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
GENERA
I NL F o R M A T T o N ------1-1
T E C H N T CH
AEL L PI N F o R M A T T o N - - 1-1

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
--- --- 1-5
W a r n i n g- - - - - - 1-5
Caution- --- 1-5

O P E R A T I NI N
GS T R U C T I o N S ---- 1-6
Conlrols 1'6
PowEO
R N / O FSFw r r c H . -'---- 16
F | B EPRo R r ------ 16
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 ) . - - -- -...- -1-7
T ] - T E N U A TCTooNNT R o-L- - - -
L i c HA ---------1-7
L A M PL I F El N D r c A T o R -'l-7
P r i n c i p l e sO f O p e r a t i o n- - 1-8
L I G HSTo U R c E ---1-8
MTP S-
R E P L A C E MLEAN -----. ---1-8
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 ---- -1-8
M U L TL| i N K TPMo R T A NM
D U L TLr T N K T
EMx p A N s r oPNo R T - - ---------1-8

S E R V T- C E --------- 1-9
C L E A N T -N- -G- - - 1-9
S U R G T CI LALLU M T N A T o R .- --1-9
M U L TL| T N K E
T xMp A N s r P
oNo R T- - - - - - - - ------1-9

T o o L SR E o U I R E D -- 1-10

T R o U B L E S H o o T- N
- -G
-- --- 1-11
C L 1 0 0S u R G r c AI L
r LUMTNAToR - - - - - 1-11
T IoSRA S S E M B-L- Y- -
C L 1 O OS U R G I C IALLL U I \ , I I N AD ... -'I-12
-
T E S T# 1 : B L o W NF U s E s - - - 1-12
TEST # 2 :1 O O
W A T TP O W ESRU P P T Y -------- 1-13
T E S T # 3C:o o L r NFGA N- - - .1-13
TEST#4: LED/OVEBTEMP
SWITCH . - - - -' 1.13
 T E s r # s :M r c R oL I N K @ E s r- - -
F T B ETR - --- -- 1-13
T E S T # 6P: o w E RS u p p L yC A L T B R A I o N ----- - 1-14

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 - - - 1.15

PoWER
S U P P LRYE M o V A L - - 1-15
PLATFoRM
EMoVAL -------- 1-16
F R o NBT E Z ERLE M o V A L -------- 1-16
FANDEFLECToR REMoVAL 1 16
C H A S SFI A
S NR E M o V A L '- ------- 1-17
L E D / O V E R T EHMAPR N E SRSE M o V A L -. -.. - 1-17
L A M PC A B L R
E EMoVAL - --- 1-17
I N T E R L oS
CwK r r c HR E N t o v A L - - - -' 1-18
PoWER E N T RMY O D U LR EE M o V A L -. - _ 1-18
CL 1 0 0 S U R G T CI A
L L U M TNAT Sr s r - - -
RoERP A TPFA R T L ----- 1-19
C L 3 0 0S U R G T CI LALLU M T N A T o R -- - ----'l 25

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 - - - 1-27

TEsr#1:BLowN
FusEs ---- 1-21
TEST#2: AuxrLrARy BoARDlNpurTERMTNALS - - - - 'l-27
: o o L r NFGA N- - - -
T E s r # 3C 127
T E s r# 4 : L E DO P E R A T o N ----- 1-27
TEST#5: MIcRoLINK@
FTBER
TEST - - - 1-2A

C L 3 O OS U R G I C AILI I U M I N A T o R
DISASSEMBLY .. - 1-29
I N T E R NMAoLD U LREE M o V A- L ----- ------129
PoWERSUPPLY REMoVAL 129
PCBA( p A R r
N o .A 4 - 1 0 6 7 0R) E M o V A L ------- 1,30
l G N r r oR
RE M o V A L .--- -- 1-31
L | N EF T L T ERRE M o V A L - -- . - 1-31
C H A S SF
I SA NR E M o V A L ---- 1-32
PowER
E N T RM
Y o D U LR
EE M o V A L -------- 1-33
PLATFoRM
EMoVAL ------ 1-34
F R o NB
T E Z ERLE M o V A L ----- 1-34
B L o w EFRA NR E M o V A. -L --------1-34
LAMP E E M o V A -L- - -
C A B LR --- 1 35
C L 3 0 0 S U R G T CIA
LLUMTNAT A R T LSr s r - - -
RoERP A TPR ----- 1-36
G L o S S A RoYF T E R N 4 S ------ 1-42

F I N A LI N S P E C T I o N -- 1-43
C L 1 O OS U R G I C IALLL U M I N A T o R -.. - 1-43
C L 3 O OS U R G I C IALLL U M I N A T o. .R . - 1-43

SPEcrFlcAroNS --- 1-45

T H E o R Y oO
FP E R A T I o N ----- 1-46
L r G HSr o u R c E ------1-46
R E P L A C E ML E
ANMTP S- -------1-46
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 --- - -- 1-46
M U L TLI I N K TPMo R T A NM
D U L TLr T N K T
EMx p A N S t oPNo R T - - ---------1-46

--- ---- ,I-47

C L 1 O OS U R G I C AI LLL U M I N A T C
oRI 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
i l l u m i n a t i of n
orthe 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
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
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
t a r r a n t ya n dc o u l d
compromiseinstrumentsafety and performance.
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
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
, r phone
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 on 1 1 o f t h i sm a n u a l .

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 ,
s c h e d u l et h e r e D a iwr 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 .

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. Welch Allyn, Ltd., Canada
4 6 1 9J o r d a nR o a d '160
M a t h e s o nB l v d .E . ,U n i t# 2
S k a n e a t e l eFsa l l sN
, Y 13153-0187 M i s s i s s a u g aC,a n a d aL 4 Z 1 V 4
Tel:1-315-685-2993 Tel:905-890-0004
Fax:315-685-2999 Fax:905-890-0008

INTERNATIONALCUSTOMERS
Welch Allyn, GmbH Welch Allyn, Ltd., Singapole
Zollerstrasse
24 300 BeachRoad,#25-08
72417 JunEngen,Germany, The Concourse
477-9211-73
fel: 011-49-7 Singapore199589
Fax.011-49-7477-9271-93 Tel:011 65-291-0882
F a x :0 1 1 - 6 5 - 2 9 1 - 5 7 8 0
Welch Allyn, Ltd., Australia Welch Allyn, China
Metro Center Room708, 22'/ lluang Pi Road,North
Unit 5 38 SouthStreet CentralPlaza
R y d a l m e r eN, S W2 1 1 6 ,A u s t r a l i a S h a n g h a2i 0 0 0 0 3
T e l :0 11 - 6 1 - 2 9 4 - 1 8 3 - 1 5 5 P R .C h i n a
F a x :0 11 - 6 1 - 2 9 4 - 1 8 3 - 6 5 0 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 ef 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
sh, i p p i n go, r f r o m i m p r o p em r aintenance se, r v r c eo, r
cleaning procedures.
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 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

A Caution- Hot SurfaceArea

A Ra^la^a

250V5A
tr,,c6 ec lr,4ert orl

5A,250V

A - Highvoltage
WARNING is present

I 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
Symboo

s C m a i n sp o w e r
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

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

@ ProtectiveEarthGround

|- ^.*l
| |f l Temperature
Storage Range
t4__l
@ Maximum
Storage
Humidity

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

Not protectedagainstthe ingressof water

aPxg
Manufacturedin accordancewith the relevantregulationsand technicalrequirementsof
Japan.

WELCHALLYN
WARNINGS
AND PRECAUTIoNS

e WARNING
/-\
. K e e oo u t o l r e a c ho f p a t i e n t .
l\
. 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 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
a n e s t h e t im
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 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
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 I n d i c e sF, i n adl r a t tM a r c h
3,1995).
. Appliedpartsattachedto this equipmentshouldbe approved1) to the MedicalDeviceDirective(93/
42/EEC)(Europe),2) approvedby a NationallyRecognized TestingLaboratory(UnitedStates),and3) by
a StandardsCouncilof Canadaaccreditedlaboratory (Canada) 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 .
. 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 m a yc a u s ep r e m a t u r e
f a i l u r eo r e x p l o s i o nof the lamp.
. The light sourcelampsare hot immediatelyafter use,allow the lampto cool for five (5)minutesafter
operation.Temperatures peakin the light Sourcesapproximately 60 secondsafterthe LightSourceis
poweredoff.

r CAUTION
. Do notplaceanythrng Do notstoreliquidabovethe LightSource.
on topof theLightSource.
lA
. 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
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
l
r a d e "o r
"Hospital
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 Table

Multi Linkn Port 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
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
Fiber
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 .

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 .
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

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 anenclosureh 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 iSc 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

. 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
N o n - c o n d u c t i vpeo t a d j u s t i n g

. 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

. outputmeter- Labsphere
Laght ModelFIMS-400P
or equivalent in lumens- CL300Surgical
thatmeasures lllu-
minator

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

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 .
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
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
Cause Remedy
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
F u s e sb l o w n Inspect,replaceand retest.Go to #1: Blown
F u s e s "o n p a g e1 2 .
Safetyinterlockopen 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
Power supplyfailure Go to #2: 100WATTPower Supply"on
p a g e1 3
L a m pn o t i n l i g h ts o u r c e 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 .
( a u d i b lcel i c k i n gh e a r d )
Defectivelampcable a n d r e t e s tl a m oc a b l e .
Reolace
(discolored, bent or broken
prongs)
( a u d r b lcel i c k i n gh e a r d )
Defectivepower supply 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
I n s p e cw
(discoloreb de , n to r b r o k e n power supply.
prongs)
( n oa u d i b l ec l i c k i n gh e a r d )
I n a d e q u a taei rf l o w f o r 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
c o o l i n gL, i g h tS o u r c eo v e r that air intake-outflow vents are cleanand not
lemperalUre blocked.Allow unit to cool and then restart
"Test " 'l
F a nf a i l u r e Go to #3: CoolingFan on page 3.
l l l u m i n a t oi sr o v e r h e a t i nngo t Verifyoperationof fans.Cleanfans and internal
d u et o c l e a r a n c e . componentsof dust.
Lamp rs at the end oi life,but VerifyLED flickerson when it is first turnedon. lf
"Test
a m b e rL E Di s i n o p e r a t i v e . 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
"Test
Powersupplyout of To go #6: Power SupplyCalibration"on
calibration. p a g e1 4 .
Velc$11yn.

Symptom Cause Remedy

Low l i gh t oulpul D a m a g e dM i c r oL i n k @
Fiber 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
o r f i b e rb u n d l e f o r d a m a g eR . eplace w i t h n e w M i c r oL i n k @ Fiber
"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 Re-insertf iber bundlecorrectly.

correctly.

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 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 .
contamrnated.

Minors dirty. Cleanmirrors.

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

d i r r o r s( p o s s i b l e
M i s a l i g n em lf abovestepsfail to improveoutput, replaceand
if unit suffersdamage) retestplatform.

Dirtyor damagedinternal Inspect,clean,and replaceif necessary.

mooute.

F i b e rb u n d l ew i l l n o t N o t a c o m p a t i b l fei b e rb u n d l e See
"Operating on page6
Instructions"
Installin LightSource Usecompatible
bundledesign
"Operatrng
I n s t a l l / F e m o vMeu l t i L i n k r M See I n s t r u c t r o n so"n p a g e6
ExpansionPort

Multi LinkrMExpansionPort RemoveMulti LinkrMFxpansionPort

installed
" "
A u d i b l e c l i c k i n go r No problem Normaloperation
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

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
. M M s h o u l dr e a d= . 7 V D C .
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

. 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

r 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
CL 100 SURGTCAL
ILLUMTNAToRDrsAssEMBLy

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).

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

o o
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.

5 . R e m o v et h e p l a t f o r mR
. einstallatio
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.

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 .
2 . R e m o v et h e 5 s c r e w ss e c u r i n g

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. is the reverseprocess.
Installation

LED/OVERTEMP
HARNESS
REMovAL

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 l t r o n tp a n e o
l ut fromchassis.

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.
U s es u p e r g l u e ( 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
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
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
. l i d eb a c kp a n e tl o t h e s i d e .

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 a s s h o w ni n 8 " o n p a g e2 4 .

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
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 e r m i n am 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 Description Photo # Bubble# Ouantity

90133 l OOWREPLACEMENT LAMP
LB-MAN.1OOW27OW MANUAL,1OOW2TOW 'l
SOLARTEC
A0-10756 'l
PANEL,
BOTTOIV,
27OW 1 1
A0-10768 L A B E LW
, A R N I N GI,L L U I V I N A T O R S 1 2 1
A0-10714 SCREW, PAINTED,XLS 1 3 12
1 0 10 0 3 3 SCREW,#8-32X 3/8,PHPS 1 4 4
101-0022 scREW,#6-32X 1/4,PHSS 1 5 2
016-0005 XLS,BUIVPER,RUBBER, 5/8 1 6 4
10 1- 0 0 6 8 S E M S ,# 6 - 3 2X 5 i 1 6 P H P S 1 1 I
A0-10683 COVER,TOEXLSCHASSIS 2 8 1
A0-10721 KAPTON
TAPE,
IOP COVER,
XLS 2 9 1
A 0 - t0 8 2 8 ,]OOW
P A N E LF, R O N TS, O L A R T E C 3 10 1
u50087 l O O WI N T E R N AM
L O D U L EA S S E M B L Y 3 1 t 1
u50081 l O O WF A ND E F L E C T OARS S E M B L Y 3 12 1
u50085 l O O WF I L T R
E ASSEMBLY 3 13 1
u50075 l O O WA L I G N E DP L A T F O R M 3 14 1
A 0 - 1 0 71 F A N ,C H A S S I SX, L S 3 15 1
A0-10856 PANEL,BACKWAVEPATTERN 3 to 1
POWERENTRYMODULE/LINEFILTER, 'l
213-0017 3 17
FUSED
102-0012 KEPS,#6.32,W/CONICAL
WASHEB 3 18 4
44-10650 WtREHARNESS, '19
l OOW
ON/OFF, 3 1
A4-10647 POWER SUPPLY
XLS 4 20 1
A0-10746 OVERTEMP/LED SW]TCHASSEMBLY 4 21 1
A0-10712 B A F F L EC, E N T E RX,L S 4 22 1
A0-'r0843 F O A M ,I G NT O R 4 40 1
101-0062 S E M S ,# 6 3 2 X 9 / 1 6P H P S 5 23 4
207-0007 G U A R DF, A N 9
, 2MM 5 24 1
105-0008 C O R D ,R E T A I N I NC
GL A M P 5 25 I
r06-0011 S T A N D O F#F8, , . 7 5 1 5 26 4
208-0016 F U S E5, A S H E E TI I I 6 27 2
44-10465 W I R EP, E MT OD I N 6 28 1
101-0073 S C R E W#, 8 - 3 2X 3 / 4 " , P H P S 6 29 4
010-0016 TUBING,
HEATSHRINK
3/4" BLACK 6 30 z.za
I010061 S C R E W#, 4 - 4 0 X 1 1 P
4 ,H P S 6 31 4
1 0 10 0 3 8 PLUG,6/25 7 32 1

PN: LB-MAN.CLSERV
ReV.A
Welc$11*.

Part Number Description Photo # Bubble# Ouantity

104 0006 W A S H E H ,C O L O H C O A I I I ) 7 33 1
104-0008 W A S H E RS, E F R A T E D 7 1
104-0007 W A S H E RF, L A T 7 35 1
102-0001 NUT,HEX 7 36 1
104-0019 W A S H E R#,4 t X I t R N A I T O O T H 7 31 2
A0-10864 LAMP,
CABLE, 3OK 8 38 1
112-0001 C A B L ET I E ,S M A L L4 " 8 39 8

124 WELCHALLYN
PHoro1

c (' lc"
--.

,, <-;-2

- =---|'
5 / ) e . "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 .
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
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
PN. LB-MAN-CLSERV
Rev.A
Cause Remedy
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
"Test
F u s e sb l o w n Inspect,replaceand retest.Go to #1: Blown
"
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
Powersupplyor auxiliary G ot o y o a r dI n p u tT e r m i n a l s
# 2 : A u x i l i a rB
boardtailure an p a g e27
L a m pn o t i n l i g h ts o u r c e 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 .
( a u d i b lcel i c k i n gh e a r d )
D e f e c t i v el a m pc a b l e Replace
a n d r e t e s tl 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 )
Defectivepower supply Inspectwiringand if it is fine, replaceand retest
(discolored, bent or broken power supply.
prongs)
( n oa u d i b l ec l i c k i n gh e a r d )
l n a d e q u a taei rf l o w f o r 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
c o o l i n gL, i g h tS o u r c eo v e r that air intake-outflow vents are cleanand not
IemperaTUre blocked.Allow unit to cool and then restart
"Test
F a nf a i l u r e Goto # 3 . C o o l i n gF a n " o n p a g e2 7 .
l l l u m i n a t oi sr o v e r h e a t i nngo t Verifyoperationof fans.Cleanfans and internal
d u et o c l e a r a n c e . componentsof dust.
L a m pi s a t t h e e n d o f l i i e ,b u t VerifyLED flickerson when it is first turned on. lf
"
a m b e rL E Di s i n o p e r a t i v e . 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 .
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 .
Welc\ffiyr..

Symptom Cause Remedy

Low light output Filterassemblyon platform Cleanor replacefiltersas necessary.
contamrnated.

Mirrorsare dirty. C l e a ntnemrrrors.

Broken
mirrors. Replaceplatform.

Misaligned (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
mirrors
if unitsuffersdamage) retestplatform.

D a m a g e dM i c r oL i n k @F i b e r 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 @
o r f i b e rb u n d l e f or damage.Replacewith new Micro Link@Fiber
"Test
or fiber bundle.Go to #5: Micro Link@Fiber
Test" on page28.

Fiberbundle not connected Be-insertf iber bundlecorrectly.

correctly.

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
L a m pn e a re n d o f u s a b l el i f e 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 be u n d l ed e s i g n
"Operatrng
Install/Remove Multi LinkrM See I n s t r u c t r o n so"n p a g e6
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
Audible" clicking
" No problem
or Normaloperation
arcrng
soundduringthe
lampignition process

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 . eplace 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
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
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 'l2VDC
, 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
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 )
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
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 .

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 .
3 . P u l lt h e i n t e r n am

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 .
a r e ao f t h e f r o n tp a n e a
w i l l f t i n t ot h e r e c e s s e d

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 gt 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

. o n l y- N O T U S E D
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

. 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

o 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 .

2 . D i s c o n n e ct h
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 .

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 rentdr baffleto

securingcenter bottomchassis
batfleto sideof a a
bottomcnassts

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 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 ) .
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

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..

is the reverseprocesswith the followingrequirements.

6. Installation

. The lockwasher is insertedbetweenthe PEIV1

and the paintedside of the back panel.

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

o 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 .

is the reverseprocess.When installingthe platform,verifythat the shroudduct,the strap,andthe

7. Installation
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 .

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 :
6 . i n s t a l l a t i oi n

. 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 Photo # Bubble# 0uantity

9 0 12 5 tN I LAMP
2 7 W RE P L A C E M
'l
t B - M A N - 1 O O W 2 7 O W MANUAL,1OOW2TOWSOLARTEC
'I
RM-LBL-023 LABEL,PROTECTIVEEARTHGROUND
A0-10755 BETEL27A 1
A0-10880 TOPCOVER, LENGTHENED 2 1
A0-10797 EXTERNAL
MODULEHOLDER,27OW 3 1
A0-10714 S C R E WP
, A I N T E DX, L S 4 Itt

A0-10768 L A B E LW
, A R N I N GI.L L U M I N A T O F S 2 5 1
101-0033 SCREW,
#8 32 X 3/8,PHPS 2 6 4
101-0022 S C B E W#, 6 - 3 2X 1 / 4 ,P H S S 2 7 8
A0-10907 CHASSIS
BASE 2 8
10 1 - 0 0 6 8 S E M S ,# 6 - 3 2X 5 / 1 6 ,P H P S 2 9 8
016-0005 X L S ,B U M P E RR, U B B E R5,/ 8 2 10 4
101,0062 S E M S ,# 6 . 3 2X 9 / 1 6 P H P S 2 11 I
207-0007 G U A R DF, A N 9
, 2MM 2 12 2
105-0008 CORD,RETAINING
CLAMP 2 13
208-0016 F U S E5, A S H E E TI I I 1 2
A0-10904 B A C KP A N E L 2 15
213-0019 ROCKEB
SWITCH, WHITE
ON/OFF, 3 16 1
A0-10906 BLOWER BRACI..ET 3 17 1
A0- 10905 CENTERBAFFLE 3 18 1
44 10670 PCBAA
, UXILIARY 3 19 1
2 1 80 0 0 3 I G N I T O F2, 7 0 W P I 3 20 1
A0-10864 CABLE, LAMP,3OK 3 21 1
105-0010 TENSIONWIRE RETAINER 3 22 4
101-0078 X 1/4,FHD,StT82DG
SCREW,4-40 3 23 1
44-10680 W I R EH A R N E S SL,E D / A U ) ? P S 3 24 1
,l
1 1 20 0 0 1 C A B L ET I E ,S M A L L4 " 3 25
A 0 - 10 8 12 DUCI NOZZLEBLOWER, 27OW 4 26 1
'1
A0-10814 STRAEAIR DUCT 4 27
u 5 0 11 7 27OWLAMP SHROUDSUB-ASSEN/BLY 4 28 1
,l
u50111 27OWADJUSTED POWER SUPPLY 4 29
213-0018 S W I T C HI,N T E R L O C K
S,N G LP O L E 4 30 1
1A20012 K E P S#, 6 _ 3 2W
, C O N I C A LW A S H E R 4 31 3
210-0001 L I NE F I L T E R6,. 0 4 , F L A N G E 4 32 I

WELCHALLYN
 PartNumber Description Photo# Bubble# 0uantity
101-0059 S I M S , # 6 - 3 2X 1 i 4 P H P S 4 33 2
P O W E RE N I R YM O D U L E/ L I N EF I L T E R ,
213-0017 4 34
F U SE D
101-0084 S C R E W#, 6 T H D F R M G ,P H P S 4 35 4
u50123 2 7 O WI N T E R N AM
L O D U L ES U BA S S M B 4 36
u50125 27OWFILTER ASSEMBLY 5 31
101-0061 S C R E W#, 4 - 4 0X 1 / 4 ,P H P S 5 38 2
u 5 0 115 27OOW
A L I G N E DP L A T F O R M 5 39
101-0073 S C R E W#, 8 - 3 2X 3 / 4 " , P H P S 5 4
44-10655 FAN,BACK,
3 WIRE,27OW 6 41 2
A4-10672 WIREHARNESS,FILTEF/GFOUND 6
44-10673 W I R EH A R NE S S ,S W I T C H / F I L T E R 6
A 4 - 1 Q 647 W I R EH A R NE S S A
, C/FILTER 6 44
109-0006 B U S H I N GO, P E N E D / C L O S E.D
5O, O 6
44 10675 W I R EH A R N E S SA,C / S W I T C H 6 46
44 10465 W I R E ,P E MT O D I N 6 47 1
44-10676 WIRE HARNESS,FILTER/PS 6 48 1
44-10678 W I R EH A R N E S SA,U X T P S 7 AO 1
A4-10677 W I R EH A R NE S S ,O N / O F F / A U X 7 50 1
101-0085 S E M S ,4 - 4 0X 3 / 8 ,P H P S 7 51 4
44-10683 F A N ,B L O W E RT, E F L O NW I R E 7 52 1
1 0 10 0 8 3 S C E E W4, . 4 0X 1 1 / 4 " , P H P SS, S 7 53 2
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 7 54 2
102-0008 NUT,KEP,4-40, HEX 1 55 2
1 0 6 - 0 01 #8
STANDOFF , ,.751 7 56 4
102-0001 NUI HEX 8 57 1
'I
104 0007 WASHER,FLAT I 58
104 0008 W A S H E RS, E R R A T E D 8 59 1
104-0019 W A S H L Rt,' 4 E X I L R N A LT O O T F I 60 2
101-0038 PLUG,6/25 8 61 1
104-0006 WASHER,
COLOR
COATED I 62 1

PN: LB-MANCLSERVRev.A
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 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
g o m m o nw i r e t e r m r n a t r o n
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 True Root Mean Squared- usedto characterize
accuracyof digitalmultFmeters.
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
s o u r c ei n g o o do p e r a t i n cgo n d i t i o n . v e r ys i xt o t w e l v em o n t h s y, o u
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
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

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 . 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
i Ie . h e c kf o r t h e f o l l o w -
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 ) .

o 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 Rn 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.
T h e I L L U M I N A T Om ( 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 .
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 .

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
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 . h e c kf o r t h e f o l
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
S i z e/ W e i g h t( C L1 0 0 ) 5 . 5 " H x 1 1 . 2 5 W
" x 1 1 . 2 5 "D / 9 . 0 1(b1 4 0 m m H
x 2 8 6 m m Wx 2 8 6 m m D / 4 . 0 k 9 )
" (140mmH
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 x 2 8 6 m m Wx 3 2 4 m m D / 5 . 0 k 9 )
SpaceRequirements M i n i m u m2 " ( 5 1 m m )a i r s p a c a
e r o u n dt o p ,b a c ka n ds i d e s
F i ni s h Paintedsurfaces- polyuretha
ne

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

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

cD.78737
l E C 6 0 1 -:11 9 8 8 / E N
6 0 6 0 1 -:' 1 9 9 0A m e n d .2 ,
l E C 6 0 1 - 1 - 2 : 1 9 9 36/0E6N0 1 - 1 - 2 : 1 9( 9C3l a s B
l E C 6 0 12 - 18 : 19 9 6 / E N6 0 6 0 1 - 2 -81: 19 9 6
s ) ,J I ST 1 0 0 1: 1 9 9 2 ,

IECClassification
TypeBF,Classl
lPXO
Operation
Continuous

The CE mark on this productindicatesthat it has beentestedto and conformswith the provisionsnoted
M e d i c aD
w i t h i nt h e 9 3 l 4 2 l E E C l e v i c eD i r e c t i v a E M Cd i r e c t i v e .
e n d8 9 / 3 3 6 E E C
EUContact: Eu r o p e a nR e g u l a t o rM
y anager
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
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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
c o n t r o l sa n d i n d i c a t o r 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
s ,
event that the fan(s)malfunctionsor if adequateair flow is blockedand/orthe internaltemperatureof the device
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 pl r o t e c t r omn echanism w i l l a u t o m a t i c a lsl yh u to f f
p o w e rt o t h e r a m p A . 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 .

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

MULT|LtNKn PoRTANDMULT|L|NK* ExpANSroN

PoRT
Internal,to both the multi LinkrMPort and Multi LinkrMExpansionPort,are patentedcouplingopticsand
mechanicsdesignedto producethe highestoutput powers.Internalto the LightSourcesare fans and heatsinks
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
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
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
CL 100 SURGTCAL
ILLUMTNAToR
CrRcurr DTAGRAM

POWER
SUPPLY DIAGBAM
BLOCK

@]4VDC
100240vAc El\,41
FILTEB t--r/ |
& I I LAI'/P
"\l I
FUSE

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

PN:LB MAN CLSERVBCv.A

\Velc\ffi*'

CL 3OOSURGICAL
ILLUMINAToR
CIRCUIT
DIAGRAM

-:

> E
c a - 3

= i----.*.

148 WELCHALLYN