PN: LB-MAN-CLSERV Rev. A 1-39...
  • Page 46 HOTO HOTO 1-40 WELCH ALLYN...
  • Page 47 HOTO HOTO PN: LB-MAN-CLSERV Rev. A 1-41...

  • Page 48: Glossary Of Terms

    True Root Mean Squared - used to characterize accuracy of digital multi-meters. Voltage -Direct Current Xenon An elemental gas used commonly used in lighting products. Used as an evaporant suppressant in tungsten halogen lamps or light emission in gaseous discharge lamps. 1-42 WELCH ALLYN...

  • Page 49: Final Inspection

    • Turn the system off and on again 3 more times. Does it light abruptly and properly? If testing has PASSED, continue. If unit fails testing, troubleshoot as necessary. CL 300 S URGICAL LLUMINATOR IMPORTANT: Clicking before the LAMP ignites is normal (10 clicks or less). Do not hot re-strike in succession.
  • Page 50 Rotate the proximal end to maximize power output and check the following: • Does the connector insert smoothly? • Does the attenuator move smoothly? • Does the Light Output measure > 361 lumens? Light output < 200 is considered the end of the life of the lamp. 1-44 WELCH ALLYN...

  • Page 51: Specifications

    Physical Size / Weight (CL 100) 5.5” H x 11.25” W x 11.25” D/9.0lb (140mmH x 286mmW x 286mmD/4.0kg) Size / Weight (CL 300) 5.5” H x 11.25” W x 12.75” D/11.1lb (140mmH x 286mmW x 324mmD/5.0kg) Space Requirements Minimum 2” (51mm) airspace around top, back and sides...

  • Page 52: Theory Of Operation

    Internal to the Light Sources are fans and heatsinks designed to reduce temperatures at the optical coupling joints thereby minimizing the possibility of damage to Micro Link® Fiber and fiber bundles. 1-46 WELCH ALLYN...

  • Page 53: Cl 100 Surgical Illuminator Circuit Diagram

    CL 100 S URGICAL LLUMINATOR IRCUIT IAGRAM A4-10646 A0-10713 ON/OFF LAMP INTERLOCK OVERTEMP SWITCH ASSY SWITCH SWITCH 1 1a 2 2a BLUE BLUE GRN/YEL LINE FILTER LAMP A0-10710 CHASSIS A0-10711 POWER SUPPLY A4-10647 POWER SUPPLY BLOCK DIAGRAM FAULT 8A @ 14VDC 100-240VAC 150VDC CURRENT...

  • Page 54: Cl 300 Surgical Illuminator Circuit Diagram

    CL 300 S URGICAL LLUMINATOR IRCUIT IAGRAM 1-48 WELCH ALLYN...
  • Page 56 Lighting Products Group 4619 Jordan Road PO Box 187 Skaneateles Falls, NY 13153-0187 Telephone: 1-315-685-2993 or 1-866-801-8428 FAX: 1-315-685-2999 www.welchallyn.com PN: LB-MAN-CLSERV Rev. A Printed in the U.S.A.

This manual is also suitable for:

Cl 100

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